OPERATOR'S MANUAL

Balance Weight Type

Forklift Truck with Battery
 CONTENTS

.About Safety 1
1.Main Use of Forklift Trucks 1
2.Working Environment and Areas of Forklift Trucks 1
3.Safety Problem Before Use 2
4.Safety Problem During Operation 6
5.Safety Problem of Battery Using 14
6.Safety Problem of Battery Using 16
7.Decal 18
.Operation Device & Use Method 25
1.Liquid Crystal Displayer 28
2.Switches 32
3.Controls 33
4.Body and Others 35
.Driving and Operation 40
1.During Break-in 40
2.Relationship Between Load and Stability of Truck 40
3.Load Center and Rated Load 40
4.Stability of Forklift Truck 41
5.Transporting and Loading the Truck 41
6.Preparation for Start 41
7.Driving 42
8.Battery's Using Method 44
9.Stacking Operation 46
10.Picking Operation 47
11.Storing 48
12.Washing the Truck 48
.Periodec Inspection & Servicing 50
1.Inspection Prior to Operation 50
2.Inspection of After Operation 56
3.Weekly(50-hour)Servicing 57
4.Mothly(200-hour)Servicing 57
5.Every Three-month(600-hour)Servicing 59
6.Semiannually(1200-hour)Servicing 59
.Others 61
1.Lubrication Points and Recommended Oil 61
2.Replacing Parts Guidance 63
 INTRODUCTION
This manual should be kept by operator and read it repeatedly.
This operators manual provides the proper operation, easy
maintenance and routine inspection.
Prior to operation, read this carefully to secure safe and efficient
materials handling by proper driving and maintenance.
This manual content might not correspond with the actual
condition because of the improving of our products.
When lend or transfer the forklift truck, this manual should be
attached to the forklift truck.
If you have any questions, please consult with the sale apartment
of our company.
And marked instruction is very important to you and others
for safety. You shall keep to the instruction.

Indicates and imminently hazardous situation which,

DANGER if not avoided, will result in death or serious injury.
You must observe this instruction.

Indicates a potentially hazardous situation which,

WARNING if not avoided, could result in death or serious injury.
You must observe this instruction.

Indicates a potentially hazardous situation which,if

CAUTTON not avoided, may result in minor or moderate injury.
You must observe this instruction.

Indicates a Statement of directly or indirectly related

NOTE
to the safety of personnel and maintain of the truck.
 .ABOUT SAFETY
Safety is your business and your responsibility. The"ABOUT SAFETY" covers
basic safety procedures and warnings of general application to the typical forklift
truck. However, safety precautions given on the following pages are also
applicable to lift trucks that have special specifications or attachments.

1.Main use of forklift trucks

1 Main use of forklift trucks
The main use of forklift trucks is handle and stack the loads that on the pallets.
When they are assembled with proper attachments, they also can handle and stack
the loads that not on the pallets.
2 Prohibitive use
The following prohibitive uses are not allow to use anyway.
Stand on the forks or pallets and rise.
Stand on the pallets to press the loads.
Hoist the loads with the steel wire rope hang on the forks directly.
Tow other trucks.
Push the loads or other trucks with forks.
Open or close the doors of other trucks with forks.

2.Working Environment and areas of Forklift Trucks

1 Ground condition
Keep good condition of flat road surface and ventilation.
Lift truck performance depends on the ground or floor conditions and travel
speed should be adjusted properly. Use extreme care when operating on a ramp or
rough ground or floor.
WARNING
When crossing the railroad, be sure to once stop and make sure to be safe.
Go around rocks and stumps. If unavoided, reduce speed and go slowly
and carefully. Use caution not to damage th bottom of truck.
When traveling on grounds covered with snow or ice, use tire chains. On such
ground conditions, avoid sudden accelerations, stops, or turns. It is good practice
to control the travel speed by accelerator pedal effort.

.2.
 WARNING
When equipped with tire chains, the truck get a larger driving power. However,
sideway anti slip performance is almost reduced so extreme care should be used.
(2)Weather condition
Do not operate the truck outside when it's raining.
CAUTION
Do not rise the mast too high in the air when it's windy, this will lead to a
dangerous condition unexpectedly.
(3)Measures against cold and hot weathers
a)Oil
Use the oil suitable for ambient temperature.
b)Battery
In cold weather
Under normal charged conditions, the freezing point of electrolyte s about -35 .
Always keep the battery in a well-charged condition since there is danger of
damaging the battery jar if electrolyte freezes. To prevent the freezing, charge at least
75% of the whole capacity.
Also it is effective to keep the specified gravity up to 1.260, but not higher than this
value.
In hot weather
As the water of electrolyte is aspecially likely to evaporate in hot weather, replanish
distilled water from time to time. Check the battery once a week, and supply distilled
water.
In a region where the ambient temperature is intensely hot, it is practicable to lower
the specified gravity of a completely charged battery down to 1.220 0.01.
Since the battery is better in efficiency under hot temperatures, no other cares are
needed.
DANGER
Gases produced by the battery can be explosive. Do not smoke, use an open flame,
create an arc or sparks in the vicinity of the battery. Ventilate well when in an enclosed
space and when charging. The battery contains SUI PHURIC ACID which causes severe
burns. Do not get in eyes, on skin or clothing. In case of contact, flush immediately and
throughly with clean water. Obtain medical attention when eyes are affected.
c) Radiator coolant
Your lift truck is generally shipped with the cooling system filled with Long life
Coolant (LLC) of 50% volumetric mixture. The freezing point of the coolant of such a
mixing ratio is -35 .
In hot weather, to maintain good cooling effect, special care should be paid to
radiator and cooling system. Parking in the shade is recommended.
3.Safety Problem Before Use
(1)Get permission from supervisor
CAUTION
Only trained and authorized operator shall be permitted to operate the truck.
The characteritic of brake, accelerator and hydraulic control levers are
different an every truck which has same specification. After getting accustomed to
operating, operate the forklift truck.

.4.
 2 Clothing of forklift truck working
CAUTION
Wear a helmet, safety shoes and a working clothes.
For security, do not wear a loose clothes which has a fear to be hooked or caught in.
When hooked the clothes, this will lead to a dangerous condition unexpectedly.

3 Do not o operater after drinking

CAUTION
Do not operater the forklift truck when you have tired, mix emotional problems.

4 Safety for your

CAUTION
Do not operater the forklift truck when you have tired, mix emotional problems.
Lighting for cperating area is needed for safety working.
Operating on a plat from and dock boards is in danger of turnover, provide wheel
stops or other positive protection to prevent a turnover.

.6.
(5) Keep clean condition of operator's compartment
CAUTION
Operator's compartment shall be kept in a clean condition at all times.
When having slippery oil hands or muddy hands, this condition will lead a
dangerous operation.
Tools and other metallic objects shall be kept away from the operator's
compartment. These obstruct the movements of lever or pedal.
(6) Truck complete
CAUTION
Truck should be equipped with an overhead guard and a load backrest.
NOTE
An overhead guard shall be used as protection against falling objects. It should
be noted that an overhead guard is intend to offer protection from the impact of
small packages, boxes, etc., Representative of job application, but not to withstand
the impact of falling capacity load. Precaution shall be taken to falling objects.
WARNING
Modifications and additions shall not be performed without the wirtten approval
of our company. Modifications might affect capacity or safety operation.
Do not install any parts blocking visibility from operating position.
(7) Periodic servicing
CAUTION
Carry out daily servicing Ok
And periodic servicing.

Operate
this truck
arfter
repairing
WARNING
When find a damage or a
fault at the truck, stop operating
the truck and inform an
employee about the truck
condition inmediately. Do not
operate the truck until the truck
has been repaired completely.

.8.
(8) Avoid fire hazard
CAUTION
Setting fire extinguisher to avoid fire hazard, accident or other indeterminism
thing. Use the fire extinguisher according to it's operating rules.
(9) Prohibition of overload
CAUTION
Do not overload and observe the allowable load and the capacity chart on the
truck. Make sure the weight of load and the center of gravity at the load position.
NOTE
Allowable capacity means what the maximum load can be put on the forks in
accordance with a load center.

(10) Using a proper pallet

CAUTION
Use a pallet which is suitable size and strength for a load.
Make sure palletised load is in proper shape and securely palletised.
Prohibition of handling materials without pallets.

Loading
OK!

.10.
4.Safety Problem During Operation
1 Cautionary proceeding for start
CAUTION
The parking brake lever is applied securely.
The directional switch lever is in "N".
Depress the clutch pedal or the brake pedal.
Adjust the seat so you can get easy access
to all hand and foot controls.
Make sure no one is under, on and close
to the truck.
2 Safety around the truck
CAUTION
When carrying the large load and visibility
is poor, make a drive backward or someone
should induces the truck.
When driving to backward, make sure no
person is around the truck. The rear view
mirror and the buzzer are for helping.
Someone should induces the truck at narrow aisle.
The driver shall be required to stop at cross aisles and other location where vision is
obstructed and make sure security at right and left of the truck.
Make sure the safety distance from sideways or plat from's edges. Working on the
sideways or plat from may cause the truck dropping, put stopper and so on.
A forklift truck is a rear wheel steering which is different from a car, slow down the
travelling speed and approach to turning corner then operate steering wheel with taking
care of a turn at the truck back.

Stop!

Keep
away!

.12.
 3 Prohibition of rough driving
CAUTION
Do not turn on the key switch with
depressing the accelerator pedal.
Slowly
Do not make a sudden start, braking
or turn. A sudden start and braking can
cause a falling of load. A sharp turn on
travelling can cause a overturn of truck
and may relater to a serious accident.
Operate hydraulic control levers
slowly when loading and unloading. There
is a danger of falling load or overturning
the truck when operating the levers
suddenly at high height position of forks.
NOTE
Do not run over bumps and obstacles scattered on the road.
When passing by the other truck, slow down the travelling speed and sound the horn.
Do not drive into a week floor or ground.
Slow down the travelling speed on a wet, slippery, uneven and inclined place,etc.
Make sure that there is sufficient clearance between mast and ceiling or entrance of a
structure.
Ouc
h!

.14.
 4 Prohibition of driving with forks
lifted up in the air
CAUTION
Do not drive with forks lifted up.
When travelling with lifted forks, this
could cause an unstable condition
and a turn over of the truck.

5 Prohibition of fork tip working

CAUTION
Do not push a load or lift up by
the tip of forks. When catch a load by
the tip of forks, it can cause jumping
up the truck or a load.

6 Prohibition of pushing and pulling working

CAUTION
Do not push or pull a load. The load would be damaged or dropped.

.16.
 7 proving on a slope
CAUTION
Drive the truck on a slop as
following.
LOADED: Drive the truck
forward to ascend and backward
to descend.
UNLOADED: Drive the truck
backward to ascend and forward
to descend.
When the truck goes down on
a slope, drive slowly with the
brakes on. Make sure that the
forks should not touch the ground.
Driving, turning and loading
shall not be taken on a slope. It
could cause turning sideways of
the truck, it is very dangerous.

8 Prohibition of off-center loads

CAUTION
Make sure if loads are arranged stable and safely, in sent the forks to the pallet
correctly and care must the taken not to handle off-center loads.
To handle off-center loads could lead to overturn the truck and falling loads.

.18.
 9 Prohibition of permitting passengers to ride
WARNING
Do not permit passenger to ride on the forks
or a pallet.
Do not ride people on the truck except driver.
Do not ride people on the truck as a
counterbalance.
Do not stand on the load or pass under forks.

10 Prohibition of putting into mast structure

WARNING
Never put any part of the body into the mast structure or between the mast and truck.
CAUTION
Keep hands and feet inside the operator's compartment. Do not put any part of
the body outside the operator compartment of the truck.

.20.
 11 Prohibition of lifting when tilting
loads forward
CAUTION
Do not lift up load and drive a
truck when tilting the mast forward.
When lifting loads or driving the truck,
tilt the mast backward enough and
stabilize the load. When travelling with
or without load, raise the forks for 150-
200mm from the floor.
Do not tilt the mast forward with
the load.
When lifting or lowering the load,
be sure to stop the truck.
Do not load and unload the load at
the condition which the truck is leaning.

150-200mm

12 Driving into trailer

CAUTION
Operater the truck at the place
where has holding means of a trailer at
docks.
Before starting operation of truck,
fix a dockboard and inspect it's strength.
When getting into or off the trailer,
drive carefully and slowly across the
dockboard or bidge plate.

13 Getting on and off truck

CAUTION
Do not jump on and off the truck.
When get on and off the truck,
grasp a grip, put on your foot at step
and supporting your body.
When getting on the truck, do not
grasp a steering wheel or hydraulic
control levers.

.22.
(14)Prohibition of loading high stacked
loads
CAUTION
Loaded load should be contacting
with a load backrest. Do not handle the
load which a exceeded height of a
backrest. When loads go over a load
backrest, there is a danger of loads's
falling against operator.
When making a double stack
loading, fasten the loads with rope to
protect falling of loads.

(15)Loosen chains
CAUTION
Do not draw out the forks from a
pallet when chains are loosen. When
chains are loosen, there is a danger of
catching loads and rack by forks or
falling of loads and overturning of truck.
NOTE
When chains are loosen, pull the
lift lever a little and lift the forks, the
loosen chains could be corrected.
After correcting the loosen chains,
draw out the forks from a pallet.

(16)Adjustment of forks
CAUTION
Adjust the spreading of forks in
accordance with a pallet size. Care must
be taken not to pitch fingers when
adjusting a spreading of forks.
When adjusting the width of forks,
make sure that the setting pin of forks
are fixed. When the forks are not fixed,
the forks could move and there is a
danger of load's crumbling and falling.

.24.
(17)Handling of wide loads
CAUTION
Careful driving should be
taken when handling long or wide
loads.
Be careful of around security
when turning, and turn slowly in
order not to move loads.
Be careful of balancing of
loads, and handle the loads at low
height position.
Lifting and lowering loads
should be slowly, and be carful of
around security.

(18)Prohitition of holding down DANGER

loads by hands OUT
CAUTION OF
ORDER
Do not hold down the loads
by hands. There is a danger of
load's falling.

(19)Parking of disabled forklift truck

NOTE
When park the off road
forklift truck, warning or "out of
order" signs shall be placed on the
truck and remove the key.
When the forks could not be
lowered by fault, place a large
mark in order not to be hit by other
truck or walkers.

(20)Information of after finished

working
NOTE
Tilt the mast ass'y forward and
fully lower the forks. If do not lower
the forks to the floor, there is a
danger of stumbling or hitting body.
Place directional switch lever
in neutral.
Apply the parking brake
securely. Parking
Turn off the key switch and brake lever
remove the key.

.26.
 21 Parking
CAUTION
Park at reserved place.
Parking place should be hard sufficiently and does not disturb a traffic.
Do not park on or near and inflammable object.
Do not park trucks on a slope. When park trucks on a slope, the trucks could move
inconceivable. When park trucks on a slop by necessity, put wheel drags securely.

5. Safely Problem During Service

1 Service place
CAUTION
Servicing facility should be provided adequate equipment and safety guards,
and this place should be appointed.
Servicing place should be a flat footing.
Servicing place should be provided for adequate ventilation.
Fire extinguishers shall be provided at the servicing facility.
2 Precautions of service
CAUTION
Smoking shall be prohibited.
Wear safeguard(helmet,shoes,glasses,gloves and boots)and suitable clothes.
Wipe off split oil at once.
On lubricating,lubricate after removing grease and dust off nipples and fittings
with a brush or a cloth.
Turn off key switch and pull out the battery plug except being in case of need.
When servicing a forklift truck, lower forks to the floor.
Clean the electrical components with compressed air.
3 Cautions of service
CAUTION
Care must be taken not to put you feet under forks and not to stumble over forks.

.28.
 When forks are lifted up, put blocks under an inner mast not to fall down
forks and mast.
Care must be taken nat to snip your hands when opening and shutting of a
floor plate and a battery cover.
When having a group work, proceed working by making a sign each other.
Use suitable tools and do not use temporary tools.
When being struck by a high voltage shock, consult a physician immediately.
Do not use a mast ass'y instead of a ladder.
4 Inspection and exchange of tyre
CAUTION
Leave a dismounting and mounting tyres to qualified service facility by our
company.
Hanling a high pressure air shall be made by authorized personnel.
When use a compressed air, wear goggle.
When dismounting the tyre, do not loosen bolts and nuts of joint rim. As inside tyre
is high pressure, there is a danger of breaking bolts, nuts and rim.
5 Jack up working(exchanging tyres)
WARNING
Do not enter under the truck while jacking up the truck.
When you jack up the forklift, make sure there is no man and cargo loaded.
When forklift lift-off the ground, you should cushion the tires to prevent the
accident.
When you jack up the forklift, brake and prevent the forklift from moving.
CAUTION
Before jacking up, make sure that nobody in the truck and no load on the truck.
When wheels rise up from ground, stop jacking up and put blocks under the truck
to prevent the truck falling down.
Before jacking up, put wheel drags.
6 Drain the waster(electrolyte, oil,etc.)
CAUTION
The waster of the forklift truck must the reclaimed obeying the government's
rules. Do not drain the waster randomly.

.30.
6. Safety Problem of Battery Using
1 No smoke
CAUTION
A battery produces hydrogengas. When making a short circuit, sparking and
a fire a cigar approaching to the battery, it causes an explosion and a fire.

2 Prevention of an electric shock

CAUTION
The battery has a high voltage. Do not touch the electric conductor of the
battery when installing and servicing. It causes a serious burn.
3 Connecting correctly
CAUTION
Do not charge the battery which the + terminal is changed places with the -
terminal. It cause heating, ignition, smoking and an ignite explosion.
4 Prohibition of putting a kind of metallic goods on the battery surface
CAUTION
Do not make a short circuit between both terminals by bolt or tool. It causes
injuries and an ignite explosion.
5 Prohibition of over discharging
CAUTION
Do not operate the truck until it does not move. The battery life will be
shortened. When the battery capacity warner flushes, charge the battery.
6 Keep clean
CAUTION
Keep the upper surface of the battery clean.
Do not use a dry cloth, a chemical fire cloth for cleaning the battery surface.
And do not cover the battery by a vinyl sheet.
It causes a ignite explosion by a static electricity.
Use a wet cloth for cleaning the top of uncovered battery.

.32.
 7 Wearing safeguard
CAUTION
When servicing the battery, wear goggle, rubbler gloves and boots.

W
ru ear
an bbe gog
d b r g gl
oo lov es,
ts es

8 Electrolyte of battery is hazardous

CAUTION
The electrolyte of battery is made of the dilute sulphuric acid. Handling
should be taken care.
When the electrolyte adheres to eye, skin and clothes, it causes to lose
eyesight and a scald.
9 Emergency first aid
NOTE
When an accident is occurred, take the emergency first aid as following and
consult a physician immediately.
Spilled on the skin: It should be washed off with water for 10-15 minutes.
Splashed in eye: It should be washed off with water for 10-15 minutes.
Flow out on a large scale: Neutralize the electrolyte of battery by the baking
soda(sodium bicarbonate) or it should washed off with water.
Swallowed: Drink milk or water on a large quantity.
Splashed on clothes: Take off clothes immediately.
10 Close the vent caps securely
CAUTION
Close the vent caps of the battery securely in order not to leak the electrolyte
of battery.
Care must be taken not to refill electrolyte excessively. An overflowed battery
could cause a electric leakage.
11 Washing
CAUTION
Do not wash the truck which the battery is getting on. If washing the battery,
it causes damage to the truck.
Tighten the vent caps in order to protect water.
12 Sea water
CAUTION
The battery should not be got wet with rain or sea water. It causes a damage
of battery or fire.

.34.
 13 Abnormal battery
CAUTION
When the battery shows the following condition, contact sale apartment of our
company of our company.
The battery stinks.
The electrolyte becomes muddy.
The temperature of electrolyte is high.
The decreasing speed of electrolyte is fast.
14 Prohibition of disassembling
CAUTION
Do not drain the electrolyte from the battery.
Do not disassemble the battery.
Do not repair the battery.
15 Storage
CAUTION
When do not use the battery for a long time, store it in the place where is well
ventilated and there is no sign of fire.
16 Abandonment of battery
CAUTION
Regarding used batteries, contact sale apartment of our company.
7.Decal
The decals sticking on the trucks are used to explain to the driver how to operate the
truck and what to pay attention to. When any of them fall off the truck, please re-stick
it at once.
1 Decal of safety
WARNING
WARING

SCI-001

.36.
2 Decal of notice
CAUTION

10%

SCI-005

3 Name plate BATTERY FORKLIFT TRUCK

Certificate
Model
Rated Capacity
Standard Load Centre
Max Lift Height
Service Weight
( Service Weight
Without Battery
Max Allowed
Battery Weight
Min Allowed
Battery Weight
Battery Voltage
Serial Number

É Ï
º É
£ Á
Ï ² ³
æ μ
Ó Ð
Ï ¹
Þ «
Ë ¾ SHANGHAISHANGLIFORKLIFT TURCK CO.,LTD.
made base:2611 baoan highway shanghai
800 820 5860 Hot line : 800 820 5860
SCI-028

.38.
4 Decal of lubrication chart

LUBRICATION SYSTEM DIAGRAM

Daily

Rear.Wheel Pump Drive

Bearing Unit

Hydroulic Oil
Steering Cyl.

Tilt Cyl.rear
Front Wheel
Bearing

Pedal For Brake Fluid

Brake

Tilt Cyl. Drive Shaft

Front Pin

Lift Chain Mast Support

Cover

Differential

Grease Wheel Bearing Grease Brake Fluid

Gear Oil Hydroulic Oil

Supply Replace

SCI-003

5 Decal of capacity chart

CAUTION

CAPACITY CHART

LIFT HEIGHT(mm)
SINGLE TYPE
3000 4000 4500 DOUBLE TYPES
4750
kg

2800 4250 5000

2600 4500
CAPACITY

2400 4750 5500

2200 5000
2000 6000
1800
1600
1400
1200
1000
500 700 900 1200 1400

LOAD CENTER(mm)

SCI-004

.40.
(6)Decal of caution before start
CAUTION

SCI-006

(7)Decal of hand brake adjustment

CAUTION

200-250N

SCI-008

(8)Decal of adding hydraulic oil

NOTE

SCI-012

.42.
(9)Decal of tyre safety(pneumatic tyres)
WARNING

SCI-015

(10)Decal of sling
CAUTION

SCI-016

(11)Decal of no entry into the space behind

the mast
WARNING

SCI-018

.44.
(12) Decal of tyre's air pressure

7kg.f/cm 2
7kg.f/cm 2

7 7
SCI-017

(13)Decal of mind your hands

WARNING

SCI-019

(14)Decal of battery
BATTERY NAMEPLATE
Model Weight Kg

Capacity AH/5HR
Voltage V
Length Mm Width Mm
Battery Box Size High Mm
Serial Number
Produce Manufacturel
É Ï
º É
£ Ï
Á ² ³
æ μ
Ó Ï
Ð Þ
¹ Ë
« ¾
2611 made base:2611 baoa n highway shanghai
800 820 5860 Hot line : 800 820 5860
SCI-071

(15)Decal of routine battery use

CAUTION

SCI-023

.46.
(16)Decal of routine battery
maintenance
CAUTION

SCI-023

.48.
 . OPERATION DEVICE & USE METHOD

Mast
Lift chain Overhead guard

Rear combination
Front small lamp light
Front big lamp

Steering wheel
Battery cover
Rear view mirror

Instruments
Count
weight
Tilt cylinder

Fork

Load backrest
Fork Rack

Front wheel

Tread board

Seat Towing pin

Side board Rear wheel Rear end plate

.50.
 Rear combination
Overhead guard Seat light
Lift chain

Front small light

Front big light Count weight

Rear view mirror

Steering wheel

Instruments

Tilt cylinder

Load backrest

Fork Rack

Fork

Front wheel

Tread board

Side board Side board Rear wheel

.52.
 Horn button
Liquid crystal displayer

Steering wheel Lift lever

Directional
switch lever

Tilt lever
Parking brake lever

Key switch

Brake pedal Accelerator pedal

.54.
1. Liquid Crystal Displayer (for ZAPI electric controller)

8
6
P N -004
4
2 00003.9h
0 CE CONTROLLER

1 Turn the key switch to "ON", the electric control circuit is on. After the screen of the
liquid crystal displayers flushes four times, the signals display.
2 Battery capacity indicator
The indicator to displayed as follows when the electrolyte level is at the highest mark.
The indicator includes 8 marks which mean 12.5% of rated capacity each mark.
The lamps in the indicator will turn off when the electrolyte level gets to next mark.
When the electrolyte level gets to the lowest mrk, the battery shall be charged.

8
6
4
2
0
3 Battery capacity warner lamp
When the battery voltage of every cell is lower than 1.75V or the electrolyte level
gets to the lowest mark, the battery capacity warner lamp flushes and the bach buzzer
sounds, After the time delay of about 20 sec., The relay for insufficient voltage protection
works to turn off the lift contacting coil. Then, the lift motor is off to avoid excessive
discharge of the battery.

4 Paking brake indicator

When the truck is parking, P displays on the liquid crystal displayer. When

Releasing The parking, P displays on the liquid crystal dispayer.

5 Direction indicator

When shift the direction switch to "Forward" position and press the accelerator pedal,

" " displays on the liquid crystal displayer. When shift the direction switch to

"Backward" position and press the accelerator pedal, " "displays on the liquid crystal

displayer. When shift the direction switch to "Neutral" position, displayer. When shift the

direction switch to "Neutral" position, " N " displays on the liquid crystal displayer.

.56.
 6 Breakdown code indicator
Anyone of breakdown code 001 to 009 represents a kinds of troubles. When a
trouble arises, the " " indicator flushes and corresponding code appears. When
breakdown code 010 or more appears, it reprears, it represents the charge in the battery
has been used up and the function 3 lights.
7 Hour displayer
The displayer is used to record the working time accumulated.
2.Liquid Crystal Displayer(for CURTIS electric controller)

12 13 8 7 1
2 4
5
P
SHANGLI

CYPD-A3

14 10 9 11 3 6
1.LCD time counter 2.Error code display window
3.Battery coulomter 4.Panel ON indication light
5.Error indication light 6.Battery quantity normal indication
7."Neutral" indication light 8."Forward" indication light
9."Backward" indication light 10."Left" indication light
11."Right" indication light 12.Hand brake indication light
13.Width lamp indication light 14.Head lamp indication light
1 Turn key switch on. Meter panel connect to 12V power supply. Meter panel
and electric control circuit connect to 48V power supply through start relay in relay
box. "Panel ON" indication light in panel on. Time counter LCD dislays "8888.8".
Error code display window diplays "88", meaning traction control equipment normal.
2 Hand brake display
When hand brake on, indication light "hand brake "in panel on Light off when hand
brake released.
3 Drive direction display
Case direction switch at neutral position, "neutral" indication light on. Case
direction switch at forward step, "forward" indiaction light on. Case directron switch
at backward step, "backward" indication light on and back drive buzzer sounds. Both
forward and backward condition, "neutral" indication light off.
4 Battery quantity display
When meter panel started, battery coulometer (3 in panel) should display battery
quantity grade. Ten electric quantity grades in coulometer, ten horizontal bars(LCD)in
panel accordingly. Battery voltage range: 41.5V-56V.
The upper LCD on means full battery quantity. The lower two coruscate alternately
means electric quantity under lower limit, battery needs charged. Display LCD decline
on grade means battery quantity drop around 8%.

.58.
 5 Battery quantity under lower limit warning
The lower two horizontal bars(LCD) in battery coulometer coruscate alternately
means electric quantity under lower limit "battery normal" indication light off. At the
same time, lift supply circuit protection relay action. The protection relay ection
according to two conditions:
Pump motor not action: shut off lift relay supply circuit immediately.
Pump moto under action: delay ten seconds(for a lift procedure accomplished),
and then shut off lift relay supply circuit.
6 Drive state display
When left turn light on, "left" indication light on. When right turn light on, "right"
indication light on. When width lamp light on, width lamp indication light on. When
head lamp light on, "head lamp" indication light on.

.60.
Instrument
The integrated instrument, using micro computer technology, have the advantage of
instant data, instant appearance and instant coutrol. This makes the operater more safe and
comfortable. The instrument has low voltage warning to protect the battery and the vehicle.
(1) Figure:

¡ ¡
+ - + -

2 Instructions
1. The voltmeter- Indicate the current voltage of the battery.
2. Light Switch.
3. Electronic Lock.
4. The alarm light of battery voltage. When the electric lock is locked, the light is on.
Thus the forklift could work normally.
5. Low-Voltage light - When battery is lack of voltage, the light on and the battery is at
low voltage. At the same time the lifting switch power has been cut. (Cathode) Then, the
lifting doesn't work prevent the battery and forklift from damaging, Based on the basic
condition of the battery forklift, 40V is set as low voltage of the 48V battery. If this low
voltage continues for seconds, the protection functions start to work.
6. Right hand light indicator.
7.Manu-brake indicator.
8. Narrow aisle warning light indicator.
9. Forward indicator.
10. Backward indicator.
11. Front light indicator.
12. Left hand light indicator.
13. Electric controller hour watch.
14. Battery malfunction code index. When the battery controller is failed. There is a
special code appeared and give the repair man information.
15. Battery malfunction indicator.

.62.
2.Switches
1 Key switch
OFF This is the position where the switch is off and the key can be put in or taken
off.
ON Turning to right from the off position closes the switch to allow the operation
of the truck.
CAUTION
Do not turn the switch on with depressing the accelerator pedal.
Be sure to take the key off when leaving the truck.
When parking the truck or charging the battery on the truck, remove the dey.

OFF
ON

12

11

2 Lamp switch
This switch is two step drawn.

Operation
OFF 1st step 2nd step
Lamp

Width lamp

Tail lamp

Head lamp

:lamp-on lamp-off

.64.
3.Controls
1 Steering wheel and steering wheel knob
The steering wheel is operated in the conventional manner, that is , when the wheel
is turned right, the truck will turn to the right; when the wheel is turned left, the truck
will turn to the left. The steer wheels are located at the rear of the truck. These cause
the rear of the truck to swing out when a turn is made.
When steering, grasp the wheel knob by left hand, while the right hand is put either
on the valve lever or the steering wheel lightly.
An electric power steering and a tilting handle are equipped for both a standard
equipment.
NOTE
Adjust the best angle corresponding to the operating position.
After adjusting the tilt angle, lock the handle by tilt knob securely.

2 Horn button
Press the rubber cover at the center of steering wheel to sound horn. The born
sounds even when the key switch is off.

Horn button

.66.
 3 Brake pedal and accelerator pedal

From left to right, there are brake pedal and accelerator pedal.
Brake pedal: Depress the brake pedal, the truck braked and the brake lamp shine at
the same time.
NOTE
When depressing the brake pedal, make sure to release your foot from the
accelerator pedal.
4 Directional switch lever

Indicate the travelling direction.

Forward travelling: Push the lever and depress the accelerator pedal.
Reverse travelling: Pull the lever and depress the acclerator pedal.
When parking the truck, return the directional switch lever to neutral.
CAUTION
Do not depress the accelerator pedal at a stroke for avoiding a sudden start
or a sudden acceleration.
5 Parking brake lever

.68.
 Prevent to move the truck, when park the truck, pull the parking brake lever fully.
In returning, push the parking brake lever to forward correctly.
NOTE
When operate the parking brake lever to forward correctly.
6 Lift lever

Pull the lift lever backward to lift up the forks. Push the lift lever forward to lift
down the forks. The lift and lower speeds can be controlled by the tilt angle of the lever.
The bigger the angle, the faster the speed.
NOTE
When turn the key switch on with pulling or pushing the lift lever, the lifting
movement will not work.
Do not make a sudden lowering and lowering stop.
7 Tilt lever
Pull the tilt lever backward to tilt the mast backward. Push the tilt lever forward to
tilt the mast forward. The backward and forward speeds can be controlled by the tilt
angle of the lever. The bigger the angle, the faster the speed.
NOTE
When turn the key switch on with pulling or pushing the tilt lever, the tilting
movement will not work.

4.Body and Others

1 Seat
Adjust operator's seat to position which is comfortable for you and provides easy
access to all hand and foot controls. The seat is unlocked by pulling the adjusting lever
up. Before proceeding with work, adjust operator's seat and make sure that it is
securely locked.
Adjustable position of the seat:(forward to backward):120mm

.70.
 For ward

Back ward

2 Overhead guard
WARNING
The overhead guard used is strong enough to meet safety standard, and
protects the operator from falling materials. It's very dangerous to dismantle or
rebuild the overhead guard, because these conditions could lead to an accident.
3 Load backrest
CAUTION
The load backrest is used to prevent the loads loading on the forks slide to
the operator. It's very dangerous to dismantle or rebuild the load backrest,
because these conditions could lead to an accident.
4 Draw-bar pin
The draw-bar pin only used for following situation:
While the truck can't moving
While transporting the truck
CAUTION
Do not operate the forklift truck as a tow tractor by using a draw-bar pin.
Do not tow the forklift truck by other truck.
5 Fork stopper
Fork stoppers are to lock the forks in position. To adjust fork spacing, pull up fork
stoppers, turn, and shift the forks to the desired positions. The fork spacing should be
adjusted according to loads to the handled.
CAUTION
The forks should be set symmetrically to truck centerline and fork stoppers
should always be set.

.72.
 When you adjust the fork spacing,
depend your body on the load backrest,
then push the forks with your feet. Do
not push the forks with your hands.

6 Safety step and safety gripe

The safety steps are provided on both
sides of the truck body. The safety gripe
is provided on the front left pillar of the
overhead guard. Use the safety step and
safety gripe facing the truck when mount
or dismount the truck.

7 Fuse box Gripe

The fuse box is located at the right
side of the cabinet inner surface.

Step

8 Brake fluid reservoir

The brake fluid reservoir is provided
at the left inside of the cabinet. This
translucent reservoir allows to inspect
the fluid level from the outside.

.74.
(9)Hydraulic fluid reservoir cap
The hydraulic fluid reservoir cap is located
at the right side under the flat board. Fill
hydraulic fluid through this filler port. The cap
is provided with the dipstick.
(10)Lamps
Two head lamps and combination
lamps(turn signal, parking and clearance) are
installed at the front side of the truck.
The combination lamps at the rear side
serve as turn signal, tail lamp, brake lamp,
parking lamp, back-up lamp and rear reflector.
CAUTION
Take care of the lamps, and wipe dirt,
Head lamp
if any, and replace any damaged lamp
immediately.
If you want to install the rear lamp,
please contact the sale apartment of our
company.
(11)Rear view mirror Rear view mirror
The rear view mirrors are located at the
Font combination lamp
right and left front foot of the overhead guard.
CAUTION
Keep the surface of the mirrors clean.
Adjust the mirrors in order to see the rear area clearly.
(12)Battery plug
The battery plug is used for connect or disconnect the battery to the electric parts of
the truck. Under the normal cases, it is connected.
CAUTION
When check the electric system, turn off the key switch and disconnect the
battery plug.
There is also some voltage in the main circuit when the key switch is in the
"OFF" position.
Do not disconnect the battery plug during operation, or the truck will not be
able to turn.

Battery plug

.76.
NOTE

.78.
 . Driving and Operation
To operate the truck safely and get the most out of it ,we describe the correct operating
procedures on the following pages.
1.During Break-in
We recommend to operate the machine under light load conditions for the first stage of
operation to get the most from it. Especially the requirements given below should be
observed while the machine is in a stage of 100 hours of operation.
CAUTION
Always warm up your machine before putting it to work irrespective of season.
Perform specified preventive maintenance services carefully and completely.
Avoid sudden stop, starts or turns.
Oil changes and lubrication are recommended to do earlier than specified.
Don't run engine at high rpm without load need lessly.
2.Relationship Between Load and Stability of Truck
The lift truck keeps the balance of weight between the truck body and the load on the
forks with the center of the front wheels as a fulcrum when the rated capacity load is
placed in position. Due care should be paid to the weight and the center of gravity of loads
to maintain the stability of the truck.
WARNING
If the rated capacity is exceeded, there is a danger of the rear wheels being raised
and in the worst case, the truck will turn over, resulting a fatal accident. As seen from the
above sketches, the load placed near the fork tips practically has the same effect that the
weight of the load is increased. In this case, the load weight it reduced accordingly.

CAPACITY CHART
SHANGLI

LIFT HEIGHT(mm)
SINGLE TYPE
3000 4000 4500 DOUBLE TYPES
4750
kg

2800 4250 5000

2600 4500
CAPACITY

2400 4750 5500

2200 5000
2000 6000
1800
1600
1400
1200
1000
500 700 900 1200 1400

LOAD CENTER(mm)

SCI-004

3.Load Center and Rated Load

The load center is the distance from the front face of the forks to the center of gravity
of the load. The chart given above shows the relation between the load center and the
weight of loads to be allowable for the 2 ton lift truck (Allowable Load). The load Chart
will be attached onto the truck. Replace damaged or missing load chart with new one.
WARNING
If a truck is equipped with a load-handling attachment such as a side shifter, load
grab or rotating clamp, its allowable load is reduced as compared with that of a
standard truck(without any attachment) due to the following reasons.
1)The load equal to the weight of attachment is reduced.
2)Since the width of attachment causes the load center to move forward the
allowable load is reduced on the sam principle as a seesaw.
The installation of attachment causes the load center to move forward, which is
called"lost load center".
Never exceed the allowable load indicated on the load chart attached onto the truck or
attachment.

.80.
4.Stability of Forklift Truck
The stability standard of lift trucks is specified by the ISO or other standards. However,
the stability stated in these standards is not applicable in all operating conditions. The
stability of your lift truck varies according to the operating conditions. In the following
operating conditions, the maximum stability is secured:
1)Ground or floor is level and hard.
2)Traveling under standard unloaded or loaded condition.
Standard unloaded conditions: This means that the forks or other load engaging means
are raised 30cm above the ground and the mast is tilted fully backward without loads.
Standard loaded conditions: This means that the forks or other load engaging means
are raised 30cm above the ground and given capacity loads at the basic load center on it
and the mast is tilted fully backward.
WARNING
Use minimum forward and reverse tilt when stacking and unstacking loads.
Never tilt forward unless load is over stable stack or rigid rack or at low lift height.

5.Transporting and loading the truck

(1)Transporting the truck
CAUTION
When tranporting the truck, riggings are used to fix the truck as well as blocks
are to be inserted under the wheels to prevent the vehicle from moving in carriage.
The truck's length, width ,height should be cared when loading it, unloading it
or transporting it on the road. And all rules must be complied with.
(2)Loading and unloading the truck
CAUTION
Please use the dockboard with enough length, enough width and enough
strength to load and unload the truck.
Apply the parking brake effectively and prevent the wheels from moving.
Fix the dockboard on the center of trailer, and there must be no grease on the
dockboard.
(3)Hanging up the truck
CAUTION
Hang up the truck by trained person.
Hook the wire at the appointed position
Use wire rope which has a sufficient strength.
The battery, mast and balance weight of the truck also have there appointed hang
up position.
6.Preparation for start
(1)Check the directional switch lever position
Put the directional switch lever to the neutral position.

.82.
 (2)Turn on the key switch
Grasp the steering wheel knob. Then turn
on the key switch.
CAUTION
After turning the key switch on, it
Turn
costs one second to start the truck.
Before turn the key switch on, the Turn
directional switch lever should be turned
to neutral.
ON
Don't depress the accelerator pedal at
a stroke for avoiding a sudden acceleration.
3 Tilting back the mast ass'y
Lift up the forks about 150-200mm from
the floor by pulling backward the lift lever.
Tilt back the mast ass'y by pulling
backward the tilt lever.
(4)Operation of the directional switch
lever
Operate the directional switch lever to
moving direction(forward backward)
Forward: Push the lever forward.
Backward: Pull the lever backward.
(5)Taking off the parking brake
Depress the brake pedal.
Push the parking brake lever forward
fully.
Grasp the steering wheel by left hand,
put right hand lightly on the steering wheel.

7.Driving
(1)Start
Take off your foot from the brake pedal
and depress the accelerator pedal gradually,
then the truck will begin to move.
Acceleration varies in accordance with
the depth of the accelerator pedal depressed.
CAUTION
Do not a sudden start and stop.
Asudden start and stop will cause the load
falling.
(2)Slow down
Reducing depressing of accelerator pedal
slows down travel speed.

.84.
 CAUTION
Slow down when
turning a corner
approaching a load or pallet
approaching storage
narrow aisle
floor/road condition is bad
(3)turning
A forklift is different from a car, because of the rear wheel steering. Slow down and
operate steering wheel paying careful attention to swing of the truck's rear end.
(4)Stopping
Slow down and apply the brake slowly.
CAUTION
Do not apply brake suddenly. A sudden stop causes a load falling.
When apply brakes suddenly on a full travelling speed, it makes the driver
bend forward and hitting to the steering wheel.

Slowly
Perfectly!!

STOP

(5)Parking
Park the truck in an out-of-traffic area and
a) Apply the parking brake by pulling up on the parking brake lever.
b) Down the forks on the ground.
c) Place the key switch in "OFF" position.
d) Remove the key and keep it .
e) Be careful while mounting and dismounting.
CAUTION
Safe parking

.86.
 a) Park your truck on a level ground-preferably in a wide area. If parking on a slope is
unavoidable, position the truck so that it cross the slope and block the wheels to prevent
accidental roll.
b) Park your truck in a designated area or out-of-traffic. If necessary, put signpost or
signal lights around the truck.
c) Park your truck on a hard ground. Aviod soft ground, deep mud or slippery surfaces.
d) If you can not lower the forks on the ground due to break-down of the loading
system, put a caution cloth to the fork end and park in an out-of-traffic area.
WARNING
Check for slippery steps and floor.
Don't dismount from the moving truck.
Never jump off the truck.
(6)Repairing of disabled forklift truck
CAUTION
If the truck occur failure suddenly during operation, please tow it away for
repairing immediately.

8.Battery's Using Method

(1)Charging
Charge the battery with the proper charger and operate it according to the stipulations
in the Operation & Service Manual for charger.
a) Do not run out of the battery's electrolyte
CAUTION
The minimum quantity of electrolyte should be kept. If the quantity is short, it
causes overheating or burning of the battery.
When the electrolyte of battery is in short supply, its lift will be shorten.
Check the electrolyte once a week.
b) Replenishment of refined water or distilled water.
Refer to Operation & Service Manual of Battery.
c) Prohibition of overcharging
d) Being well ventilated place

.88.
 CAUTION
Charge the battery at a place where is well ventilated and does not get with in the rain.
e) Open the battery cover
CAUTION
When charging the battery, hydrogen gas is occurred. Open the battery cover
under charging, make it not being closed.
f) Check for terminal, cable and plug.
CAUTION
Prior to charging, check determine if the plug and cable are not damaged.
Do not charge the battery which has condition as following.
The electrode of plug is damaged.
The terminal and cable are rusted.
These cause sparks, damages of burn and ignite explosions.
g) Charging after turning off the key switch.
h) Check for specific gravity
Measure the specific gravity of all cells before charging.
Any abnormality within the battery could be found and an accident prevented by
knowing the specific gravity before and after charging.
i) Pulling out or putting on the plug should be done by holding plug itself not cable.
CAUTION
Do not pull cables.
When cable and plug has damaged. Contact sale apartment of our company.
Replace them.
j) Discontinuance of charging
CAUTION
When discontinue the charging of battery, operate it according to the
stipulations in the Operation & Service Manual for the charger.
When pull out the plug of charger under charging, it causes sparks which is
dangerous.
(2)Exchanging battery
When truck is continued to operate over a working shift and battery energy is
consumed, change the battery with another battery which is charged fully at the time of
shift and then charge the dismounted battery fully.
CAUTION
When exchange a battery, make sure that the battery should match with the
truck. (1-1.5t Forklift 48V, the capacity don't less than 400Ah, 2-2.5t Forklift 48V, the
capacity don't less than 620Ah).When use a battery which does not match with the
truck, it causes a shortage of working or a turnover of truck under travelling.
Exchanging battery should be done on a flat floor.
Exchanging the battery should be done by observing the following instruction.
CAUTION
When exchange the battery by operating another forklift truck, provide
suitable slings(attachment).
Hanging the battery should be made by specified personnel.

.90.
 a) Disconnect the battery plug.
b) Open the battery cover.
Locking the battery cover by gas spring or others to avoid the falling down of the
cover, the injury of people or damage of the truck body.
c) Loose the fixed unit of the battery.
d) When lifting the battery box out of the truck, care must be taken not to hit the
steering wheel or others.
e) After installing a full charged battery, fix it and
connect the battery plug securely.
f) Close the battery cover.
CAUTION
Care must be taken not to squeeze your fingers
when open or dose the battery cover.
When hang up the battery box, care must be
taken not to hit at the frame with swinging it.
9. Stacking Operation
CAUTION
Check the following items before starting
operation of truck.
Make sure that there is not load's
falling and damage of load at loading area.
Make sure that there is no objects and
stacking is carried out safely.
When stacking a load, observe the following
procedures.
(1)Slow down the travel speed when
approaching a stacking area.
(2)Stop the truck in front of stacking area.
(3)Check for safety around the stacking area.
(4)Adjust the truck position which a Make sure

load(pallet) locates in front of the stacking area.

(5)Tilt the mast to vertical position and lift
up the forks above the stacking position.
(6)Check the stacking position and move
forward and stop slowly at the proper position.
(7)Make sure the load is just above the
stacking position and lower the forks slowly.
Make sure the load stacked correctly.
NOTE
When the load is not aligned at front/rear
ends of the load or pallet;
a) Lower the forks until the load weight
on the forks becomes free.
b) Move the truck backward about 1/4
length of the forks.
C) Lift(50-100mm) the forks again and
move to forward then lower the load slowly at
a proper stacking position.

.92.
 (8) Check clearance backward and move Make sure
backward avoiding hitching forks to pallet or
load.
(9) Make sure the tips of forks are off the
load or pallet, and lower the forks to the
position for running(150-200mm above the
floor).

10.Picking Operation
When picking up the loads, observe
following procedures.
(1)Slow down the travelling speed when
approaching a load to be picked up.
(2)Stop the truck in front of the load
(about 30cm between the load and the fork
tips).
(3)Adjust the truck position which a
forks locates in front of the load.
(4)Make sure safety of the load which is
not collapsed.
(5)Tilt the mast to vertical position.
(6)Check the inserting position and move
the truck forward slowly until the forks are
fully inserted into the pallet.
NOTE
When it is difficult to insert the forks
fully into the pallet:
a)Insert the forks by its 3/4 length and
lift up the pallet a little(50-100mm),and
draw out the pallet about 100-200mm and
lower the pallet again.
b)Insert the forks fully to the pallet.
(7)After inserting the forks, lift up the
pallet(50-100mm).
(8)Check the clearance and move the
truck backward until the load is lowered.
(9)Lower the load up to 150-200mm
above the floor.
(10)Tilt the mast backward for stabilizing
the load.
(11)Carry the load to its destination.

150-200mm

.94.
11.STORING
(1)Before storing
Before storing your lift truck, clean it thoroughly and perform inspection using the
following procedures.
a)Wipe away grease, oil etc. Adhering to the body of the truck with waste cloth, and
use water, if needed.
b)While washing the truck body, check general condition of the truck. Especially
check the truck body for recess or recess or damage and tires for wear or nails or stones in
the tread.
c)Check for leakage of hydraulic oil, engine oil, fuel, or coolant.
d)Aply grease, where needed.
e)Check for looseness of hub nuts, cylinder piston rod joints.
f)Check mast rollers to see that they rotate smoothly.
g)Prime oil into the lift cylinders by actuating the lift cylinders at the full stroke.
WARNING
If at any time your lift truck is found to be in need of repair, defective, or in any
way unsafe, the condition should be reported to the supervisor, and the truck should
be taken out of service until it has been restored to safe operating condition.
(2)Daily storage
a)Park the lift truck at a specified place and block the wheels.
b)Place the shift lever(s) in the neutral position and apply the parking brake securely.
C)Remove the key and keep it sure.
(3)Long time storage
Perform the following service and checks in addition to the "DAILY STORING"
Services.
a)Taking the rainy season into cosideration, park the machine at a higher and hard
ground.
b)Dismout the battery from the machine.
Even though the machine is parked indoors, if the place is hot or humid, the battery,
should be kept in a dry, cool place. Charge the battery once a month.
c) Apply antirust to the exposed parts such as cylinder rods and shafts which tends to
rust.
d)Cover components such as the breather and air cleaner which may be caught with
humidity.
e)The machine should be operated at least once a week. Fill the cooling system, if
cooling water is discharged, and mount the battery. Remove grease from the cylinder rods
and shafts. Start the engine and warm up thoroughly. Move the machine a little forwards
and backwards. Operate the hydraulic controls several times.
f) Avoid parking on soft grounds such as an as phalt ground in summer.
(4)To operate the forklift truck after a long time storage.
a)Remove antirust from the exposed parts.
b) Discharge foreign matter and water from the hydraulic oil reservoir.
c)Charge the battery and mount it on the machine. Connect the cables.
d) Perform pre-oprational checks carefully.

12.Washing the truck

(1)No washing the truck and the battery with water.
a) It is absolutely forbidden to wash the cable, the connector and the plug.
b) Outside of the battery box can be washed. But do not let the water go into the
battery box or the electrolyteto prevent the battery lifte from shortening.

.96.
(5)Washing Parts Notice

Part Water Caution

Forklift surface, mast, Prevent inner side of the spare parts from watered.
fork, tire rear axle, Yes The counter weight top contains electric device,
count weight do not water.

Side cover, Flat board Yes Side cover is can not enter too much water.

Use compressed air, or cloth;

Front cover, Water only for disassembly the parts and assembled
No
Flat board when fully dried.

Cowl, Steering wheel No Use compressed air, or cloth

Steering Wheel, Use compressed air, or cloth

No
Instrument
Motor No Use compressed air, or cloth

.98.
 . Periodic Inspection & Servicing
Complete inspections of the forklift truck prevents faults previously and extends
and usable period of the truck. Hours shown below are based on 8-hour operation per a
day and 200-hour operation per a month.
CAUTION
Only trained and authorized serviceman shall be permitted to service and truck.
Inspection prior to operation, inspection of after operation, weekly servicing and
monthly servicing are all could be done by the operator.
1.Inspection Prior to Operation
Inspecting the truck prior to operation should be done for safety operation and
keep good condition of the truck. This is a duty in law. When revealod fault, contact
the sale apartment of our company.
CAUTION
A small fault could cause a serious accident. Do not operate or move the
truck prior to finishing repair works and inspect.
Inspecting trucks should be made on a flat floor.
Trucks in need of inspection to electrical system shall have the key switch
turned off and the battery disconnected prior to such inspection.
(1)Check points and contents

No. Check points Contents

1 Brake pedal Depth of foot brake pedal and braking force
Braking
system 2 Brake oil Quantity and stain
3 Parking brake Pulling Depth of lever and operation force

Steering 4 Play of steering wheel Loosened, ply and/or vertical movement

system 5 Power steering operating Operating of all parts
6 Function Function, any crack, lubricant
Hydraulic 7 Oil piping Oil Leakage
system &
mast 8 Hydraulic oil Appropriate quantity
9 Lift chains Equal tension of chains on R.H. And L.H.
10 Tyres Air pressure, abnormal wearing and/or damage
Wheel
11 Hub nuts Securely tighten
Confirmation of state of battery capacity
Battery 12 Charging indicator and specific gravity, plug is
securely connected.
Head lamps, tail lamps,
Lamps & back lamps, turn signal Turn on and off, sound
13
Horn lamps and horn
Monitor & When key switch is turned on,
lamps 14 Function "MONITORING OK"is displayed

15 Overhead guard, load backrest Fitting bolts and nuts are tighten
Others
16 Others than the above Any abnormality

.100.
 2 Inspection Procedure
a Check of foot brake pedal
Check performance of brake and make sure that it is over 50mm from the floor plate
when depressing the brake pedal fully.
Proper braking distance without a load is about 2.5m.

b Check of brake oil

CAUTION
Remove the cap of brake oil tank and check the quantity and condition of the
brake oil.

Brake oil tank cap

Brake oil tank

c Check of parking brake lever

Pulling the parking lever and to see:
Suitable pulling stroke
Braking force
Damaged parts
Lever operation force(standard 17-22kg) is suitable for operator or not.
Adjustment should be done by a screw which located on the top of lever.

Parking
brake lever

.102.
 d)Check of play of steering wheel
Turn the steering wheel clockwise and counterclockwise lightly and check to see if
there is play. Appropriate play is 500-100mm. The steering wheel moves forward and
backward by about 7 ,this is normal play.

PLAY
50mm-100mm

e)Check of power steering function

Turn the steering wheel to clockwise and counterclockwise, check the power
steering operation.
f)Check of function
Check if lifting and tilting operation is smooth.

g)Check of oil piping

Check for any oil leakage from the lift cylinders, tilt cylinders and oil piping.
h)Check of hydraulic oil
Check oil lever, using the oil level dip stick with the forks lowered on the floor.
Appropriate oil quantity is within the range of H to L.

.104.
 Models H L
Level gauge
10 23l(6.1 21l(5.5
CPD
15 imperial gallon) imperial gallon) H
10S 25l(6.6 25l(6.1 L
CPD imperial gallon) imperial gallon)
15S
Hydraulic tank
20 27l(7.1 25l(6.6
CPD imperial gallon) imperial gallon)
25
31l(8.0 29l(7.7
CPD 30 imperial gallon) imperial gallon)

i) Check of lift chains

Lift up forks by 200-300mm above the floor, and make sure lift chains are
equivalent in tension.
Check the finger bar if it does not decline either to right or left side. If the tension
is different, adjust using the chain anchor bolts.
CAUTION
After having adjusted, tighten up the double nuts securely.

Lift chain

Chain anchor bolt

Double nuts

Pin

j) Check of tyres(pneumatic tyres)

Measure the air pressure by using the tyre gauge after removing the cap. After
checking air pressure, make sure air does not leak from the vale before replacing the cap.
CAUTION
Air pressure for forklift truck is higher than a normal car, do not raise the
pressure over the appointed pressure.

Fork Standard Air Pressure kPa

type
Tire CPD10 CPD15 CPD20 CPD25 CPD30

Front 8.50 7.00 7.00 9.00 8.00

Rear 8.00 8.00 8.00 9.00 7.00

.106.
 Check of tyres(solid tyres)
Check the tyre and ti's side face if there is any damage or craze. Check the rim if
there is any distortion or damage.
k) Check of hub nuts
Check if the hub nuts are loosen by tightening them with using a box wrench.
Torque moment for hub nuts:
Front:18 7-8 140N.m
Rear:15 41/2-8 120N.m

1)Check of charging
Measure the specific gravity of battery. When they show 1.275-1.285 at 30
conversion, the battery is full charged. And check the terminals which are loosen and
the cable which is damaged.

lug
er yp
B att

m)Check of head lamps, turn signal lamps and horn

Check if lamps turn on. Check if horn sounds.

L Left turn N

N Neutral R

R Right turn

.108.
 Push and Ring

n) The horn sounds when pressing the part shown by the arrow.

8
6
P N -004
4
2 00003.9h
0 ANTAI ELECTRONICS CO.,LTD

P
SHANGLI

CYPD-A3

.110.
 ¡ ¡
+ - + -

o)Check of overhead guard and load backrest

Check if any fitting bolts or nuts are not loosen.
p) Others
Check for any other abnormality.
CAUTION
Be sure to turn off the key switch and disconnect the battery plug while
checking electric system except turning on the lamps and checking operation.

2.Inspection of After Operation

When close working, remove stains on the truck and inspect the truck as following
items.
(1)Deterioration or leakage at all parts.
(2)Deformed, distorted, worn or cracked members.
(3)Apply grease in accordance with condition.
(4)Lift forks to the maximum lift height was not used in the day's operation,
provide oil to cover at internal cylinders for preventing rust).
(5)Verify an abnormal part which observed any defects during operation.
CAUTION
A small fault could cause a serious accident. Do not operate or move the truck
prior to finishing repair works and inspect.

.112.
3.Weekly(50-hour) Servicing
Inspect the following servicing in addition to the inspection prior to operation.

Check points Contents

Electrolyte quantity Check the electrolyte level. When the level is low, replenish
with refined water.

Specific gravity of Measure the specific gravity and temperature of electrolyte

electrolyte of all sells.

Cleaning of battery Clean the top of uncovered batteries and vent caps.

Check of contactors Polish the roughness of the contact by a sand paper.

CAUTION
Be sure to disconnect the battery plug when inspecting the electrical system.
(1)Check for quantity of electrolyte
CAUTION
After completed the replenishment, close the vent caps securely.
Do not replenish over the water. Flooding could make an electric shock.
(2)Check for specific gravity of electrolyte
Measure the quantity and specific gravity of all cells.
Normal: When all sell's specific gravity are the same figure as converted figure at
30, it is normal.
Abnormal: When the specific gravity is less than 0.05 from the average figure of
others, it is abnormal.
(3)Cleaning of battery
Keep dry condition by wiping off with a wet cotton cloth to protect corrosion at the
connecting area of top batteries.
CAUTION
Cleaning of the battery should be done before charging.
Wear rubber gloves and boots to prevent a electrical shock.
Handle the battery plug not to touch water.
The inside of vent caps will be stained. Clean them as following procedures.
a)Remove the vent caps.
b)Wash the inside of vent caps with a neutral cleaner.
c)Install the vent caps.
CAUTION
Make sure the vent caps are closed securely.
(4)Check of contractor
Put in a sand paper between the contacts and push the movable contact to close and
then draw out the sand paper. Repeat this procedure.

.114.
 System No . Check points and contents
1 General Distortion, crack and abnormal noise
Truck 2 Horn Sound
3 Accessories Head lamp
turn signal lamp Function
4 Battery electrolyte Quantity, specific gravity and clean
5 Terminal plug Damage and clean
6 Key switch Function
7 Contractors Contact and function
8 Micros witch Function
Battery,
9 Controller Function
Charger &
10 Traction motor Brush
commutator Wearing and spring force
Electric Brush
11 Hydraulic motor commutator Wearing and spring force
system
12 P. S. Motor Brush
commutator Wearing and spring force
13 PET chopper unit Current limitation and fuction
14 Fuses Looseness and capacity
15 Wiring, terminal Damage and looseness
16 Steering wheel Play and movement
17 Steering link Lubrication
18 Gear case Oil quantity, leakage and abnormal noise
19 Fitting nuts for tyres Looseness
20 Tyres Damage and wearing
21 Lift chain Lubricant and tension
22 Cylinder rod guide pins Looseness and damage
23 Lift bracket Adjustment,lubricant,crack and distortion
24 Forks Crack and transformation
Drive, 25 Lift rollers Adjustment and lubricant
Steering, 26 Mast rollers Adjustment and lubricant
Mast, 27 Outer mast, inner mast Jolt
Hydraulic 28 Lift cylinder Oil leakage
& 29 Tilt cylinder Oil leakage
Braking 30 Control valve Function and oil leakage
system 31 Hydraulic tank Oil quantity and leakage
32 H. P. Hoses Oil leakage and transformation
33 Overhead guard, load backrest Damage, crack and transformation
34 Brake linkage Lubricant and movement
35 Parking brake lever Adjustment and lubricant
36 Bolts and nuts Looseness
37 Powr steering Function

.116.
5.Every Three-month(600-hour) Servicing
At the same time with the every three month (600-hour) servicing, repeat the
sequence of monthly (200-hour) servicing. When adjustment or replacement of part
should be necessary, call qualified serviceman of our company.

Check points Contents

Polish up the roughness of the contact with sand paper.

Contactors
When roughness is excessive, replace it.
Motors Wearing of the carbon brushes.

6.Semiannually(1200-hour) Servicing
At the same time with the semiannually (1200-hour) servicing, repeat the sequence
of every three monthly (600-hour) servicing. When adjustment or replacement of part
should be necessary, call qualified serviceman of our company.

Check points Contents

Contractors When roughness of the contact is excessive, replace it.

Motors Wearing of the carbon brushes.

Front axle Change of gear oil.

Hydraulic oil Strain and change of hydraulic oil.

Oil filter Cleaning the oil filter.

Brake oil Stain and change of the brake oil.

NOTE
Inspection of carbon brush
Raise up the whole spring and then pull out the carbon brush to check. Check if the
surface of the commutator is rough and wearing has gone over the wearing limitation.

Model Applied H Wearing limit Q'ty

Traction 28mm 15mm 8

CPD10-CPD30 Hydraulic 28mm 15mm 8

Power steering 22mm 12mm 8

.118.
NOTE

.120.
 . Others
1.Lubrication Points and Recommended oil
1 Lubrication point
Replace FO Hydraulic oil
Replenishment GO Gear oil
Check and adjust CG Chassis grease
BO Brake oil W Pure water

Lifting chain CG
Brake pedal CG

Brake oil tank BO BO

Steering gear CG

Turning
CG
column jacket

Tilt cylinder's
CG
pin oil

Mast footstep CG

Driving axle GO

Battery W Oil filter Oil tank FO

.122.
Lifting chain CG

200H

BO BO Oil tank GO
Brake oil tank
200H 1200H 25H 1200H

Turning column
jacket CG

200H
Tilt cylinder's
CG
pin axle
200H

Turning column
jacket bearing CG

200H

Mast footstep CG

Driving 200H
axle GO GO

1200H 600H 200H

Turning
Battery W axle footstep CG
200H
25H

Turning axle Pin CG

200H

(2)Recommended oil

Manufacture Shell ESSO Mobile Brand for

use home users
Hydraulic Hydraulic oil 28
system Tellus oils 32 Poweerlex 32 N32

Gear oil Spirax Ep90 ESSO Gear Oil Mobilube BX-80 85W/90
GP-90
3# lithium
Grease Alvania Grease2 base grease
Retinax A (drop point 170)

Shell Brake ESSO Fluid H. Mobil brake 4604 Compound

Brake fluid Fluid H.D. Brake Fluid Fluid(SAI70RI) brake fluid
H.D. 400

.124.
2.Replacing Parts Guidance
1 Replacing fuses
CAUTION
Besure to disconnect the battery plug.

Replacing procedure

Fuses Loosen the mounting nuts and remove the fuses.

Cartridge fuse Loosen a cap and remove the fuse.

Insufficient tightening cause a poor contacting and it will lead to

making failures. Tighten the nuts securely.

CAUTION
Besure to use the prescribed fuses.
A Fuse 400A(for travel)
B Fuse 400A(for hydraulic)
C Fuse 50A(for power steering)
D Cartridge fuse 10-15A(for control circuit)

.126.
 : 2611
Address: 2611 Bao'an Highway, Shanghai, China
(Tel): 86-21-69156666
(Fax): 86-21-69156000
(P.C.): 201801
(Website): http://www.salcn.com