CQD20-H Electric Reach Truck

 Operation manual
 Parts catalogue
 Contents
Introduction ............................................................................................................................... 1

I. Technical parameters: ..................................................................................................2

II. Struture ............................................................................................................................. 5

III. Safety Norms ................................................................................................................. 15

IV. Drive and operation .................................................................................................... 21

V. Usage, maintenance and charge of storage battery .......................................23

VI. Inspection before operation .................................................................................... 29

VII. Inspection after operation ....................................................................................... 30

VIII. Periodic maintenance and repair ........................................................................... 30

IX. The store, transportation and loading of the truck .........................................35

X. Tow of the truck ........................................................................................................... 36

XI. (Dis)assembly of removable parts .........................................................................36

XII. Common faults and trouble shooting ...................................................................39

Introduction
CQD series electric reach truck adopts battery as power source (lithium battery is optional), DC or AC
motor as power, and drives the truck through gear transmission. The lifting of fork depends on lifting
motor and hydraulic transmission to push the oil cylinder up and down to lift goods. The mast or fork can
be tilted back and forth or moved back and forth, making the operation more flexible and convenient. The
truck has the characteristics of flexibility and portability, high efficiency, stable operation, simple and
convenient operation, safety and reliability, low noise and no pollution. It adopts a 48 V high-capacity
battery, which greatly prolongs the use time after one charge.
The truck is suitable for goods stacking and handling on hard and flat ground.
 Operating environment
a. Height above sea level shall not exceed 1200m;
b. Ambient air temperature shall not be above +40℃ nor below -25℃;
c. Under an environmental temperature of +40℃, relative humidity shall not above 50%; with a
lower temperature, a larger relative humidity is allowable.
d. Hard and flat ground.
e. e. It is forbidden to use the truck in inflammable, explosive environment, or in corrosive
environment such as acid or alkali environment.
Attention
The instruction manual shall be kept by the operator, and shall be read by the operator until he gets
a full understanding.
The instruction manual is composed of correct operation, convenient and simple maintenance, and
routine inspection.
The instruction manual shall be carefully read before operation, for purpose of correct drive and
suitable maintenance to ensure safe and effective material transportation.
The instruction may be in disagreement with practical product due to product innovation.
The instruction manual shall be accompanied with in case leasing or transfer.
Please come into contact with our sales department in case of any problem.

Description of symbol：Regulations of the following symbols are of great importance to your safety and
others as well. Please observe these regulations:
Indicates an impending danger. Deaths or severe injuries would be
Danger resulted without any precaution or avoidance. You must observe
those requirements.
Indicates a potential danger. Deaths or severe injuries would be
Warning resulted without any precaution or avoidance. You must observe
those requirements.
Indicates a potential danger. Moderate injuries would be resulted
Caution without any precaution or avoidance. You must observe those
requirements.
You shall pay attention to statements that are in direct or indirect
Notice
relation with personal security and forklift maintenance.

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I. Technical parameters:
1. CQD20-H outline drawing：

2
2. CQD20-H basic parameter：
1.1 Manufacturer (abbr.)

CQD20H
CQD20
1.2 Model (7.4m＜lifting
(lifting height≤7.4m)
height≤14m)
Characteristics

1.3 Drive type Electric Electric

1.4 Operator type Seat Seat

1.5 Rated capacity Q(kg) 2000 2000

1.6 Load center distance c(mm) 600 600

1.8 Load distance x(mm) 377 377

1.9 Wheelbase Y(mm) 1510 1510

Weight

2.1 Service weight(with battery) kg 3605 4750

3.1 Wheel (Rubber, PU) PU PU

3.2 Tyre size, front mm 343x140 343x140

3.3 Tyre size, rear mm 340x114 340x114

Chaisis

Wheels, number front/rear

3.5 1x/2 1x/2
(× = driving wheels)

3.6 Tread, front b10(mm) 0 0

3.7 Tread, rear b11(mm) 1146 1196

Tilt of mast/fork carriage

4.1 α/β(°) 2/4 2/4
forward/backward

4.2 Height, mast lowered h1(mm) 2340 4190

4.3 Free lift h2(mm) 1400 3250

4.4 Lifting height h3(mm) 5000 10200

4.5 Height, mast extended h4(mm) 5940 11140

Height of overhead guard

4.7 h6(mm) 2210 2210
(cabin)
Seat height relating to
Dimensions

4.8 h7(mm) 1000 1000

SIP/stand height

4.10 Height of wheel arms h8(mm) 360 360

4.19 Overall length l1(mm) 2466 2466

4.20 Length to face of forks l2(mm) 1396 1396

4.21 Overall width across chassis b1Ib2(mm) 1270/1260 1345/1260

Fork dimensions DIN ISO

4.22 s/e/l(mm) 40/120/1070 40/120/1070
2331
Fork carriage DIN 15 173，
4.23 2B 2B
class/type A，B

4.24 Fork-carriage width b3(mm) 928 928

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 4.25 Fork spread b5(mm) 708 708

Distance between wheel

4.26 b4(mm) 900 900
arms/loading surfaces

4.28 Reach distance l4(mm) 600 600

Ground clearance, below

4.31 m1(mm) 70 70
mast
Ground clearance, centre of
4.32 m2(mm) 80 80
wheelbase
Aisle width for pallets 1000 ×
4.34.1 Ast(mm) 2849 2849
1200 crossways
Aisle width for pallets 800 ×
4.34.2 Ast(mm) 2899 2899
1200 lengthways

4.35 Turning radius Wa(mm) 1783 1783

4.37 Length across wheel arms l7(mm) 1960 1960

5.1 Travel speed, laden/unladen Km/h 10.5/11 10.5/11

5.2 Lift speed, laden/unladen m/s 0.29/0.45 0.35/0.45 0.29/0.45 0.35/0.45

Performance

5.3 Lower speed, lade/unladen m/s 0.5/0.5 0.5/0.5

5.4 Reach speed, laden/unladen m/s 0.12/0.12 0.12/0.12

5.7 Gradeability, laden/unladen % 10/10 10/10

6.1 Drive motor rating S2 60 min kW 6.5 6.5

6.2 Lift motor rating at S3 15% kW 8.2 12 8.2 12

Motor

48/500 48V/350 48/500 48V/350

Battery voltage/nominal
6.4 V/Ah （Lead-acid (Lithium （Lead-acid (Lithium
capacity K5
battery） battery) battery） battery)

6.5 Battery weight（±5%） kg 870 220 870 220

Max.lifting height h3(mm) 3000 3500 4000 5000 6200 7400 8000

Capacity,mast extended kg 2000 2000 2000 2000 1800 1600 1500

Height,mast lowered h1(mm) 2240 2490 2740 2340 2740 3190 3390

Free lift h2(mm) 0 0 0 1700 1800 2250 2450

Height, mast extended h4(mm) 3940 4400 4940 5940 7140 8340 8940

Max.lifting height h3(mm) 8600 9500 10200 11100 12000 12500 14000

Capacity,mast extended kg 1400 1200 1150 1000 900 850 750

Height,mast lowered h1(mm) 3590 3890 4190 4490 4790 4956 5556

Free lift h2(mm) 2650 2950 3250 3550 3850 4016 4616

Height, mast extended h4(mm) 9540 10440 11140 12040 12940 13440 14920

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II. Struture
1. Truck structure

1 Mast master assembly: imported mast is stronger, more accurate and more stable, which prolongs its
service lift.
2 Mid cylinder master assembly：Offset designed mid cylinder to wider the driver’s view.
3 Load backrest assembly: protect the driver from being injuried by the falling goods.
4 Fork carriage assembly: used to hang the fork, owning the function of tilting forward and backward
and side shifting.
5 Fork：Intensively forged fork with higher capacity and longer service lift.
6 Camera (option): Stainless camera whose protective level is I69, anti-viberation level is 10G. It
enables the driver to see front clearly, which increases stacking efficiency.
7 Rear wheel: Endurable PU wheel with the founction of hydraulic braking (optional rlectromagnetic
braking). It realizes more stable driving, shortor braking distance, inertia free impact.
8 Sliding frame assembly: Makes the mast reach forward and backward.
9 Truck frame assembly: Low gravity center and a strong and wide chaisis make the truck go smoothly.
10 Battery: big lead-acid battery to extend the using time. Eco-friendly Lithium battery is optional.
11 Front wheel: endurable PU wheel. Drivingand steering integrated design to save space; The
high-power drive motor is equipped with regenerative braking function to make driving and braking
more effective. It is equipped with EPS and has the function of automatic return to normal after
startup.
12 Foot brake: to brake during traveling.
13 Accelerator：Controls the starting, acceleration, deceleration and parking. When the accelerator is
slowly depressed, the truck starts to drive. The more the accelerator is depressed, the faster the truck
will travel. When the accelerator is fully depressed, the truck will travel at the maximum speed.
14 Safety seat：Equipped with high backrest and high elastic shock absorption seats; the standard safety
belt and outer handrail improve the operation safety; a storage compartment is designed behind the
seat back; OPS function is set. (I.e. driver off position protection function).
15 Instrument panel：Refer to the introduction in the following content.
16 Display screen：Optional at the truck equipped with maunal multi-way valve.

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17 Headlight：Provides sufficient light for the operator to stack. Headlights are standard, while the rear
lights are optional.
18 Rearview mirror: makes the operator see the sight behind.
19 Overhead guard: Protects the operator from being hurt by the falling goods.
20 Warning light: Lights up when the truck goes backward, warning others not to approach.

2. Introduction of operational software

2.1 Instrument panel（Solenoid valve）

① Steering wheel: Used to adjust the driving direction. Rotate the steering wheel and the adjustment
angle will be displayed in the intelligent display screen.
② USB port: Charges mobile phones and other devices.
③ Electric lock: Used to control the connection and disconnection power supply. When the truck is
equipped with the password lock, click this switch and enter the corresponding password in the
intelligent display screen (the initial password is 999999) to start the truck. Click again to turn it off;
when a mechanical lock is equipped, the key shoud be kept by the driver or manager. Be sure to turn
off the power supply when leaving the truck and take away the electric lock key to avoid accidents
caused by other personnel.
④ Switch retained: Controls the expansion function module (fan, red light, blue light, etc.).
⑤ Intelligent instrument: Refer the coming content for more information.
⑥ Lift lever: Controls the lifting and lowering of the forks. When it is pulled, the fork lifts; whenit is
pushed, the fork lowers.
⑦ Reach lever: Control the mast to reach forward and backward. When it is pulled, the mast reaches
backward. When the lever is pushed, the mast reaches forward.
⑧ Tilt lever: Used to control the fork to control forward and backward. When the handle is pulled, the
fork tilts forward. When it is pushed, the fork tilts backward.
⑨ Sideshift lever:Control the fork’s lateral movement. When the lever is pulled, the forks move to the
right. When it is pushed, the forks move to the left.
⑩ Emergency stop switch: Control the main power supply. When it is rotated and pulled up, it is in the
power on state, and when it is pressed down, it is in the power off state. This switch can also be used
as an emergency power off switch. When the truck is out of control for some reason, press this
switch immediately to cut off the power supply to avoid dangerous accidents.
⑪ Horn: Press this button to sound and warn.
⑫ Direction switch: used to control the driving direction. When I’ts switched to the forward direction and
step on the accelerator, the truck will travel forward; when it’s switched to the backward direction and

6
 press the accelerator, the ftruck will travel backward. When the direction switch is switched to the
middle, it is in the neutral state.

2.2 Intelligent instrument（Solenoid valve）：

2.2.1 Display screen

① Pointer: Displays the current angle or speed.

② Driving angle: Displays the current angle status of the steering drive wheel.

③ Driving direction: When is on, the forklift is moving forward; When lights up, the forklift is
retreating.
④ Traveling speed: Displays the current traveling speed, in km/h.
⑤ Usage time: Displays the cumulative working time, in hours.

⑥ Brake symbol: Lights up at braking state and goes out when the brake is released.

⑦ Lifting direction: when is on, it indicates that the fork is lifting; When lights up, it

indicates that the fork is lowering.

⑧ Lifting height: Displays the current height of the fork, in meters.
⑨ Lifting speed: Displays the current lifting speed of the fork, in km/h.
⑩ Horn button: press this button, the horn will sound.
⑪ Travel backward button: press this button and pedal on the accelerator, the truck will travel backward.
⑫ Throttle: displays the acceleration state when the accelerator is pressed.
⑬ Neutral key: press this keythe forklift is in neutral.
⑭ Travel forward button: press this button and step on the accelerator again, the forklift will travel
forward.
⑮ Warning zone: appears when there is misoperation.

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⑯ Status bar: displays EPS electric powered steering status, TRV drive status, HYD hydraulic status.
⑰ Weight display area: displays the current weight of goods (for reference only).
⑱ Power display area: when the battery is fully charged, the area displays full power. When the power of
the battery pack decreases gradually with the use of the car, the indicator lights go out from right to
left, and the power percentage will also tell you the current remaining power; When only the last grid
is on, or when there is only 10% power left, the battery pack must be charged.
⑲ Date display area: displays the date.
⑳ Speed gear control: Press this button, the driving speed gear will be switched; There are four gears in
total: M1 is the first gear, and the corresponding maximum driving speed is 7km/h; M2 is the second
gear, and the corresponding maximum driving speed is 8km/h; M3 is the third gear, and the
corresponding maximum driving speed is 9km/h; M4 is fourth gear, and the corresponding maximum
driving speed is 10km/h.
○
21 Headlight: Press once to turn on the headlight, and twice to turn off.
○
22 Volume: Press to adjust the volume
○
23 Canera: Press to display the image content fed back by the front camera of the fork.
○
24 Others: Press others to enter the more options page. Click again to return.

2.2.2 Others

1 Warning light：Press once to turn on the warning light, twice to turn off;
2 Height positioning system: Press to enter the system, refer to 2.2.3 for more information;
3 180° rotation：Press to rotate the driving wheel 180°;
4 360° rotation：Press to rotate the driving wheel 360°;
5 AGV system：Optional;
6 Video：Press to start film;
7 Setting: Press to display system setting, and swich language (Chinese/English) by pressing
Language.

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2.2.3 Altitude positioning system
Press the Altitude positioning system button to enter the system. This system is mainly used for
indoor warehouse stacking. According to the set value, it can accurately locate the height of each rack
layer, so as to improve the stacking efficiency.

2.2.3.1 Select layer

At the page of Altitude positioning system, click Select Layer . In this page, the rack height is set
according to the height of each rack later of the actual warehouse. After setting, select the rack height
and the fork will automatically lift or lower to this position. At the same time, it also has the function of
rack height monitoring. Click OK to complete the setting and return to the Altitude positioning system
page.

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2.2.3.1.1 Rack height monitoring
At the page of select layer, click Monitorin, and click Return to return.

2.2.3.1.2 Rack height setting

At the page of Select Layer to enter the page of rack height setting,click CANCEL to return.

Click to enter the page of height value setting

Enter the height value, click ENTER to confirm and return to the page of Rack height setting
Finish entering all height values, click OK to return.

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2.2.3.2 Free height setting
At the page of Altitude Positioning System, click Free height to enter to set a free height, click
RETURN to return.

Click to enter the page of setting height value

Enter the wanted height value, click ENTER to return;

The fork will stop at the set height.

2.2.3.3 Parameter setting

At the page of Altitude Positioning System, click Parameter to enter the password page;

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 Enter the right password and click ENTER to the page of parameter setting

Click to the setting page

Enter the original value and the coefficients (suggested to be 0 and 1). Click ENTER to confirm and
retur.
2.3 Instrument panel（manual multi-way valve）：

1 Steering wheel：Adjust the traveling direction. Traveling angle shows at the display screen;
2 USB port: Charge portable device like cellphone;
3 E-lock: Turn on/off the truck. The key should be kept by the operator or the truck owner. Turn off the

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 power supply and put away the key when leaving the truck in case of any accident caused by
incorrect use;
4 Switch retained: Control extra functions like fan, red or blue light;
5 Multi-functional screen: See 2.4 for more information.
6 Lift lever：Lift and lower the fork. Pull it to lift, while push it to lower.
7 Reach lever：Control the fork to reach forward/backward. Pull it to reach backward, while push it to
reach forward.
8 Tilt lever：Control the fork to tilt forward/backward. Pull it to tilt the fork forward, while push it to tilt
the fork backward.
9 Side shift lever: Control the fork to shift to left/right. Pull it to make the forks shift to right, while
push it to make the forks shift to left.
10 Emergency stop switch：Control the power supply. Rotate and pull it to electrify the truck, and press
it down to shut down the truk. This switch is also used as an emergency stop witch. Once the truck is
out of control, press it immediately to stop the truck right away;
11 Horn:Make the horn sound;
12 Direction switch：Control the traveling direction. Turn the direction switch the forward and step on the
accelerator, the forklift will travel forward; turn the direction switch backward direction and press the
accelerator, the forklift will travel backward. When it is turned to the middle gear, it is in the neutral
state.

2.4 Multi-functional instrument（Manual multi-way valve）：

2.4.1 Warning indicator

No. Name Description
1 Turtle slow The indicator is on when the truck travels slowly
2 Fault The dicator is on when there is a fault
3 Battery The indictor is on when the power is≤ 20%
4 No lift The indictor is on when the power is≤ 10%
5 Seat The indicator is on when the operator is off the seat
6 Brake The indicator is on at braking

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2.4.2 Master page
No. Name Description
1 Hour meter Displays cumulative working time, with a maximum of 5 digits
2 Wheel angle The arrow indicates the wheel direction
3 Working module Displays working module among “S(slow)”、“P”、“E”
4 Speed Displays driving speed in km/h or MPH
5 BDI Displays power amount
“ ↑ ”shows up if the gear stick is in "Drive forward";
6 Forward/backward indicatior “ ↓ ”shows up when the gear stick is in"Drive backward";
No arrow symbol shows up when the gear stick is in "Neutral".

2.4.3 Key function

Symbol Name Description
Move the curse up or add the number by 1, or switch to S
UP
module (slow) at the master page
Move the curse left, or switch to P module (fast) at the master
Left
page
Move the curse right, or switch to E module (mid-speed) at the
Right
master page
Move the curse right, minor the number by 1,or switch to S
Down
module (slow) at the master page

Cancel Cancel or return

Confirm Confirm or enter the menu

2.5 Seat adjustment

The truck adopts high elastic damping seat, and the height, front and rear distance, backrest angle
and armrest position of the seat can be adjusted.

1 Safety belt：to protect the driver. It must be worn over operation.

2 Height adjusting rotary knob：to adjust the height of the seat. Rotate clockwise to increase the height;
Rotate counterclockwise to reduce the height.
3 Front and rear adjusting lever：to pull the lever upward, then drag the seat forward and back, adjust

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 the seat position back and forth.
4 Armrest adjusting rotary knob: Rotate the knob clockwise to adjust the armrest upward; rotate the
knob counterclockwise to adjust the armrest downward.
5 Cushion adjusting rotary knob: to turn the knob clockwise and adjust the backrest to a proper angle.

III. Safety Norms

 Explanations to the warning signs

The two warning signs indicate that:

1) never stand under fork arms in avoidance of
being hurt by the falling goods. Never stand
on fork arms in avoidance of falling down.
2) never reach your hands or other parts of
your body into here, otherwise you will be in
danger of being hurt by clamping.

 Hints related to safety devices:

In the structural graphics of the entire truck, No. 28 parts is a high-bit speed limiting switch
which moves when the height of fork arms exceeds the height of free lift, and when side oil cylinder
begin to lift. If this switch acts, the running speed of truck will be limited within 31m/h. So the safety
of aloft work will be ensured. Do check this switch regularly to ensure the normal work of this switch.
If it is damaged, the travel speed with fork arms in high position can not be decreased. Do stop
using the truck and repair or change the switch.

Warning:
Please pay attention to the following items first before operation :
1) Electric forklift is limited to utilization indoor with a hard flat floor. Operation in inflammable,
explosive environment or corrosive environment such as acid or alkaline condition shall be strictly
forbidden.
2) Only drivers who have received formal training or are authorized can be allowed to drive the forklift.
3) Read this instruction carefully before operation so as to master the performance ; check the truck
whether it is in its normal condition before each operation. It is forbidden to use faulty forklift; repair
by untrained persons is forbidden as well.
4) Do not reach out the mast and the fork at the same time to avoid forklift overturning.
5) As for stacking, center of gravity of the goods must be within range of the two forks. It is forbidden
to stack loose goods
6) The forklift shall travels slowly when forks pass in or out of goods rack. Sudden start or emergency
brake is forbidden. It is forbidden to turn within range of the goods rack. Slowly movement in straight
way must be promised.
7) The forklift must slow down in case of cornering. An abrupt turn is strictly forbidden during fast
travel.
8) The fork must be lowered below 1m in case of turning. High-lever turning is strictly forbidden.
9) Ground clearance of the fork shall be not in excessive of 0.5m in case of long-distance carriage. And
the mast shall be retracted with a small tilt angle backward for purpose of stabilization of the goods.
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10) Fore-and-aft movement mast shall be operated in a slow way if there are goods on the forks. An
abrupt push or pull of the fore-and-aft movement operating handle is prohibited.
11) Never stand on fork arms or pass across below the fork arms, or around the truck when stacking the
goods.
12) It is strictly forbidden to operate with people standing on the forks.

1. Specification of safety operation:

Warning
Wind force takes a direct effect on reliability and safety . Operation of the truck shall be forbidden in
case of a wind force above 8 degrees. Precautions shall be taken in forklift operation under a wind force
around 4~ 7 degrees, and lifting height and loading capacity shall be lowered accordingly.

1) Training of driver

Notice
Even though forklifts may have the same technical parameters, there may be differences on functions
of operating handles of braking, accelerating, and hydraulic system, and performances of those trucks
as well. Never drive the forklift until you get familiar with all those operations.

2) Wear of the driver during forklift driving:

Notice
Please put on protection cap, safety shoes, and protective clothes. Do not wear clothes that are too
loose for sake of being caught, which would result in danger.

3) Rules that must be observed:

Notice
Never drive the forklift when you are tired or un-concentrated, with an injection of drug, or after a
liquor drinking.
 Safety rules and regulations shall be observed during operation or maintenance .

4) Safety of working place:

Notice
The maximum grade ability stipulated in the parameter list refers to the capability of the truck crossing
obstacles. The mast shall be retracted and the forks will be lowered into the lowest position in case of
climbing. Goods lifting must be forbidden on slope.
a. Electric forklift is limited to utilization indoor with a hard and flat surface. It is strictly forbidden to
operate the forklift in inflammable, explosive environment or corrosive environment such as acid or
alkaline condition.
b. Good roadway condition shall be kept and the traffic should be smooth.
c. Sufficient light ray shall be ensured on working place.
d. Fire extinguishing appliances shall be equipped in the places where forklift and charging is operated.
The extinguishing appliances shall comply with the requirement of extinguishing fire of solid

16
 combustible matter and electric apparatus.
e. The value of the truck noise mentioned in instruction is measured under the condition of new forklift
running on flat, smooth and hard ground. If the traffic surface is bad or the tyre of truck is damaged,
the noise may be amplified.

5) Integrity shall be realized:

a. The forklift is equipped with blind goods rack and canopy guard shelves. Please do not dismantle the
canopy guard shelves.

Notice
Blind goods rack is used to protect objects from falling off. It shall be noted that blind goods rack is
used to prevent small items or light boxes from falling, but falling caused by a rated load would not be
prevented. Preventive measures shall be taken for potential falling objects.

Warning
Do not make modifications on the forklift.
b. Please observe safety rules and regulations of your working place during operation, inspection, and
maintenance .
c. No modification or addition shall be made to the forklift without written permission by our company. A
modification may have a negative effect on its rated load or safe operation.

6) Prepare safety operation procedure:

Safety operation procedure shall be formulated with consideration of practical situations before
operation . Safety shall be taken into full consideration in preparation of the safety operation procedure.

7) Operation of the truck under unsafe condition is strictly forbidden:

a. Operation under unsafe condition is forbidden, such as under conditions with uneven floor, or
impeded road. Lifting on slope is strictly forbidden.
b. Faulty forklift is forbidden to use.
c. Make sure a daily inspection of the truck would be taken. Please immediately repair or replace in case
of any abnormal conditions.

8) Overloading operation of the truck is forbidden:

Warning
Overloading operation of the truck is forbidden. Overloading operation would cause damage to the
forklift, and even result in tilting.
 Load curve shall be based on in operation.

9) Use suitable pallet:

Suitable pallet shall be used when loose goods are carried or stacked. And the goods shall be fixed
tightly for sake of falling down.
The palate shall be of suitable dimensions, neither too wide nor too large.

10) Electrical System Check

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 Notice
Before checking the electrical system, turn off the key switches, the emergency isolating switches and
pull off the chief power supply plug as well.

2. Safety Operation Specification

1) Check the safety condition around the forklift:

Notice
Before starting up the forklift, please ensure that there is no person around it.

Notice
If the driver’s view is shielded by the bulky goods carried, please drive backwards or drive under the
guidance of other working personnel.

Notice
Ensure no people around the forklift when driving backwards.

Notice
Driving through the narrow access shall be guided by working personnel.

Notice
At crossroad or other places impeditive for view, the driver shall not drive until there is no person at
both sides.

Notice
Keep concentration when operating forklift.

Caution
The driving mechanism of the truck is installed on the backside. Due to this difference from common
trucks, the backside of the truck swings comparatively fast when turning around. For this reason, to
prevent collision with other objects nearby the backside of the truck, do drive or turn slowly.

2) Strictly forbid harsh driving

Warning
When braking the forklift, never adopt the method of emergent reverse running.

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 Notice
Never start up, brake or turn abruptly.
 Abrupt start-up or braking may cause the falling of goods.
 Abrupt turning during traveling may cause the tilting of the truck and result in serious accident. Do
decelerate and take care to turn.

Notice

Observe all items of safety rules on working place. Decelerate and sound horn when meeting other
forklifts or trucks. Avoid driving in places with bad view.

Notice
Ensure to provide certain clearance among mast, roof and entrance.

3) Forbid rapid travel with fork arms rising up:

 When the fork arms are lifted higher than 2m, high speed running is forbidden. Under this condition,
never make the mast tilt and the fork arms side shift. When operating with the fork arms lifted,
unstable state and truck tilting may appear. So, operate with extreme care.

4) Forbid operating with the tip of fork arms:

Notice
In order to avoid damage or tilting , never squeeze, push or lift goods with fork tip.

5) Forbid push and pull operation:

 Never push and pull goods with forklift, which can damage truck or goods because of excessive
resistance.

6) Collision avoidance:

Warning
Never stand on fork arms or pass across below the fork arms.

7) Stabilize the goods:

 When running, the mast of the truck shall be tilted to certain position for sake of good stabilization.
 When running (loaded or unloaded), the distance between fork arms and ground level shall be
300-400mm.

8) Never drive too close to roadside:

Notice
Ensure to provide enough distance between the forklift and roadside or platform edge.
 When running on narrow road or platform, keep a certain safety distance with the edge against
falling off the truck.

19
9) Drive on slope

Notice
The following rules shall be observed when driving on slope:
Running with goods: Forward running when going upslope, backward running when going down slope.
Running without goods: Backward running when going upslope; forward running when going down
slope.

Warning
Avoid turning or loading and unloading operation on slope; otherwise the forklift can go tilting.
3. Operating specification

Notice
The forklift can only carry goods under rated capacity.
1) Forbid operation overloading.
2) Goods transported shall comply with the load curve of the truck, never operate with overload.
3) Transportation with overload can depress the back wheels’ pressure against ground, which can cause
slipping of the driving wheel and loss of direction control.
4) Forbid deflective loading and piling.
5) Passengers on forklift must be forbidden.
6) Never enter the mast mechanism
7) Never push or pull the handle abruptly
8) Under the cases that the fork arms with goods are at high position, the forward tilting operation of
mast is forbidden.
9) The height of goods is forbidden to be overhigh. The height of goods shall not exceed shielding rack.
Goods shall lean against the shielding rack. The goods piled by overlapping shall be fastened by
ropes to prevent collapsing. Under the compulsory cases that the height of goods exceeds that of
shielding rack, fasten the goods by ropes or put them in box. In this way, the danger that the driver
is hurt by falling goods can be avoided.
10) Never use the forklift as towing truck.
11) According to the size of loading pallet, the distance between fork arms shall be adjusted to the most
appropriate position. After adjustment lock it with locating pin.
12) When transporting over-wide goods, the driver shall be extremely careful to turn slowly to keep
balance of the goods and to lower down the goods to the largest possibility. Decelerate when ascent
and descent, meanwhile, watch around for sake of safety.
13) The faulty forklift for future repair must not be parked at places impeditive for traffic. Lower down
the fork arms to the lowest position and put on the warning board. Pull off the key. If the fork arms
are fail to lower down for reason of malfunction, hang the warning board on the fork arms to prevent
crushing passersby.
4. Important notice after operation:
1) Parking: Park the forklift at appointed place. Never park the truck on slope.
Ensure the following points to be achieved before leaving away the forklift:
a. Rise the fork arms to the highest point without load for several times. It can prevent rust of the
oil tank and other components unused for a long period.
b. Move the door backward. The mast tilts forward slightly. Lay down the fork arms naturally.
20
 c. Turn the steering wheel to the middle position.
d. Turn off the key switch and the power switch.
2) Clean up the forklift:

Notice
When cleaning up the electrical system, use compressed air but not water.
3) Charge:

Warning
Open flame is forbidden to appear at the charge places, otherwise, explosion or fire disaster can be
caused.
 Make a record of charge. As for the charge method, refer to the part about storage battery operation.

IV.Drive and operation

1. Prepare before operation:

Warning
Never use the faulty forklift.
 Before operation, check the forklift to make sure: whether oil leakage of hydraulic pipe exists,
whether all the supporting wheels work well, whether blocking phenomenon appears. Never use the
faulty forklift.
 Check the charge quantity of storage battery. Never use the forklift with empty batteries. Otherwise,
the lifetime of storage battery can be reduced greatly. More seriously, the storage batteries can be
damaged.
 Check the braking of the truck and the ascent, descent, running forward and backward.
 When getting on the truck, grasp hand rest with left hand and step on the stages with left foot. When
getting off the truck, grasp hand rest with right hand and support with left hand on the seat cushion,
then get off slowly. Never grasp the steering wheel or operating handle when on and off the truck,
and never jump on and off.
 After getting on the forklift, adjust the longitudinal separation of seat according to the practical
situation of driver. The adjusting method is to pull the handle under seat and then pull the seat
forward or backward.

2. Driving:
1) Start-up

Warning
When forking goods or moving goods, never step on the accelerator pedal abruptly to start up the
truck.
Sit on the seat of the truck; pull the power switch upwards to turn on the power. Turn the switch of
electric lock to ON position. Turn the direction switch to forward or backward position, hold the steering
wheel with left hand, and then step on the accelerator slowly until the truck starts up slowly.
2) Decelerate:
The driving motor is separately excited motor. The running speed of motor is controlled by speed
regulation actuator all the time. So, if you lift up your foot stepping on the accelerator panel, the truck will
decelerate slowly.
21
 Warning
When running, never lift up your foot stepping on the accelerator panel abruptly, otherwise, the forklift
will brake emergently.

3) Turning:

Caution
The driving mechanism of the truck is installed on the backside. Due to this difference from common
trucks, the backside of the truck swings comparatively fast when turning around. For this reason, to
prevent collision with other objects nearby the backside of the truck, do drive or turn slowly.

Danger
When the fork arms are at the higher position, turning is forbidden. Turning must not be made until the
fork arms are lowered down within the height of 0.4m.
The driver shall be seated with the right gesture: face up the steering wheel, operate the steering
wheel by left hand. When running forward, if the steering wheel turns counterclockwise, the forklift will
turn counterclockwise. If the steering wheel turns clockwise, the forklift will turn clockwise. When running
backward, if the steering wheel turns counterclockwise, the forklift will turn clockwise. If the steering
wheel turns clockwise, the forklift will turn counterclockwise.
4) Braking:
When the fork arms are at the higher position, please step on the braking panel slowly.
5) Piling operation:

Notice
Before operating forklift, do check the following items:
Ensure no goods falling and damaged in the loading area.
Ensure no goods or objects impeditive for safety.
The following procedure shall be observed for goods stacking：
1 Decelerate when approaching the stacking area;
2 Stop ahead of the stacking area;
3 Inspect safety condition around the stacking area;
4 Adjust position , placing it in front of place where goods locate;
5 Adjust the mast to be perpendicular to the ground. Slowly move the forklift, and stop at a
distance around 5cm from the goods;
6 Push forward the forward movement operation handle, making the fork insert into the bottom of
the goods as deeply as possible;
7 Pull backward inclination handle of the mast, making the mast incline backward;
8 Pull backward lifting operation handle of the fork, making goods rise to the position with a
distance around 10cm between bottom of the goods and ground jack of the fork;
9 Slowly pull movement operation handle of the mast, making the mast moving to the nearest
position;
10 Slowly start the forklift, travel to back part of the stacking area, and stop steadily;
11 Push inclination operating handle of the mast, adjusting it to vertical position;
12 Pull backward the lifting operation handle of the fork, raising goods to a position with a distance

22
 of 5-10cm between bottom of the goods/ pallet and goods rack;
13 Push forward the forward movement handle, making the goods precisely go into the goods
section. Then slowly lower the fork, leaving bottom of the goods with a distance around 3-5cm;
14 Pull backward the movement operation handle of the mast, drawing out the fork. Then slowly
travel the forklift backward, making the fork totally leave out of the goods;
15 Lower the fork to a height around 30cm above the ground, and drive the truck out of stacking
area.

Notice
If the goods hasn’t been put on the rack or bracket:
a. Please lower down the fork arms until they no longer bear weight.
b. Forklift backs off by 1/4 of the fork arm’s length.
c. Raise up the fork arms by 50-100 mm, move the truck forward and then put the goods on
appropriate places.

6) Unpiling:
When unpiling, comply with the following procedure:
1 Decelerate when approaching the goods to be moved.
2 Stop in front of goods (3cm between goods and tip of fork arms)
3 Ensure the goods to be within load and adjust the location of truck. Adjust the mast to make it
vertical to ground.
4 Watch the position of fork arms, move the truck forward simultaneously, and then stop when the
fork arms are 3-5cm far away from goods.
5 Push mast moving handle to move the mast forward, through which the fork arms can insert to
the bottom of goods as deeply as possible.
6 Pull mast lifting handle to lift the goods to the position 5-10 cm higher than the goods rack.
7 Pull mast moving handle to move the mast backward, and then move forklift backward slowly to
separate the goods and rack completely.
8 Lower down fork arms to the position 30 cm higher than ground level.
9 Drive the truck away from goods area.

V. Usage, maintenance and charge of storage battery

Diagram of charging

23
Charging steps:
1) Pull out the battery connector from the vehicle body;
2) Connects the battery connector with the charger connector;
3) Insert the charger power plug into the socket;
4) Turn on the power switch of the charger and start charging after a few seconds.

1. Initial charge

Warning
Hydrogen is aggregated in the battery box when charging. For this reason, the charging condition shall
be good ventilated. In avoidance of explosion and fire disaster, open flame is forbidden.

1.1 Initial charge shall be made for new battery, i.e. the first time charge. Clean up the surface of the
battery before the initial charge, and then check for damage to ensure reliable connection.
1.2 Open gas cap.
1.3 Under the condition that the charge devices work well, pour sulfuric acid electrolyte with density of
1.260±0.005 (25℃) and temperature less than 30℃ into the batteries. Make sure the electrolyte
level 15 to 25 (mm) higher than the protection plate. To make the electrolyte filter in the pores of
pole plates and division plates, through which, the ascending temperature caused by chemical
reaction in electrolyte can descended again, the battery need to be laid down for 3 to 4 hours, no
more than 8 hours. Initial charge can not be carried out until the electrolyte temperature lower down
less than 35℃ (Cool down in the cold water box if necessary). After laying down the electrolyte, its
level lowers down. Make up the electrolyte.
1.4 The sulfuric acid electrolyte is composed of the battery sulfuric acid which conforms to the national
standard GB4554－84 and distilled water. Never replace with industrial sulfuric acid and tap water.
The conversion formula under the standard temperature (25 ℃ ) and density of electrolyte is as
follows:
D25＝Dt+0.0007(t25)
In which, D25：Density of electrolyte at 25℃
Dt：Actual density of electrolyte at t℃
t ：Temperature of electrolyte when measuring density
1.5 Dry up the electrolyte spilled on the surface of battery. Connect the positive and negative poles of
batteries with those of D.C. source (charger) respectively and then turn on the power. Charge with
the current of 60A (the current of the first stage). After the charge voltage achieves 57.6V
(24×2.4V=57.6V), switch to the 30A current of the second stage for continuative charge. When
charging, the temperature of electrolyte shall never exceed 45℃. When the temperature raising up
nearly to 45℃, reduce the current by half or stop charging temporarily. After the temperature reduce
below 35℃, continue charging. However the charge time need to be extended appropriately.
1.6 Criterion of full charge: Charge until the voltage achieves 64.2V (24×2.6V=62.4V) during the second
stage. The voltage vibration is less than 0.005 (V) .The electrolyte densities achieve 1.280±0.005
(25℃). No apparent changes appear within 2 hours. Densely dotted fine bubbles appear abruptly. All
these phenomenon above accounts for the full charge of the battery. The charging capacity is 4 to 5
times of rated capacity. The charging time is 70 hours or so.
1.7 To control the content of sulfuric acid in electrolyte accurately, the electrolyte density of every battery
shall be checked at the end of charging. If unconformity is checked out, adjustment shall be carried
out by distilled water or sulfuric acid with the density of 1.40, and the density and level of electrolyte

24
 shall be adjusted to the specified value within 2 hours under charging state.
1.8 Wipe up the surface of battery after initial charge. Before put in use, the cover of the push-push type
vent plug shall be closed.
2. Use and maintenance
2.1 To ensure the lifetime of battery, the battery in use shall be in the state of full charge. Never use
those without enough charge. Watch the discharging extent closely when using. Over discharging is
forbidden, that is to say when the voltage reduces to 1.7V/set (the total voltage reduces to
1.7V×24=40.8V), as well as the electrolyte density reduces to 1.17, discharging shall be stopped and
charging shall be made in time and long time laying-aside is forbidden. This type of charging which
happens regularly during using is named common charge.
2.2 Common charge: As for the current of common charge, of which the first stage is 56A, the second
stage is 28A. The charge method is the same as that of initial charge, in which the supplied charges
covers a percentage of 130 to 140% of the discharging charges, the charge time is 15 hours or so.
2.3 The battery in normal use shall avoid overcharging. However, as for the following several cases,
appropriate overcharge for battery is necessary, i.e. named equalizing charge:
a) The lagging batteries in battery pack indicate those with lower voltage when discharging and
repaired batteries because of malfunction. (During equalizing charge, the positive and negative
pole of lagging battery shall be connected with those of D.C. source respectively.)
b) As for batteries in normal use, equalizing charge shall be carried out every 2 to 3 months.
c) As for batteries unused for a long period, equalizing charge shall be carried out before using.
2.4 Equalizing charge:
a) Charge with current of 8A.
b) The charging voltage achieves 62.4V (24×2.6V=62.4V). Charging shall be kept on with current
of half value (4A) when bubbles appear in the electrolyte.
c) After full charge, stop for 0.5 hour and then charge with current of 2A for 1 hour.
d) Stop for 0.5 hour again and then charge with current of 2A for 1 hour.
e) Repeat step d until the bubble appears acutely in battery whenever the charger switches on.
3. Keep and storage
The storage battery shall be kept in clean, dry and ventilated warehouse within the temperature
range of 5 to 40℃. The valid storage period is 2 years. Safekeeping shall be made within storage period
according to the following requirements:
a) Avoid direct sunlight. The distance from heat source shall not less than 2m.
b) Avoid contact with any harmful substance. No metal impurity shall fall inside the battery.
c) No inversion, no mechanical collision or heavy weight is permitted.
d) Storage with electrolyte is forbidden. Under special cases that the storage with electrolyte is
necessary, the density and solution level of electrolyte shall be adjusted to the specified value.
Whenever one month of storage period expires, a complementary charge shall be made.
4. Operation of electrolyte
1) Density check
The suction type densimeter shall be used to check density. During operation, avoid spilling out the
electrolyte, and do wear protection appliance.
2) Operation besides check
Consult professional personnel, especially when complementing electrolyte (dilute sulfuric acid).
3) Electrolyte leakage
As for the electrolyte leakage resulting from storage battery tilting and damage, emergency
treatment shall be made at once (See emergency treatment item).

25
5. Operation of storage batteries during the final stage of their lifetime
1) Operation of storage batteries during the final stage of their lifetime
When the lifetime of storage battery is about to terminate, the electrolyte in single battery reduces
very fast. By this reason, distilled water shall be complemented everyday.
2) Treatment of exhausted battery
As for the exhausted battery, draw out the electrolyte and decompose the battery. It can be
discussed that whether the exhausted battery shall be recycled by the battery manufacturer.
6. Emergency treatment
1) The electrolyte spills on skin: wash with large amount of water
2) The electrolyte spills into eyes: wash with large amount of water, and then seek help from specialized
doctor.
3) The electrolyte spills on clothes: take off clothes right away, wash with water, and then flush with
week basic soap solution.
4) The electrolyte leakage: in case of electrolyte leakage outside, Neutralize it with lime, strong carbonic
acid soda or carbonic acid soda, and then flush with large amount of water.
7. Charger
If the charger you use is full automatic type. It must meet with the following 2 requirements:
a) The output voltage of charger: 48V
b) The output current of charger: 60A
If the charger you use is semi automatic or manual variable, please charge the battery pack
according to the requirements of use and maintenance mentioned in the second tip.

8. User Requirements for the Secondary On-board Li-ion Battery System

This URD is generally applied into the usage , maintenance and any other operations occur to the
Li-ion batteries (Secondary On-board Li-ion Batteries System) on both electric storage and logistic trucks .
8.1 Requirements on operators
1) Relevant people who are able to use, maintain and take any actions to Li-ion batteries on all electric
storage and logistic trucks (hereinafter referred to as operators).
2) All operators only are allowed to operate the Li-ion batteries under the backgrounds of professional
training , acquiring certain knowledge of Li-ion batteries, and obtaining certifications from relevant
departments.
8.2 Safety Regulation
1) These signs shown below might be found either on the Li-ion battery cases or on the trucks, which
are set on the consideration of the safeties of the batteries as well as the operators. All the
operations must be under the guidance of them.
High Voltage Warning：
It indicates a possible danger of lightning shock. All the electric work of the equipment must
be finished only by qualified professional workers. Unauthorized disassembly is prohibited

Corrosive Risk Sign：

It indicates to pay attention to protect the products when unsafe factors exist over the
production.

Waterproof & Humidity proof Sign：

It indicates to protect the products from rain, water and humidity.

26
 No Fire Sign：
It indicates that fire is prohibited in this area when the product is on.

Do Not Step Sign：

It indicates the products must not be stepped on.

2) The use of Li-ion battery trucks shall be in accordance with the requirements of temperature,
humidity and environment specified in the truck instructions, and the maintenance and disassembly
of lithium battery shall be carried out when the battery case is clear without any foreign bodies,
especially metal tools, and there are no impurities or blockages in the air duct.
3) Operators are forbidden to short-circuit connect lithium batteries, otherwise the system will be
seriously damaged and people will be injured.
4) Li-ion batteries should be kept away from heat , fire and avoid long time direct sunlight. Li-ion
batteries must not be placed in liquid (such as water, solvent) or high humid environment to avoid
damages caused by leakage or short circuit.
5) Installation, commissioning and maintenance of lithium batteries in rain and snow weather should be
carried out indoors to prevent short circuit caused by rainwater entering Li-ion battery system..
6) Because of the communication protocol between the management of lithium batteries and trucks, it
is prohibited to interchange lithium batteries with the same voltage and capacity on different trucks
without the permission of the host plant.
7) It is forbidden to mix Li-ion batteries with other batteries in one truck. For the truck that is about to
replace batteries, it is necessary to check up whether the new batteries are with the same model
and with the same group or not before restart it.
8) The Li-ion battery cases shall be transported and moved strictly in accordance with the regulations
without any improper operations like towing, prying and kicking, which will cause mechanical impact
on the batteries, such as dropping, impacting and pressing. It’s highly prohibited to overlap, upside
down and side-up lithium battery cases.
9) It is necessary to ensure the correct connection and normal operation of the lithium battery
management system whether charging or discharging, and to ensure the normal communication
between the lithium battery management system and the truck system.
10) Li-ion batteries are prohibited to contact and to be placed together with objects that will possibly
cause a short circuit. Sharp stuff and workers in clothes and accessories with metal are not permitted
to get close to Li-ion batteries.
11) Periodically check the lithium battery information displayed by truck meters. If there is any problem,
do not open and operate the battery case by yourself. Contact relevant technical personnel
immediately for further guidance.
12) Unauthorized disassembly, damage and installation of lithium battery components are strictly
prohibited. It is forbidden to dissect lithium batteries or lithium battery groups without authorization
in order to avoid danger. Non-professional workers are forbidden to replace the data transmission
page and voltage acquisition page of lithium battery management system to prevent short-circuit
damages to system components and even cause fire. Safety warning signs must be obeyed for
safety ’s sake.
13) If operators find any of the following situations or have any concerns about the safety of the product,
shut down the truck first, and take measures like disconnecting the power connection to ensure the

27
 safety of both the operators and the truck, then immediately contact the relevant personnel for
further guidance. Solutions provided as follow:
a) Contact relevant technicians for emergency repair when see the signs of overheating, smoking,
sparking; battery pack damage (such as rupture), battery leakage; battery system case and
power cord take in water.
b) Contact relevant technicians for an overhaul when see ruptures or damages of the power cord,
plug, extension cord, protective device; or when confronted with the problems that don’t threat
personal or truck’s safety , like the truck fails to work normally.
8.3 Requirements on Charging the Li-ion batteries
1) The charging temperature range is 0-50 ℃ . Li-ion batteries are not allowed to charge in the
environment below 0 ℃ except those with heating system. Low-temperature charging will cause
lithium evolution and affect the service life of Li-ion batteries.
2) The charging place should keep clean and well ventilated, and always keep away from inflammable
and explosive articles. Fireworks are strictly prohibited in the charging area.
3) Operators are suggested to help themselves to charge only with the certain charging equipment
coming with the truck from the manufacture to maximize the safety performance of Li-ion batteries.
Make sure to connect the positive and negative poles correctly and never do reverse charging.
4) After the battery is fully charged, unplug the charging line in time to avoid other safety problems.
5) Abnormal termination of charging may occur during the charging process of lithium batteries. For
example, if the charging voltage is too high or the charging current is too large. The phenomenon is
defined as "Abnormal Termination of Charging". When it occurs, it may indicate the leakage of
lithium batteries or failure of some parts. It is necessary to notify relevant technicians for a complete
inspection, finding out the causes and solving them before resuming the charge.
8.4 Requirements on discharging the Li-ion batteries
1) Discharge temperature range is -20-60℃.
2) When a lithium battery fault is found in display during the start-up or operation of a truck, the cause
of the fault should be inquired according to the display code and the schedule of the truck instruction,
and the technical personnel should be notified to deal with it in time.
3) It is necessary to ensure that lithium batteries are not less than 50% charged before maintenance or
repair.
4) To prevent damages of lithium batteries caused by over discharge, it is necessary to charge lithium
batteries in time when the instrument displays low charge alarm.
8.5 Requirement on transportation and unloading
1) Firm out packages are highly required when Li-ion batteries are about to transport.
2) Sign of water proof, sing of humidity, sign of upward, sign of careful and light handling shall be
attached to the out packages. In case of being damaged, the battery cases must be placed upward
according to the sign.
3) When the lithium batteries are dislocated or extruded during transportation, the exposed wiring
harness and connectors should be checked to see if the lithium batteries are damaged or deformed.
In case of smoke, sparking, stay away from the scene immediately, and professional technicians
should be notified.
8.6 Requirements on the storage
1) The storage of lithium batteries should be in clean and ventilated rooms with ambient temperature
ranging from - 10 ~35 ℃ (recommended storage temperature ranging from 0 ~25℃). Long-term
storage batteries (more than 3 months) should be placed in an environment with temperature of 25
±3 ℃) and relative humidity of 65 (±20%).

28
2) The contact between lithium battery and corrosive chemicals or gases shall be avoided, so as to
prevent the corrosion of lithium battery or its connecting parts, affecting the appearance and service
life of the battery.
3) Keep Lithium batteries away from fire and heat, meanwhile, keep the batteries dry.
4) Insulation, waterproof and dustproof are required over the storage. Make sure that the protective
cover plate above the lithium battery case is fixed tightly without defects and damages. The battery
case should be covered with insulation materials and sealed if there is no sealing cover plate.
5) When lithium batteries are to be stored, the charge should be above 30%. In order to prevent over
discharge during long-term storage (more than 3 months), batteries should be charged regularly,
keeping the charge at 50%-80%.
6) It is required to conduct a charge check once a month for those long-term parking trucks. After check,
make sure the charge is between 50% and 80%. Charge it till the required amount if the charge is
insufficient.
7) Long-term idle lithium batteries need periodic charge-discharge activation and a standard
charge-discharge cycle once a month.

VI.Inspection before operation

For the sake of safety operation and good situation of the truck, it is compulsory to check the forklift
completely before operation. Contact the sales department of our company when founding problems.
 Check point and Check content:
No. Check point Check content

When the brake pedal is stepped on forward or backward, feel whether

1 Brake pedal
the force used is appropriate or not.
Braking system
Whether brake distance is proper when the whole truck is loaded. (2m at
2 Brake performance
the maximum speed.)
Steering wheel
3 Degree of tightness and rotary flexibility.
control
Steering system
Reliability of Whether oil leakage appears on the steering device, high pressure pipe
4
Hydraulic turning and hydraulic motor.

5 Function Function，Crack or not，lubricating or not.

Hydraulic 6 Oil pipe Leakage or not.

system and mast 7 Hydraulic oil Appropriate oil quantity.

8 Lifting chain Elasticity of chain.

Screws and all the

9 Check all the fasteners of the truck’s 3 wheels, i.e. screws, loose or not.
fasteners
Wheels
Compare the parameter list, replace the wheel when its diameter
10 Wear status
reduces by 5%.

11 Charge Confirm the display state of the battery capacity.

Battery 12 Electrolyte The solution level and density of electrolyte.

13 Connecting line The connecting line and socket shall be firm.

14 Horn Press down the horn button to check whether the horn sounds.
Horn
15 Backing up buzzer Step on the backward pedal to check whether the buzzer sounds.

29
 Turn on the switch of electric lock to check whether the instrument
Instrument 16 Function
displays normally.

17 Shielding rack Shielding rack shall be installed firmly.

Others 18 Fork arms Damaged or not. If there is any crack.

19 Other components Abnormal or not

VII. Inspection after operation

After operation, the smudge on forklift shall be wiped out. Besides, the following check shall be
carried out:
 Whether damage or oil leakage appears on any components
 Keep visibility of all graphics context marks such as warning signs, nameplate, figure of load curve and
notice board. These marks are able to instruct, caution and warn the operator to some degree.
 The situation about deformation, distortion, damage or breakage
 Add lubricating oil and grease if necessary.
 After operation, rise up the fork arms to the maximum height for several times
 Replace the component, which cause malfunction during operation

VIII. Periodic maintenance and repair

Comprehensive check for forklift can avoid malfunction and ensure the service lifetime. The time
listed in maintenance regulation is based on the cases that the forklift works for 8 hours per day and 200
hours per month. For the sake of safety, maintenance shall be carried out according to maintenance
procedure.

Notice
All the repair work shall be carried out by professional personnel.

1. Precautions during maintenance:

Notice
The components for replacement shall be produced completely by our company. When replacing
components of the trucks, the components with the same safety requirement with the original design
shall be used.

Notice
The lubricating oil and hydraulic oil in use shall be recommended by our company.
1) Places for maintenance

Notice
The places shall be appointed and they can provide other services such as hanging and safety
protection facility etc.
The places shall have level ground and good ventilation.
The places shall be equipped with fire-extinguishing plant.

30
2) Precautions before repair and maintenance:

Notice
 No smoking.
 Arrange the self-protection work.
 Wipeout the effusive oil in time.
 Before adding lubricating oil, clean up the original dirty oil or dust on the joint with brush or cloth.
 Except certain situation, turn off the key switch and pull off the power plug.
 Lower down the fork arms to ground when carrying out maintenance.
 Ensure no goods on the forklift when demounting the high pressure fuel pipe. Besides, the fork
arms shall be decreased to the extreme lower position, by this way, the pressure of hydraulic
system can be released.
 For the reason that there are capacitors storing a little amount of electric energy in circuit, so
before contacting the binding post of the main circuit, discharge at first.
 Clean the electric section with compressed air, never flush with water.
 When the forklift requires high-position maintenance, the altitude safety protection must be
carried out for the repairing and maintenance personnel.

2. Inspection and maintenance before the new forklift put into operation
In order to follow the industry related regulations and ensure the absolute security to the forklift in
the transportation, for new ex-factory forklift, it is possible that there is no electrolyte inside storage
battery before the first use (except the inland sale).
The electrolyte of storage battery is prepared well before the forklift leave the factory, and it is filled
into the storage battery by the professional personnel before the first use. First, place the forklift to the
site with good ventilation, open the lid of storage battery box, and open all the top plastic lids of storage
battery. The plastic pot with storage battery electrolyte inside is raised using plastic funnel, and the
electrolyte is poured into the storage battery in a slow way until the liquid level can be seen. After all the
storage battery is filled, the plastic lid is screwed down. If the electrolyte spills out of the storage battery,
it should be wiped immediately with cloth, in order to prevent eroding truck body and decreasing the
insulated resistance of the whole machine.

3. Daily inspection
 Inspection of hydraulic oil level: lower the fork to the lowest position, turn the cover of oil tank, and
look over the oil level shown by dipstick. The distance between oil level and cover of oil tank is about
30mm. Recommendatory trademark for the hydraulic oil should be chosen.
 Check the capability of storage battery: refer to the use and maintenance of storage battery.

4. The inspection according to the need

 Clean the forklift
 Clean and lubricate the lifting chain
 Inspect and screw down each fastener
 Inspect the damage state of wheels

31
5. The inspection and maintenance after 50 hours （Weekly）
No. Inspection and maintenance

1 Stepping on the advancing pedal or back pedal lightly, a noise is from brake.

Braking system 2 The oil dirt and dust on the turning gearwheel should be cleaned.

3 The clearance between brakes should be keep 0.6mm 0.4--0.8.

Inspect the liquid level of electrolyte, pure water can be used for supplement if the liquid
Capability of electrolyte 4
level is too low.

density of electrolyte 5 The specific gravity should be1.28g/ml after discharged.

Clean the storage battery 6 Lid the cover, and flush with tap water.

Inspect the contactor 7 Burnish the coarse surface of contacts using sand paper.

6. The inspection and maintenance after 200 hours（Monthly）

Besides the weekly maintenance, the following maintenance should be carried out:
No. Inspection position Inspection content

1 Whole status Abnormal or not.

Whole truck
2 Horn Sound
When you step on the forward or backward pedals,
3 Accelerator pedal
whether the forklift starts stably.
4 Brake Whether the brake distance is proper..
Manipulation of steering
5 Degree of tightness and turning flexibility.
wheel
The reliability of hydraulic Whether redirector, high-pressure oil pipe and
6
steering hydraulic motor leak or not.
Steering system, braking
system, hydraulic system Function ， whether there are cracks and lubricate
7 Mast
and lifting system instances or not.
Function ， whether there are cracks and lubricate
8 roller
instances or not.
9 Oil pipe Whether oil pipe leak or not.

10 Hydraulic oil The right quantity of oil.

11 Lifting chain Degree of tightness for chain.

12 Electrolyte Liquid level，specific gravity and cleanness

13 Plug Function, whether it is damage or not

14 Key switch Function

15 Contactor Contact performance and function

Storage battery, charger and
electric appliance system 16 Inching switch Function

17 Controller Function

18 Fuse Whether it is perfect or not

Wiring harness and
19 Whether flexible and whether damaged or not.
connection terminals

32
7. Maintenance for 600 hours（every three months）
During the maintenance every three months, the monthly maintenance process shall be repeated.
Inspection position No. Inspection content

1 Burnish the coarse surface of contacts using sand paper.

Contactor
2 Replace according to the status when the function is not well.

Motor 3 Wearing status of carbon brush and selenium rectifier.

8. The maintenance of 1200 hours（every six months）

During the maintenance for a half year, the maintenance process for three months shall be repeated,
and when the parts must be adjusted and replaced please contact with maintenance personnel of our
company.
Inspection position No. Inspection content

Decelerate box 1 Replace the gear oil

Oil filter 2 clean

Brake 3 The damage status of brake slices

Replace hydraulic oil (Replace hydraulic oil after six months for new truck. Afterward
Hydraulic system 4
replace hydraulic oil every year)

9. Recommended working medium

1) Hydraulic oil:
a. When it is normally loaded, we advise:
Hydraulic oil ： LHPISOVG46 ， in accordance with standard DIN51524T.2, the average sustained
temperature should between 40 degrees to 60 degrees.
b. When it is over loading, we advise:
Hydraulic oil ： LHPISOVG68 ， in accordance with standard DIN51524T.2, the average sustained
temperature is above 60 degrees.
c. When it is under loading with low temperature, we advise:
Hydraulic oil: HLPISOVG32, in accordance with standard DIN51524T.2, the average sustained
temperature is below 60 degrees.
d. At the occasion with variable loading, we advise:
All the working conditions mentioned above can use the hydraulic oil in accordance with standard
DIN51524T.2 for replacement. The viscidity of lubricating oil is very high (mostly used hydraulic oil).
If it is difficult to buy hydraulic oil, SAE20W/20 engine oil can be used to substitute HLP68 hydraulic
oil.
2) Gear oil：
Hyperbola gear oil 85W-90(GL-5)
3) Lubricating Grease:
Lithium grease of type 3

Notice
All kinds of depleted hydraulic oil, gear oil and grease will pollute the environment. For this reason,
recycle the replaced working medium or treat according to local pertinent regulations

33
10. Wearing parts replacement
1) Side lifting cylinder

①Dust ring DH45 ②Seal ring UHS45 ③Guiding sleeve ④O ring60X3.55 ⑤Hood
⑥Composite bush ⑦Cylinder ⑧Plunger ⑨Semi ring ⑩Wear ring

2) Middle lifting cylinder

①Piston rod ②Dust ring 55 ③Seal ring 55 ④O ring 70X3.2 ⑤Retaining ring
⑥O ring 64.4X3.1 ⑦Vent plug ⑧Cylinder ⑨Combined seal ring 70 ⑩Wear ring
⑪Piston

3) Tilting cylinder

①Dust ring DHS26 ②Wear ring ③Hood ④Seal ring UNS26 ⑤O ring 50X3.55
⑥Piston rod ⑦Seal ring UHS40 ⑧Cylinder assembly

34
4) Reaching Cylinder

①Cylinder ②Cotter pin ③Nut M16X1.5 ④Washer ⑤Seal ring UHS40

⑥O ring 13.1X2.65 ⑦Wear ring ⑧Piston ⑨Piston rod ⑩O ring 43.7X3.55
⑪Seal ring UHS26 ⑫O ring 25.8X3.55 ⑬Dust ring DH26 ⑭Guiding sleeve ⑮Piston rod joint

11. Maintenance period of consumables and partial of parts

Items Maintenance scope Maintenance period Remarks
Front wheel bearing Replacement 2000 hour
Mast roller Replacing lubricant grease 1000 hour
Carriage roller Replacing lubricant grease 1000 hour
Guide rail of mast and carriage Replacing lubricant grease 1000 hour
Gear box Replacing lubricant oil 1000 hour
Brake fluid Adding At any time
Hydraulic oil Replacement 1000 hour
High pressure fuel pipe Replacement 2000 hour Replace when damaged
Filter of hydraulic reservoir Cleaning 1000 hour
Lifting chain Lubricating 200 hour Replace when damaged
Check for carbon brushes and
Driving motor 1000 hour
bearings
Check for carbon brushes and
Steering motor 1000 hour
bearings
Check for carbon brushes and
Oil pump motor 1000 hour
bearings

IX.The store, transportation and loading of the truck

1. The store of the truck
If forklift is not used for over two months, it should be placed in the room which is in good ventilation, no
frost, clean and dry; also the following measures should be taken:
 Clean the forklift thoroughly.
 Lift and descend the fork completely for several times, check it is normal or not.
 Low the fork rack to the lowest, and mated with supporting block, in order to release the load
bearing on the chain.
 Support the side near to driver of truck with square timber to lift the driving wheels of truck from the
ground.
 Check hydraulic oil level, and add some oil if necessary.
 Wipe a layer flimsy oil or grease on all the bared surface of mechanical parts.
 Lubricate the forklift.
 Check the status of storage battery and electrolyte, and imbrue the non-acid lubricating grease to

35
 the connecting pole of storage battery.
 All the electrical contacts should be sprayed using appropriate contacts spray.
2. Transportation of the truck
If the truck requires to be transported for a long distance, support the side near to driver of truck
with square timber to lift the driving wheels of truck from the ground. The front wheel of the truck shall
be fixed stably by sphenoid wood block. Fasten the forklift to transporting truck with ropes.
3. Loading and unloading of the truck
Before loading forklift, check out the nameplate for the total weight of the truck to choose
appropriate hoisting handling equipment. The hoisting of the truck shall be kept level, and landing shall
be kept slow and stable. The personnel around shall watch for safety. One of the personnel is responsible
for conducting. If the other forklift is used for loading and unloading, please watch the bottom situation .
Take care to insert the fork arms to the bottom, in avoidance of damaging the driving wheel, balance
wheel and forward wheel.

X. Tow of the truck

When forklift cannot start up due to malfunction, it is needed to move to the right position, please
follow the methods below:
a) Turn off the power supply and pull off power connector when towing the forklift. If the forklift is
switched on when towing, the controller will be burned out.
b) Make a good connection between forklift and traction pole using soft cord and the maximum
dragging speed can not exceed 3km/h.
c) This forklift cannot be used as towing truck. That is to say, never use this forklift to tow the other
truck or objects.

XI. (Dis)assembly of removable parts

1. Weight and size of removable parts
Parameter Fork Battery Mast
Weight Size Weight Size Weight Size
Mode kg mm kg mm kg mm

CQD20-5M 126 120X40X1070 840 1160X344X752 1040 525X875X2250

CQD20-6.2M 126 120X40X1070 840 1160X344X752 1225 525X875X2650

CQD20-7.4M 126 120X40X1070 840 1160X344X752 1432 525X875X3100

CQD20-H-8M 126 120X40X1070 840 1160X344X752 1525 525X875X3300

CQD20-H-8.6M 126 120X40X1070 840 1160X344X752 1617 525X875X3500

CQD20-H-9.5M 126 120X40X1070 840 1160X344X752 1756 525X875X3800

CQD20-H-10.2M 126 120X40X1070 840 1160X344X752 1895 545X950X4100

CQD20-H-11.1M 126 120X40X1070 840 1160X344X752 2034 545X950X4400

CQD20-H-12M 126 120X40X1070 840 1160X344X752 2175 545X950X4700

CQD20-H-12.5M 126 120X40X1070 840 1160X344X752 2252 545X950X4866

CQD20-H-14M 126 120X40X1070 840 1160X344X752 2550 545X950X5466

36
2. Fork (dis)assembly
When the transportation of the truck, the fork arms may need to be demounted, then the following
method shall be followed:
1) Demount the screws between the beams below the fork rack.
2) Move the fork arms to the middle, the fork arms shall be just over the gap in the middle of the
beams below the fork rack.
3) Lift up the fork arms from the fork tip, and then demount it.
4) Mount the fork arms to the fork rack in adverse sequence. Take care when demounting the fork
arms. Never put hand into the gap between the fork rack and fork arms. It is extremely easy to
be hurt by clamping here.

3. (Dis)assembly of battery pack

Step 1: move the pull rod on the right side of the seat
downward;
Step 2: move the mast reach button to make the mast
assembly drive the battery forward, turn off the power
supply, and then pull out the battery connector from the
truck body;
Step 3: remove the battery baffle;
Step 4: move the battery to the battery or the other
available transportation tools;
Step 5: after the battery is replaced, fix the battery baffle,
connect the battery connector to the truck body, turn on
the power supply, pull the mast reach button backward to
make the mast assembly drive the battery backward and
the battery will return automatically.
Note: add electrolyte by finishing step 1 and 2.

37
4. (Dis)assembly of mast
1) as shown in the figure, lift the mast upward with lifting equipment, but the front wheel cannot be off
the ground. Remove all oil pipes connected to the mast.
2) as shown in the figure, remove the 8 screws fixing the mast.
3) lift the mast away from the forklift.
4) the installation of the mast is opposite to the above process. Note that after the mast is installed,
please press the heavy object on the fork and exhaust the air at the upper end of the middle oil
cylinder.

5) High line encoder installation instruction

High line encoder shall be installed as instruction after mast and oil pipes of the reach truck are
connected.

(1) Install the high line encoder (2) Route the line around the rolling
assembly and rolling bearing bearing as shown in the picture.
assembly.

38
 (3) Fix the ring of the pulling line to the (4) Place the protective plate of the
position shown in the picture rolling bearing, then connect the high
line encoder harness properly.

XII. Common faults and trouble shooting

Faults Possible cause Trouble shooting
The oil-absorptive filter is blocked Clean or replace the oil-absorptive filter
Fasten the tie-in, check the oil level, or add some
The oil-absorptive tube leaks and the oil are foaming.
oil
Abnormal noise Hydraulic pump or motor is damaged. Replace
Pressurize the malfunction, and make the air enter oil
Repair or replace
pump.
The viscidity of oil is not correct, oil level is too low. Replace the oil or add some oil
Malfunction in pump oil-absorptive, and noise exists. Replace the oil or add some oil

Hydraulic system Oil pump is damaged Replace

disability or the There is malfunction in valve arrays. Clean or replace
pressure is too
The pipeline is broken or leaking. Replace the pipeline or screw down the tie-in.
low
The viscidity of oil is not suitable; the leakage loss is too
Change the oil.
great.
Refer to the treatment methods for abnormal
The cause is the same as that of abnormal noise.
noise.
The oil pressure
is not stable The lifting cylinder or tilting cylinder is wearing. Replace the cylinder sleeve or seal parts
The quantity of oil is not enough Add oil
Storage battery is used up. Inspect, charge, or replace the storage battery
The tie-in of electrical wire is loosened. Screw down the tie-in screw
The forklift The fuse is burn out. Replace the fuse
cannot start Replace the seat chair, or make the switch plug
The seat chair switch is damaged.
short circuit.
The accelerator is damaged. Replace accelerator

The direction is The revolution transmitter is broken. Check out or replace the broken one.
ineffective. Electric power steering is broken. Check out, maintain or replace the broken one.
Brake cannot
The attrition slices of the brake are damaged Replace
work
Not release after The return spring of brake is damaged. Open the brake and inspect it.
braked There is too much dust in the brake. Open the brake and clear.

39
 Relife valve pressure adjustment
The pressure of the relief valve has been adjusted when the forklift leaves the factory, and the user
shall not adjust it at will, otherwise it will bring danger to the hydraulic system and the safety of the truck.
If the oil pressure is inconsistent with the specified value, please adjust it by professionals according to
the test method specified in JB/T 3300 standard:
1) Unscrew the measuring hole plug at the inlet of the multi-way valve and install a pressure gauge
with a range greater than 20MPa.
2) Operate the tilt joystick and measure the system pressure when the cylinder stroke reaches the
bottom.
3) When the oil pressure is inconsistent with the specified value, loosen the lock nut of the overflow
valve, turn the pressure regulating screw left and right, and adjust the pressure to the specified
value
4) Tighten the lock nut after adjustment.

Adjusting screw
Adjusting screw
Lock nut
Lock nut

Manual multi-way valve Electromagnetic multi-way valve

40
 Hydraulic schematic diagram（manual multi-way valve）：

 Hydraulic schematic diagram (Multiway solenoid valve)

41
 Electrical schematic diagram

42
 Manual multi-way valve

43
 Driving motor controller fault code (Solenoid valve)
Code Fault display Possible causes
Error
20 accelerator pedal switch is activated Accelerator pedal switch signal input in advance
at start
Error
21 the direction switch is activated at The direction switch signal is input in advance
start
Error
22 the front and rear direction switches Forward / reverse switch signals are input at the same time
are activated at the same time
Error
Accelerator analog signal is lower than "accelerator analog error low"
23 accelerator pedal analog value is out
Value or higher than "accelerator analog error high value"
of range
The controller does not receive the accelerator pedal switch signal,
Error
24 but the accelerator mode
accelerator pedal analog fault
Analog signal has input
1. Check whether the insulation of CAN communication line 33 / 21 is
good and whether the resistance between line 33 and 21 is 60 Ω;
2. If there is a remote module, remove it first and then test it;
3. Check whether each controller does not work (for example, check
whether the controller fault indicator is on);
Error 4. Monitor whether there are error frames in the can system. If so,
31
driver can communication failure eliminate the error frames (such as lithium battery CAN interference).
If there is interference in DC pump control, shield the communication
fault; Other communication problems can also be detected by this
method. For example, the truck is normally used but the instrument
direction display is stuck, or there is no lifting tilt but the walking is
normal.
Error
32 Need charging
low battery voltage
Error
34 Abnormal 12V / 5V power supply line of controller
traction drive internal error
Error
35 multiple pump action switches are Reset the pump control switch
activated at the same time
Error
36 Reset tilt switch
the tilt switch is active at start
Error
37 the sideshift switch is activated at Reset sideshift switch
start
Error
38 the accessory switch is activated Reset accessory switch
when starting
39 Error Reset the lift switch

44
 the lift switch is activated at start-up
Error
40 the shift forward / backward switch Reset the fore-and-aft switch
is activated at start
Error
41 Recalibrate the lifting analog quantity
lifting analog value is out of range
Error
42 forward and backward analog value Recalibrate the forward and backward analog quantity
is out of range
Error
the tilt back analog value is out of Recalibrate the tilt back analog
43 range
44 Error
shift left and right analog value out of Recalibrate left-right shift analog
range
1. Compare whether the monitoring temperature of the controller is
Warning
significantly different from the actual temperature;
traction Driver Low Temperature
2. The controller is broken.
1. Compare whether the monitoring temperature of the controller is
significantly different from the actual temperature;
81 2. Check whether sufficient silicone grease is applied between the
82 controller and the electric control aluminum plate and between the
Warning
electric control aluminum plate and the truck body;
traction driver high temperature
3. Check whether the operating current of the controller is
significantly higher than the commissioning current (it can be asked
from relevant technical personnel);
4. The controller is broken.
Error
83 traction drive temperature sensor Controller failure
error
Warning
84 [refer to the inspection method when ACS controller reports 86 fault]
low traction motor temperature
1. Compare whether the monitoring temperature of the controller is
significantly different from the actual temperature;
2. Check whether there is open circuit or poor insulation in the wiring
from the controller to the motor temperature sensor;
3. Measure whether the resistance value of the motor temperature
Warning sensor is normal (the resistance value is about 600 Ω at room
85
high traction motor temperature temperature), and whether the insulation with the motor line and
truck body is normal;
4. Check whether the operating current of the controller is
significantly higher than the commissioning current (it can be asked
from relevant technical personnel);
5. The controller is broken.
86 Error 1. Compare whether the monitoring temperature of the controller is

45
 traction motor temperature sensor significantly different from the actual temperature;
error 2. Check whether there is open circuit or poor insulation in the wiring
from the controller to the motor temperature sensor;
3. Measure whether the resistance value of the motor temperature
sensor is normal (the resistance value is about 600 Ω at room
temperature), and whether the insulation with the motor line and
truck body is normal;
4. The controller is broken.
1. Check the wiring from motor encoder to controller for open circuit
or poor insulation;
2. Check whether the encoder is installed in place or installed in the
Error
87 opposite direction;
traction motor speed sensor error
3. Replace the encoder (for the newly replaced encoder, confirm
whether the wiring definition is consistent with the original encoder);
4. The controller is broken.
Warning 1. Measure the battery voltage;
88
traction driver voltage high 2. Check the cable for looseness or poor insulation
Warning 1. Measure the battery voltage;
89
traction driver voltage low 2. Check the cable for looseness or poor insulation
Warning
90 For protection after refreshing the program, restart the key
traction drive default value is loaded
Battery power and voltage are both low
Warning Motor over temperature or controller over temperature,
91
traction driver energy limiting mode Truck limit output. Find out according to other fault codes reported at
the same time
1. Measure whether there is battery voltage on the 28 pin line of the
controller (it needs to be turned on)
Key switch (measurement);
Error 2. Measure whether the insulation of line 29 / 4 / 16 / 24 / 25 is good;
97
traction drive output port error 3. Measure the resistance between pin 29 and line 4 / 16 / 24 / 25
respectively (the normal resistance value is determined according to
the specific wiring);
4. The controller is broken.
Error 1. Check whether the motor line has open circuit or poor insulation;
101
traction motor driver short circuit 2. The controller is broken.
1. Compare whether the monitoring temperature of the controller is
significantly different from the actual temperature;
2. Check whether sufficient silicone grease is applied between the
controller and the electric control aluminum plate and between the
Error
102 electric control aluminum plate and the truck body;
traction drive temperature high
3. Check whether the operating current of the controller is
significantly higher than the commissioning current (it can be asked
from relevant technical personnel);
4. The controller is broken.
103 Error 1. Compare whether the monitoring temperature of the controller is

46
 high traction motor temperature significantly different from the actual temperature;
2. Check whether there is open circuit or poor insulation in the wiring
from the controller to the motor temperature sensor;
3. Measure whether the resistance value of the motor temperature
sensor is normal (the resistance value is about 600 Ω at room
temperature), and whether the insulation with the motor line and
truck body is normal;
4. Check whether the operating current of the controller is
significantly higher than the commissioning current (it can be asked
from relevant technical personnel);
5. Controller failure
Error [refer to the inspection method when ACS controller reports 101
104
traction drive overcurrent fault]
1. Check whether the battery voltage is too low;
2. Check whether the precharge resistance is normal;
3. Measure whether the insulation between the motor line and the
truck body is normal;
Error
105 4. Check whether there are other wiring (including the power line
traction drive precharge timeout
connected to the pump control) on the controller B + terminal except
the normal contactor copper bar. If
If yes, it needs to be removed before testing;
5. The controller is broken.
Error 1. Measure the battery voltage;
110
traction driver voltage low 2. Check the cable for looseness or poor insulation
Error 1. Measure the battery voltage;
111
traction driver voltage high 2. Check the cable for looseness or poor insulation
Error
113 the safety pedal switch is activated Reset the safety pedal switch
when starting
1. Check whether the wiring from the accelerator to the controller has
poor insulation, unplug the accelerator plug-in, and test whether
there is still code 114 (if yes, go to the next step, if not, it is
accelerator fault);
2. Check whether the wiring from the motor encoder to the controller
has poor insulation, unplug the motor encoder plug-in, and test
Error whether there is 114 code (if yes, proceed to the next step; if not, it
114 traction drive internal power supply is the motor encoder fault);
failure 3. Check whether the wiring from the lifting speed regulation sensor
to the controller has poor insulation, unplug the lifting speed
regulation sensor plug-in, and test whether there is still code 114 (if
there is, proceed to the next step, if there is no, it is accelerator fault)
[it is not necessary to check if there is no lifting speed regulation
function or semi AC truck];
4. The controller is broken.
Warning 1. Compare whether the monitoring temperature of the controller is
121
pump driver low temperature significantly different from the actual temperature;

47
 2. The controller is broken.
1. Compare whether the monitoring temperature of the controller is
significantly different from the actual temperature;
2. Check whether sufficient silicone grease is applied between the
controller and the electric control aluminum plate and between the
Warning
122 electric control aluminum plate and the truck body;
pump driver temperature high
3. Check whether the operating current of the controller is
significantly higher than the commissioning current (it can be asked
from relevant technical personnel);
4. The controller is broken.
Error
123 Controller failure
pump driver temperature sensor error
1. Compare whether the monitoring temperature of the controller is
significantly different from the actual temperature;
2. Check whether there is open circuit or poor insulation in the wiring
from the controller to the motor temperature sensor;
Warning
124 3. Measure whether the resistance value of the motor temperature
pump motor temperature low
sensor is normal (the resistance value is about 600 Ω at room
temperature), and whether the insulation with the motor line and
truck body is normal;
4. The controller is broken.
1. Compare whether the monitoring temperature of the controller is
significantly different from the actual temperature;
2. Check whether there is open circuit or poor insulation in the wiring
from the controller to the motor temperature sensor;
3. Measure whether the resistance value of the motor temperature
Warning sensor is normal (the resistance value is about 600 Ω at room
125
pump motor temperature high temperature), and whether the insulation with the motor line and
truck body is normal;
4. Check whether the operating current of the controller is
significantly higher than the commissioning current (it can be asked
from relevant technical personnel);
5. The controller is broken.
1. Compare whether the monitoring temperature of the controller is
significantly different from the actual temperature;
2. Check whether there is open circuit or poor insulation in the wiring
Error from the controller to the motor temperature sensor;
126 pump motor temperature sensor 3. Measure whether the resistance value of the motor temperature
failure sensor is normal (the resistance value is about 600 Ω at room
temperature), and whether the insulation with the motor line and
truck body is normal;
4. The controller is broken.
1. Check the wiring from motor encoder to controller for open circuit
Error or poor insulation;
127
pump driver speed sensor failure 2. Check whether the encoder is installed in place or installed in the
opposite direction;

48
 3. Replace the encoder (for the newly replaced encoder, confirm
whether the wiring definition is consistent with the original encoder);
4. The controller is broken.
Warning 1. Measure the battery voltage;
128
pump driver voltage high 2. Check the cable for looseness or poor insulation
Warning 1. Measure the battery voltage;
129
pump driver voltage low 2. Check the cable for looseness or poor insulation
The default value of warning pump
130 For protection after refreshing the program, restart the key
driver is loaded
1. Check whether the wiring from the accelerator to the controller has
poor insulation, unplug the accelerator plug-in, and test whether
there is still code 114 (if yes, go to the next step, if not, it is
accelerator fault);
2. Check whether the wiring from the motor encoder to the controller
has poor insulation, unplug the motor encoder plug-in, and test
whether there is 114 code (if yes, proceed to the next step; if not, it
Error
134 is the motor encoder fault);
pump driver internal error
3. Check whether the wiring from the lifting speed regulation sensor
to the controller has poor insulation, unplug the lifting speed
regulation sensor plug-in, and test whether there is still code 114 (if
there is, proceed to the next step, if there is no, it is accelerator fault)
[it is not necessary to check if there is no lifting speed regulation
function or semi AC truck];
4. The controller is broken.
1. Measure whether there is battery voltage on pin 19 of the
controller (it needs to be turned on)
Error Key switch (measurement);
137
pump driver output port failure 2. Measure whether the insulation of line 19 / 2 / 10 is good;
3. Unplug the fan relay and seat buzzer respectively for test;
4. The controller is broken.
Warning
1. Check whether the motor line has open circuit or poor insulation;
138 pump driver overcurrent or short
2. The controller is broken.
circuit
Error 1. Check whether the motor line has open circuit or poor insulation;
141
pump driver short circuit 2. The controller is broken.
1. Compare whether the monitoring temperature of the controller is
significantly different from the actual temperature;
2. Check whether sufficient silicone grease is applied between the
controller and the electric control aluminum plate and between the
Error
142 electric control aluminum plate and the truck body;
high pump driver temperature
3. Check whether the operating current of the controller is
significantly higher than the commissioning current (it can be asked
from relevant technical personnel);
4. The controller is broken.
143 Error 1. Compare whether the monitoring temperature of the controller is

49
 high pump motor temperature significantly different from the actual temperature;
2. Check whether there is open circuit or poor insulation in the wiring
from the controller to the motor temperature sensor;
3. Measure whether the resistance value of the motor temperature
sensor is normal (the resistance value is about 600 Ω at room
temperature), and whether the insulation with the motor line and
truck body is normal;
4. Check whether the operating current of the controller is
significantly higher than the commissioning current (it can be asked
from relevant technical personnel);
5. The controller is broken.
1. Check whether the wiring from the accelerator to the controller has
poor insulation, unplug the accelerator plug-in, and test whether
there is still code 114 (if yes, go to the next step, if not, it is
accelerator fault);
2. Check whether the wiring from the motor encoder to the controller
has poor insulation, unplug the motor encoder plug-in, and test
Error whether there is 114 code (if yes, proceed to the next step; if not, it
144 pump driver internal power supply is the motor encoder fault);
failure 3. Check whether the wiring from the lifting speed regulation sensor
to the controller has poor insulation, unplug the lifting speed
regulation sensor plug-in, and test whether there is still code 114 (if
there is, proceed to the next step, if there is no, it is accelerator fault)
[it is not necessary to check if there is no lifting speed regulation
function or semi AC truck];
4. The controller is broken.
1. Check whether the battery voltage is too low;
2. Check whether the precharge resistance is normal;
3. Measure whether the insulation between the motor line and the
Error truck body is normal;
145
pump driver precharge timeout 4. Check whether there are other wiring (including the power line
connected to the pump control) on the controller B + terminal except
the normal contactor copper bar. If so, remove it first and then test;
5. The controller is broken.
Error 1. Measure the battery voltage;
150
pump driver voltage low 2. Check the cable for looseness or poor insulation
Error 1. Measure the battery voltage;
151
pump driver voltage high 2. Check the cable for looseness or poor insulation
Warning
152 Both the travel + pump enter the energy limiting mode
enters the energy limiting mode
Error 1. Check whether the motor line has open circuit or poor insulation;
201
steering driver short circuit 2. The controller is broken.
1. Compare whether the monitoring temperature of the controller is
Error significantly different from the actual temperature;
202
steering driver temperature high 2. Check whether sufficient silicone grease is applied between the
controller and the electric control aluminum plate and between the

50
 electric control aluminum plate and the truck body;
3. Check whether the operating current of the controller is
significantly higher than the commissioning current (it can be asked
from relevant technical personnel);
4. The controller is broken.
1. Compare whether the monitoring temperature of the controller is
significantly different from the actual temperature;
2. Check whether there is open circuit or poor insulation in the wiring
from the controller to the motor temperature sensor;
3. Measure whether the resistance value of the motor temperature
Error sensor is normal (the resistance value is about 600 Ω at room
203
high steering motor temperature temperature), and whether the insulation with the motor line and
truck body is normal;
4. Check whether the operating current of the controller is
significantly higher than the commissioning current (it can be asked
from relevant technical personnel);
5. The controller is broken.
Error
[refer to the inspection method when ACS controller reports 114
204 steering drive internal power supply
fault]
failure
1. Check whether the battery voltage is too low;
2. Check whether the precharge resistance is normal;
3. Measure whether the insulation between the motor line and the
Error truck body is normal;
205
steering drive precharge timeout 4. Check whether there are other wiring (including the power line
connected to the pump control) on the controller B + terminal except
the normal contactor copper bar. If so, remove it first and then test;
5. The controller is broken.
Error 1. Measure the battery voltage;
206
steering driver voltage low 2. Check the cable for looseness or poor insulation
Error 1. Measure the battery voltage;
207
steering driver voltage high 2. Check the cable for looseness or poor insulation

Error The output pulses of steering wheel sensor and steering motor are
208 quite different, so it is necessary to check the encoder of steering

speed life count timeout motor and steering wheel sensor

Error
209 Steering wheel sensor error
steering wheel encoder fault
1. Check the wiring from motor encoder to controller for open circuit
or poor insulation;
2. Check whether the encoder is installed in place or installed in the
Error
210 opposite direction;
steering driver speed sensor failure
3. Replace the encoder (for the newly replaced encoder, confirm
whether the wiring definition is consistent with the original encoder);
4. The controller is broken.

51
 1. Compare whether the monitoring temperature of the controller is
significantly different from the actual temperature;
2. Check whether there is open circuit or poor insulation in the wiring
Error from the controller to the motor temperature sensor;
211 steering motor temperature sensor 3. Measure whether the resistance value of the motor temperature
failure sensor is normal (the resistance value is about 600 Ω at room
temperature), and whether the insulation with the motor line and
truck body is normal;
4. The controller is broken.
Error
212 steering driver temperature sensor The controller is broken.
failure
If the steering contactor cannot be closed or the circuit from the
Error
213 driving line of the steering contactor to the controller is damaged,
steering contactor failure
check the circuit
Error
214 steering driver valve control relay nothing
failure
Error After startup, the steering controller cannot find the zero position, so
215
steering start calibration failure it is necessary to check the proximity switch
Error
217 [refer to the inspection method when ACS controller reports 97 fault]
steering driver output port failure
1. Compare whether the monitoring temperature of the controller is
significantly different from the actual temperature;
2. Check whether there is open circuit or poor insulation in the wiring
from the controller to the motor temperature sensor;
Warning
218 3. Measure whether the resistance value of the motor temperature
steering motor temperature low
sensor is normal (the resistance value is about 600 Ω at room
temperature), and whether the insulation with the motor line and
truck body is normal;
4. The controller is broken.
1.Compare whether the monitoring temperature of the controller is
significantly different from the actual temperature;
2. Check whether there is open circuit or poor insulation in the wiring
from the controller to the motor temperature sensor;
3.Measure whether the resistance value of the motor temperature
Warning
219 sensor is normal (the resistance value is about 600 Ω at room
steering motor temperature high
temperature), and whether the insulation with the motor line and
truck body is normal;
4.Check whether the operating current of the controller is
significantly higher than the commissioning current (it can be asked
from relevant technical personnel);5. The controller is broken.
1.Compare whether the monitoring temperature of the controller is
Warning
220 significantly different from the actual temperature;
steering Driver Low Temperature
2.The controller is broken.

52
 1.Compare whether the monitoring temperature of the controller is
significantly different from the actual temperature;
2. Check whether sufficient silicone grease is applied between the
controller and the electric control aluminum plate and between the
Warning
221 electric control aluminum plate and the truck body;
steering driver temperature high
3.Check whether the operating current of the controller is
significantly higher than the commissioning current (it can be asked
from relevant technical personnel);
4.The controller is broken.
Warning 1. Measure the battery voltage;
222
steering driver voltage high 2. Check the cable for looseness or poor insulation
Warning 1. Measure the battery voltage;
223
steering driver voltage low 2. Check the cable for looseness or poor insulation
Error
231 [refer to the inspection method when ACS controller reports 31 fault]
traction driver can timeout
Error
232 [refer to the inspection method when ACS controller reports 31 fault]
pump driver can timeout
Error
233 [refer to the inspection method when ACS controller reports 31 fault]
steering driver can timeout
1. Check whether the wiring from the motor encoder to the controller
has poor insulation, unplug the motor encoder plug-in, and test
Error whether there is 114 code (if yes, proceed to the next step; if not, it
234
steering drive internal error is the motor encoder fault);
2. The controller is broken;
3. Check the angle sensor wiring
Warning
235 For protection after refreshing the program, restart the key
steering drive default load

 Driving motor controller fault code （Manual multi-way valve）

Code Fault display Troubleshooting
13 HPG CONTROLLER EEPROM KO Reset key
ERROR
20 Incorrect start Accelerator pedal switch Release pedal switch
active before key on
ERROR
21 Incorrect start Forward switch or reverse Turn off the direction switch
switch active before key on
ERROR
22 Forward switch and reverse switch active at Direction switch fault
the same time
ERROR
23
Throttle analog value out of range
Throttle fault or analog need to be calibrated
ERROR
24
Throttle analog fault
30 VMN LOW HPG controller battery voltage low need charge

53
 HPG controller battery voltage low
ERROR
31 Check CAN wire of controller and display
Traction controller CAN communication fault
ERROR
32 Need charge
Battery voltage low
NO FULL COND.
33 Reset key
DC MOTOR VOLTAGE HIGH
ERROR
34 Reset key
CPU fault
ERROR
36 Incorrect start Tilt switch active before key Reset tilt switch
on
ERROR
37 Incorrect start Side switch active before key
Reset side switch
on
ERROR
38 Incorrect start Attachment switch active Reset attachment switch
before key on
ERROR
39 Incorrect start Lift switch active before key Reset lift switch
on
ERROR
40 Lift analog fault or need to be calibrated
Lift analog value out of range
ERROR
43 Steer analog fault or need to be calibrated
Steer analog value out of range
WARNING
44 Truck speed is too high alarm
Traction controller speed protection
WARNING 1. Traction controller encoder fault
45
Traction controller encoder fault 2. Traction motor speed sensor connection wire is open
I=0 EVER
49 HPG CONRTOLLER SENSOR FAULT
DC MOTOR OPERATING CURRENT IS ZERO
STBY I HIGH
53 HPG CONRTOLLER OVER CURRENT
HPG CONRTOLLER OVER CURRENT
TH. PROTECTION
HPG CONTROLLER TEMPERATURE
62 HPG CONTROLLER TEMPERATURE
HIGH NEED COOL
HIGH
BATTERY LOW
66 HPG CONTROLLER BATTERY LOW NEED CHARGE
HPG CONTROLLER BATTERY LOW
DRIVER SHORTED
74 HPG CONTROLLER DRIVER SHORTED
HPG CONTROLLER DRIVER SHORTED
COIL SHORTED
76 HPG CONTROLLER COIL SHORTED
HPG CONTROLLER COIL SHORTED
VACC NOT OK
78 HPG CONTROLLER VACC NOT OK
HPG CONTROLLER VACC NOT OK
79 INCORRECT START HPG CONTROLLER INCORRECT START

54
 HPG CONTROLLER INCORRECT START
WARNING
81 Traction controller temperature is low alarm
Traction controller temperature is low
WARNING
82 Traction controller temperature is high alarm
Traction controller temperature is high
ERROR
83 Traction controller temperature sensor fault
Traction controller temperature sensor fault
WARNING 1. Traction motor temperature is low
84
Traction motor temperature is low 2. Traction motor temperature sensor is fault
WARNING 1. Traction motor temperature is high
85
Traction motor temperature is high 2.Traction motor temperature sensor is fault
ERROR 1. Traction motor temperature sensor is fault
86
Traction motor temperature sensor fault 2.Traction motor temperature sensor connection wire is open
ERROR 1. Traction motor encoder fault
87
Traction motor encoder fault 2. Traction motor speed sensor connection wire is open
WARNING 1. DC bus voltage high
88
DC bus voltage of traction controller is high 2. The ramp is too steep
WARNING
89 Need to charge or check power wiring
DC bus voltage of traction controller is low
WARNING
90 The default value of the traction controller is Reset key
updated
WARNING
91 Battery low truck speed limit
Traction drive limit
ERROR
97 Check the wire of open drain of traction output open or short
Open drain of traction output open or short
WARNING
98 Check power wiring
Traction controller over current or short
ERROR 1. Check power wiring
101
Traction controller short 2. Controller enable before contactor pull
ERROR
102 Traction controller temperature is high cut Traction controller temperature is high need cool
back
ERROR 1. Traction motor temperature is high need cool
103
Traction motor temperature is high cut back 2. Traction motor temperature sensor fault
ERROR 1. Truck overload or Mechanical clamping
104
Traction controller over current 2. Traction motor speed sensor fault
ERROR
105 Replace the pre charge resistance
Traction controller precharge failed
ERROR
110 DC bus voltage of traction controller is low Battery need charge
cut back
ERROR
111 DC BUS voltage of traction controller is high DC BUS voltage of traction controller is high cut back
cut back

55
 ERROR
DC BUS voltage of traction controller is high cut back(Hardware
112 DC BUS voltage of traction controller is high
monitoring)
cut back(Hardware monitoring)
ERROR Traction motor temperature sensor or speed sensor connection
114
Internal power supply error wire is open
WARNING
121 Pump controller temperature is low alarm
Pump controller temperature is low
WARNING
122 Pump controller temperature is high alarm
Pump controller temperature is high
ERROR
123 Pump controller temperature sensor fault
Pump controller temperature sensor fault
WARNING 1. Pump motor temperature is low
124
Pump motor temperature is low 2. Pump motor temperature sensor fault
WARNING 1. Pump motor temperature is high
125
Pump motor temperature is high 2. Pump motor temperature sensor fault
ERROR 1. Pump motor temperature sensor fault
126
Pump motor temperature sensor fault 2. Pump motor temperature sensor connection wire is open
ERROR 1. Pump motor speed sensor fault
127
Pump controller encoder fault 2. Pump motor speed sensor connection wire is open
WARNING
128 DC BUS voltage of pump controller is high
DC BUS voltage of pump controller is high
WARNING
129 Check power wiring
DC BUS voltage of pump controller is low
WARNING
130 The default value of the pump controller is Reset key
updated
WARNING
132 Battery voltage low need charge
Pump drive limit
ERROR
137 Check the wire of open drain of pump output open or short
Open drain of pump output open or short
WARNING
138
Pump controller over current or short
ERROR
141
Pump controller short Check power wiring
ERROR
142 Pump controller temperature is high cut
back
ERROR Pump motor temperature is high
143
Pump motor temperature is high cut back alarm
ERROR
144 Reset key
Pump controller current calibration error
ERROR
145 Replace the pre charge resistance
Pump controller precharge failed
ERROR
150 DC BUS voltage of pump controller is low cut back
DC BUS voltage of pump controller is low

56
 cut back
ERROR
151 DC BUS voltage of pump controller is high DC BUS voltage of pump controller is high cut back
cut back
ERROR
DC BUS voltage of pump controller is high cut back(Hardware
152 DC bus voltage of pump controller is high
monitoring)
cut back(Hardware monitoring)
ERROR
153 Reset key
Pump controller CPU fault
156 Temperature protection Temperature protection
157 BMS over temperature protection BMS over temperature protection need cool
158 BMS single body over discharge BMS single body over discharge need charge
159 BMS over voltage protection BMS over voltage protection
161 DISPLAY CAN FAULT CHECK DISPLAY AND CONTROLLER CAN CONNECTION
163 BMS over current BMS over current
164 Charge protection Charge protection
Seat switch off after a period of time,the
165 Reset direction switch
direction of the request to reset
168 BMS indicates Limit Current alarm BMS indicates Limit Current alarm
169 BMS indicates cutoff Current alarm BMS indicates cutoff Current alarm
170 BMS indicates brake Current alarm BMS indicates brake Current alarm
171 BMS CAN Error BMS CAN Error
200 Proportional valve error Proportional valve error
241 HPG CONTROLLER CAN BUS KO CHECK CAN WIRE OPEN AND CAN SPEED RATE
HPG CONTROLLER BATTERY OVER
242 HPG CONTROLLER BATTERY OVER VOLTAGE
VOLTAGE
243 HPG CONTROLLER KEY SHORTED HPG CONTROLLER KEY SHORTED
WATCHDOG HPG CONTROLLER WATCHDOG
244
HPG CONTROLLER WATCHDOG ERROR ERROR
WAITING FOR MC
246 HPG CONTROLLER WAITING FOR MAIN TURN OFF THE PUMP CONCTACTOR PARAMETER
CONTACTOR

57
 Maintenance and repairing reading card:
Items Maintenance time Maintenance Part Material used Maintenance personnel Remarks

 Customer advisement feedback:

Items Happening time Location of faults Reason of faults Trouble-shooting Remarks

58