EP EQUIPMENT CO.,LTD.

is one of the With business all over the world, EP has

world’s leading companies manufacture, thousands of employees and hundreds
design material handling equipment and of agents worldwide to provide our
provide related service. With over global customers with prompt local
100,000 square meters plant it produces service.
over 100,000 trucks per year, and
provides professional, effective and Based on the concept of sharing
optimized material handling solutions economy , EP also offer rental service
worldwide, until now it has developed for various logistics equipment. Adhering
three major kinds of business: to the idea “Making the leasing of logistic
· Material handling equipment: Focus equipment more simple”, EP is devoted
on electric forklift and warehouse to providing customized one-stop
equipment leasing solutions for our customers with
·OEM parts: Global parts supply our high quality, reasonable price and
·Imow industry,online: One-stop prompt rental service.
industrial products supply
EP’s mission&vision is “ Let more people
Guided by our customer-oriented apply the electrical material handling
concept, EP has developed service equipment to relieve the intensity of
centers in more than 30 countries labour” and “Let’s grow together”.
around the world, from which customers
are able to receive timely local service. EP EQUIPMENT CO., LTD
Moreover, 95% of warranty parts can be Address: No.1 Xiaquan Village, Lingfeng
shipped out within 24 hours after been Street, Anji ,Huzhou ,Zhejiang, China
ordered. Through our online after-sales Tel: + 86-0571-28023920
service system, customers can process Fax: + 86-0571-28035616
their warranty claims, order spare parts Website: www.ep-ep.com
and consult the operation manuals, Email: service@ep-ep.com
maintenance materials and spare parts
catalogs.
 Foreword
Thanks for your purchasing our forklift truck.
This forklift truck is our company’s new product. It has the beautiful shape, small
dimensions, low gravity.
Please operator and whom in charge of the truck must read the manual carefully
before operate the truck.
We have the right to improve the truck, maybe there are some difference
between your product and the description in this manual.
If you have any questions please keep in touch with the sales department or let
the agents know.
Forklift truck ICE301B has already passed CE certificate.

Notes:
1. This manual is used for operation and maintenance , the detail parameter
s, size and specifications in context is only for reference , the real parameters
will depend on sale files.
2. Manual pictures for reference only, the real car shall prevail, and shall not
affect the manual use.

ALL RIGHT RESERVED COPYRIGHT

I
 WARNING!
TO PREVENT SETIOUS RISK OF INJURY TO
YOUORSELF AND OTHERS OBSERVE THE
FOLLOWING SAFETY INSTRUCTIONS.
These truck may become hazardous if adequate maintenance is neglected. Therefore,
adequate maintenance facilities, trained personnel and procedures should be
provided.

Maintenance and inspection shall be performed in conformance with the following

practices:

1. A scheduled planned maintenance, lubrication and inspection system should be

followed.

2. Only qualified and authorized personnel shall be permitted to maintain, repair,

adjust, and inspect truck.

3. Before leaving the truck:

– Do not park the truck on an incline.
– Fully lower the load forks.
– Push the travel combination switch to neutral ,prevent the truck started unexpected.
– Press the emergency stop switch .
– Set the key switch to the "OFF" position and remove the key.

4. Before starting to operate truck:

– Be in operating position
– Place directional control in neutral
– Before operating truck, check functions of lift systems, directional control,speed
control,steering, warning devices and brakes.

5. Avoid fire hazards and have fire protection equipment present. Do not use open
flame to check lever, or for leakage of electrolyte and fluids or oil. Do not use open
pans of fuel or flammable cleaning fluids for cleaning parts.

6. Brakes,steering mechanisms, control mechanisms,guards and safety devices shall

be inspected regularly and maintained in legible condition.

7. Capacity, operation and maintenance instruction plates or decals shall be

maintained in legible condition.

8. All parts of lift mechanisms shall be inspected to maintain them in safe operating
condition.

II
9. All hydraulic systems shall be regularly inspected and maintained in conformance
with good practice. Cylinders, valves and other similar parts shall be checked to
assure that "drift" has not developed to the extent that it would create a hazard.

10. Truck shall be kept in a clean condition to minimize fire hazards facilitate
detection of loose or detective parts.

Modifications and additions which affect capacity and safe truck operation shall not be
performed by the customer or user without manufacturers prior written approval.
Capacity, operation and maintenance plates or decals shall be changed accordingly.

III
 INDEX
Correct use and application

1. Truck Description
1.1Application........................................................................................................2
1.2 Assemblies......................................................................................................3
1.3 steer and instrument display........................................................................ 4
1.3.1Steering wheel[15].................................................................................5
1.3.2key switch[13].........................................................................................5
1.3.3 Instrument and display[11].................................................................. 6
1.3.4Emergency disconnect switch [17]..................................................... 7
1.3.5Travel switch [14]...................................................................................7
1.3.6 Levers/buttons...................................................................................... 8
1.3.7 Pedal...................................................................................................... 8
1.3.8 Body and others....................................................................................9
1.4 Identification points and data plates......................................................... 11
1.4.1Truck data plate................................................................................... 13
1.4.2 Capacity chart..................................................................................... 14
1.5.Standard Version Specifications............................................................... 14
1.5.1Performance data for standard trucks..............................................14
1.5.2Dimensions................................................................错误！未定义书签。

2. Commissioning
2.1Using the Truck for the First Time.............................................................. 21
2.2During brake-in.................................................................. 错误！未定义书签。

3.Operation
3.1Safety Regulations for the Operation of Forklift Trucks..........................24
3.2 Operate and run the truck.......................................................................... 31
3.2.1 Preparing............................................................................................. 31
3.2.2 Switching on the truck....................................................................... 31
3.2.3Travelling, Steering, Braking..............................................................32
3.2.4 Collecting and depositing loads....................................................... 33
3.2.5Check after operation......................................................................... 34

4.Battery Maintenance & Charging

4.1 Safety regulations for handling acid batteries.........................................35
4.2 Battery type & dimension........................................................................... 35
4.3Charging the battery.....................................................................................36
4.3.1Charging the battery........................................................................... 36
4.3.2Charging battery....................................................... 错误！未定义书签。
4.3.3Daily charging........................................................... 错误！未定义书签。

IV
 4.4Battery removal and installation................................................................. 37
4.4.1 Removal the battery...........................................................................37
4.5The proportion and level of electrolyte...................................................... 37
4.5.1 Inspect electrolyte................................................... 错误！未定义书签。
4.5.2Replenish the distilled water...................................错误！未定义书签。
4.5.3 Reading the specific gravity.................................. 错误！未定义书签。
4.6 battery maintenance....................................................................................38

5.Forklift Truck Maintenance

5.1Operational safety and environmental protection....................................39
5.2 Maintenance Safety Regulations.............................................................. 39
5.3 Servicing and inspection............................................................................ 40
5.3.1 Maintenance Checklist...................................................................... 41
5.4 Lubrication Schedule.................................................................................. 43
5.4.1Fuels, coolants and lubricants...........................................................45
5.5Deposit........................................................................................................... 46
5.5.1Deposit the truck for a short time......................................................47
5.5.2Deposit the truck for a long time....................................................... 47

6.Troubleshooting

V
 Correct use and application
The truck described in the present operator manual is an industrial truck designed for
lifting and transporting load units.
It must be used, operated and serviced in accordance with the present instructions.
Any other type of use is beyond the scope of application and can result in damage to
personnel, the truck or property. In particular, avoid overloading the truck with loads
which are too heavy or placed on one side. The data plate attached to the truck or the
load diagram are binding for the maximum load capacity. The industrial truck must not
be used in fire or explosion endangered areas, or areas threatened by corrosion or
excessive dust.
Proprietor responsibilities
For the purposes of the present operator manual the “proprietor” is defined as any
natural or legal person who either uses the industrial truck himself, or on whose behalf
it is used. In special cases (e.g. leasing or renting) the proprietor is considered the
person who, in accordance with existing contractual agreements between the owner
and user of the industrial truck, is charged with operational duties.
The proprietor must ensure that the truck is used only for the purpose it is intended for
and that danger to life and limb of the user and third parties are excluded.
Furthermore, accident prevention regulations, safety regulations and operating,
servicing and repair guidelines must be followed. The proprietor must ensure that all
truck users have read and understood this operator manual.
Failure to comply with the operator manual shall invalidate the warranty. The same
applies if improper work is carried out on the truck by the customer or third parties
without the permission of the manufacturer’s customer service department.
Attaching accessories
The mounting or installation of additional equipment which affects or supplements the
performance of the industrial truck requires the written permission of the manufacturer.
In some cases, local authority approval shall be required.
Approval of the local authorities however does not constitute the manufacturer’s
Approval.

1
 1. Truck Description
1.1Application
The electric forklift truck is use for industrial floors and industrial elevator.
The capacity can be obtained from the data plate.
The capacity with respect to lift height and load center of gravity is indicated on the
capacity chart.

2
1.2 Assemblies

Item Component Item Component

1 Counter weight 9 Load backrest
2 Caution light 10 Forks
3 Overhead Guard 11 Steer wheels
4 Steering wheel 12 Battery hood
5 Rearview mirror 13 Chassis
6 Mast 14 Seat
7 Headlight 15 Drive wheels
8 Small headlight 16 Rear combination lights

3
1.3 steer and instrument display

Item Component Item Component

17 Display unit 24 Accelerator pedal
18 Lifting lever 25 Brake pedal
19 Tilting lever 26 Emergency stop switch
20 Side lever 27 Hand brake lever
21 Attachment lever 28 Steering column tilting angle
22 Caution light switch 29 Travel combination switch
23 Key switch 30 Combined lamp switch

4
1.3.1Steering wheel[4]
The steering wheel is operated in the conventional manner, that is, when the wheel is
turn right , the truck will turn to the right; When the wheel is turn left, the truck will turn
to the left. When press the horn button,it will sound.

1.3.2key switch[23]
The key switch has two “ON / OFF”
position. Truck power supply is break off
when the key turn "OFF". Truck power
supply is turn on when the key turn "ON".
You should push the travel combination
switch to neutral and release the
accelerator pedal, then turning the key
switch to “on” position clockwise.
Removing the key prevents the truck from being switched on by unauthorised
personnel.

Warning!
Turning the key switch “on” does not make the forklift truck move, if the travel
combination switch is not in the neutral position or the accelerator pedal is
being pressed. Error code maybe appear, don’t worry about it. When the forklift
can be operated then the error code should be disappeared.

5
1.3.3 Display unit [17]

Item Description
LED (1) displays the remaining charge.when 1st block and 2nd block
1
blinks alternatively,it indicates low power needs to be charged

2 LED (2) displays remaining charge percentage;

LED (3) always on, it indicates interlock switch opened, LED(3) flashing,
3
it indicates interlock switch closed, the display start timing.

4 LED (4) displays the the fault code.

5 LED (5) displays the total running time

normally.

Error Code
Controller 2 = traction controller
1
number 5 = Pump controller
2 Error code note
Controller 0 = master controller
3
number 2 = slave controller

6
Scan and download App through
QR code labelled on the truck

1.Register a new account;

2.Activate Bluetooth and connect the truck;

3.Monitor battery status and truck location in real time.

1.3.4 Emergency stop switch [26] Warning!

When happen emergency, presses down Please don’t use the emergency
the emergency stop switch, the main disconnect switch to substitute the
power of the truck will be cut off. function of key switch

1.3.5 Travel combination switch[29]

The travel switch is for switching between forward and backward moves. When the
lever is pushed forward and accelerator pedal pressed, the forklift trucks moved
forward. When the lever is pushed backward, the forklift trucks moved backward.

Warning!
While traveling，if change the travel switch，electric braking will operate，speed will
lower until stop，then travel to the opposite direction.

Warning!
Turning the key switch “on” does not make the forklift truck move, if the travel
switch is not in the neutral position or the accelerator pedal is being pressed. In this
case, the travel combination switch should be returned to neutral and move you
foot from the accelerator pedal. Then the truck can be operated.

7
1.3.6 Levers/buttons
Lifting lever/button [18]
The forks can be raised or lowered by pulling backwards or pushing the
lever. Lifting speed can be controlled by tilt backwards angle of lever while
the lowering speed can be controlled by tilt forwards angle of the lever.
(The forks can be raised or lowered by pressing the lifting button or the
down button.)
The motor speed or accelerator pedal does not have to do with the
lowering speed of the forks.

Tilting lever/button [19]

The mast can be tilted by operation of this tilting lever. Pulling on this lever
backwards will tilt the mast backwards, and pushing it forwards will tilt the
mast forwards. The tilt speed can be controlled by tilt angle of the lever.
(The mast can be tilted by pressing the button.)

Warning!
The tilt lock mechanism built in the hydraulic control valve does not
allow the mast to tilt forwards while the engine is being shut down
even if the tilt lever is pushed forwards.

Side lever/button[20]
The fork can be move to side by operation of this lever. The move speed can be
controlled by tilt angle of the lever.
You don't have the lever, when you truck use two unite valve.

1.3.7 Pedal Warning!

Brake pedal [25] No permitted to press the brake pedal
Press this pedal to slow or stop the and the accelerator pedal at one time,
truck. At the same time, the brake light otherwise, it should harm the traveling
comes on. motor.

Accelerator pedal [24]

As the accelerator pedal is slowly pressed, the drive motor start turning and the forklift
truck will start to move. According to the force applied to the pedal, the speed is
adjusted with not steps.

Warning!
Before open the key switch to press the accelerator pedal, the more function digital
indicator shall show alarm information. Then you must release the accelerator
pedal.
When loosen the accelerator pedal, truck can make soft brake because of electric
control’s regenerate brake.

8
1.3.8 Body and others

Chassis[13]
The chassis, in conjunction with the counterweight, forms the supporting base
structure of the truck. It is used to support the main components.

Seat and adjusting lever[14]

Pull the driver seat forward-backward with
adjusting lever(2), and move the seat
forward or backward to proper position.
Release the adjusting lever, the driver seat
will be locked.

Warning!
Lock the driver seat forward-backward
adjusting lever on the set position.

Adjust seat back

Driver sits on.
Pull forward the seat back adjusting switch (1) , and adjust the back inclination.
Release the switch, the seat back will be locked.

Safety belt
Fasten safety belt before driving. It protects driver when accidents happen. Regularly
clean and check safety belt, avoid dirt.

Regular check items realted to the safety belt:

1)cut or frayed straps;
2)worn or damaged hardware, including anchor points;
3)buckle or retractor malfunction;
4)loose stitching.

Correctly use safety belt

Sit on the seat correctly.

9
Check if the safety belt twisted.
Fasten the safety belt and check safety belt lock.

Periodically check the safety belt

Check if safety belt is damaged or cracked.
Check if the metal pieces of safety belt(including anchor point) are worn or damaged.
Check if lock catch for safety belt or traction machine functions normally.

Overhead safe guard

The overhead guard used is strong enough to meet safety standard, and protects the
operator from falling materials.It is forbidden for use a truck that does not with
safeguard.

Fork stopper
Fork stoppers are locked the forks in position. To adjust fork spacing, pull up fork
stoppers, turn and shift the forks to the desired position. The fork spacing should be
adjusting according to loads to be handled.

Warning!
-The forks should be set
symmetrically to machine centerline
and fork stoppers should always be
set..
-There are one gaps on the beam of
load bracket. It is used in attach
forks.
-It is forbidden to lock the fork on the

Step and safely grip

The steps are provided on side of the
truck body. The safely grip is provided on
the front left pillar of the overhead guard. Warning!
Use the safely step and safely grip facing The brake fluid is poisonous, be careful
the truck when mounting and dismounting do not drop down. When add brake
the truck. fluid, be careful do not let dirt and other
thing drop into reservoir cup.

Brake fluid reservoir cup

The brake booster is located on the panel in the front of the truck.

10
1.4 Identification points and data plates

Sling label Notice “No standing under

the load carriage”label

Bolt fastening label

Hand brake label

Air pressure of pneumatic

tire label

“Instruction” label

Gas spring indicator label

Wear the helmet when driving No driving in the rain

“Fill port”label
“Anti-pinch” label

11
If the truck will turn over, do not attempt to get out of the truck,
because the speed of overturn is much faster than you. You
should hold the steering wheel handle, and this practice will let
you in the seats.

It is forbidden to flush the forklift with water pipe.

12
 1.4.1Truck data plate

Item Description Item Description

1 Manufacturer 9 Drive output(kw)

2 Vehicle name 10 load-lift height table

3 Model no. 11 License no.

4 Serial no. 12 Load capacity(kg)

5 Date of build 13 Load center(mm)

6 Truck weight with battery(kg) 14 Max. allowable battery weight(kg)

7 Truck weight without battery(kg) 15 Min. allowable battery weight(kg)

8 Voltage(V)

13
For queries regarding the truck or ordering spare parts please quote the truck serial
number(3).

1.4.2 The load capability chart

The capacity plate gives the capacity
(Q) of the truck in kg for a vertical mast.
The maximum capacity is shown as a
table with a given load centre of gravity
D (inmm) and the required lift height H
(in mm).
The capacity plate of the truck indicates
the truck's capacity with the forks as
originally supplied.

1.5.Standard Version Specifications

Technical specification details in accordance with VDI2198. Technical modifications
and additions reserved.

1.5.1Performance data for standard trucks

14
1.1 Manufacturer Code Unit /
1.2 Model designation ICE251
1.3 Drive unit Electrics
1.4 Operator type seated
1.5 rated capacity Q t 2.5
1.6 Load center distance c mm 500
1.8 Load distance，centre of drive axle to fork x mm 495
1.9 Wheelbase y mm 1595
2.1 Service weight （include battery） kg 3770
2.2 Axle loading, laden driving wheels /steering wheels kg 5490/780
Axle loading, unladen driving wheels /steering
2.3 kg 1450/2320
wheels
3.1 Tyre type,driving wheels /steering wheels pneumatic tyre
3.2 Tyre size, driving wheels（diameter×width） mm 7.00-12-12PR
3.3 Tyre size, steering wheels（diameter×width） mm 6.00-9-10PR
3.5 Wheels, number driving/steering (x=drive wheels) mm 2x/ 2
3.6 Tread, Driving wheels b10 mm 970
3.7 Tread, Steering wheels b11 mm 975

15
4.1 Tilt of mast/fork carriage forward/backward α/ β (°) 6/ 10
4.2 Height, mast lowered h1 mm 2060
4.3 Free lift （load backrest） h2 mm 140
4.4 Lift height h3 mm 3000
4.5 Height, mast extended h4 mm 4050
4.7 Height of overhead guard (cabin) h6 mm 2160
4.8 Seat height h7 mm 1095
4.12 Tow center of pin height h10 mm 435
4.19 Overall length l1 mm 3573
4.20 Length to face of forks l2 mm 2503
4.21 Overall width b1/ b2 mm 1154
4.22 Fork dimensions s/ e/ l mm 40×125×1070
4.23 Fork carriage class/type A, B 2A
4.24 Fork carriage width b3 mm 1090
4.31 Ground clearance, laden, below mast m1 mm 100
4.32 The minimum ground clearance of frame m2 mm 150
4.34.1 Aisle width for pallets 1000 × 1200 crossways Ast mm 3985
4.34.2 Aisle width for pallets 800 × 1200 lengthways Ast mm 4195
4.35 Turning radius Wa mm 2290
5.1 Travel speed, laden/ unladen km/ h 11/12
5.2 Lifting speed, laden/ unladen m/ s 0.28/0.37

16
5.3 Lowering speed, laden/ unladen m/ s 0.45/0.5
5.5 Drawbar pull, laden/unladen N 15/15
5.6 Max. drawbar pull, laden/unladen (time) N ——
5.7 Gradeability, laden/unladen % ——
5.8 Max. gradeability, laden/unladen % 15/15
Hydraulic /
5.10 Service brake type
Mechanical
park brake type Mechanical
6.1 Drive motor rating S2 60 min kW 10
6.2 Lift motor rating at S3 15% kW 12
6.3 The maximum allowed size battery mm 731X 608X326
6.4 Battery voltage/nominal capacity K5 80V205AH
6.5 Battery weight kg /
8.1 Type of drive unit AC
10.5 Steering type Hydraulic
10.7 Sound pressure level at the driver’s ear dB (A) ﹤74

17
18
 1.6Relationship between load and stability of truck
It is very important for operator to know the truck’s structure and relationship between
load and stability.

Warning! The structure of the truck

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

Warning! Load center

There is difference because of the
loads’ shape, gravity, such as box,
board and large roller. It is very
important to distinguish the
difference and the gravity center of
loads.

19
Warning! Gravity and stability
The combined center that is composed
of the barycenter and the load center
determine the stability of lift trucks.
When unloaded, the barycenter does
not change; when loaded, the
barycenter is determined by the truck
and the load’s center.
The barycenter is also determined by
the tilting and lifting of the mast.
The combined center is determined by
these factors:
Load’s size, weight and shape.
The lifting height.
The tilting angle.
The pressure of the tire.
The radius of turning.
The road and grade’s angle.

Warning! the stability zone of the barycenter

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

20
Transport and Commissioning

2.1Transport
2.1.1Lifting the truck by crane
• The Fork Lift Truck is designed for material
handling only, It is inappropriate for
long-distance transportation. The Fork Lift
Truck must be transported by ship, train or
lorry, of 5T loading.
• Use a lifting sling to hoist the truck.
• Use the steel wire ropes to tie the holes in
the two side of the outside mast’s beam and
the rear of truck’s body, then use the lifting
device to hoist the truck.
•The steel wire rope attach to the
counterweight should through the safeguard
gap, and make the safeguard not be distorted.

Warning!
·When hoist the truck, don’t coil the overhead guard with the steel wire.
·The steel wire ropes and the lifting device must be very firm to support the truck
because the truck is very heavy.
·Don’t lift the truck by hoist the overhead guard.
·When lifting the truck, don’t take anybody below the truck.

21
2.1.2Securing the truck during transport
The truck must be securely fastened when
transported on a lorry or a trailer.
- Parking the truck securely on a lorry or a
trailer. See "Safety Regulations for the
Operation of Forklift Trucks" .
- The rope is used to fix the truck must be
firm enough. The rope round the mast above
the beam and fixed to truck.
- Check both sides need to fix.
Loading must be carried out by staff specially
trained. In each case correct measurements
shall be determined andappropriate safety
measures adopted.
2.1.3 Towing
·The towing rod on the bottom of the counter balance is used to pull and drag the
truck.

Warning!
a. Don’t tie the wire ropes on the
incorrect position.
b. Don’t carry a load to wire ropes
suddenly.

Towing procedure
You can tow the forklift to the safe place with towing
rod when the forklift can’t run.
Don’t tow the truck of which its steering system or brake system has been damaged.
– Press the emergency stop button.
– Lower the goods, but do not allow the fork arms to touch the ground.
– Remove the load.
– Pull on the hand brake lever.
– The driver should operate the steering wheel during towing, and the brake when
necessary.
– Do not exceed the truck's maximum working speed when towing.

2.2 Using the Truck for the First Time

Only operate the truck with battery current. Rectified AC current will damage the
electronic components. Cable connections to the battery (tow leads) must be less
than 6 m .

22
Preparing the truck for operation after delivery or transport
Procedure
– Check the equipment is complete.
– Check the hydraulic oil level.
– Install the battery if necessary, (see "4.4 Battery removal and installation" ).
– Charge the battery, (see "4.3 Charging the battery" ).

2.3 During brake-in

We recommended operating the machine under light load conditions for the first stage
of operation to get the most from it. Especially the requirements given below should
be observed while the machine is in a stage of 100 hours of operation.
1. Must prevent the new battery from over discharging when early used.
2. Perform specified preventive maintenance services carefully and completely.
3. Avoid sudden stop, starts or turns.
4. Oil changes and lubrication are recommended to do earlier than specified.
Limited load is 70～80% of the rated load.

23
 3.Operation
3.1Safety Regulations for the Operation of Forklift Trucks
Safety is your business and your responsibility. The “Safety Instructions” 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.
Read this manual thoroughly and become completely familiar with your truck to get
the most out of it.

1. Know your truck

For the purpose of doing material handling job, the forklift truck is different from
general passenger cars in structure as follows:
- Poor front view due to the hoist system.
- Rear wheel steering lets the rear of the truck swing outwards when going round
comers .
- Compactly designed, the forklift truck is heavy. Most of the weight of the truck and
loads is on the front wheels when loaded so the truck lacks stability.
- Read the operator’s manual and name plates on the truck, and become familiar with
your truck and operating procedures. If there is something in the manual you do not
understand, ask After-sales service personnel to explain it to you.

2. Get permission from supervisor

Only trained and authorized operator shall be permitted to operate the truck.

3. Make periodic checks

Inspect the truck at periodic intervals for oil or water leak, deformation, lousiness, etc.
If neglected, short life of components will be caused and in the worst case a fatal
accident would occur.
make sure having replaced good parts during periodic check.
Wipe off oil, grease or water from the floor board and foot and hand controls, if any.
Strictly prohibit smoking and spark nearby the storage battery when checking it.
If maintenance on high position, such as mast, please be careful to prevent fall down
or be clamped.
Be careful do not be scalded when inspect the motor, controller and etc.

4. Stop using the forklift when it is in trouble

whatsoever in trouble, you must stop the forklift, hang a mark of “danger” or “trouble”
and take off the key, at the same time inform the manager.
only after the trouble is removed, you may use the forklift.

5. Protect yourself
Operator must wear helmet, safety shoes and work clothes.

24
6. Prevent exploding
Because there will bring exploding gas in the bosom
of the battery, prohibit any flame nearby it absolutely.
Don’t let any tools close the two terminal of the battery
to avoid spark or short circuit.
Make sure to operate the truck on concrete firmly
enough or bituminous macadam.
The weather of working condition is:
Air temperature -20℃~40℃
Wind speed: Less than 5m/s.
Air specific humidity: Less than 90%. (Temp at
20℃).
Truck cannot be operated in explosive gas
environments.

7. Mount properly
Never mount or dismount the moving truck. Use the
safety step(s) and safety grip facing the truck when
mounting or dismounting the truck.

8. Never move controls unless properly seated

Never attempt to work the controls unless properly
seated.
Before staring, adjusting the seat so you can get easy access to all hand and foot
controls.

9. Start safely
Before staring up, make sure that:
The parking brake lever is applied securely.
The travel combination switch is in neutral.
Before staring, make sure no one is under, on and
close to the truck.
Don’t step the accelerate pedal or control the lifting
lever or tilting lever before turning on power.

10. Prohibit sudden stop or turning

Operate the controls smoothly. Avoid sudden stops
or turns.
It is dangerous to make a sharp brake. Otherwise
the truck has the possibility of overturn.

25
11. Pay attention to the route of the truck
·Pay attention to the route of the truck, be sure to make a wide sight.

12. Don’t offer rides to others

Never allow other person(s) to ride on the
forks, pallets or on the truck.

13. Know the load to be handled

Taking account of the shape and material of loads to be handled, use a proper
attachment and tools.
Avoid hoisting the load, with wire rope hung the forks or attachment, since the wire
rope may slide off. If needed, a qualified personnel for slinging operation should
perform, making use of a hook or crane arm attachment.
Take care not to protrude the forks out of the load. The protruded fork tips may
damage or turn over the adjacent load.

14. Know capacity of truck

Know the rated capacity of your lift truck and its
attachment, if any, and never exceed it.
Do not use a man as an additional counterweight.
It’s quite dangerous.

15. Don’t daydream

Keep your mind on your work. Learn to
anticipate danger before it arises.

16. Remain seated

Keep your head, hands, arms, feet and legs within
the confines of the operator’s compartment.
Never reach into upright for any reason.

17. Use proper pallet

26
The pallet and skid used should be strong enough to endure the load. Never use
damaged or deformed ones.

18. Use proper attachment

We afford all type of attachment, such as rotating roll clamp, bale clamp, side shifter,
and crane jib. You should refit the truck under ours license if you
want. It is forbidden to refit it by yourself.

19. Attach safeguard and load bracket

Safeguard protect you do not be hurt by the goods fallen. Load
bracket protect you load goods smoothly. It is forbidden to use
truck without safeguard or load bracket.

20. Forbidden walk down or up the fork

It is forbidden to walk down the fork or the attachment.
It is forbidden to walk up the fork or stand on the fork.

21. Avoid be clamped by the mast

It is forbidden to put your hands, arms or head stretch
between the mast and safeguard.
It is forbidden to put your hands in inner and outer mast.

22. Prohibit load off center

The goods is liable to drop turning or passing rough
road when it departures the center. And the forklift
may turn over more probably.

27
23. Don’t stack load too high on forks
Don’t stack loads on forks in such a way that the top
of loads exceeds the load backrest height. If
unavoidable, make the load stable securely. When
handling bulky loads that restrict your vision operate
the truck in reverse or have a guide.

24．Don’t tilt the mast with load high

Use minimum forward and reverse tilt when stacking
and unstacking loads. Never tilt forward unless load
is over stack or at low lift height.
When stacking loads on a high place, once make the
mast vertical at a height of 15 to 20 cm above the
ground and then lift the load farther. Never attempt to
tilt the mast beyond vertical when the load is raised
high.
To unstack loads from a high place, insert forks into the
pallet and drive backwards, then lower the load. Tilt the
mast backwards after lowering. Never attempt to tilt the
mast with the load raised high.

25. To handle bulky loads

When handling bulky loads, which restrict your vision, operate the machine In reverse
or have a guide. When you have a guide, make sure you understand hand, flag,
whistle or other signals.
When operating with long loads such as lumber, pipe, etc., or in the case of the
Large-sized model or the truck with spreader, be extremely careful of load end swing
at corners or in narrow aisles. Be alert for fellow workers.

26. Carry the load low

It is dangerous to travel with forks higher than appropriate position regardless of
whether loaded or not. Keep the good traveling posture. (When traveling, the forks
should be 15 to 30 cm above the ground or floor.)
Do not operate the side shift mechanism, if equipped, when the forks are raised and
loaded, since this will cause the truck to be unbalanced.

27. Tilt backward when loaded

Travel with load as low as possible and tilted back. If operating with steel pallet or the
like, be sure to tilt back the mast to prevent it from slipping off the forks.

28
28. Watch for doorways and Slow down at
corners
Watch for branches, cables, doorways, or
overhangs. Use caution when working in
congested areas.
Slow down and sound horn at cross aisles
and other locations where vision is
restricted.When make a turn, be sure the
speed of the truck is lower than the 1/3 max.
of allowable speed.

29. Keep some distance from roadside and flat

roof
Affirm keeping some distance from roadside
and flat roof.

30. Driving over a dock-board or bridge-plate

Before driving over a dock-board or bridge-plate, be
sure that it is properly secured and strong enough to
sustain the weigh. Check the ground or floor
condition of working area in advance.

31. Back down and drive up

When operating loaded truck, have the rear end of
your machine pointed downhill.
When operating unloaded truck, have the rear end of
your machine pointed upgrade.
32. Avoid work on a grade
Never lift loads with the truck inclined. Avoid loading
work on a grade.
33. Never lift a load over anyone
Never permit anyone to stand or walk under
upraised forks or other attachments if machine is so
equipped. If unavoidable, use a safety stand or block
to prevents a possibility of fork attachments falling
down or moving unexpectedly.

34. Check work ground area

Inspect the surface over which you will run. Look for holes, drop-offs, obstacles, and
look for rough spots. Look for anything that might cause you to lose control, bog down
or upset.
Clear away trash and debris. Pick up anything that might puncture a tire or let the load

29
lose balance.
Slow down for wet and slippery roads. Stay away from the edge of the road.
If the ground is bumpy, it will cause the truck bump and bring much noise.
Do not operate the truck when the weather is execrable, such as windy, thunder storm,
snow and etc. Especially when wind speed is higher than 10m/s, don’t operate the
truck outside.

35. Parking correctly

Pulling the hand brake when parking on flat. If necessarily parking on ramp, you
should place the wedges under wheels.
Descending and a little forward tilting the fork, shut off key switch and take off key.
Pull out the battery plug.
The parking place must be far away from fireworks.

36. Towing
You can tow the forklift to the safe place with towing pin when the forklift can’t run.
Don’t tow the truck which steering system or brake system has been damaged.

30
37. Nameplate
There is operate method and warning label on the truck. Please operate the truck
obey the rules on the label and this manual.
Often inspect the nameplate, when damaged or lost please replace it.

38. Noise
The noise of truck is less than 75dBA, test method is use a decibel tester to record the
voice 7 meters far away from truck. The decibel near operator’s ear is less than
95dBA.

39.Vibration and acceleration

When unlading, operator’s vibration of acceleration is about 0.74m/s2; when laden, is
about 0.18m/s2; so when operate on a uneven ground, it may cause more vibration
for truck and operator

3.2 Operate and run the truck

3.2.1 Preparing
Before the truck can be commissioned, operated or a load unit lifted, the driver must
ensure that there is nobody within the hazardous area.

Checks and operations to be

performed before starting daily
Warning!
work
Before operating the truck, check all
– Visually inspect the entire truck (in
controls and warning devices for
particular wheels and fork) for obvious
proper operation. If any damage of
damage.
fault is found, don’t operate truck until
– Visually inspect the battery and cable
corrected.
connections.

3.2.2 Switching on the truck

⑴Put the travel combination switch to center position.
⑵Plug into the connector if necessary;
⑶Turn on key switch
Close the wheel lever with left hand and turn on the key switch with right hand.
⑷Tilt back the mast
Control the lifting lever to set the bottom of the fork 150-200mm above the ground.
Control the tilting lever to fully tilt back the upright.
⑸Control shift lever

31
 Forward：Push forward the direction switch.
Backward：Pull backward the direction switch.

3.2.3Travelling, Steering, Braking

Traveling
Step the accelerate pedal slowly, the
truck will travel forward or backward. Warning!
Decrease speed Don’t step the accelerate pedal and
Loosen the accelerate pedal slowly, brake pedal at the same time.
the truck will decelerate.

Notice!
Decelerate the truck in the situations following:
·turning; ·close the load
·close the deposit area ·enter a narrow passage;
·the condition of road surface is bad.

Steering
Unlike general passenger-cars, the
Notice!
steer wheels are located at the rear of
Drive the truck slowly and control the
the truck. These cause the rear of the
steering wheel carefully, assure there is
truck to swing out when turning.
enough space to steer.
Slow down the truck and move toward
the side to which you are turning. The steer hand wheel should be turned a bit earlier
than as with the front wheel steering car.

Stopping or parking the truck

① Slow down and press the brake
pedal to stop the truck. Warning!
②Place the travel combination switch ·Don’t dismount from the moving truck.
in neutral. Never jump off the truck.
③Down the forks on the ground. ·Don’t parking the truck on the working
④Place the key switch in “OFF” to shut area.
off the battery. Remove the key and
keep it.

32
3.2.4 Collecting and depositing loads
Pick up
· The forks should be adjusted space to
maintain proper balance of load.
·Place the truck right in front of the load to be
handled.
·The pallet should be evenly positioned across
both forks.
·Insert forks into the pallet as far as possible.
·To raise loads from the ground：
① Once lift the forks 5 to 10 cm off the ground
or floor and make sure loads rest stable.
② Then, tilt the mast backwards fully and lift
forks up to 15 to 20 cm off ground then start
running.
When handling bulky loads which restrict your
vision, operate the truck in reverse except when
climbing grades.

Stacking load
· When approaching the deposit area slow
down your truck.
·Once stop the truck right in front of the area where your load is to be deposited.
·Check the condition of the deposit position.
·Tilt the mast forward until forks become horizontal. Raise forks until they are a little
higher than the deposit position.
· Move forward to place the load Warning!
directly over the desired area and stop ·Never tilt the mast with loads upraised
the truck. 2m or more.
· Make sure your load is just over the ·Don’t leave or dismount from the truck
desired area. Slowly lower the load into when the load is raise high.
position. Make sure the load is
securely stacked.
·Disengaged forks from the load by using necessary lift-tilt operation and then back
away.
· After making sure the fork tips leave the load, lower the forks to the basic position
(15 to 20 cm off the ground).
·Tilt the mast backwards .

33
Un-stacking load
·When approaching the area where the load is to be retrieved, slow down your truck.
·Stop the truck in front of the load so that the distance between the load and fork tips
is about 30 cm.
·Check the condition of the load. Warning!
· Tilt the mast forward until forks If the forks are hard to be fully
become horizontal. Elevate forks up to inserted, use the following procedure:
the position of the pallet or skid. Move forward and insert 3/4 of the
· Make sure forks are positioned forks. Raise the forks 5 to 10 cm and
properly for the pallet. Move forward move backward 10 to 20 cm with the
slowly to insert forks into the pallet as pallet or skid on the forks, and then
far as possible and then stop the truck. lower the pallet or skid on the stack.
· Raise the forks 5 to 10 cm off the Move forward again to insert the forks
stack fully.
· Check all around the truck to insure
that the path of travel is unobstructed
and back away slowly.
·Lower forks to a height of 15 to 20 cm above the ground. Tilt the mast backward fully
and move to the desired area.

3.2.5Check after operation Warning!

Clean and check the truck after · If you find any trouble, must repair it in
operation: the day.
·Damage or leakage. ·prohibit operate the forklift before
·Add grease if necessarily. repairing it completely.
·Check the tyre if it is damaged or inset
with foreign body.
·Check the wheel hub nut if it is loose.
·Check the height of electrolyte surface.
·If you haven’t lift the fork to the max. height in the day, you should lift it to the max.
height 2～3 times.

34
 4.Battery Maintenance & Charging
4.1 Safety regulations for handling acid batteries
1. No firing
Explosive gas ， smoking ， flame and
sparkle easily give off in the battery,
each can cause battery explosion.

2. Protection against electric shock

·Battery has high voltage and energy.
·Do not bring short circuit.
·Do not approach tools to the two poles
of the battery，which can cause the sparkle.

3. Correct wire connection

·Not allowing changing from anode to cathode，otherwise，resulting in sparkle burning
and explosion.

4. Do not overuse battery

·If you use up the energy of battery till the forklift immovability, you will shorten its
working hours.
·Shower for battery appears need for charge，please charge it quickly.

4.2 Battery type & dimension

Battery type & dimension as follow :
Tuck Battery type Voltage/ Charger Charging
type rated time(h)
capacity

ICE251 Lithium-ion 80V/155Ah 30A 5h

battery

When replacing or installing batteries, ensure that the battery is correctly secured in
the battery hood of the truck.

35
4.3Charging the battery
4.3.1Charging the battery
Attentions for charging
1. Please charge in the well-ventilated and appointed site.

2. Mark ‘no smoking’ on charging.

3. Inspect wire and pin.

·ahead of charging ， please examine
wire and connector whether good
condition.
·When wire and connector are
damaged，please do not charge.

4. In charging ， electrical source

switch or battery connector are not
close ， or ， which destroys connector
and electrical units as a rule.

4.3.1 Charging Procedure

Insert the electric switch key and turn clockwise;
Tilt the lift mast forwards slightly. The truck must
be stationary on the ground;
Pull the hand brake;
Press the emergency stop switch;
Connect charger connector to the battery
connector（1）;
Switch on the charger and charge the battery in
accordance with the battery and charging station
manufacturers’ instructions;
5. After the battery is fully charged. first close the
charger，then remove the connector.

36
4.4 Battery removal and installation
4.4.1 Removal the battery
a.Take out the battery
1. Press the switch(1), open the battery hood(2), expose the battery;
2. Disconnect the battery wires harness from the truck;
3. Attach the lifting hook to the battery.
4.Sling the battery to a certain height with a hoist, then move it rightwards;

Install according to the reverse order of removal.

37
4.5Battery maintenance

1. Remaining clean battery

Keep dryness and cleanness on the surface of
battery .the point for connecting with wire is also
dry and clean.(See the APPENDIX)

38
 5.Forklift Truck Maintenance
5.1Operational safety and environmental protection
· The fork lift truck needs termly inspection and
maintenance, make it in good working Notice!
condition. ·No smoking.
· Inspection and maintenance are usually ·You should shut off key switch and
ignored, you must find the problems and solve pull off the plug before service.（except
it in time. some trouble shooting）.
· Use the provided spare parts. ·Clean the electric part with compress
· Don’t use different oil when changing or air, do not with water.
adding oil. ·Do not place your hands, feet or any
· Forbid to repair the fork lift truck if you haven’t part of body into the gap between the
been trained. mast and instrument.
· Don’t rave about oil out of date.
· Maintenance on schedule.
· After you make a maintenance, you’d better make a record.

5.2 Maintenance Safety Regulations

Maintenance personnel
Forklift Truck must only be serviced and maintained by the manufacturer’s trained
personnel.
The manufacturer’s service department has field technicians specially trained for
these tasks. We therefore recommend a maintenance contract with the
manufacturer’s local service centre.

Lifting and jacking up

When the Forklift Truck is to be lifted, the lifting gear must only be secured to the
points specially provided for this purpose.
When jacking up the Forklift Truck, take appropriate measures to prevent it from
slipping or tipping over (e.g. wedges, wooden blocks). You may only work underneath
a raised load handler if it is supported by a sufficiently strong chain.

Cleaning
Do not use flammable liquids to clean the Forklift Truck.
Prior to cleaning, all safety measures required to prevent sparking (e.g. through short
circuits) must be taken. For battery-operated Forklift Truck , the battery connector
must be removed. Only weak suction or compressed air and non-conductive antistatic
brushes may be used for cleaning electric or electronic assemblies.

39
If the Forklift Truck is to be cleaned with a water jet or a high-pressure cleaner, all
electrical and electronic components must be carefully covered beforehand as
moisture can cause malfunctions.
Do not clean with pressurised water.
After cleaning the Forklift Truck , carry out the activities detailed in the
“commissioning(on page 17)” section.

Electrical System
Only suitably trained personnel may operate on the Forklift Truck ’s electrical system.
Before working on the electrical system, take all precautionary measures to avoid –
electric shocks.
For battery-operated Forklift Truck , also de-energise the Forklift Truck by removing
the battery connector.

Welding
To avoid damaging electric or electronic components, remove these from the Forklift
Truck before performing welding operations.

Settings
When repairing or replacing electric or electronic components or assemblies, always
note the truck-specific settings.

Tyres
The quality of tyres affects the stability and performance of the Forklift Truck . When
replacing factory fitted tyres only used original manufacturer’s spare parts, as
otherwise the data plate specifications will not be kept.
When changing wheels and tyres, ensure that the Forklift Truck does not slew (e.g.
when replacing wheels always left and right simultaneously).
Hydraulic hoses
The hoses must be replaced every six years. When replacing hydraulic components,
also replace the hoses in the hydraulic system.

5.3 Servicing and inspection

Thorough and expert servicing is one of the most important requirements for the safe
operation of the Forklift Truck . Failure to perform regular servicing can lead to truck
failure and poses a potential hazard to personnel and equipment.
The service intervals stated are based on single shift operation under normal
operating conditions. They must be reduced accordingly if the Forklift Truck is to be
used in conditions of extreme dust, temperature fluctuations or multiple shifts.
The following maintenance checklist states the tasks and intervals after which they
should be carried out. Maintenance intervals are defined as:
W = Every 50 service hours, at least weekly
A = Every 500 operating hours

40
 B = Every 1000 operating hours, or at least annually
C = Every 2000 operating hours, or at least annually
W service intervals are to be performed by the customer.
In the run-in period - after approx. 100 service hours - or after repair work, the owner
must check the wheel nuts/bolts and re-tighten if necessary.
5.3.1 Maintenance Checklist

Maintenance
interval ●
W A B C
Braking Check magnetic brake air gap. ●
Electrical Test instruments, displays and control switches. ●
system Test warning and safety device. ●
Make sure wire connections are secure and check for
●
damage.
Test micro switch setting. ●
Check contactors and relays. ●
Fix the motor and cable. ●
Power Visually inspect battery. ●
supply Visually inspect battery plug. ●
Check battery cable connections are secure, grease
●
terminals if necessary.
Travel Check transmission for noise and leakage. ●
Check travel mechanism, adjust and lubricate if
●
necessary.
Check wheels for wear and damage. ●
Check wheel suspension and attachments. ●
Check drive support plate. ●
Truck Check chassis for damage. ●
frame Check labels. ●
Check mast attachment. ●
Check screw connections. ●
Check gates and panels are secure and free of damage. ●
Hydraulic Test hydraulic system. ●
operations Check that hose and pipe lines and their connections are
●
secure, check for leaks and damage.
Check cylinders and piston rods for damage and leaks,
●
and make sure they are secure.
Check hydraulic oil level. ●
Replace hydraulic oil. ●

41
 Maintenance
interval ●
W A B C
Lifting Check lifting chains and chain guides for wear, adjust and ●
grease
Check Load handler and Pallet for wear and damage. ●
Perform sight check of rollers, sliding elements, and stops ●
Steering Test electric steering. ●
system
Check steering toothing for wear and lubricate. ●
Lubrication Grease the vehicle in accordance with the lubrication ●
schedule.

Gearbox Replace gear oil once every 1000 hours

42
5.4 Lubrication Schedule

43
44
5.4.1Fuels, coolants and lubricants

Handling consumables: Consumables must always be handled correctly. Follow the

manufacturer’s instructions.

Improper handling is hazardous to health, life and the environment. Consumables

must only be stored in appropriate containers. They may be flammable and must
therefore not come into contact with hot components or naked flames.

Only use clean containers when filling up with consumables. Do not mix consumables
of different grades. The only exception to this is when mixing is expressly stipulated in
the Operating Instructions.

Avoid spillage. Spilled liquids must be removed immediately with suitable bonding
agents and the bonding agent/consumable mixture must be disposed of in
accordance with regulations.

Name Trademark, code name Amount Postion

Hydraulic
Hydraulic oil L-HM46# See Table1
system
4.5L (Align with
Gear oil 85W-90GL-5 Drive axle
oiling port)
After the gas
within the
system is Brakes
Brake Fluid ZSM207DOT3 completely
discharged, add
to 2/3 of
the oil cup
Appropriate Sliding Surface
Lubrication grease Polylub GA 352P (See Table2)
amount

45
 Table
Lifting Lifting
Quantity Quantity
Mast height Mast height
（L） （L）
（mm) （mm)
2000 30 2500 38
2500 34 2700 38
2-stage Full
2700 34 3000 42
Mast
3000 36 3300 42
（ICE301B)
3300 36 3600 40
2-stage
3500 38 4000 42
Mast
3600 38 4300 38
（ICE301B)
4000 42 4500 40
3-stage
4300 42 4800 42
Mast
5000 44
（ICE301B)
4500 44 5500 46
6000 48

Lifting
Quantity
Mast height
（L）
（mm)
3000 36
3300 36
3500 38
3600 38
3700 39
2-stage Mast 4000 42
（ICE251B) 4300 42
4500 44
5000 46

46
5.5Deposit

5.5.1Deposit the truck for a short time

1 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 crosses the slope and block the
wheels to prevent accidental roll.
Make sure the travel combination switch on neutral
position.
2 Pull up the hand brake lever.
3 Shut off switch and control the lift and tilt lever
several times so that the inner pressure in the hydraulic
tube will decrease.
4 Cut off the power to the truck.
5 Take away the key and deposit it in a safe position.

5.5.2Deposit the truck for a long time

On the basic of the “deposit” you should do these checks and maintain additional:
1 Take out plug to prevent discharge and stay to dark place.
2 Brush antirust oil on those parts which is exposed such as piston rod and axle.
3 Put a cloth on vent-plug.
4 Mantle the truck with mantle.
5 Add grease at all lubricate point.
6 Fill up the truck body and counter weight with block to reduce bearing of the two
rear wheels.

Warning!
a.The block must be single and hard enough to support the truck.
e.Don’t use a block with high than 300mm（11.81 inch）.
c.Lift the truck to height of placing on the bearing block.
d.Place two same size blocks under the left and right sides of the truck.
e.After supporting the truck with block, swing the truck forward, backward, left and
right, check its safety.

⑦ Run the truck once a week. Lift the fork to the highest height some times.
⑧ Check proportion and lever of electrolyte.
⑨ Charge the battery equally once a month.

Warning!
·Carry out equalize charging before storing.
· Carry out equalize charging once every 15 to 30 days during the following
storage period. 47
 6.Troubleshooting
6.1 Drive System
4 wheel counter balanced battery forklift truck adapt structure of driving transverse ,
driven motor rated capacity see "1.5.1Performance data for standard trucks" .

Trouble Probably cause Method of troubleshooting

Too much noise When

Gear clearance is too big. Adjust.
traveling or change direction

Too much worn of gear. Replace.

Too much noise when

Oil level is low. Add oil.
traveling

Gear clearance is too big. Adjust.

Too much worn of gear. Replace.

48
6.2 Steering System
Steering system include rear steering axle and steering device.

Trouble Diagnostic:

Condition Probable cause Corrective action

Tighten nuts or
1．Oil leaking occurs between sections
replace seals
Leaking in 2．Damage of seal in shift necking Replace
steering device 3．Damage of seal in safety valve Replace
Grinding shim or
4．Not flat of shim in limiting position bolt
replace it
1．Not enough oil supported by pump Adjust control valve

2．Air enters in the line of steering gear Bleed the air

3．Not enough oil in tank Fill oil

4．Too low pressure setting of the relief valve Adjust pressure or
in the dividing valve or blocking in valve clear dirt

5．Too high viscosity oil Replace wrong oil

High effort for 6．The steering fails to return to its natural
steering of Replace wrong
position due to breakage of locking spring or
failure to rotate spring
insufficient spring pressure
steering wheel
7．Break or deform of swivel pin Replace it

8．Break or deform of coupling Replace coupling

9．Wrong in spring or safety valve Replace spring

10 ． Too much internal leakage in the Replace seal or

steering cylinder cylinder
11．Deform of steering axle Repair it
1．Damage of bearing fitted in swivel pin Replace bearing
Free play in
2．Two much clearance in rim bearing Adjust
hand wheel
and wobble in 3 ． Too much clearance between steering
Replace rotator or
wheels rotator and stator and descend of volume
stator
efficiency
Front Left and right
wheel does not match Controller parameter is not correct. Adjust
to rear wheel

49
6.3 Brake System
Trouble diagnostic
Condition Probable cause Corrective action
Oil leakage in brake lines. Correct and replenish.
Air in brake lines. Bleed air.
Insufficient Water or oil on linings. Clean or replace.
brake force Uneven wear or contact of brake linings. Grind or replace.
Improper functioning of master cylinder Correct or replace.
or wheel cylinder.
Clogged oil lines. Clean.
No free play of brake pedal. Adjust.
Improper shoe sliding. Adjust.
Improper operation of wheel cylinder. Adjust or replace.
Faulty piston cup. Replace.
Brake dragging
Weak or broken return springs. Replace.
Clogged master cylinder return port. Clean.
Clogged oil lines. Clean.
Wheel bearing out of adjusting. Adjust or replace.

6.4 Hydraulic System

The high pressure oil from main pump goes to control valve, then goes to lifting
cylinder or tilting cylinder. When lifting and tilting spool is in neutral, the lifting pump is
out off work. When pulling lifting spool, high pressure oil goes to the bottom of lifting
cylinder piston and then push piston rod under. When pushing lifting spool, it is that
bottom of lifting cylinder piston connects with low pressure line and then piston rod
drops by deadweight and weight of cargo. In this time, oil from lifting cylinder goes by
unidirectional speed limiting valve so as to control the falling speed, then the lifting
pump out off work also. When operating tilting spool, high pressure oil goes to one
house of tilting cylinder and another connects with low pressure line so as to make
mast tilt forward or backward.

6.4.1 Main Pump

Trouble Probable cause Corrective action
Low oil level in tank. Add oil to specified level.
No oil from
Clogged suction pipe or Clean oil line and tank. If oil is dirty,
oil pump
strainer. change.

50
 Low
discharge Worn bearing damaged
Replace faulty parts.
pressure on backup ring and O-ring.
oil pump.
Worn bearing damaged
Replace faulty parts.
backup ring and O-ring.
Readjust to specified pressure using
Low Maladjusted relief valve.
pressure gauge.
discharge
Retighten suction side pipe.
pressure on
Add oil in oil tank.
oil pump.
Air in oil pump. Checks pump oil seal.
Do not operate pump until bubbles in
tank disappear.
Cavitation due to crushed
Adjust or replace crushed hose and
suction hose or clogged
clean strainer.
strainer.
Air being sucked from loose
Retighten each joint.
suction side joint.
Noisy oil ·replace with new oil having proper
pump viscosity for temperature at which
Cavitation due to too high oil
pump is to be operate.
viscosity.
·to operate when oil temperature is
normal.
Determine cause of bubbles and
Bubbles in hydraulic oil.
remedy.
Oil leaking Faulty oil seal on pump, faulty
from oil O-ring or worn sliding Replace faulty parts.
pump surfaces on pump.

6.4.2 Control Valve

Trouble Probable cause Corrective action

Loose of pressure-adjust screw. Readjusted and retighten.

Distorted or damaged
Pressure of relief pressure-adjust spring. Replace.

valve is not steady Worn or blocked relief valve

core. Replace or clean.
or too low.
Examine and repair
Pump abated.
pump.

Trouble Probable cause Corrective action

51
 Fork tilt forward Replace valve core and tilt
Worn or damaged tilt lock valve.
when control lever lock valve as an assemble.
is used while
Broken tilting lock spring. Replace spring.
engine is off.

Replace valve core and tilt

Fork tilt forward Worn or damaged tilt lock valve.
lock valve as an assemble.
when control lever
Broken tilting lock spring. Replace spring.
is used while
Damaged tilt valve plunger
engine is off. Replace O-ring.
O-ring.

Mast is unstable Replace tilt relief valve

Malfunctioning tilt relief valve.
when tilting forward. assembly.

Valve body and spool valve is

Replace spool valve with
worn and clearance between
specified clearance.
Lowering distance them is too great.

of mast is big when Spool valve is not in center. Keep being in the center.

spool valve is in the Examine and repair

Cylinder seal abated.
center. cylinder.

Taper valve is worn or blocked Replace or clean taper

by dirt. valve.

Damaged or distorted
Replace spring.
reposition-spring.
Spool valve is not
Dirt exists between valve body
return neutral Clean.
and spool valve.
position.
Blocked control device. Adjusted.

Not coaxial parts at reposition Reinstall，be coaxial

Damaged O-ring. Replace.

Faulty seal of joint. Check and retighten.

Leakage
Clean seal plate and
Loose seal plate.
retighten blots.

52
 Loosed lock-nut of relief valve and
connect-nut between plate and Tighten.
plate.

Adjusting the pressure of the main relieve valve

The pressure of the main relieve valve is all ready adjusted in the factory, and it can’t
be adjusted generally. The following is an example of 1.8t truck to specify how to
adjust the pressure.
(1). Put 125 percent of the rated load (2000kg) on the forklift stable.
(2).Step the accelerated pedal to the end, control the lift pole, if the forklift can get the
height of 300mm, the main relieve valve is all right. Otherwise, adjust it as step (3).
(3).If the forklift can’t work, enhance the pressure main relieve valve, remove the front
soleplate, loosen the tightening nut of the main relieve valve, screw the adjusting nut
clockwise to enhance the pressure of the main relieve valve. If the height of lift is
higher than 300mm, screw the adjust nut
anti-clockwise to reduce the pressure. Warning ！
(4).Step the accelerated pedal to the end ·The load should be put stably.
to make the forklift in the height range of ·Don’t adjust if the pressure is already
0-300mm. Otherwise, adjust it as step (3). adjusted correctly.
(5).Retighten the tightening nut, fix it on
the front soleplate.

53
6.5 Lifting System

Condition Probable cause Corrective action

1.Tilt cylinder and ring

Replace piston ring tilt cylinder.
Fork arm abraded excessively
carrier or mast
tilt by itself. 2. The hydraulic control valve
Replace it.
spring is inoperative.

The fork arms 1. Caused by piston jamming

Replace the faulty parts.
carrier moves or bent piston rod.
up and down 2. Too much dirt is
sluggishly. Strip it down and clean.
accumulated in the cylinder.
1. Carriage bracket assembly Adjust clearance with thrust
out of adjustment. metal and carriage side roller.
2. Insufficient clearance
between inner and outer Adjust clearance with rollers.
masts or rollers and mast.
Forks are lifted
or lowered 3. Biting foreign materials
Remove foreign materials.
unsmooth. between moving parts.
Apply grease on contact
4. Insufficient lubrication.
surfaces of sliding parts.（butter）
5. Bent carriage bracket
Repair or replace.
assembly.
Forks are lifted 1. Lift chains out of
Adjust lift chains.
unevenly adjustable.
Condition Probable cause Corrective action
1. Grease stiffened or dirt
Lift roller does
accumulated on lift roller and Clean and lubricate lift rollers.
not rotate
mast sliding surfaces.

54
 2. Improperly adjusted lift
Adjust.
roller.
1. Insufficient lubrication. Lubricate.
2. Improperly adjusted lift
roller, side roller and Adjust.
back-up metal.
Excessive
mast noise By adjusting shims and rubber
3. Rubber pad on lower of pad, piston rod is in touch with
outer mast is useless for bottom of cylinder body after
container fork lift truck. inner mast is in touch with rubber
pad.

1 ． Excessive wear occurs

between the oil pump body Replace the worn parts or the oil
and gears, causing too much pump.
clearance.

2. The lifting jack piston

Yx-ring has worn, resulting in Replace Yx-ring.
excessive inner leaks.

3. Springs of the multiple

control valve and its relief
Replace.
valve are inoperative oil
leaks.

4.Excessive wear occurs of

Insufficient lift the hydraulic control valve,
power or no lift resulting in excessive oil Replace.
movement. leaks.
5. Oil leaks occur between Dismantle for regrinding the joint
the hydraulic control valve surfaces and reassemble the
sections. valve.
6. Leakage occur in the Tighten the joint nuts and inspect
hydraulic pipe. the seal for damage.
Change the wrong hydraulic oil
7. The hydraulic oil
or stop operation for reducing the
temperature is too high. Oil
oil temperature. Find out the
viscosity is too low and the
reasons for high oil temperature
rate is insufficient.
and eliminate the trouble.
8. The load carried is beyond
Observe the lifting capacity limit.
the designed capacity.

55
6.6 Electrical System
6.6.1 Fault Codes

Error Message
Possible cause Fault elimination
Error Error text
- Turn off one or both inputs
dedicated to the bumper
functionality;
The two digital inputs dedicated to - If the alarm occurs even if the
162 BUMPER STOP the bumper functionality are high at inputs are in the rest position,
the same time. check if the micro-switches are
stuck.
- In case the problem is not solved,
replace the logic board.
The controller detected a difference
between the estimated absolute
orientation of the rotor and the
HOME position of the index signal (ABI Repeat the auto-teaching
176 encoder).
SENS.ERR XX procedure.
It is caused by a wrong acquisition
of the angle offset between the
orientation of the rotor and the index
signal.
PWM ACQ.
164
ERROR

This is a safety related test. It is a This alarm could be caused by a

self-diagnosis test that involves the CAN bus malfunctioning, which
8 WATCHDOG
logic between master and blinds master-supervisor
supervisor micro-controllers. communication.

56
 Error Message
Possible cause Fault elimination
Error Error text
- Check if there is a short circuit or
a low-impedance conduction path
between the negative of the coil
and -BATT.
- The EVP driver is shorted (output - Collect information about:
A19). o the voltage applied across the
EVP DRIV. - The microcontroller detects a EVP coil,
215
SHORT. mismatch between the valve o the current in the coil,
set-point and the feedback of the o features of the coil.
EVP output. Ask for assistance to Your dealer
in order to verify that the software
diagnoses are in accordance with
the type of coil employed.
- If the problem is not solved, it
The software is not compatible with
the hardware. Each controller
produced is “signed” at the end of
- Upload the correct firmware.
line test with a specific code mark
CONTROLLER - Ask for assistance to your dealer
239 saved in EEPROM according to the
MISM. technician in order to verify that
customized Part Number.
the firmware is correct.
According with this “sign”, only the
customized firmware can be
uploaded.
- Check if there are wrong
This alarm can appear only in a
connections in the external wiring.
Traction + Pump configuration.
- Using the TESTER function,
There is an input mismatch
verify that the seat inputs are in
SEAT between the traction controller and
222 accordance with the actual state of
MISMATCH the pump
the external switch.
controller relatively to the seat input
- In case no failures/problems
(A6): the two values recorded by the
have been found, the problem is in
two controllers are different.
the controller, which has to be

57
 Error Message
Possible cause Fault elimination
Error Error text
This fault is displayed when the Fault at startup or in standby:
controller detects an undervoltage - Fault can be caused by a key
LOGIC FAILURE condition at the key input (A1). input signal characterized by
19
#1 Undervoltage threshold depends on pulses below the undervoltage
the nominal voltage of the threshold, possibly due to external
controller. loads like DC/DC converters
starting-up, relays or contactors
Fault in the hardware section of the
LOGIC FAILURE The failure lies in the controller
18 logic board which deals with voltage
#2 hardware. Replace the controller.
feedbacks of motor phases.

A hardware problem in the logic

board due to high currents
LOGIC FAILURE The failure lies in the controller
17 (overload). An overcurrent condition
#3 hardware. Replace the controller.
is triggered even if the power bridge
is not driven.

- Check that the battery has the

same nominal voltage of the
The logic board measures a key
inverter.
VKEY OFF voltage that is constantly out of
220 - Check the battery voltage, if it is
SHORTED range, below the minimum allowed
out of range replace the battery.
value.
- In case the problem is not solved,
replace the logic board.

- Check the wiring, in order to

verify if LC coil is connected to the
This fault appears when no load is right connector pin and if it is not
connected between the NLC output interrupted.
230 LC COIL OPEN
(A16) and the positive voltage (for - If the alarm is still present, than
example +KEY). the problem is inside the logic
board;
replace it.

58
 Error Message
Possible cause Fault elimination
Error Error text

Ask for assistance to your dealer

The error between the Iq (q-axis
IQ technician in order to do the
245 current) setpoint and the estimated
MISMATCHED correct adjustment of the motor
Iq is out of range.
parameters.

- Check the motor power cables.

- Check the impedance between
Before switching the LC on, the U, V and W terminals and -Batt
software checks the power-bridge terminal of the controller.
INIT VMN LOW voltage without driving it. The - Check the motor leakage to truck
207
01/02/03 software expects the voltage to be frame.
in a “steady state” value. If it is too - If the motor connections are OK
low, this alarm occurs. and there are no external low
impedance paths, the problem is
inside the controller. Replace it.

- Check the motor power cables;

- Check the impedance between
Before switching the LC on, the U, V and W terminals and -Batt
software checks the power-bridge terminal of the controller.
INIT VMN HIGH voltage without driving it. - Check the motor leakage to truck
206
81/82/83 The software expects the voltage to frame.
be in a “steady state” value. - If the motor connections are OK
If it is too high, this alarm occurs. and there are no external low
impedance paths, the problem is
inside the controller. Replace it.

59
 Error Message
Possible cause Fault elimination
Error Error text
Cause1: - If the problem occurs at start-up
Before switching the LC on, the (the LC does not close), check:
software checks the power bridge: it o motor internal connections
turns on alternatively the low-side (ohmic continuity);
31 VMN HIGH
power MOSFETs and expects the o motor power cables connections;
phase voltages decrease down to o if the motor connections are OK,
-BATT. If the phase voltages are the problem is inside the controller.
higher than 10% of the nominal Replace it.
Cause1: - If the problem occurs at start up
Start-up test. Before switching the (the LC does not close at all),
LC on, the software checks the check:
power bridge: o motor internal connections
it turns on alternatively the high-side (ohmic continuity);
30 VMN LOW power MOSFETs and expects the o motor power-cables
phase voltages increase toward the connections;
positive rail value. If one phase o if the motor connections are OK,
voltage is below 66% of the rail the problem is inside the
voltage, this alarm occurs. controller;
Cause2: replace it.

At each start-up the supervisor

micro-controller checks that the This type of fault is not related to
HW FAULT
227 hardware circuit intended to enable external components. Replace the
11/12/13
and disable the LC driver (A16) logic board.
works properly.

At each start-up the supervisor

micro-controller checks that the This type of fault is not related to
HW FAULT
227 hardware circuit for enabling and external components. Replace the
01/02/03
disabling of the power bridge works logic board.
properly.

60
 Error Message
Possible cause Fault elimination
Error Error text
- Verify LC coil is properly
connected.
The voltage feedback of LC driver - Verify CONF. POSITIVE LC
POSITIVE LC (A16) is different from expected, i.e. parameter is set in accordance
213
OPEN it is not in accordance with the with the actual coil positive supply
driver operation. (see paragraph 8.2.5). Software,
depending on the parameter
value, makes a proper diagnosis;

Ask for assistance to your dealer

The error between the Id (d-axis
FIELD ORIENT. technician in order to do the
253 current) setpoint and the estimated
KO correct adjustment of the motor
Id is out of range.
parameters.

Before driving the LC coil, the

controller checks if the contactor is
stuck. The controller drives the
power bridge for several dozens of It is suggested to verify the power
CONTACTOR
37 milliseconds, trying to discharge the contacts of LC; if they are stuck, is
CLOSED
capacitors bank. If the capacitor necessary to replace the LC.
voltage does not decrease by more
than 20% of the key voltage, the
alarm is raised.

The LC coil is driven by the

- LC contacts are not working.
controller, but it seems that the
Replace the LC.
CONTACTOR power contacts do not close. In
38 - If LC contacts are working
OPEN order to detect this condition the
correctly, contact your dealer
controller injects a DC current into
technician.
the motor and checks the voltage
on power capacitor. If the power
Ask for assistance to your dealer
The error between the power
POWER technician about the correct
212 setpoint and the estimated power is
MISMATCH adjustment of the motor
out of range.
parameters.

61
 Error Message
Possible cause Fault elimination
Error Error text
- Check if the SET KEY VOLTAGE
parameter in the ADJUSTMENT
list is set in accordance with the
WRONG KEY The measured key voltage is not key voltage.
170
VOLT. the right one for the inverter. - Check if the key voltage is ok
using a voltmeter, if not check the
wiring.
- In case the problem is not solved,
- Check that the SET BATTERY
At start-up, the controller checks the parameter in the ADJUSTMENT
battery voltage (measured at key list matches the battery nominal
WRONG SET
251 input) and it verifies that it is out of a voltage.
BAT
±20% range around the nominal - Through the TESTER function,
value. check that the KEY VOLTAGE
reading shows the same value as
- Verify the motor phases
Short circuit between two motor connection on the motor side
MOT.PHASE
phases. The number that follows - Verify the motor phases
SH.36
the alarm identifies where the short connection on the inverter side
MOT.PHASE
196 circuit is located: - Check the motor power cables.
SH.37
- 36 U – V short circuit - Replace the controller.
MOT.PHASE
- 37 U – W short circuit - If the alarm does not disappear,
SH.38
- 38 V – W short circuit the problem is in the motor.
Replace it.

The current sensor or the current

In standby, the sensor detects a
53 STBY I HIGH feedback circuit is damaged.
current value different from zero.
Replace the controller.

Reset the alarm by switching key

off and on again.
The motor current has overcome If the alarm condition occurs
180 OVERLOAD
the limit fixed by hardware. again, ask for assistance to your
dealer technician. The fault
condition could be affected by
wrong adjustments of motor

62
 Error Message
Possible cause Fault elimination
Error Error text
When the key is switched on, the - Check if an external load in
inverter tries to charge the power parallel to the capacitor bank,
capacitors through the series of a which sinks current from the
CAPACITOR PTC and a power resistance, capacitors-charging circuit, thus
60
CHARGE checking if the capacitors are preventing the caps from charging
charged within a certain timeout. If well. Check if a lamp or a dc/dc
the capacitor voltage results less converter or an auxiliary load is
than 20% of the nominal battery placed in parallel to the capacitor
voltage, the alarm is raised and the bank.
- Check if there are wrong
connections in the external wiring.
- Using the TESTER function,
Input mismatch between Hard&Soft verify that inputs are in
input (A11) and tiller/seat input (A6): accordance with the actual state of
185 TILLER ERROR
the two inputs are activated at the the external switches.
same time. - Check if there is a short circuit
between A11 and A6.
- In case no failures/problems
have been found, the problem is in

This fault is signaled when there is This type of fault is not related to
248 NO CAN MSG. no communication with the external components; replace the
supervisor uC. logic board.

The algorithm implemented to

check the main RAM registers finds Try to switch the key off and then
WRONG RAM
210 wrong contents: the register is on again, if the alarm is still
MEM.
“dirty”. This alarm inhibits the present replace the logic board.
machine operations.

- Check if there is a short or a low

impedance pull-down between
DRIVER
74 The driver of the LC coil is shorted. NLC (A16 (A36) and –BATT.
SHORTED
- The driver circuit is damaged;
replace the logic board.

63
 Error Message
Possible cause Fault elimination
Error Error text
The LC coil driver is not able to This type of fault is not related to
CONTACTOR
75 drive the load. The device itself or external components; replace the
DRIVER
its driver circuit is damaged. logic board.
- Check the connections between
the controller outputs and the
loads.
This alarm occurs when there is an - Collect information about
overload of the MC driver (A16) and characteristics of the coils
EB driver (A17). As soon as the connected to the two drivers and
MC-EF COIL
223 overload condition disappears, the ask for assistance to your dealer
SHOR.
alarm will be removed automatically technician in order to verify that
by releasing and then enabling a the maximum current that can be
travel demand. supplied by the hardware is not
exceeded.
- In case no failures/problems
have been found, the problem is
This fault is displayed when the
controller detects an overvoltage
condition.
Overvoltage threshold depends on
the nominal voltage of the
controller.
Nominal Voltage:24V 36/48V
72/80V 96V;
Undervoltage threshold :35V 65V
If the alarm happens during the
115V 130V
brake release, check the line
VDC LINK As soon as the fault occurs, power
202 contactor contact
OVERV. bridge and MC are opened. The
and the battery power-cable
condition is triggered using the
connection.
same HW interrupt used for
undervoltage detection, uC discerns
between the two evaluating the
voltage present across DC-link
capacitors:
- High voltage Overvoltage
condition
- Low/normal voltage
Undervoltage condition

64
 Error Message
Possible cause Fault elimination
Error Error text

- Check that the sensor used is

compatible with the software
release.
- Check the sensor mechanical
This alarm occurs if the absolute installation and if it works
position sensor is used also for properly.
SPEED FB. speed estimation. If signaled, it - Also the electromagnetic noise
175
ERROR means that the controller measured on the sensor can be a cause for
that the engine was moving too the alarm.
quick. - If no problem is found on the
motor or on the speed sensor, the
problem is inside the controller, it
is necessary to replace the logic
board.
- Check the electrical and the
mechanical functionality of the
This fault occurs in the following encoder and the wires crimping.
conditions: the frequency supplied - Check the mechanical
to the motor is higher than 40 Hz installation of the encoder, if the
ENCODER and the signal feedback from the encoder slips inside its housing it
82
ERROR encoder has a jump higher than 40 will raise this alarm.
Hz in few tens of milliseconds. This - Also the electromagnetic noise
condition is related to an encoder on the sensor can be the cause
failure. for the alarm. In these cases try
to replace the encoder.
- If the problem is still present
after replacing the encoder, the
Mismatch between “ENCODER Set the two parameters with the
WRONG ENC
181 PULSES 1” parameter and same value, according to the
SET
“ENCODER PULSES 2” parameter adopted encoder.

- Check that motor phases are

correctly connected.
The DC-link voltage drops to zero - Check that there is no
POS. EB.
195 when a high-side MOSFET is dispersion to ground for every
SHORTED
turned on. motor phases.
- In case the problem is not
solved, replace the controller.

65
 Error Message
Possible cause Fault elimination
Error Error text

- Check that the battery has the

same nominal voltage of the
The logic board measures a key
inverter.
VDC OFF voltage value that is constantly out
200 - Check the battery voltage, if it is
SHORTED of range, above the maximum
out of range replace the battery.
allowed value.
- In case the problem is not
solved, replace the logic board.

This alarm occurs only when the

controller is configured to drive a - Re-cycle the key.
PMSM and the feedback sensor - Check the sensor in order to
selected in the HARDWARE verify that it works properly.
POWERMOS
233 SETTINGS list is ENCODER - Check the wiring.
SHORTED
ABI + PWM. - If the problem occurs
The controller does not detect permanently it is necessary to
correct information on PWM input at substitute logic board.
start-up.

This alarm occurs when the A/D If the problem occurs

237 ANALOG INPUT conversion of the analog inputs permanently it is necessary to
returns frozen values, on all the replace the logic board.
converted signals, for more than

This alarm occurs when a mismatch

is detected between the setpoint for
The failure lies in the controller
CTRAP the overcurrent detection circuit
235 hardware. Replace the logic
THRESHOLD (dependent on parameter DUTY
board.
PWM CTRAP) and the feedback of
the actual threshold value.

66
 Error Message
Possible cause Fault elimination
Error Error text

The controller receives from the

CAN bus the message that another
controller in the net is in fault
WAITING FOR condition; as a consequence the Check if any other device on the
224
NODE controller itself cannot enter CAN bus is in fault condition.
into an operative status, but it has to
wait until the other node comes out
from the fault status.

- Check the battery charge and

charge it if necessary.
- If the battery is actually charged,
measure the battery voltage
The battery charge is evaluated to
through a voltmeter and compare
be lower than 10% of the full charge
it with the value in the BATTERY
66 BATTERY LOW and the BATTERY CHECK setting
VOLTAGE reading in the
is other than 0 (refer to SET
TESTER function. If they are
OPTION menu).
different, adjust the ADJUST
BATTERY parameter with the
value measured through the
voltmeter.
- If the problem is not solved,
DATA The alarm ends when the
247 Controller in calibration state.
ACQUISITION acquisition is done.

This is a warning to point out that it Turn on the CHECK UP DONE

CHECK UP
249 is time for the programmed option after that the maintenance
NEEDED
maintenance. service.

67
 Error Message
Possible cause Fault elimination
Error Error text

Connect the Console to the

WARNING
244 Warning on supervisor uC. supervisor uC and check which
SLAVE
alarm is present.

Controller is acquiring data from the The alarm ends when the
171 ACQUIRING A.S.
absolute feedback sensor. acquisition is done

173 ACQUIRE END Absolute feedback sensor acquired.

The acquiring procedure relative to

ACQUIRE
172 the absolute feedback sensor
ABORT
aborted.

- Check the wirings.

This alarm occurs only when the
- If the motor direction is correct,
controller is configured as PMSM
swap the sin and cos signals.
and the feedback sensor selected is
168 SIN/COS D.ERR - If the motor direction is not
sin/cos.
correct, swap two of the motor
The signal coming from sin/cos
cables.
sensor has a wrong direction.
- If the problem is not solved,
contact your dealer technician.

68
 Error Message
Possible cause Fault elimination
Error Error text
- Check the wirings.
This alarm occurs only when the - If the motor direction is correct,
controller is configured as PMSM swap A and B signals.
ENCODER
169 and the feedback sensor selected is - If the motor direction is not
D.ERR
the encoder. The A and B pulse correct, swap two of the motor
sequence is not correct. cables.
- If the problem is not solved,
contact your dealer technician.

The EVP driver (A19) is not able to This fault is not related to external
EVP DRIVER
240 drive the EVP coil. The device itself components. Replace the logic
OPEN
or its driving circuit is damaged. board.

No load is connected between the - Check the EVP condition.

214 EVP COIL OPEN NEVP output (A19) and the - Check the EVP wiring.
electrovalve positive terminal. - If the problem is not solved,
replace the logic board.

At start-up, the hardware circuit This type of fault is not related to

HW FAULT EV
238 dedicate to enable and disable the external components. Replace
XX
EV drivers is found to be faulty. the logic board.

- Check the encoder condition.

- Check the wiring.
- Through the TESTER function,
The traction rotor is stuck or the check if the sign of FREQUENCY
211 STALL ROTOR encoder signal is not correctly and ENCODER are the same and
received by the controller. if they are different from zero
during a traction request.
- If the problem is not solved,
replace the logic board.

69
 Error Message
Possible cause Fault elimination
Error Error text
A HW or SW defect of the Execute a CLEAR EEPROM
non-volatile embedded memory procedure (refer to the Console
storing the controller parameters. manual). Switch the key off and
208 EEPROM KO This alarm does not inhibit the on to check the result. If the alarm
machine operations, but it makes occurs permanently, it is
the truck to work with the default necessary to replace the
values. controller. If the alarm
disappears, the previously stored

The controller has restored the

- A travel demand or a pump
default settings. If a CLEAR
request cancel the alarm.
PARAM EEPROM has been made before
209 - If the alarm appears at key-on
RESTORE the last key re-cycle, this warning
without any CLEAR EEPROM
informs you that EEPROM was
performed, replace the controller.
correctly cleared.

This alarm occurs when there is an - Check the EVs conditions.

COIL SHOR.
241 overload of one or more EV driver. - Check the wiring.
EVAUX
As soon as the overload condition - Collect information about
has
Onebeen removed,
or more the alarm
on/off valve drivers are characteristics of EV coils and
not able to drive the load.
- 02 EV1
CONT DRIV EV The device or its driving circuit is
232 - 04 EV2
XX damaged. Replace the controller.
- 08 EV3
- 20 EV4
If more than one output is affected
by this fault condition, the code
One or more on/off valve drivers are
shorted.
- 02 EV1 - Check if there is a short circuit
- 04 EV2 or a low impedance path between
DRV SHOR EV - 08 EV3 the negative terminal of the coils
234
XX - 20 EV4 and -BATT.
If more than one output is affected - If the problem is not solved,
by this fault condition, the code replace the logic board.
shown will correspond to the sum of
the faulty-EVs codes.

70
 Error Message
Possible cause Fault elimination
Error Error text

At start-up, the hardware circuit This type of fault is not related to

HW FAULT EB
229 dedicated to enable and disable the external components. Replace
01/02/03
EB driver (A18) is found to be faulty. the logic board.

- Check if there is a short or a low

impedance path between the
- The EB driver is shorted.
negative coil terminal and -BATT.
- The microcontroller detects a
- Check if the voltage applied is in
254 EB. DRIV.SHRT. mismatch between the valve
accordance with the parameters
setpoint and the feedback at the EB
set.
output.
- If the problem is not solved,
replace the controller.

The EB coil driver is not able to This type of fault is not related to
246 EB.DRIV.OPEN drive the load. The device itself or external components. Replace
its driving circuit is damaged. the logic board.

This fault appears when no load is - Check the EB coil.

connected between the NEB output - Check the wiring.
216 EB. COIL OPEN
(A18) and the EB positive terminal - If the problem is not solved,
PCOM (A17). replace the logic board.

- Check that handbrake is not

active by mistake.
- Check the SR/HB input state
through the TESTER function.
221 HANDBRAKE Handbrake input is active. - Check the wirings.
- Check if there are failures in the
microswitches.
- If the problem is not solved,
replace the logic board.

71
 Error Message
Possible cause Fault elimination
Error Error text

THROTTLE A wrong profile has been set in the Set properly the throttle-related
243
PROG. throttle profile. parameters.

- Check that LIFT and LOWER

requests are not active at the
same time.
Both the pump requests (LIFT and - Check the LIFT and LOWER
187 LIFT + LOWER LOWER) are active at the same input states through the TESTER
time. function.
- Check the wirings.
- Check if there are failures in the
micro-switches.
- Activate the tiller/seat input.
Tiller/seat input has been inactive
228 TILLER OPEN - Check the tiller/seat input state
for more than 30 seconds.
through the TESTER function.
- Check the wirings.

At start-up the amplifiers used to This type of fault is not related to

252 WRONG ZERO measure the motor voltage sense external components. Replace
voltages above 3 V or below 2 V. the logic board.

This kind of fault is not related to

THERMIC SENS. The output of the controller thermal
250 external components. Replace
KO sensor is out of range.
the controller.

72
 Error Message
Possible cause Fault elimination
Error Error text
The temperature of the controller It is necessary to improve the
base plate is above 85 °C. controller cooling. To realize an
TH.
62 The maximum current is adequate cooling in case of
PROTECTION
proportionally decreased with the finned heat sink important factors
temperature excess from 85 °C up are the air flux and the cooling-air
to 105 °C. At 105°C the current is temperature. If the thermal

The CPOT BRAKE input read by Check the mechanical calibration

BRAKE RUN the microcontroller is at its and the functionality of the brake
204
OUT maximum value without the potentiometer. If the alarm is still
hand-brake request. present, replace the logic board.

The hour-meter of the controller is

Reload HM from
0 transferred and recorded on the
MDI
hour-meter of the standard MDI.
- Check the temperature read by
This warning occurs when the the thermal sensor inside the
temperature sensor is open (if motor through the MOTOR
MOTOR
65 digital) or if it has overtaken the TEMPERATURE reading in the
TEMPERAT.
MAX MOTOR TEMP threshold (if TESTER function.
analog). - Check the sensor ohmic value
and the sensor wiring.
- If the sensor is OK, improve the

73
 Error Message
Possible cause Fault elimination
Error Error text
- Check the temperature read by
The temperature sensor has the thermal sensor inside the
MOTOR TEMP.
178 overtaken the STOP MOTOR motor through the MOTOR
STOP
TEMP. threshold TEMPERATURE reading in the
TESTER function.
- Check the sensor ohmic value

- Check if the resistance of the

sensor is what expected
SENS MOT
The output of the motor thermal measuring its resistance.
218 TEMP
sensor is out of range. - Check the wiring.
KO
- If the problem is not solved,
replace the logic board.

The controller receives from EPS

EPS RELAY
205 information about the safety Verify the EPS functionality.
OPEN
contacts being open.
At key-on and immediately after - Check the wirings.
that, the travel demands have been - Check the mechanical
turned off. calibration and the functionality of
78 VACC NOT OK This alarm occurs if the the accelerator potentiometer.
ACCELERATOR reading (in - Acquire the maximum and
TESTER function) is more than 1 V minimum potentiometer value
above the minimum value acquired through the PROGRAM VACC
during the PROGRAM VACC function.
- Check wirings.
- Check microswitches for
Incorrect starting sequence. failures.
Possible reasons for this alarm are: - Through the TESTER function,
INCORRECT
79 - A travel demand active at key-on. check the state of the inputs is
START
- Man-presence sensor active at coherent with microswitches
key on. states.
- If the problem is not solved,
replace the logic board.

74
 Error Message
Possible cause Fault elimination
Error Error text

- Check that travel requests are

not active at the same time.
- Check the FW and BW input
states through the TESTER
This alarm occurs when both the function.
80 FORW + BACK travel requests (FW and BW) are - Check the wirings relative to the
active at the same time. FW and BW inputs.
- Check if there are failures in the
microswitches.
- If the problem is not solved,
replace the logic board.
- Acquire the maximum and
minimum potentiometer values
The CPOT input read by the through the PROGRAM VACC
microcontroller is not within the MIN function. If the alarm is still
VACC OUT OF
226 VACC ÷ MAX VACC range, present, check the mechanical
RANGE
programmed through the calibration and the functionality of
PROGRAMM VACC function the accelerator potentiometer.
- If the problem is not solved,
replace the logic board.

- Ask for help to your dealer

86 PEDAL WIRE KO This is not implemented in ACE3.
technician.

Upload the correct software

WRONG SLAVE Wrong software version on
197 version or ask for assistance to
VER supervisor uC.
your dealer technician.

The maximum current gain

Ask for assistance to your dealer
parameters are at the default
technician in order to do the
236 CURRENT GAIN values, meaning that the maximum
adjustment procedure of the
current adjustment procedure has
current gain parameters.
not been carried out yet.

75
 Error Message
Possible cause Fault elimination
Error Error text

Wait until the end of the

PARAM Master uC is transferring
199 procedure. If the alarm remains
TRANSFER parameters to the supervisor.
longer, re-cycle the key.

The hour-meter of the controller is

0 Reload HM transferred and recorded on the /
hour-meter of the standard MDI.

The voltage read by the - Acquire the maximum and

STEER SENSOR
179 microcontroller at the minimum values coming from the
KO
steering-sensor input is not within steering potentiometer through
the STEER RIGHT VOLT ÷ STEER the STEER ACQUIRING function.

At start-up there is a mismatch in

M/S PAR CHK the parameter checksum between Restore and save again the
198
MISM the master and the supervisor parameters list.
microcontrollers.

Check in the HARDWARE

TORQUE There is an error in the choice of the
201 SETTINGS menu the value of
PROFILE torque profile parameters.
those parameters.

76
APPENDIX

77
Lithium Battery Use and Maintenance Manual

Table of Content
Chapter 1 Safety Precautions................................................................................................ 1
Chapter 2 Battery Introduction and Instructions..................................................................2
2.1 Battery Introduction................................................................................................... 2
2.2 Instructions..................................................................................................................2
2.3 Display Instrument.....................................................................................................3
2.4 Battery Nameplate.....................................................................................................4
Chapter 3 Charging................................................................................................................. 5
Chapter 4 Storage....................................................................................................................7
Chapter 5 Transportation........................................................................................................7
Chapter 6 Common Problems and Solutions...................................................................... 8
Chapter 7 Maintenance...........................................................................................................9
7.1 Daily Maintenance..................................................................................................... 9
7.2 Regular Maintenance................................................................................................ 9
7.3 Disposal of Used Battery Packs ...........................................................................10

78
Chapter 1 Safety Precautions

CAUTION
• DO NOT short-circuit the positive and negative terminals of the
battery.
• Do not collide, handle gently, and avoid the battery being subjected
to excessive vibration, external impact, high drop, etc.
• DO NOT place the battery or battery pack in a corrosive chemical
environment.
• DO NOT charge the battery without a charging device or with a
PROHIBITION charging device that we do not recognize.
• DO NOT expose the battery or leave it in an environment above
45 °C for a long time.
• DO NOT disassemble, squeeze, puncture or heat the battery.
• Lithium batteries are forbidden for those who lack the knowledge of
safe use of lithium batteries.
• DO NOT immerse the battery in water or other conductive liquids.
• DO NOT use the battery in series or in parallel with other models or
types of batteries.
• Serial and parallel operation of a complete power supply system
containing a lithium-ion battery protection circuit board or battery
management system is prohibited.

• It is strictly forbidden to hot swap battery

• It is easy to cause fire and electric shock

• Be aware of corrosion
• It may cause battery damage and shorten battery life

• No burning
• It may cause battery explosion

79
Chapter 2 Battery Introduction and Instructions

2.1 Battery Introduction

Battery model ICE301B Battery weight /

Rated voltage 80V Cell material LFP

Rated capacity 220AH Battery size 705X565X266mm

Charger voltage 80V Charger current 65A

2.2 Instructions
1. Due to the product in transit or inventory, the lithium battery must be fully charged
with the vehicle-specific charger before the first use (do not mix with other models of
chargers or use other modified equipment), and then it can be used;
2. The lithium battery should be used at an
ambient temperature of 0°C ~ 40°C, do not Caution!
use or store the battery near a fire source/heat Ambient temperature for use:
source where the temperature is outside the 0°C ~ 40°C
temperature range;
3. Lithium battery has the performance of charging and using whenever it is necessary,
when the battery is low, please charge it in time to avoid over-discharge; the replaced
battery should also be charged in time to avoid damage caused by over-discharge of
the battery after self-discharge.
4. Do not place metal objects (such as wrenches, knives) on the lithium battery, or
other objects that may cause short-circuiting of the battery to avoid short circuit
between the positive and negative terminals;
5. Do not bump or strike the lithium battery during use, if the battery leaks or smells,
please stop using it immediately and keep away from the fire source.
6. If the battery life is significantly shortened, please contact the after-sales for check;
7. If the lithium battery fails and cannot be used, please remove the battery from the
handling equipment, the trained personnel can use our BMS special reading
instrument to read the information for preliminary judgment; for problems that cannot
be solved, please contact the after-sales service department for solutions;
8. Before installing and removing the battery, be sure to read the user manual; the
weight of the battery body is evenly distributed, please pay attention to the installation

80
 and removal when there is an external weight; please use two hooks to hang on the
lifting rings during the lifting process, and gently lift it to keep it stable and not inclined;
9. The operator must read the instructions carefully before use and receive relevant
safety training to be able to handle emergencies;

2.3 Display Instrument

Display status 1 Display status 2

No. Name Description

When all 10 cells are on, it indicates that the battery is full;
When the first cell and the second flash alternately, it
1 Energy display indicates that the battery is low and must be charged.
The battery remaining capacity is displayed; “100%”
indicates that the battery is fully charged.

2 Total voltage The sum of the total voltages of the lithium battery series

3 Temperature Battery temperature

4 Charging current Current value when charging the lithium battery

5 Maximum cell voltage Maximum value of cell voltage

Cell No. of maximum

6 The specific cell which is of the maximum voltage
cell voltage

7 Minimum cell voltage Minimum value of cell voltage

Cell No. of minimum

8 The specific cell which is of the minimum voltage
cell voltage

81
2.4 Battery Nameplate

No. Name No. Name

1 Battery model 4 Cell Type
2 Nominal Voltage 5 Nominal Capacity
3 Nominal Energy 6 Version NO.
7 Battery Weight 8 Date
9 Serial No.

82
Chapter 3 Charging

1. This battery can only be charged with the vehicle-specific charger, other chargers
may cause battery damage.
2. The normal charging temperature range of the battery is: 5°C ~ 40°C, please do
not charge in the environment beyond the normal temperature range;
3. If the charging is still not completed within the specified time, stop charging the
battery;
4. During the charging operation, it is necessary to have professional personnel to
operate and care, in order to ensure that the
Warning!
charging plug and socket work normally without heat,
Lithium batteries are strictly
to ensure that the charging device works normally, to
prohibited from overcharging
ensure that the battery pack and its protection circuit
and overdischarging.
work normally, and the whole power supply system
has no sign of short circuit, over current, over
temperature or overcharge.
5. When charging, connect the battery plug connector to the charger plug connector,
and there will be contactor sound; after starting charging, the circular display meter
will display the total voltage, the maximum and minimum cell voltages, power,
temperature, charging current and other information; pay particular attention to the
charging current and the maximum and minimum cell voltages, as well as the
voltage difference between them; if there is abnormality, stop charging in time and
contact the after-sales service department for solutions.

Caution!
1. The normal charging temperature range of the battery is: 5°C~40°C.
2. The voltage difference between the maximum and minimum cell voltages during
charging is less than 0.1V.
3. The lithium battery voltage matches the charger voltage.
4. The charger should be periodically checked for charging overvoltage protection
device.

83
Charging procedure:
• Move the forklift truck to the vicinity of the charger.
• Check the charger before starting charging.
• Check if the battery voltage to be charged matches the charger. (Please refer to the
nameplate for rated output of the charger)
• Connect the output plug of the charger to the plug of the lithium battery box on the
forklift truck.

Chapter 4 Storage

1. Try to ensure that the battery or battery pack's power is 60% before long-term
storage as the battery has the function of self-discharge, be sure to charge the battery
once every 3 months to ensure the battery power is 60%;
2. The battery should be stored in a temperature environment of 0°C~40°C;
3. Store in a dry, ventilated and cool environment,
Caution!
avoid direct sunlight, high temperature, high humidity,
Ambient temperature for storage:
corrosive gas, severe vibration, etc.
0°C~40°C
4. DO NOT stack, stacking of this series of products
is not allowed.
5. DO NOT store under the condition that the load or the hidden load is connected,
that is, it is prohibited to have any form of discharge behavior when storing;
6. If the battery is found to be bulged, cracked, or has a low voltage value after
long-term storage, the battery may be damaged; please contact the relevant technical
department of the company for technical support.
7. After not using the battery for a long time, do not charge or discharge the battery if
the smell of leakage is found near the battery.

84
Chapter 5 Transportation

1. During the loading, unloading and transportation process, severe vibration and
large external impact should be avoided, and throwing, rolling, inverting, squeezing
and excessive stacking are prohibited;
2. Prevent rain during transportation;
3. Ensure that the battery or battery pack has been disconnected from the load or
charging device before transportation, without any form of charging and discharging.

Warning!
Don't bump, handle gently.

85
Chapter 6 Common Problems and Solutions

During the use and maintenance of the lithium-ion battery, the battery or battery
system may have one or more of the following abnormal conditions, please organize
the professional engineers and technicians to perform the necessary processing
according to the instructions in this manual; if you have any questions about the status
or solutions, please contact the relevant technical department or after-sales service
department of the company to obtain professional technical support.
1. If the battery is found to have abnormal mechanical characteristics such as swelling,
cracked casing, melted casing deformation, and distortion of the casing before and
during installation, stop using the battery immediately and store it separately;
2. If abnormalities such as looseness, cracks, cracks in the insulation layer, burn
marks, etc. of the battery's pole pressing bolts, conductive strips, main circuit wires
and connectors are found before and during the installation, stop using the battery
immediately, check the reason for analysis and give it a fix;
3. If the polarity of the positive and negative terminals of the battery is found not match
the polarity identification before installation, please stop using the battery immediately
and contact the after-sales service department to replace the battery or obtain other
solutions;
4. If the temperature of the battery exceeds 65°C before and during installation, stop
using the battery immediately and leave it separately, if the temperature continues to
rise, it needs to be buried with sand;
5. If the battery is found to emit smoke before and during installation, immediately stop
using the battery and bury it with sand, and notify the after-sales service department
of the company for record and obtain technical support;

86
Chapter 7 Maintenance

7.1 Daily Maintenance

1. It is necessary to arrange professionals for care during the charging operation,
especially when the battery is almost fully charged; make sure that the plug and the
socket are in good contact during the charging process to ensure that the charging
device works normally and ensure that the connection points of the battery pack are in
good contact. If an abnormality occurs, the battery needs to be repaired before
charging;
2. Check the battery voltage, temperature, voltage difference, etc. displayed on the
circular display meter before charging and discharging to ensure that all values are
within the normal range;
3. If there is a large amount of dust, metal shavings or other debris on the upper cover
and poles of the battery pack, use compressed air or dry cloth to clean it in time, avoid
cleaning with water or water-soaked objects;
4. When charging and discharging, try to avoid water or other conductive liquids
splashing on the top cover and poles of the battery, for example, being exposed to
heavy rain during use;
5. Estimate the charging time and discharging time of the battery according to the
actual status of use of the battery or battery pack, observe whether there is any
abnormality in the battery or battery pack at the end of charging and the end of
discharging, such as the voltage difference of the battery.

7.2 Regular Maintenance

1. Check the nodes such as the conductive strips and voltage collection terminals for
looseness, shedding, rusting or deformation, etc., to ensure that the series-parallel
harness used in the battery pack is firm and reliable (once a month);
2. Check the battery casing for cracks, deformation, loose poles, bulging and other
abnormal conditions (once a month);
3. Check the reliability of the charging device to ensure that the charging device
performs the charging action in accordance with the voltage regulation and current
regulation signals sent by the BMS and to ensure that the battery will not be
overcharged (once a month);
4. Check discharge protection equipment, such as fast-acting fuses, DC contactors,
relays, etc., to ensure that the battery pack can be quickly disconnected from the main
circuit in the event of a dangerous situation such as short circuit or overcurrent (once

87
a month);
5. Check the insulation resistance between the battery pack and the vehicle body to
ensure that the resistance value meets the Chinese national standard ( 500Ω/V) and
to ensure that there is no electric leakage with the battery (once a month);

7.3 Disposal of Used Battery Packs

To prevent environmental pollution, the battery should be sent to a local recycling
center or a dedicated lithium bat.

88