Hi Range

ELECTRIC STACKER CDD12/14/16/20-AC1

CDD12/14/16/20-AZ3
CTD12/14/16/20-AC1
CTD12/14/16/20-AZ3
CDD12/14/16/20-AC1S
CDD12/14/16/20-AZ3S
CTD12/14/16/20-AC1S
CTD12/14/16/20-AZ3S-
OPERATION AND MAINTENANCE MANUAL

Original Instruction

HANGCHA GROUP CO., LTD.

11/2018
 FOREWORD
Thank you very much for purchasing the A series hi range electric stacker of Hangcha Group .
A series hi range electric stacker is a newly developed product for warehouse logistic, it owns
characteristics as advanced performance, comfort operation, safety and security, low maintenance
cost, and is an ideal tool for handling goods in warehouse, supermarket and workshop.
Part one of this manual is about the brief introduction and correct operation of the hi range electric
stacker, which will tell you how to operate safely and maintain preventively; part two will tell you
the structure, working principle and maintenance of the hi range electric stacker. In order to
guarantee safety and utilize the truck performance to the best, relevant operator and maintainer
must read this manual.
Because of the update and improvements of our products, there may be some differences
between this operation manual contents and your forklift truck.
If you have any questions, please contact HANGCHA GROUP CO., LTD. sales company or the
agent.

© 11/2018 HANGCHA GROUP CO., LTD

 Content
Part Ⅰ: Operation and maintenance ........................................................................................... 1
1 Truck Introduction.................................................................................................................... 1
1.1 General .................................................................................................................................... 1
1.2 Use occasion and condition..................................................................................................... 3
1.3 Main part name ........................................................................................................................ 4
1.4 Display and control .................................................................................................................. 7
1.4.1 Display ..................................................................................................................................... 8
1.4.2 Control ................................................................................................................................... 10
1.4.3 Others .................................................................................................................................... 12
1.5 Standard technical data ......................................................................................................... 13
1.6 Product plates and warning labels location ........................................................................... 27
2 Safety Rules .......................................................................................................................... 29
3 Transport ............................................................................................................................... 32
3.1 Lifting by crane ...................................................................................................................... 32
3.2 Securing the truck during transport ....................................................................................... 33
3.3 How to remove a broken truck............................................................................................... 34
4 Battery ................................................................................................................................... 35
4.1 Attention for using battery ...................................................................................................... 35
4.2 Dimension/Service Weight .................................................................................................... 37
4.3 Charging the battery .............................................................................................................. 38
4.4 Replacing the battery ............................................................................................................. 43
5 New truck breaking-in ........................................................................................................... 44
6 Operation............................................................................................................................... 45
6.1 Check before operation ......................................................................................................... 45
6.2 Starting up.............................................................................................................................. 47
6.3 Travelling................................................................................................................................ 48
6.4 Braking ................................................................................................................................... 50
6.5 Steering.................................................................................................................................. 50
6.6 Stopping ................................................................................................................................. 50
6.7 Loading .................................................................................................................................. 50
6.8 Unloading ............................................................................................................................... 51
6.9 Parking ................................................................................................................................... 53
7 Deposit the truck ................................................................................................................... 54
7.1 Deposit the truck for long time ............................................................................................... 54
7.2 Start running after deposit for a long time ............................................................................. 54
8 Maintenance .......................................................................................................................... 55
8.1 Maintenance general ............................................................................................................. 55
8.2 Periodic maintenance schedule............................................................................................. 56
8.3 Truck used oil and lubrication ................................................................................................ 61
8.4 Replace the key safe parts periodically ................................................................................. 64
8.5 Screw down the wheel retaining nut...................................................................................... 64
8.6 Removing the hood................................................................................................................ 65
8.7 Remove the fence.................................................................................................................. 66
8.8 The installation of the load backrest ...................................................................................... 67
9 Relevant safety directive or standard (CE) ........................................................................... 68
Part Ⅱ: Structure, Principle and Maintenance ......................................................................... 70
1 Drive system.......................................................................................................................... 70
1.1 Reduction box ........................................................................................................................ 71
1.1.1 Working principle ................................................................................................................... 72
1.1.2 Dismount and assemble order .............................................................................................. 73
1.1.3 Notice to installment and use ................................................................................................ 73
1.1.4 Fault and troubleshooting...................................................................................................... 73
1.2 Motor ...................................................................................................................................... 74
1.3 Electromagnetic brake ........................................................................................................... 81
1.3.1 Working principle ................................................................................................................... 82
1.3.2 Brake installment ................................................................................................................... 83
1.3.3 Brake air gap adjustment ...................................................................................................... 85
1.3.4 Maintenance .......................................................................................................................... 86
1.3.5 Common fault and troubleshooting ....................................................................................... 87
2 Hydraulic system ................................................................................................................... 88
2.1 Hydraulic system working principle ....................................................................................... 89
2.2 Hydraulic unit ......................................................................................................................... 90
2.3 Hydraulic unit dismantle ........................................................................................................ 94
2.4 Hydraulic system fault diagnosis and correction ................................................................... 95
3 Electric system ...................................................................................................................... 96
3.1 Principles of electrical system ............................................................................................... 96
3.2 AC motor controller .............................................................................................................. 100
3.2.1 Maintenance ........................................................................................................................ 100
3.2.2 Diagnosis and troubleshooting ............................................................................................ 101
3.2.3 LED Status Indicator ........................................................................................................... 105
3.2.4 Fault code table ................................................................................................................... 106
Attachment：Table for bolt’s tightening torque .............................................................................116
 Part Ⅰ: Operation and maintenance
1 Truck Introduction
1.1 General
This manual introduces A series hi range electric stacker.
According to different operation way, it has two types as pedestrian-type and Stand-on type.
Users can get relevant information as rated load from the product model. Model CDD20-AC1S as
an example:
CDD20-AC1S
Mode
CDD20-AZ3S
CDD Electric stacker
20 Rated load capacity×100kg
A Product serial number
C1, Z3 Controller type
S Stand-on type
B Straddle legs type

Rated capacity usually does not equal the allowable lifting capacity. Please refer to the load curve
chart on the truck for approved lifting capacity.

1
Truck body system
– Beautiful and compact outline, concise and fluent line.
– Chassis welded by high-performance steel plate guarantees enough load capacity.
– Chassis adopts 4-wheel structure, including one drive wheel, one auxiliary wheel as
stabilizing and two load wheels, thus guarantee the good stability and safe travelling.
– Hang-on foldable damping pedal as optional
Driving system
– Adopted suspension design guarantees well wheel and ground contact, light turn and
convenient operation.
– Divide into manual steering and electric steering.
Braking system
– It owns three emergency braking functions as release brake, reverse brake and
electromagnetic brake to ensure travelling safety.
– It owns slope anti-slide function to ensure safety.
Operation steering system
– New ergonomics designed control handle owns acceleration, reversing, horn, braking,
lifting/lowering, emergency reverse functions, thus makes operation easier.
– Emergency reversing button on the control handle head can prevent driver from hurt when
encountering emergency in backward driving.
– Low speed travel function can move the truck slowly. It can stack goods even in very narrow
place.
– Newly designed floatable suspension system makes steering more convenient.
– Steering angle +/- 90°.
Hydraulic system
– Modularization hydraulic power unit owns low noise, low vibration, stable and reliable lifting
and lowering.
Mast
– Good mast vision, easy installation and maintenance.
– Mast lifting height is optional.
Electric system
– 24V Electric system
– CURTIS or ZAPI AC control system
– Multi-function instrument owns electric quantity display, time and fault diagnosis function.
– Emergency stop switch
– Own electric lift limited and controller intelligent limited function
– Electric wiring adopts waterproof connector.

2
1.2 Use occasion and condition
Truck in this manual is only for lifting and transporting loads.
It must be used, operated and maintained according to the information in this manual. Any other
uses are outside the design envelope and can lead to injury to persons or damage to equipment or
property.
Only used in specified place and condition：
– Use in specified rated load.
– Used in specified area as factory, tourist attraction and recreation place.
– Used on the flat ground, that is fixed and owns enough carrying capacity.
– It is prohibited to pass the bulge or cavity as the small wheel diameter may cause truck tipping
over.
– Used on the road with good vision and equipment use license.
– Max. uphill grade when driving is 6%.
– It is prohibited to travel crosswise or obliquely. When go uphill with loads, keep the loads in
front; when go downhill, keep people in front.
For truck operation, the following normal climatic conditions apply:
– Average ambient temperature for continuous duty: ＋25℃;
– Maximum ambient temperature, short term (up to 1h): ＋40℃;
– Lowest ambient temperature for trucks intended for use in normal indoor conditions:＋5℃;
– Lowest ambient temperature for trucks intended for use in normal outdoor conditions:－20℃;
– Altitude: up to 2000m.
Please read other safety rules in this manual, it is important to your personal safety, working staff
and goods safety.

WARNING
 Do not carry people.
 Do not over load.
 Do not push and pull loads.

3
1.3 Main part name

15

13

12

1 11

10

8 9

Pedestrian-type: CDD12/14/16/20-AC1, CDD12/14/16/20-AZ3

15

14
 15

14

13

12
2

3 11

10

8 9

Stand-on type: CDD12/14/16/20-AC1S, CDD12/14/16/20-AZ3S

5
Item Description Item Description

1 Control handle 9 Frame

2 Instrument 10 Load wheel

3 Arm guard lock switch 11 Fork

4 Arm guard 12 Key switch

5 Rear hood assy 13 Emergency stop switch

6 Driving wheel 14 Battery cover

7 Pedal 15 Mast

8 Auxiliary wheel

6
1.4 Display and control

20
21 21
22 22

19 19
16 18
17
13

1 12

7
1.4.1 Display recharged.
Curtis 840 Instrument [2] Hourmeter indicator(green LED)
Said when the green LED light is normally on
the timer is timing, the smallest unit of time for
0.1 hours.
Every time when starting the vehicle LCD
screen will display the vehicle's total run time,
this time is for regular maintenance on the
basis of the vehicle.
Zapi MDI-CAN Instrument [2]

Dot-matrix LCD display

The display screen is 8 alphanumeric

characters, dot-matrix LCD liquid crystal
display, can display vehicles fault code, battery
soc and total running time.
Vehicles when the normal operation of the
ALARM LED LCD DISPLAY
display shows the battery remaining power.
LED function
Service indicator(red LED)
The MDI-CAN has only a LED. This LED
When the controller to detect fault information,
is red and lights and blinks when an alarm is
the red LED indicator light flashing, at the
present.
same time LCD display shows two digits of the
Display function
fault code.When there are multiple fault fault
code alternates between interval of 2
seconds.Fault code corresponding fault
information to view in this paper, the fault code
table.
Three symbols inform the operator as
BDI indicator(yellow LED)
follows:
When battery remaining power less than 20%,
Turtle Symbol:
the yellow LED indicator lights flashing,
warned "depleted", at the same time LCD
display shows "20%" for 1 seconds after into
"Low BDI". It is normally off; when it appears (fixed) it

When the yellow LED indicator lights flashing, shows activation of the “soft” mode of the truck,

vehicle lifting by automatic locking function, in which maximum speed and acceleration are

running speed is reduced.At this time should reduced;

be immediately available for vehicles Monkey Wrench Symbol:

8
 appears. The string shown on the display is
XXAYY, where XX and AYY represent
respectively the alarmed node and the alarm
It is normally off; when it appears (fixed) it
code. The alarm code meaning must be
shows the request of programmed
present in the controller user manual.
maintenance or the Alarm state. In this case
the relative code will be displayed. The
information supplied by the MDI-CAN can be
extremely useful. Failures can be quickly
identified by the Operator or Service
Technician thereby finding the fastest solution
to the problem.
Hourglass Symbol:

Battery State of charge

It is normally off; it blinks when the Hour Meter

is working.
Hour meter The battery's State of Charge indication is
An alpha-numeric liquid crystal display is integrated in the LCD display; it is shown by
fitted in the centre of the unit that shows the ten notches. Each notch represent the 10% of
Hours Worked. The display is backlight (the the battery charge. As the battery becomes
backlight is normally lighted). discharged, the notches turn off progressively,
one after the other, in proportion to the value of
the residual battery charge. This value, sent to
the MDI-CAN by the controller via CANUS, is
displayed in the Tester Menu of the Zapi
Console connected to the controller. When
BATTERY LOW alarm appears on the
controller, the battery symbol which is under
the notches blinks.
Alarms
Low speed indicator [18]
The same display can also indicate the
Alarm state, showing a Code corresponding to
the type of Alarm. To attract attention, the Red
LED will start blinking when an Alarm is
generated.
When an Alarm is generated, the Red
LED blinks to attract the attention of the When this light is on, the truck is in low speed

operator. The symbol of Monkey Wrench also mode.

9
1.4.2 Control
Control handle [1]

Key switch [12]

Control truck steering and braking.

When turn the control handle right and left, it
can realize the truck right and left turn. The
max turning angle of this handle is about 175°.
When press the handle to horizontal position Turn on the key switch, and the power is on. Turn

or push up to vertical position, it can realize off the switch, and the power is off. Turn off the

the truck brake. These two positions are set by key switch before charging.

brake inching switch. Normal is open circuit, Emergency stop switch [13]
working status is closed, brake inching switch
is normally at horizontal or vertical position is.
Arm guard lock switch [3]
Open or fold the arm guard, then release the
lock condition.
When fold the arm guard, push the arm guard Press this switch, power is off. Press it when
lock switch with one hand and the other hand emergency or no use. If re-start needed, pull
press the arm guard until it rotates to certain upward.
angle, release arm guard lock switch and press Emergency reverse button [16]
the arm guard to lock position.

This switch is at the head of control lever, once

When open the arm guard, push the arm guard touch this button, the truck moves forward. It is
lock switch with one hand and the other hand lift used to protect people from being clamped by
up the arm guard until it rotates to certain angle, the control handle.
release arm guard lock switch and lift the arm This switch is also called belly switch.
guard to lock position. Low speed switch button [17]

10
Press this button and indicator light[19] is on, it
means the truck changes to low speed travel
mode. When in low speed mode, the truck will
travel in low speed, 40% of max. travelling
speed.
– Press this control handle downwards.
Press this button and indicator light[19] is off, it
Turn this button towards the side of body
means the truck changes to normal travelling
gradually with thumb.
mode.
– Truck travels to the handle side(or pedal).
Direction and speed control button [19]

CAUTION
After the finger is released, the direction
and speed button will reset itself and the
truck will stop by brake. So do not
loosen the knob when the truck is
requested to continue driving.
Horn button [20]
This button is at both sides of control lever
head, one linkage per left and right. It is to
The button is located on the front of the control
control travelling direction and travelling
handle upper surface. Press down the button,
speed.
and the horn sounds.
Truck travels to the fork side
Lifting button [21], lowering button [22]

The lifting button and the lowering button are

– Press this control handle downwards. located on both side surface of the middle
– Turn this button from the side of body to control handle. Press the lifting button, and the
outside gradually with thumb. forks move up; press the lowering button, the
– Truck travels to the fork side. forks go down.
When the capacity of batteries is consumed up
Truck travels to the handle side(or pedal)
to 80%, the lifting function will be locked.

11
1.4.3 Others
Rear hood assembly [5]

When check battery, take out the plug, charge

or replace the battery, you can easily open the
There install main parts as hydraulic unit, main battery cover.
drive unit and electric system etc. under the
CAUTION
hood. When check or maintain, please open  When closing the battery cover,
the rear hood. protect your fingers from being
Fork [11] clamped.
Forks can be lifted or lowered to fetch goods.
Pedal（Only for stand-on type）[7]
Because of fourar mechanism, forks assembly
will move horizontally a distance when forks lift
or lower.

CAUTION
 It is forbidden to put hands, feet or
any part of the body between lift assy
This pedal can be folded so that you can put
and truck frame when lifting or
down the pedal and stand on it when operating
lowering.
the truck for a long distance. When transporting
Load wheel [10] at a narrow space, folding the pedal, stand on
There is one load wheel under each front ground to operate the truck.
outrigger to ensure longitudinal stability.
Check the load wheel to find if there is disrepair
or abnormal wear according to necessity. If
there is disrepair on the load wheel or its inner
bearing, suspend the truck off the ground or
jack the front outrigger off the ground, replace
the worn load wheel or the worn bearing, and
renew sufficient multi-purpose grease on the
bearing.
Battery cover [14]

12
1.5 Standard technical data
The following technical data are all standard data. Our company reserves the right of alteration
and extension.

Model CDD12-AC1 CDD14-AC1 CDD16-AC1 CDD20-AC1

Characteristics

Operator type Pedestrian Pedestrian Pedestrian Pedestrian

Load capacity Q (kg) 1200 1400 1600 200

Load center c(mm) 600 600 600 600

Wheelbase y(mm) 1405 1405 1425 1425

Weight Service weight with battery kg 1177 1182 1215 1258

Tyre type PU PU PU PU

Tyre size/Quantity,operator side mm Φ230×75/1 Φ230×75/1 Φ230×75/1 Φ230×75/1

Wheels﹠Tyres

Tyre size/Quantity,load side mm Φ85×70/4 Φ85×70/4 Φ85×70/4 Φ85×70/4

Auxiliary wheel size/Quantity mm Φ140×55/1 Φ140×55/1 Φ140×55/1 Φ140×55/1

Tread, operator side b10(mm) 525 525 525 525

Tread, load side b11(mm) 385 385 385 385

Lift height h3(mm) 2700 2700 2700 2700

Fork height, lowered h13(mm) 90 90 90 90

Overall length L1(mm) 20251) 20251) 20451) 20451)

Overall width b1(mm) 800 800 800 800

Dimensions

Fork size s/e/L(mm) 65×185×1150 65×185×1150 65×185×1150 65×185×1150

Outside fork width b5(mm) 570/680 570/680 570/680 570/680

Ground clearance, center of wheelbase, min m2(mm) 30 30 30 25

Min, right angle stacking aisle width1000×1200

Ast(mm) 25121) 25121) 25321) 25321)
across forks
Min, ringht angle stacking aisle width 800×1200
Ast(mm) 24811) 24811) 25011) 25011)
across forks

Outer turning radius, min Wa(mm) 1643 1643 1663 1663

Travel speed, laden/unladen km/h 6.0/6.0 6.0/6.0 5.0/6.0 5.0/6.0

Performance

Lift speed, laden/unladen mm/s 87/133 129/198 108/160 98/160

Lowering speed, laden/unladen mm/s 155/158 213/200 185/155 195/155

Max Gradeability, laden/unladen % 8/16 8/16 5/16 516

Drive motor power kW 1.5 1.5 1.5 1.5

Motor﹠Battery

Lift motor power kW 2.2 3.0 3.0 3.0

Battery voltage, rated capacity V/Ah 24/240 24/240 24/280 24/280

Optional battery voltage, rated capacity V/Ah 24/340 24/340 24/340 24/340

Controller mode Curtis AC Curtis AC Curtis AC Curtis AC

Note：1）Triplex Mast +21mm.

13
 Model CDD12-AZ3 CDD14-AZ3 CDD16-AZ3 CDD20-AZ3
Characteristics

Operator type Pedestrian Pedestrian Pedestrian Pedestrian

Load capacity Q (kg) 1200 1400 1600 200

Load center c(mm) 600 600 600 600

Wheelbase y(mm) 1405 1405 1425 1425

Weight Service weight with battery kg 1177 1182 1215 1258

Tyre type PU PU PU PU

Tyre size/Quantity,operator side mm Φ230×75/1 Φ230×75/1 Φ230×75/1 Φ230×75/1

Wheels﹠Tyres

Tyre size/Quantity,load side mm Φ85×70/4 Φ85×70/4 Φ85×70/4 Φ85×70/4

Auxiliary wheel size/Quantity mm Φ140×55/1 Φ140×55/1 Φ140×55/1 Φ140×55/1

Tread, operator side b10(mm) 525 525 525 525

Tread, load side b11(mm) 385 385 385 385

Lift height h3(mm) 2700 2700 2700 2700

Fork height, lowered h13(mm) 90 90 90 90

Overall length L1(mm) 20251) 20251) 20451) 20451)

Overall width b1(mm) 800 800 800 800

Dimensions

Fork size s/e/L(mm) 65×185×1150 65×185×1150 65×185×1150 65×185×1150

Outside fork width b5(mm) 570/680 570/680 570/680 570/680

Ground clearance, center of wheelbase, min m2(mm) 30 30 30 25

Min, right angle stacking aisle width1000×1200

Ast(mm) 25121) 25121) 25321) 25321)
across forks
Min, ringht angle stacking aisle width 800×1200
Ast(mm) 24811) 24811) 25011) 25011)
across forks

Outer turning radius, min Wa(mm) 1643 1643 1663 1663

Travel speed, laden/unladen km/h 6.0/6.0 6.0/6.0 5.0/6.0 5.0/6.0

Performance

Lift speed, laden/unladen mm/s 87/133 129/198 108/160 98/160

Lowering speed, laden/unladen mm/s 155/158 213/200 185/155 195/155

Max Gradeability, laden/unladen % 8/16 8/16 5/16 516

Drive motor power kW 1.5 1.5 1.5 1.5

Motor﹠Battery

Lift motor power kW 2.2 3.0 3.0 3.0

Battery voltage, rated capacity V/Ah 24/240 24/240 24/280 24/280

Optional battery voltage, rated capacity V/Ah 24/340 24/340 24/340 24/340

Controller mode ZAPI AC ZAPI AC ZAPI AC ZAPI AC

Note：1）Triplex Mast +21mm.

14
 h4
h1

1245

760

a/2
145

ME
ST
RG
EN CY

Wa

L2

15
y

Ast
L1
m2
C
X
I

a/2 s

b11
h13
e
h3
b5
 Model CDD12-AC1S CDD14-AC1S CDD16-AC1S CDD20-AC1S
Characteristics

Operator type Stand-on Stand-on Stand-on Stand-on

Load capacity Q (kg) 1200 1400 1600 200

Load center c(mm) 600 600 600 600

Wheelbase y(mm) 1405 1405 1425 1425

Weight Service weight with battery kg 1310 1315 1362 1405

Tyre type PU PU PU PU

Tyre size/Quantity,operator side mm Φ230×75/1 Φ230×75/1 Φ230×75/1 Φ230×75/1

Wheels﹠Tyres

Tyre size/Quantity,load side mm Φ85×70/4 Φ85×70/4 Φ85×70/4 Φ85×70/4

Auxiliary wheel size/Quantity mm Φ140×55/1 Φ140×55/1 Φ140×55/1 Φ140×55/1

Tread, operator side b10(mm) 525 525 525 525

Tread, load side b11(mm) 385 385 385 385

Lift height h3(mm) 2700 2700 2700 2700

Fork height, lowered h13(mm) 90 90 90 90

Overall length(fold the pedal) L1(mm) 20751) 20751) 20951) 20951)

Overall length(unfold the pedal) L1(mm) 25071) 25071) 25271) 25271)

Overall width b1(mm) 800 800 800 800

Dimensions

Fork size s/e/L(mm) 65×185×1150 65×185×1150 65×185×1150 65×185×1150

Outside fork width b5(mm) 570/680 570/680 570/680 570/680

Ground clearance, center of wheelbase, min m2(mm) 30 30 30 25

Min, right angle stacking aisle width1000×1200

Ast(mm) 25131) 25131) 25331) 25331)
across forks
Min, ringht angle stacking aisle width 800×1200
Ast(mm) 24821) 24821) 25021) 25021)
across forks

Outer turning radius, min Wa(mm) 1642 1642 1662 1662

Travel speed, laden/unladen km/h 7.0/7.0 7.0/7.0 7.0/7.0 7.0/7.0

Performance

Lift speed, laden/unladen mm/s 87/133 129/198 108/160 98/160

Lowering speed, laden/unladen mm/s 155/158 213/200 185/155 195/155

Max Gradeability, laden/unladen % 10/16 10/16 8/16 8/16

Drive motor power kW 2.2 2.2 2.2 2.2

Motor﹠Battery

Lift motor power kW 2.2 3.0 3.0 3.0

Steering motor power kW 0.2 0.2 0.2 0.2

Battery voltage, rated capacity V/Ah 24/280 24/280 24/340 24/340

Optional battery voltage, rated capacity V/Ah 24/340 24/340

Controller mode Curtis AC Curtis AC Curtis AC Curtis AC

Note：1）Triplex Mast +21mm.

16
 Model CDD12-AZ3S CDD14-A Z3S CDD16-A Z3S CDD20-A Z3S
Characteristics

Operator type Stand-on Stand-on Stand-on Stand-on

Load capacity Q (kg) 1200 1400 1600 200

Load center c(mm) 600 600 600 600

Wheelbase y(mm) 1405 1405 1425 1425

Weight Service weight with battery kg 1310 1315 1362 1405

Tyre type PU PU PU PU

Tyre size/Quantity, operator side mm Φ230×75/1 Φ230×75/1 Φ230×75/1 Φ230×75/1

Wheels﹠Tyres

Tyre size/Quantity, load side mm Φ85×70/4 Φ85×70/4 Φ85×70/4 Φ85×70/4

Auxiliary wheel size/Quantity mm Φ140×55/1 Φ140×55/1 Φ140×55/1 Φ140×55/1

Tread, operator side b10(mm) 525 525 525 525

Tread, load side b11(mm) 385 385 385 385

Lift height h3(mm) 2700 2700 2700 2700

Fork height, lowered h13(mm) 90 90 90 90

Overall length(fold the pedal) L1(mm) 20751) 20751) 20951) 20951)

Overall length(unfold the pedal) L1(mm) 25071) 25071) 25271) 25271)

Overall width b1(mm) 800 800 800 800

Dimensions

Fork size s/e/L(mm) 65×185×1150 65×185×1150 65×185×1150 65×185×1150

Outside fork width b5(mm) 570/680 570/680 570/680 570/680

Ground clearance, center of wheelbase, min m2(mm) 30 30 30 25

Min, right angle stacking aisle width1000×1200

Ast(mm) 25131) 25131) 25331) 25331)
across forks
Min, ringht angle stacking aisle width 800×1200
Ast(mm) 24821) 24821) 25021) 25021)
across forks

Outer turning radius, min Wa(mm) 1642 1642 1662 1662

Travel speed, laden/unladen km/h 7.0/7.0 7.0/7.0 7.0/7.0 7.0/7.0

Performance

Lift speed, laden/unladen mm/s 87/133 129/198 108/160 98/160

Lowering speed, laden/unladen mm/s 155/158 213/200 185/155 195/155

Max Gradeability, laden/unladen % 10/16 10/16 8/16 8/16

Drive motor power kW 2.2 2.2 2.2 2.2

Motor﹠Battery

Lift motor power kW 2.2 3.0 3.0 3.0

Steering motor power kW 0.2 0.2 0.2 0.2

Battery voltage, rated capacity V/Ah 24/280 24/280 24/340 24/340

Optional battery voltage, rated capacity V/Ah 24/340 24/340

Controller mode ZAPI AC ZAPI AC ZAPI AC ZAPI AC

Note：1）Triplex Mast +21mm.

17
 h4

h1

1419
b1
614 1100

460 1015

160

432

a/2
260

Wa

L2

18
y

L1

Ast
m2
C
X
I

s
a/2
b11
h13
e
b5
 Model CTD12-AC1 CTD14-AC1 CTD16-AC1 CTD20-AC1
Characteristics

Operator type Pedestrian Pedestrian Pedestrian Pedestrian

Load capacity Q (kg) 1200 1400 1600 200

Load center c(mm) 600 600 600 600

Wheelbase y(mm) 1405 1405 1425 1425

Weight Service weight with battery kg 1247 1252 1285 1328

Tyre type PU PU PU PU

Tyre size/Quantity,operator side mm Φ230×75/1 Φ230×75/1 Φ230×75/1 Φ230×75/1

Wheels﹠Tyres

Tyre size/Quantity,load side mm Φ85×70/4 Φ85×70/4 Φ85×70/4 Φ85×70/4

Auxiliary wheel size/Quantity mm Φ140×55/1 Φ140×55/1 Φ140×55/1 Φ140×55/1

Tread, operator side b10(mm) 525 525 525 525

Tread, load side b11(mm) 1000/1170/1370 1000/1170/1370 1000/1170/1370 1000/1170/1370

Lift height h3(mm) 2700 2700 2700 2700

Fork height, lowered h13(mm) 50 50 50 50

Overall length L1(mm) 19801) 19801) 20001) 20001)

Overall width b1(mm) 1100/1270/1470 1100/1270/1470 1100/1270/1470 1100/1270/1470

Dimensions

Fork size s/e/L(mm) 35×100×1070 35×100×1070 35×100×1070 40×122×1070

Outside fork width b5(mm) 210～790 210～790 210～790 210～790

Ground clearance, center of wheelbase, min m2(mm) 40 40 40 40

Min, right angle stacking aisle width1000×1200

Ast(mm) 25471) 25471) 25671) 25671)
across forks
Min, ringht angle stacking aisle width 800×1200
Ast(mm) 25161) 25161) 25361) 25361)
across forks

Outer turning radius, min Wa(mm) 1643 1643 1663 1663

Travel speed, laden/unladen km/h 6.0/6.0 6.0/6.0 5.0/6.0 5.0/6.0

Performance

Lift speed, laden/unladen mm/s 87/133 129/198 108/160 98/160

Lowering speed, laden/unladen mm/s 155/158 213/200 185/155 195/155

Max Gradeability, laden/unladen % 8/16 8/16 5/16 516

Drive motor power kW 1.5 1.5 1.5 1.5

Motor﹠Battery

Lift motor power kW 2.2 3.0 3.0 3.0

Battery voltage, rated capacity V/Ah 24/240 24/240 24/280 24/280

Optional battery voltage, rated capacity V/Ah 24/340 24/340 24/340 24/340

Controller mode Curtis AC Curtis AC Curtis AC Curtis AC

Note：1）Triplex Mast +21mm.

19
 Model CTD12-AZ3 CTD14-AZ3 CTD16-AZ3 CTD20-AZ3
Characteristics

Operator type Pedestrian Pedestrian Pedestrian Pedestrian

Load capacity Q (kg) 1200 1400 1600 200

Load center c(mm) 600 600 600 600

Wheelbase y(mm) 1405 1405 1425 1425

Weight Service weight with battery kg 1247 1252 1285 1328

Tyre type PU PU PU PU

Tyre size/Quantity,operator side mm Φ230×75/1 Φ230×75/1 Φ230×75/1 Φ230×75/1

Wheels﹠Tyres

Tyre size/Quantity,load side mm Φ85×70/4 Φ85×70/4 Φ85×70/4 Φ85×70/4

Auxiliary wheel size/Quantity mm Φ140×55/1 Φ140×55/1 Φ140×55/1 Φ140×55/1

Tread, operator side b10(mm) 525 525 525 525

Tread, load side b11(mm) 1000/1170/1370 1000/1170/1370 1000/1170/1370 1000/1170/1370

Lift height h3(mm) 2700 2700 2700 2700

Fork height, lowered h13(mm) 50 50 50 50

Overall length L1(mm) 19801) 19801) 20001) 20001)

Overall width b1(mm) 1100/1270/1470 1100/1270/1470 1100/1270/1470 1100/1270/1470

Dimensions

Fork size s/e/L(mm) 35×100×1070 35×100×1070 35×100×1070 40×122×1070

Outside fork width b5(mm) 210～790 210～790 210～790 210～790

Ground clearance, center of wheelbase, min m2(mm) 40 40 40 40

Min, right angle stacking aisle width1000×1200

Ast(mm) 25471) 25471) 25671) 25671)
across forks
Min, ringht angle stacking aisle width 800×1200
Ast(mm) 25161) 25161) 25361) 25361)
across forks

Outer turning radius, min Wa(mm) 1643 1643 1663 1663

Travel speed, laden/unladen km/h 6.0/6.0 6.0/6.0 5.0/6.0 5.0/6.0

Performance

Lift speed, laden/unladen mm/s 87/133 129/198 108/160 98/160

Lowering speed, laden/unladen mm/s 155/158 213/200 185/155 195/155

Max Gradeability, laden/unladen % 8/16 8/16 5/16 516

Drive motor power kW 1.5 1.5 1.5 1.5

Motor﹠Battery

Lift motor power kW 2.2 3.0 3.0 3.0

Battery voltage, rated capacity V/Ah 24/240 24/240 24/280 24/280

Optional battery voltage, rated capacity V/Ah 24/340 24/340 24/340 24/340

Controller mode ZAPI AC ZAPI AC ZAPI AC ZAPI AC

Note：1）Triplex Mast +21mm.

20
 h4

h1
1245

760

a/2
145

ME
ST
RG
EN CY

Wa

L2

21
y
S

Ast
L1
m2
X
I

a/2

e
h13
b5
b11 h3
 Model CTD12-AC1S CTD14-AC1S CTD16-AC1S CTD20-AC1S
Characteristics

Operator type Stand-on Stand-on Stand-on Stand-on

Load capacity Q (kg) 1200 1400 1600 200

Load center c(mm) 600 600 600 600

Wheelbase y(mm) 1405 1405 1425 1425

Weight Service weight with battery kg 1380 1385 1432 1475

Tyre type PU PU PU PU

Tyre size/Quantity,operator side mm Φ230×75/1 Φ230×75/1 Φ230×75/1 Φ230×75/1

Wheels﹠Tyres

Tyre size/Quantity,load side mm Φ85×70/4 Φ85×70/4 Φ85×70/4 Φ85×70/4

Auxiliary wheel size/Quantity mm Φ140×55/1 Φ140×55/1 Φ140×55/1 Φ140×55/1

Tread, operator side b10(mm) 525 525 525 525

Tread, load side b11(mm) 1100/1270/1470 1100/1270/1470 1100/1270/1470 1100/1270/1470

Lift height h3(mm) 2700 2700 2700 2700

Fork height, lowered h13(mm) 50 50 50 50

Overall length(fold the pedal) L1(mm) 20301) 20301) 20501) 20501)

Overall length(unfold the pedal) L1(mm) 24621) 24621) 24821) 24821)

Overall width b1(mm) 1100/1270/1470 1100/1270/1470 1100/1270/1470 1100/1270/1470

Dimensions

Fork size s/e/L(mm) 35×100×1070 35×100×1070 35×100×1070 40×122×1070

Outside fork width b5(mm) 210～790 210～790 210～790 210～790

Ground clearance, center of wheelbase, min m2(mm) 40 40 40 40

Min, right angle stacking aisle width1000×1200

Ast(mm) 25461) 25461) 25661) 25661)
across forks
Min, ringht angle stacking aisle width 800×1200
Ast(mm) 25151) 25151) 25351) 25351)
across forks

Outer turning radius, min Wa(mm) 1642 1642 1662 1662

Travel speed, laden/unladen km/h 7.0/7.0 7.0/7.0 7.0/7.0 7.0/7.0

Performance

Lift speed, laden/unladen mm/s 87/133 129/198 108/160 98/160

Lowering speed, laden/unladen mm/s 155/158 213/200 185/155 195/155

Max Gradeability, laden/unladen % 10/16 10/16 8/16 8/16

Drive motor power kW 2.2 2.2 2.2 2.2

Motor﹠Battery

Lift motor power kW 2.2 3.0 3.0 3.0

Steering motor power kW 0.2 0.2 0.2 0.2

Battery voltage, rated capacity V/Ah 24/280 24/280 24/340 24/340

Optional battery voltage, rated capacity V/Ah 24/340 24/340

Controller mode Curtis AC Curtis AC Curtis AC Curtis AC

Note：1）Triplex Mast +21mm.

22
 Characteristics Model CTD12-AZ3S CTD14-AZ3S CTD16-AZ3S CTD20-AZ3S

Operator type Stand-on Stand-on Stand-on Stand-on

Load capacity Q (kg) 1200 1400 1600 200

Load center c(mm) 600 600 600 600

Wheelbase y(mm) 1405 1405 1425 1425

Weight Service weight with battery kg 1380 1385 1432 1475

Tyre type PU PU PU PU

Tyre size/Quantity,operator side mm Φ230×75/1 Φ230×75/1 Φ230×75/1 Φ230×75/1

Wheels﹠Tyres

Tyre size/Quantity,load side mm Φ85×70/4 Φ85×70/4 Φ85×70/4 Φ85×70/4

Auxiliary wheel size/Quantity mm Φ140×55/1 Φ140×55/1 Φ140×55/1 Φ140×55/1

Tread, operator side b10(mm) 525 525 525 525

Tread, load side b11(mm) 1100/1270/1470 1100/1270/1470 1100/1270/1470 1100/1270/1470

Lift height h3(mm) 2700 2700 2700 2700

Fork height, lowered h13(mm) 50 50 50 50

Overall length(fold the pedal) L1(mm) 20301) 20301) 20501) 20501)

Overall length(unfold the pedal) L1(mm) 24621) 24621) 24821) 24821)

Overall width b1(mm) 1100/1270/1470 1100/1270/1470 1100/1270/1470 1100/1270/1470

Dimensions

Fork size s/e/L(mm) 35×100×1070 35×100×1070 35×100×1070 40×122×1070

Outside fork width b5(mm) 210～790 210～790 210～790 210～790

Ground clearance, center of wheelbase, min m2(mm) 40 40 40 40

Min, right angle stacking aisle width1000×1200

Ast(mm) 25461) 25461) 25661) 25661)
across forks
Min, ringht angle stacking aisle width 800×1200
Ast(mm) 25151) 25151) 25351) 25351)
across forks

Outer turning radius, min Wa(mm) 1642 1642 1662 1662

Travel speed, laden/unladen km/h 7.0/7.0 7.0/7.0 7.0/7.0 7.0/7.0

Performance

Lift speed, laden/unladen mm/s 87/133 129/198 108/160 98/160

Lowering speed, laden/unladen mm/s 155/158 213/200 185/155 195/155

Max Gradeability, laden/unladen % 10/16 10/16 8/16 8/16

Drive motor power kW 2.2 2.2 2.2 2.2

Motor﹠Battery

Lift motor power kW 2.2 3.0 3.0 3.0

Steering motor power kW 0.2 0.2 0.2 0.2

Battery voltage, rated capacity V/Ah 24/280 24/280 24/340 24/340

Optional battery voltage, rated capacity V/Ah 24/340 24/340

Controller mode ZAPI AC ZAPI AC ZAPI AC ZAPI AC

Note：1）Triplex Mast +21mm.

23
 h4

h1

1419
b1
614 1100

460 1015

160

432

a/2
260

Wa

L2

24
y
S

L1

Ast
m2

C
X
I

a/2
e

b5
b11
Mast Specification：1.2t/1.4t/1.6t

Max Lifting Ground Lowered Extended

Mast type Height Clearance,fork Height Height Free lift
h3 (h3+h13) h1 h4
mm mm mm mm mm

2000 2090 1542 2542 90

2500 2590 1792 3042 90

2700 2790 1892 3242 90

3000 3090 2042 3542 90

Double
3300 3390 2192 3842 90
cylinders
duplex wide 3500 3590 2292 4042 90
view
3600 3690 2342 4142 90

3800 3890 2442 4342 90

4000 4090 2642 4642 90

4300 4390 2792 4942 90

2000 2090 1595 2595 1090

2500 2590 1845 3095 1340

2700 2790 1945 3295 1440

Duplex full-free 3000 3090 2095 3595 1590
wide view
3300 3390 2245 3895 1740

3500 3590 2345 4095 1840

3600 3690 2395 4195 1890

3500 3590 1844 4214 1220

3700 3790 1909 4409 1290

4000 4090 2009 4709 1390

4300 4390 2109 5009 1490

Triplex full-free
wide view 4500 4590 2159 5159 1590

4700 4790 2259 5459 1590

5000 5090 2354 5744 1700

5200 5290 2409 5909 1790

25
Mast Specification：2.0t

Max Lifting Ground Lowered Extended

Mast type Height Clearance,fork Height Height Free lift
h3 (h3+h13) h1 h4
mm mm mm mm mm

2000 2090 1647 3647 90

2500 2590 1897 3147 90

Double 2700 2790 1997 3347 90

cylinders 3000 3090 2147 3647 90
duplex wide
view 3300 3390 2297 3947 90

3500 3590 2397 4147 90

3600 3690 2447 4247 90

2000 2090 1700 2700 1090

2500 2590 1950 3200 1340

2700 2790 2050 3400 1440

Duplex full-free 3000 3090 2200 3700 1590
wide view
3300 3390 2350 4000 1740

3500 3590 2450 4200 1840

3600 3690 2500 4300 1890

3500 3590 1944 4314 1130

3700 3790 2009 4509 1200

4000 4090 2109 4809 1300

Triplex full-free
wide view 4300 4390 2209 5109 1400

4500 4590 2259 5259 1500

4700 4790 2359 5559 1500

26
1.6 Product plates and warning labels location
Plates and labels, such as nameplate, load curve plate, warning labels must be legible, if
identification is unclear, and must be replaced.
The figure below shows the approximate location of the various identity resides. Before operating
the truck, please understand the meaning of the various identities.

WARNING

WARNING

OP
EM
RG

ST
E
EN CY

ELECTRIC STACKER
MODEL-TYPE

SERIAL NO. RATED CAPACITY kg

LOAD CENTER mm WEIGHT WITHOUT BATTERY kg

BATTERY VOLTAGE V MAX.ALLOWABLE BATTERY WEIGHT kg

RATED DRIVE POWER kW MIN.ALLOWABLE BATTERY WEIGHT kg

MAX .LIFT HEIGHT mm YEAR OF MANUFACTURE

HANGCHA GROUP CO.,LTD.

Add: Lin'an Economic Development Zone,Zhejiang,China License No.：TS2510002-2016

27
Item Description
Nameplate: The rated capacity on the nameplate is the max. load capacity by the label
25 listed equipment. Any change to the forklift or other equipment may change rated
capacity.
26 Manufacturer’s logo

27 Key switch：“OFF” position is off，“ON” position is on.

28 Emergency stop label：“O” means disconnect, “I” means connect

29 Warning label: It’s prohibited to carry people or stand under the forks.

30 Hoist label: Fixed point when using the crane to handle equipment.

31 Load curve label

32 Hazard label: Risk of trapping when mast extended.

Warning label: it is forbidden that the operator`s foot is not on the platform during
33
operation.

34 Hydraulic oil label: Add hydraulic oil.

35 Series tonnage label: A series, rated capacity is X×100kg

28
2 Safety Rules battery when checking.
– Be careful of scald when checking motor
1) Only trained and authorized operator shall
and controller.
be permitted to operate the forklift.
7) The controller equips with energy
accumulator, do not touch between B+
and B- to avoid electric injury. If you need
check or clean the controller, connect
load(like contactor coil or horn) between
controller B+ and B- to discharge the
2) Operator must wear helmet, working controller capacity.
shoes and uniform.

8) Whenever you find the forklift abnormal,

3) Never take people. stop the truck, put on the DANGEROUS
or FAULT sign to the truck, remove the
key, and report to the managing person.
Only after eliminating the fault can you
use the truck.
– If there occurs to fault, battery electrolyte,
hydraulic oil or brake fluid leakage when
lifting loads, going up and down the slope,
4) It is not allowed to reconfigure the truck
please organize staff to repair.
without manufacturer’s permission.
5) Do not work in flammable and
combustible environment.
6) Check the oil, fluid leakage, deformation, Dangerous

flexibility in certain time. If neglected,

service life of forklift will be shortened and
in serious condition there will be accident.
– Make sure change the “safety parts”
during the schedule maintenance.
– Wipe off the oil, grease or water on the 9) Internal battery may generate explosive
soleplate, foot pedal and control stick. gas, it’s prohibited any flame close the
– No smoking or any spark, smoke near the battery. Never allow the tools close two

29
 poles of the battery to avoid spark or short it is not allowed to run on the street, and
circuit. only for driving in specified stacking place.
18) It’s forbidden to put the head, hand, foot
or body under the forks. Never stand on
the fork.

WARNING

10) The work ground of forklift shall be solid

and smooth concrete surface or similar
ones. Pre-check the ground condition of
working site. Tidy the working site, clean
19) It’s forbidden to put the head, hand, foot
obstacle, sweep macadam, muddy sand
or body into the space between the
and wipe off greasy dirt.
chassis and lifting component, once
11) Do not overload. Before operation, first
clipped, it is dangerous to your life. It’s
know the curve chart on the load curve
forbidden to put the head, hand, foot or
plate well, which indicates the relation
body into the space between fork and link
between rated load and load center.
mechanism. Crushing and shearing
12) Before start, press the horn and make
hazards for the operator of
sure no people around.
pedestrian-controlled trucks featuring
13) Goods are not allowed to deviate the fork
foldable platforms and reach trucks,
center, when goods is deviating the fork
between parts of the environment and the
center, turn or pass uneven road, you are
truck during travelling forward
easily to fall. Meanwhile, possibility of
turnover will increase.

WARNING

20) Make the loads in front when climbing the

slope. It’s prohibited to turn on the slope,
or there’s danger of tipping over. Avoid
14) Avoid sudden drive, stop or turn. working on the slope.
15) Do not drive the truck when the forks in 21) Do not use truck under the weather of
high position. sand, snow, thunder, storm, typhoon, etc.
16) When handling bulky loads, which restrict Avoid using the truck when the wind
your vision, please operate the machine in speed is larger than 5m/s.
reverse or have a guide. – The weather condition: temperature:
17) Cause the wheels of pallet truck is small, -5℃～40℃, wind speed: less than 5m/s;

30
 air relative humidity: less than 90%（20℃）. business, may the user arrange for a
Altitude should not exceed 2000m. modification or alteration to a powered
22) After power off, brake industrial truck, however, that the user
．．．．．． ．．． ．． ．．．． ．．．．works
．．． and
．．．．．．the
．．
truck can not must do the following:
．．．．．． ．．． ．．be
．．． towed(dragged)
．．．． ．．．．．．．．．
23) As to stand -on truck, stand on firmly – Arrange for the modification or
．．． ．． ．．．．． ．．． ．．．．．． ．．．．． ．． ．．．．．
and alteration to be designed, tested
．．． hold
．．．．．the
．． handle
．．．． ．．． tightly.
．．．．．．． When
．．．．
turning, the and implemented by an
．．．．．．．．． ．． speed
．．．．． should
．．．．．． be lower
．． ．．．．．
than
．．．．．3km/h.
．．． ．． engineer(s)；
24) There’s warning and operation method on – Maintain a permanent record of the
truck label. Please obey the requirement design, test(s) and implementation of the
in this manual and the truck label when modification or alteration;
operation. Check label, identification plate, – Make appropriate changes to the capacity
replace damaged or fallen ones. plate(s), decals, tags and instruction
25) Fire extinguisher shall be equipped at the manual;
work site. Users can choose truck – Affix a permanent and readily visible label
equipped with fire extinguisher. Driver and to the truck stating the manner in which
manger should be familiar with the fire the truck has been modified or altered,
extinguisher position and application together with the date of the modification
method. or alteration and the name and address of
the organization that accomplished those
tasks.

26) Use tray when carrying small items, do

not place on the fork directly
27) Do not wash the inner of the truck, do not
place the truck outdoors and exposed to
the rain.
28) Before dismantle or repair the truck,
remove the battery plug firstly.
29) The truck should be used under the
environment of the light is enough.
30) Only in the event that the truck
manufacturer is no longer in business and
there is no successor in the interest to the

31
3 Transport
The forklift truck is designed for short-distance lifting, lowering and transporting load units, not
suitable for long-distance travel. If needed, the forklift truck must be transported by using lifting
device or platform to place on truck or trailer.

3.1 Lifting by crane

WARNING
 Only use lifting gear with sufficient capacity (for truck weight see truck nameplate).
 Do not stay under the truck when hoisting the truck.
 When hoisting or laying down, it should be stable and slow to avoid collision or
accident.
Procedure:
– Park the truck securely.
– Secure the lifting slings to the strap point, and prevent them from slipping. Crane slings
should be fastened in such a way that they do not come into contact with any attachments
when lifting.
– Load the truck and park it securely at its destination.

32
3.2 Securing the truck during transport
Correctly fix the forklift truck to avoid move when using truck or trailer.
Procedure:
– Park the truck securely.
– Sling the tensioning belt around the truck and attach it to the fastening rings of the
transporting vehicle.
– Use wedges to prevent the truck from moving.
– Tighten the tensioning belt with the tensioner.

WARNING
 The truck or trailer must have fastening rings.
 Use wedges to prevent the truck.
 Only use tension belt or fastening belt of good nominal strength.

33
3.3 How to remove a broken truck
It’s not allowed to tow the forklift truck on the ground directly when the truck is broken down or
damaged since the brake of the truck is closed under normal circumstances. Appropriate vehicles
should be used to remove the broken trucks.

WARNING
 Do not tow the broken trucks on the ground directly, or else the braking system
would be damaged.

34
4 Battery add distilled water to the level appointed.

4.1 Attention for using battery WARNING

 The shortage of the electrolyte will
1) No firing
cause the storage battery
Explosive gas can be produced in the internal
overheated, even cause the system
of storage battery, smoking, flame and sparkle
part of storage battery and electric
can easily cause storage battery explosion.
combustion.
 Vitriol include in the electrolyte can
create burns, see doctor for
emergency treatment quickly if
touch it un-carefully.
Splashing to the skin or eyes：wash
with water 15~20 minutes;
2) Protection against electric shock Splashing to the clothes：take it off

CAUTION immediately.
 Storage battery has high voltage and Careless drinking ： drink plenty of
energy. water and milk.
 Do not bring short circuit.  Wearing glasses, rubber overshoes
 Do not approach tools to the two and rubber glove.
poles of the storage battery, which Keep battery clean
can cause the sparkle or short Keep dryness and cleanness on the surface of
circuit. storage battery. The poles for connection are
3) Correct wire connection also dry and clean. Operator must screw down
Never allow wrong connect of battery anode the vent-cover of storage battery.
and cathode, otherwise it may cause sparkle,
CAUTION
burning or explosion.
 Do not use dry cloth or fiber cloth to
4) Do not over-discharge
clean the storage battery, avoid
– Never charge only when the stacker can’t
static to cause the explosion.
move, this will shorten the battery working
 Pull out storage battery plug.
hours.
 Clean with wet cloth.
– When two flashing lights of the power
 Wearing glasses, rubber overshoes
indicator flash, please charge
and rubber glove.
immediately.
5) Inspection for electrolyte
– It is forbidden to use the stacker when the
electrolyte is in shortage.
– Inspect electrolyte level every week.
When electrolyte level is low, you must

35
Measures in summer
In summer, water in the electrolyte is easy to
evaporate, therefore, electrolyte must often be
inspected if electrolyte is low, you must add
distilled water to the level appointed.

CAUTION
 Do not over fill distilled water. Spilt
electrolyte will cause corrosion and
electricity leakage.
Measures in winter
– Keep effective and good surrounding for
charging.
– When it is cold, pull out the storage
battery pin to prevent discharging.
– Take measures such as covering storage
battery for warmth.
– Don’t park the truck in cold outdoor or cold
storage for a long time.
– Charge in time after work.

36
4.2 Dimension/Service Weight
CDD12/14/16/20-AC1()
CDD12/14/16/20-AZ3() CDD16/20-AC1S()
Item CDD12/14/-AC1S() CDD16/20-AZ3S()
CDD12/14/-AZ3S()

Length（L） mm 650 650

Width（W） mm 249 249

Height（H） mm 625 625

Allowable lightest kg 200 260

Allowable heaviest kg 295 295

L W

WARNING
 Battery weight and dimensions have considerable influence on operational safety of
the truck.
 When installing or replacing battery, be sure that battery in the fixed position.

37
4.3 Charging the battery
Charging steps
– Drive the truck to appointed charging place, park
the truck and render if safe.
– Open the battery cover (10).
– Remove the battery plug from the truck socket
（31）.
– Connect the charging plug (32) to battery plug (31).
14
– Plug the charger plug into proper power socket.
– Start the charging procedure according to the
charger operation instructions.
– End charging according to the charger operation
instructions after the battery fully charged.
37
– Remove the battery plug (31) from the charger.
38
– Connect the battery plug（31）with truck socket and
cover the battery hood(10).
After charging, the truck can be used.

WARNING
 Please charge in the well-ventilated and appointed site.
 Mark ‘No smoking’ when charging and prepare extinguisher.
 Before charging, please examine wire and electrical outlet for damage, otherwise do
not charge.
 Open the hood and storage battery lid to release the explosive gas when charging.
 Never place metal object on the battery.
 In the progress of charging, do not pull out power switch and battery plug, otherwise
it may damage plug and electrical units. Generally press down the stopping button
firstly, and then take out the plug.

38
Daily charging with a little harm;

·The storage battery that has been made first e. It often be charged deficient or has not
charging and used in normal condition, then been used for a long time;
charged again, it is named daily charging. f. Check or clean sediment after taking
·Its way is almost same as the first charging. out the storage battery group
·The recharging volume is 1.2 times than the
The way of equalizing charging：
last electric discharging. But the new storage
battery’s former five times’ charging volume (PCA Automatic Charger Operation

should be 1.5 times than the last electric Instruction)

discharging. ① Firstly, charge the storage battery
·During any charge, the temperature of normally, and then rest for 1 hour after
electrode should not exceed 45℃, otherwise the end of charge.
it should be taken measures such as
② Charge it again with the second phase
reducing artificially charging current or lowing
current of normally charge until the
the temperature. If the temperature still does
electrolyte gives off a large number of
not drop, you should stop charging till the
bubbles, and then stop charging for 1
temperature drops down.
Adopt intelligent charging to do daily charge, hour.
the former five times of new battery should do ③ Do it several times as mentioned above
equalizing charging according to operation until the voltage and the density keep
instructions of intelligent charger. invariable and the storage battery gives
Equalizing charging off a large number of bubbles
·During using of the storage battery, it often
immediately when charge again.
occurs to disequilibrium among the voltage, Additional charge
density and capacity. ·If one day’s work cannot be fulfilled in one
·Compared to most of the batteries, several charge, carry out additional charge during
storage batteries’ proportion of voltage and breaks.
·When the temperature of circumstance is
electrolyte rises slowly during the course of
low, carry out additional charge.
charge and discharge, its storage battery’s
Charge for long-term storage
proportion of voltage and electrolyte
·Carry out equalizing charging before storing.
declines faster than most of other batteries.
·Carry out equalizing charging once every 15
·Make equalizing charging in the following to 30 days during the storage period.
case：
The proportion and level of electrolyte
a. discharge voltage often drop down
WARNING
final voltage;
 If the level of the electrolyte is low,
b. discharge current is often larger;
using the storage battery will cause the
c. not charge in time after discharge; storage battery over-heat and shorten
d. the electrolyte is mixed with impurity the storage battery’s service life.

39
 1． Inspect electrolyte
The storage battery without a dobber
It is proper to pour the electrolyte 15-20mm
above the electrode plate.
The storage battery with a dobber
According to the dobber of the ventilation
cover, read the level position of the
electrolyte.

The storage battery without a dobber

When the electrolyte is above 15-20mm of
the electrode plate, stop replenishing
④ After replenishing the distilled water,
close the ventilation cover and box cap.
⑤ Use the damp cloth to clean the
surface of storage battery cells.
2． Replenish the distilled water
·Wear the blinkers, rubber shoes and WARNING
 It is not permitted to exceed the
rubber glove.
appointed top level when
① Use the measuring cylinder to take out
replenishing the distilled water.
the distilled water with a certain
Adding too much will result in
quantity.
leakage of electrolyte, and it will
② Open the battery ventilation cover or fill
damage the truck when charging or
cap.
discharging.
③ Imbibe distilled water with injector and
 Draw it out with injector if adding too
then supply it into the storage battery.
much.
The storage battery with a dobber
When the red dobber rises, the white line 3． Reading the specific gravity
appears, please stop replenishing. 1）The specific gravity of the electrolyte will
change as the temperature changes.

40
 ① Use thermometer to measure the
temperature for electrolyte.
② Put the straw of densimeter into
electrolyte uprightly, extrude rubber
tube with hand and the electrolyte will
be sucked into the glasses tube and
then the floater of the densimeter will
float.
③ Numerate the reading of the
densimeter. 3） Conversion of the specific gravity
The specific gravity at the standard
CAUTION 0
 The dobber of densimeter must rise temperature of 30 C should be converted as
follow:
uprightly without depending on the
D30= Dt + 0.0007( t - 30 )
glass pipe.
Therein to：D30 ——the specific gravity at the
standard temperature of 300C
Dt ——the specific gravity at the
temperature of t0C.

t ——the temperature of the distilled

water during convert.
·The specific gravity referred in this book is
measured all at the temperature of 30℃.

Charger：
Storage battery of this truck equips with PCA
Automatic Charger Operation Instruction.
1． The charger is automatic high
frequency charger. The capacity voltage
is 220V AC. The input current is not less
than 15A. The output voltage is DC 36V.
Maximum charge current is 35A. The total
charge procedure is automatic. For more
2） Measuring the proportion information please refer to charger
Use gravimeter to calculate the electrolyte manual.
proportion. 2． Connection with earth wire for using.
3． When replace the fuse, first plug out
the plug.
4． Non-specialized person can’t open the
hood to check or repair.
5． Do not rebuild or disassembly charger.
6． Prevent charger overheat in high

41
 temperature seasons, that will hurt
charger, if necessary can pause charge.
If you don’t want use automatic option, you
should adjust the charge current, charge
voltage, charge time and etc. manually. And
you should measure the specific gravity of
electrolyte on time to assure the battery can
be charge at best state. To adjust the
parameter of charger, please see the
following battery charging.

42
4.4 Replacing the battery
Battery replacing steps：
– Park the truck and render it safe.
– Open the battery cover（14）.
– Remove the battery plug (37) from truck socket,
and place the battery plug and cable into the
battery tank (39), ensure that it does not scratch
37
cable when removing the battery.
– Hang the hoisting tool to the two hoisting hole of
the battery tank (39) and fix it. 39

– Use the crane to hoist the battery vertically.

Installation is in the reverse order of operations. Check 14

for correct mounting position and connection of the

battery.

WARNING
 Battery box is very heavy, be careful to avoid damage.
 Make sure the lifting capacity of the crane is larger than battery weight.
 Disposal to the waste battery should accord with local environment regulation.
 When replacing the battery, ensure that the battery of the same specification,
dimension and weight is fitted.

43
5 New truck breaking-in
We recommended operating the truck under light load conditions for the first stage of operation to
get the most from it. Especially the requirements given below should be observed while the truck is
in a stage of 100 hours of operation：
– Avoid the new battery over discharging in early period.
– Perform specified preventive maintenance services completely.
– Avoid sudden stop, start or turn.
– Limited load is 70%～80% of the rated load.
– Often check and fasten the fasteners of each joint part in running-in period
– After running-in finished, replace hydraulic oil and gear oil.

44
6 Operation
6.1 Check before operation
In order for the safety truck operation and
keep the truck in good condition, before
starting the truck, you must check it carefully.
1) Oil leak and liquid leak check
Park the truck, and check the truck for
Close the hood, and open the battery cover
hydraulic oil, gear oil or electrolyte leak.
2) Fork check 6) Battery check

Check the fork and see whether bending or – Check the battery cover board. See

crazed. whether the battery fixed reliably.

3) Front/rear wheel and balance wheel – Check proportion of electrolyte. Refer

check to “battery” section.

Check the wheel and see whether there is any – Check the terminal for loose or

crazed, damaged, or abnormal wearing. damage. Otherwise adjust or replace.

Check the wheel fasteners for looseness.

Inspect whether there is rope on the wheel.

Plug in and turn on the key switch.

7) Instrument display check
Refer to instrument part.
8) Lifting and lowering button
Press the lifting button and check the fork
4) Check front fork and linkage lifting condition. Press the lowering button,
mechanism check the fork lowering condition. Check if the
Check the fork and linkage mechanism, see lifting system has abnormal sound.
whether bending or crazed. 9) Forward and reverse running condition
Whether appear interfere when move, Tilt the handle to some degree, gradually
movement point wear whether severe. press the accelerator button to the outside of
5) Hydraulic oil check the body with thumb, and inspect the forward
Open the hood running condition; gradually press the
Loosen the hydraulic oil filler cap, pull out accelerator button to the inside of the body
dipstick, and check if the oil level within the with thumb, and inspect the reverse running
scales. Add oil when insufficient. condition.

45
10) Brake system
When the truck run forward or backward, push
the handle to vertical position or press to level
position to check the brake condition.
11) Steering system
Left or right turn the handle to make the truck
run around 3 turns, and then check if the
steering system is normal.
12) Check chain tensity
– Lift forks up 10～15cm.
– Press the middle of the chain and see if
the left & right tensity is the same.
– Tensity adjustment：screw off the nut①,
adjust nut ② to keep the same tensity of
the two chains, and then tighten the nut
①.

13) Horn
Press the horn button to check sound.
14) Appearance
Check the truck appearance for clean, rust or
paint spalling.
15) Others
Check whether there is any abnormal noise,
whether wiring is regular or fastener loosens
etc.

46
6.2 Starting up
Procedure:
– Plug into the plug.
– Turn on the key switch（3）.
– Pull up the emergency disconnect switch（11）.
– If you need to stand on the pedal to operate for the stand-on type truck, you need open the
pedal

OFF ON

13
4
12

CAUTION
 Make sure the work ground is hard enough to support the truck.
 Be careful to control the truck’s speed.

47
6.3 Travelling
Pedestrian-type
Driver should walk in front of the truck and keep at the side front of the truck when travelling. One
hand holds the handle, and operate travel switch with thumb. Always watch moving direction and
guide truck. Or hold the handle with both hands and push the truck go forward.

CAUTION
 Operator must wear protective boots.
 When enter narrow area as lift, first get fork go.
 Keep road clean and wipe greasy dirt, water or other easily causes slipping dirty.
 Crushing and shearing hazards for the operator of pedestrian-controlled trucks
featuring foldable platforms and reach trucks, between parts of the environment and
the truck during travelling forward.
Travelling on the slope：
When going uphill and downhill without load, keep the fork to downhill direction; when going uphill
and downhill with load, keep the fork to uphill direction.

WARNING
 No turn, inclines when going uphill and downhill.
 Never park on the slope.
 Slow down when going downhill and ready for braking.
 Travel according to regulated route.
 The road should keep clean, no slipping

48
Stand-on type

19
B1

B2

Slow down
– Slowly loosen the thumb, the direction speed control button will return automatically and the truck
slows down.
Stand-on type
– Start up the truck
– Open the pedal
– Step on the pedal
– Swivel the control handle to driving range (F).
– Adjust the direction speed control button (17) to the desired direction
– Control truck speed by direction speed control button (17). Speed is controlled by rotating the
driving switch, and the maximum rotation can get fast speed.
Others refer to pedestrian-type contents.

49
6.4 Braking
– When the thumb off the direction speed control button, pull the handle to braking range (B1 or
B2) position or vertical position, the truck brakes.

CAUTION
 When release the control handle, the handle swivel into the braking range slowly or
nor enter braking range, do check the reason and eliminate the fault. Replace gas
spring if necessary.

6.5 Steering
– Hold the left and right handle of control handle with both hands, and decline to some degree,
move the handle to left or right to release truck steering.
When turn to left, the truck turns left.
When turn to right, the truck turns right.

6.6 Stopping
– Release the direction-speed knob. Decrease the speed.
– Return the control handle to vertical position.
– Drop the fork to the lowest position.
– Turn off the switch to “OFF” position, press down the emergency disconnect switch, pull out
the battery plug, and take off the key.
– Fold up.

6.7 Loading
Procedure:
– Drive the truck carefully up to the loads.

– Adjust fork height to make the forks in the tray.

– Go forward and make the forks in the tray.

50
– Raise the loads several centimeters to make sure if the loads are firm.

– Travel the truck off the area.

– Drop the load to lower position

6.8 Unloading
Procedure:
– Approach the deposit area.

– Raise the loads to correct height.

51
– Travel forward, put the load on the unloading position and then stop.

– Make sure the loads are right above, drop the forks slowly until the forks are out of the load.

– Travel backward and make the fork out of the load.

– Drop down the forks to proper position.

52
6.9 Parking
Procedure:
– Drive the truck to safe area or appointed area.
– Fully lower the forks.
– Turn off the key switch(3), and remove the key.
– If park for long time, press the emergency disconnect switch(11) and take out the battery plug.

13
4
12

53
7 Deposit the truck
7.1 Deposit the truck for long time
– Fully check the truck, especially check the wheel damage.
– Check fluid oil and electrolyte for leakage.
– Apply lubrication grease.
– Check the joint face of cylinder piston rod for looseness, and if scratch on the piston rod
surface. Apply anti-rust oil to piston rod or easily rusty axle.
– Cover the whole truck.
– Check specific gravity of electrolyte and liquid level once a month.
– Do equalizing charge to the battery once a month.

7.2 Start running after deposit for a long time

– Remove rust preventive oil on exposed parts.
– Clean impurity and water of the hydraulic oil tank.
– Recharge battery, fit on truck and connect.
– Carefully check before start. Inspect starting, travelling, slowing down, steering, braking and
parking etc. function.

54
8 Maintenance
8.1 Maintenance general
– The forklift truck needs inspection and maintenance periodically, to make it in good working
condition.
– Inspection and maintenance are usually ignored, you’d better find the problems early and
solve it in time.
– Use authentic parts of Hangcha Group.
– Don’t use different oil when changing or adding oil. Don’t rave about oil and electrolyte used at
will, and carry on handling according to the local environmental protection laws and
regulations.
– Draw up complete maintenance plan.
– After you make maintenance, you’d better make a record.
– Forbid to repair the forklift truck if you haven’t been trained.

CAUTION
 No fire.
 You should shut off key switch and pull off the plug before service.（except some
trouble shooting）.
 Clean the electric part with compress air, and do not with water.
 Do not stretch your hands, feet or any part of body into the gap between the lifting
assembly.
 When the working environment is severe, maintain in advance.

55
8.2 Periodic maintenance schedule
D= work every 8 hours(or per day)

W= work every 40 hours(or per week)

M= work every166 hours(or per month)

T= work every 500 hours(or 3 months)

S= work every 1000hours(or 6 months)

〇 —Check, revise, adjust

× —Replace
Battery
Service
Service required Tools D W M T S
item

Electrolyte level Eyeballing 〇 〇 〇 〇

Electrolyte proportion Densimeter 〇 〇 〇 〇

Battery quantity 〇 〇 〇 〇 〇
Storage battery

Terminal looseness 〇 〇 〇 〇 〇

Looseness of connecting wire 〇 〇 〇 〇 〇

Cleanness of the battery surface 〇 〇 〇 〇

If there are tools on the battery 〇 〇 〇 〇 〇

The tightness and smoothness of

〇 〇 〇 〇
air cap

Far away from firing 〇 〇 〇 〇 〇

Controller
Service
Service required Tools D W M T S
item

Check wear condition of connector 〇 〇

Check the running condition of

Controller

〇 〇
contactor
Check interlock inching switch for
〇 〇 〇 〇
running
Check the connection among motor,
〇 〇
battery and power unit

56
Motor

Service
Service required Tools D W M T S
item
Clean the foreign body on the motor
〇 〇 〇 〇
Clean or replace the bearing
〇
DC motor

Check the carbon brush and

commutater for worn, whether spring 〇 〇or× 〇or×
is normal
Whether the connection is correct and
〇 〇 〇
firm.
Brush carbon powder on shift plate
〇 〇
and shift device.
Clean the foreign body on the motor
〇 〇 〇 〇
Clean or replace the bearing
〇
AC motor

Check if there is abnormal vibration,

〇 〇or× 〇or×
noise, if pedestal is firm.
Whether the connection is correct and
〇 〇 〇
firm.
Check if the temperature or current is
〇 〇
normal.

Driving system

Service
Service required Tools D W M T S
item
Reduction box

Check for noise 〇 〇 〇 〇 〇

Check for leakage 〇 〇 〇 〇 〇

Two
Add lubricating grease
years

Bearing lubrication 〇 〇 〇 〇
mechanism
Steering

Check if the steering flexible 〇 〇 〇 〇 〇

Check for noise 〇 〇 〇 〇 〇

Control handle swivel angle 〇 〇 〇 〇 〇

Wheel（Drive wheel, auxiliary wheel, load wheel）

Service
Service required Tools D W M T S
item
Eyeballi
Check for abrasion or cracks 〇 〇 〇 〇 〇
ng
Wheel

Check for bolt fastening and

〇 〇 〇 〇
re-tighten.
Check if there is foreign body like rope
〇 〇 〇 〇 〇
on the wheel

57
Brake system

Service
Service required Tools D W M T S
item
Check for brake condition when the
control handle on horizontal position 〇 〇 〇 〇 〇
inching
switch
Brake

and vertical position.

Check the inching switch for
〇 〇 〇
looseness or damage.

Check the installation for fastening. 〇 〇 〇

Electromagnetic

Check the surface abrasion for

〇 〇
brake

equality.
Check if the clearance is proper and
〇 〇
adjust, if necessary.
Check the brake for flexibility and
〇 〇 〇 〇 〇
effective.
Hydraulic system

Service
Service required Tools D W M T S
item

Check for oil level, change oil 〇 〇 〇 〇 ×

Hydraulic
reservoir

Clean suction strainer 〇

Clean foreign matter 〇

Check for block, return spring stuck or

solenoid

〇 〇 〇
valve

damage

Check for wiring looseness. 〇 〇 〇

Check for oil leakage 〇 〇 〇 〇 〇

Safety valve

Check for safety valve operation

〇 〇 〇
condition.
Oil
Measure safety valve pressure pressure 〇
gauge
Check for oil leak, looseness,
〇 〇 〇
Piping,

collapse, deformation and damage

joint

×
Replace hoses.
1-2years
Check hydraulic pump for oil leakage
Hydraulic

〇 〇 〇 〇 〇
pump

or noise

Check pump drive gear for wear 〇

Check for inching switch work

〇 〇 〇
inching

condition.
switch
Lifting

Check inching switch for looseness or

〇 〇 〇
damage.

58
Lifting assembly

Service
Service required Tools D W M T S
item
Check chain for tension, damage or
〇 〇 〇 〇 〇
rust
Chain & chain wheel

Add lubrication for chains 〇 〇 〇

Check chain wheel for deformation or

〇 〇 〇
damage
Check chain wheel bearing for
〇 〇 〇
looseness

Pin shaft lubrication 〇 〇 〇

Check piston rod, rod screw and

Test
connection for looseness, deformation 〇 〇 〇 〇 〇
hammer
Lifting cylinder

or damage

Check for operation 〇 〇 〇 〇 〇

Check for oil leak 〇 〇 〇 〇 〇

Check lifting cylinder fixed bolt for

〇 〇
looseness.
Check welded parts of beam and
outer and inner masts for defective, 〇 〇 〇
Mast & fork carriage

cracks or damage
Check outer and inner masts for
〇 〇 〇
defective weld, cracks or damage
Check for defective weld, cracks or
〇 〇 〇
damage of fork carriage

Check roller bearings for looseness 〇 〇 〇

Check rollers, roller pins and welded

〇 〇 〇
parts for cracks or damage
Check forks for damage,
〇 〇 〇
deformation or wear
Fork

Check fork base and hook welding for

〇 〇 〇
defective cracks or wear

59
Others

Service
Service required Tools D W M T S
item

Wire damage or looseness 〇 〇 〇 〇

Wire
Looseness of circuit joint 〇 〇 〇
Emergency
disconnect Check for work condition 〇 〇 〇 〇 〇
switch
Direction and
speed control Check for work condition 〇 〇 〇 〇 〇
button
Lifting, lowering
Check for work condition 〇 〇 〇 〇 〇
switch
Check for work and
Horn 〇 〇 〇 〇 〇
installation condition
Check meters for proper
Meters 〇 〇 〇 〇 〇
operation
Pedal(only for Check the pedal if folded up
〇 〇 〇 〇 〇
stand-on type) and down normally.

60
8.3 Truck used oil and lubrication
C

C
B

A C

Filler plug for hydraulic oil

Hydraulic oil drain plug.
Gear oil add plug
Gear oil drain plug
Lubrication part
Grease nipples

Code Designation Mark, code Remark

Normally：L- HM32
A Hydraulic oil High and cold environment：L- Hydraulic system
HV32
B Gear oil GL-5 85W/90 Reduction box

Automobile general 3 # lithium

C Grease Nozzle and lubrication
base lubricant

61
Replace gear oil
– Park the truck at level ground.
– Wipe off oil add and drain plug.
– Unscrew oil add plug（46）.
– Place an appropriate container under oil
drain plug(47), unscrew oil drain plug(47), 46

and drain the oil to the container.

– After oil in the reduction box drains,
re-tighten the drain plug（47）.
– Add appointed gear oil（GL-5 85W/90）. In
order to add oil easily, add with help of
funnel and tube. When oil overflows from the
oil filler, it means oil is enough.
– Re-tighten oil add plug(46), and clean the
residual oil on the reduction box surface.

47
Warning
 Handle the exhaust oil according to
relevant rules of the state and never
dump at will.

OIL

46

62
Replace hydraulic oil
– Park the truck at level ground.
– Wipe off oil add and drain plug.
– Unscrew oil add plug（48）
– Place an appropriate container under oil 48
drain plug(49), unscrew oil drain plug(49),
and drain the oil to the container.
– After oil in the reduction box drains,
re-tighten the drain plug（49）
– Add appointed gear oil （ L- HM32 ） to
allowable scale range. In order to add oil
easily, add with help of funnel and tube. 49

– Re-tighten oil add plug(48), and clean the

residual oil on the reduction box surface.

WARNING 48
 Handle the exhaust oil according to
relevant rules of the state and never
dump at will.

49

OIL

48

49

63
8.4 Replace the key safe parts periodically
Users should replace the parts periodically according to the following table. If the part is abnormal
before the replacing time, it should be replaced immediately.

Key safe part’s description Term of using (year)

Hydraulic hose for lifting system 1～2

High-pressure hose, hose for hydraulic

2
system
Inner sealing element, rubber matter of the
2
hydrulic system

8.5 Screw down the wheel retaining nut

Re-tighten the wheel retaining nut after break-in ends. Check and tighten wheel retaining nut
periodically.
– Screw down the wheel retaining nut with torque spanner to specified order（45）.
– Screw down with 10N.m torque.
– Screw down with 80N.m torque.

2
45
4

5
1
3

64
8.6 Removing the hood
Procedure:
– Park the truck securely.
– Open the arm guard(4).Only for the stand on type
– Put down the folding pedal (7).Only for the stand on type
– Undo the four groups of bolts(45)on the panel(5)with a wrench.
– Lift the hood(5),remove it from the truck and place it securely next to the truck.
The panel is now disasdembled.
Instead of the installation sequence and disassembly sequence.
45 45

5 5

45

7
45

Warning
 When hood was removed, Prohibited operating forklift .
 When hood was removed, before the repair, must to discharge (such as controller)
energy storage components.

65
8.7 Remove the fence
Procedure:
– Park the truck securely.
– Undo the six groups of screws(47) on the fence(46) with a wrench.
– Lift the fence(46),remove it from the truck and place it securely next to the truck.
The fence(46) is now disasdembled.
Instead of the installation sequence and disassembly sequence.

WARNING
 When the fence removed, there is a risk of trapping when mast extended. It is
forbidden to any parts of the body reach through the mast.

47

46

47

66
8.8 The installation of the load backrest
The electric stacker without load backrest,but with four installed threaded hole. If you
want to install load backrest(48), only need to use four composite bolt(49) and tighten.

WARNING
 Install retaining load backrest clamp hand danger. Be careful.

48

49

67
9 Relevant safety directive or standard (CE)
After CE certificated, the truck meets the following directive and standard:
– 2006/42/EC machinery directive（namely Directive of the council of the laws of the member
states concerning machinery）, 2000/14/EC Noise Directive（Namely Directive of the council
of the laws of the member states concerning noise radiation of outdoor equipment）;
– EN ISO3691-1:2015 Industrial trucks — Safety requirements and verification — Part 1:
Self-propelled industrial trucks, other than driverless trucks, variable-reach trucks and
burden-carrier trucks
EN16307-1:2013+A1:2015 (Industrial trucks. Safety requirements and verification.
Supplementary requirements for self-propelled industrial trucks, other than driverless trucks,
variable-reach trucks and burden-carrier trucks)
– EN1175-1:1998+A1:2010 Safety of industrial trucks - Electrical requirements - Part 1: General
requirements for battery powered trucks, EN1726-1:199 Safety standard for machinery
industrial vehicle, EN1757-2:2001 harmonized standard;
– Main safety elements are in accordance with 2006/42/EC machinery directive as well as
EN1175-1:1998+A1:2010, EN1726-1:1998, EN1757-2:2001 standard;
Electronic components design and manufacture meet low-voltage apparatus directive
2006/95/EC;
Noise is calculated according to EN12053:2001+A1:2008：pallet truck noise, sound pressure
value
Lifting: right ear73.4dB, left ear72.5dB
Going forward: right ear72.4dB, left ear71.5dB
– Vibration data are according to the EN13059:2002+A1:2008 Safety of industrial trucks - Test
methods for measuring vibration, determined by ISO5349-2:2001, ISO2631-1:1997standard,
meet 2002/44/EC directive：handle vibration amplitude is 0.2977m/s2.
– Electromagnetic compatibility is calculated according to EN12895:2000 and meet
2004/108/EC directive.

68
69
 Part Ⅱ: Structure, Principle and Maintenance
1 Drive system
Drive system is vertically arranged and rigid coupled with the frame. Drive system is mainly
consisted of drive seat, reduction box, drive wheel, drive motor and electromagnetic brake etc..

8
2

4
6

1. Electromagnetic brake
2. Drive motor
3. Steering gear wheel（only for electric steering）
4. Steering pinion（only for electric steering）
5. Reduction box
6. Drive wheel
7. Steering motor（only for electric steering）
8. Encoder
9. Drive seat
Fig. 2-1 Drive diagram of drive unit

70
1.1 Reduction box
The truck used reduction box, light and controllable vehicle driving device, which adopts two
grades reduce speed gear, namely grade-one cylindrical gear and grade-two spiral bevel gear.
This reduction gear box owns traits like small size, light weight, large transmission ratio, small
radius of gyration, high efficient and simple structure, which enables turn on site and equip with
motor vertically that cause the radius of gyration on the carriage is small. Moreover, this reduction
gear box does not need to shift, but realize direction shift (forward or reverse) directly by motor
positive inversion, and is easy to use and maintain.

1. Housing 12.Gasket 22.Connection tray

2. Adjusting shim 13.Hexagon bolt 23.O-ring
3. Tapered roller bearing 14. Adjusting shim 24.Hexagonal socket cap screw
4. Gasket 15. Driving spiral bevel 25.Air plug assembly
5. Oil seal gear 26.Cover plate
6. Connecting flange 16. Tapered roller bearing 27.O-ring
7. Stud 17.Driven gear 28.Sealer
8. Hexagon nuts with flange 18. Adjusting shim 29. Magnetic plug
9. Tapered roller bearing 19.Gasket 30. Hexagonal socket head plug
10. Driven spiral bevel gear 20.Nut 31. O-ring
11.Adjusting shim 21.Driving gear
Fig.2-1 Structure diagram of reduction box

71
1.1.1 Working principle
Simple figure of reduction box is as Fig.2-1, motor driving gear 1 drives driven gear 2, driven gear
2 drives driving spiral bevel gear 3 to transfer to driven spiral bevel gear 4, then the driven spiral
bevel gear 4 drives the output of output flange 5. Power transmission order is that 1(driving motor),
2(driving gear), 3(driven gear), 4(gear shaft), 5(annual gear) drive the wheel output. Moreover, this
reduction box does not need to shift, but realize direction shift (forward or reverse) directly by
motor positive inversion, and is easy to use and maintain.

1. Driving gear(pinion gear)

2. Driven gear
3. Driving spiral bevel gear
4. Driven spiral bevel gear
5. Output flange
Fig.2-1 Drive picture of reduction box

72
1.1.2 Dismount and assemble order
Dismount and disassemble the reduction box according to the following order:
– Dismantle driving wheel (wheels);
– Open oil discharging bolt and discharge the oil;
– Disassemble swing bearing and top shell articles;
– Disassemble driven cylindrical gear
– Open the cover, disassemble driven spiral bevel gear and output flange etc.
1.1.3 Notice to installment and use
– Before installing, you should wipe the oil on the surface of the shell.
– In case that the oil leaks during use, you are not allowed to dismount and disassemble the
product.
– Prevent the assembling surface and exposed flange from being knocked or damaged,
otherwise it may influence the installment and use precision.
– Working oil should keep clean, the new machine should change new oil in 50 hours for the
first use and every 1000 hours later.
– Working oil should in accordance with brand no.（GL-5 85W/90）.
1.1.4 Fault and troubleshooting

Fault Probably cause Method of Fault eliminating

① Lack of oil Add oil

Low efficient transmission and ② Quantity of the oil is

Replace
overheat oil temperature ineligible
③ Gear or bearing is
Replace
damaged
Unstable running Replace
①Gear or bearing is damaged
Oil leakage Replace
① Wear or damage of oil seal

②Leakage from the gasket Screw bolt or replace

73
1.2 Motor
Traction motor
Traction motor is three phase AC motor, maintenance-free, but needs periodical check and clean.

When tighten the upper nut on the wiring board, lock the lower nut to avoid looseness, and the

suggested tightening torque is T=10.2～12.4N.m.

Rated Rated Rated Max. Rated Insulatio Frequen Quota Temp. Remark
power voltage current current speed n grade cy
kW V A A r/min Hz min ℃

1.5 16 90 170 2295 H 79.6 S2-60 40 Pedestrian

2.2 16 125 235 2985 H 103 S2-60 40 Stand-on

W V U

Lifting bolt

Speed sensor

Thermistor

74
Steering motor
DC steering motor is permanent magnet brush motor with planetary reduction box.
①Output shaft
②Output shaft bearing
③Annular gear
④Second stage planet gear
⑤Split type planet carrier
⑥First stage planet gear
⑦Motor shaft
⑧Motor shaft bearing
⑨Motor housing
⑩Motor stator
⑪Motor rotor
⑫Motor rear cover

Technical parameter

Rated Rated Rated Rated Brush Rated Quota Insulatio Protectio Temperature
power voltage current speed service life torque n grade n grade
kW V A r/min h N.m min ℃

0.2 24 13 3300 2000 0.562 S2-10 B IP20 -10～40

Motor wiring and direction of rotation

Check motor turn from motor output shaft：

Red outgoing line connects power positive, black outgoing line connects

power negative, output shaft rotates in clockwise.

Red outgoing line connects power negative, black outgoing line

connects positive power, output shaft rotates in counterclockwise.

Replace brush

Brush service life is 2000hrs. When replace brush, use “00” thin emery

cloth to burnishing it. During burnishing you can haul the emery cloth

leftward or rightward. After burnish the brush and clean the commutator

with emery cloth, the motor with load should run with low voltage and

limited speed, in order for safety, till the brush’s working face is shined.

75
Motor use notice
– Parts of stator have been adjusted; users mustn’t unpack and adjust randomly.
– Keep clean and dry around the motor, place no other material on its inner or outer.

– Wipe off the sand and other adhesion on the housing in order not to affect heat dissipation.

– It’s prohibited to use with overload.

– It’s prohibited to coexist with strong magnetic object.

– Make sure the correct of input voltage grade.

– If there is abnormal odor in use, park to check immediately.

– The cabling between motor and controller should be as short as possible.

– During motor travelling, if there happen electric leakage, speed drops suddenly, severely

vibrate, too hot with smoke, or electric contact sparking smoke, turn off the power

immediately for check.

– Often check if the motor over heats.

– Often check motor wiring contact screw for looseness, sparking smoke or insulation aging.

Replace brush：

Brush service life is 2000hrs. When replace brush, use “00” thin emery cloth to burnishing it.

During burnishing you can haul the emery cloth leftward or rightward. After burnish the brush and

clean the commutator with emery cloth, the motor with load should run with low voltage and

limited speed, in order for safety, till the brush’s working face is shined.

76
AC Motor fault diagnosis

Fault Probable cause

①Power is not on(at least two phase off)
After power is on, the motor does not
②Fuse fusing(at least two phase fusing)
rotate, but without noise, odor or
③Overcurrent relay adjusts too small
smoke.
④Wiring error of control equipment
①Lack one phase power, or reverse connection of
stator coil one phase
After power is on, the motor does not ②Short circuit of stator winding
rotate and fuse burnout. ③Grounding of stator winding
④Wiring error of stator winding
⑤Fuse section too small.
①Open circuit of stator, rotor winding(one phase
disconnection) or one phase power is off.
②Start and end of the winding outgoing line wrongly
connect or internal winding oppositely connect.
③Power return contact loosens and contact resistance
After power is on, the motor does not
is large.
rotate but with buzzing noise.
④Motor load too large or rotator locks.
⑤Power voltage too low.
⑥Small motor assembles too tight or bearing grease
too hard.
⑦Bearing seizing-up.
①Power voltage too low.
②△ Motor wrongly connected to Y
③Cage rotor open weld or crack
Motor starts hard, and the motor
④Local coil of stator and rotor wrongly or oppositely
speed is much lower than rated
connected.
speed with rated load.
⑤Add too much number of windings when repair motor
winding.
⑥Motor overload.
①When rewind, numbers of stator three-phase winding
is not equal.
Current is unbalance when motor
②Two ends of winding wrongly connected
without load and three phases differ a
③Unbalance power voltage.
lot.
④There is interturn short circuit or coil oppositely
connected in the winding.
Motor without load, while loaded, ①Guide bar of cage rotor open weld or crack
ammeter indicator is unstable and ②Wound rotor fault(one phase open circuit) or bad
swings. brush and collecting ring short circuiting device contact.

77
 Fault Probable cause
①Reduce too much number of stator windings when
repair motor winding.
②Power voltage too high.
③Y connected motor wrongly connect to Δ
Motor without load, current is
④During motor assemble, rotor oppositely connects,
balance, but the value is large
make stator core unaligned, effective length shortens.
⑤Air gap over large or uneven.
⑥When remove old winding for overhaul, use improper
way that burn the iron core.
①Insulation paper of rotor and stator or slot wedge
rubs.
②There is foreign body as sand in oil or bearing wear.
③Stator and rotor core loosen.
Abnormal noise when motor runs ④Bearing lack oil.
⑤Air duct stuffing or fan rubs the fan housing.
⑥Stator and rotor core rub.
⑦Power voltage too high or imbalance.
⑧Wrongly stator winding or short circuit.
①Too big wear bearing clearance
②Uneven air gap
③Rotor imbalance
④Revolving shaft bend.
Big motor vibration during running ⑤Iron core deforms or loosens.
⑥Housing or basic capacity is insufficient.
⑦Motor foot screw loosen
⑧Open circuit of cage rotor open welding, open circuit
of wound rotor, or winding fault with stator.
①Over much or few grease
②Bad oil quantity and contains impurity.
③Mismatch between bearing and journal or end
cap(too loose or too tight)
Bearing overheat. ④Eccentricity of bearing bore, rub with the axle.
⑤Motor end cap or bearing cap not even assembled
⑥Coupling between motor and load not adjust
⑦Too large or too small bearing clearance
⑧Motor axle bend.
①Too high power voltage, greatly increase the core
Motor overheating or smoking
heating.

78
 Fault Probable cause
②Too low power voltage, the motor drives rated load,
over large current heats the winding.
③When remove winding for overhaul, use improper
way that burn the iron core.
④Rotor and stator core rub.
⑤Motor overloads or start up frequently.
⑥Cage rotor break.
Motor overheating or smoking
⑦Motor lacks phase, two phases run.
⑧After rewinding, dipping paint of stator winding is
improper.
⑨In high temperature, much dirt on the motor surface
or ventilation duct block.

79
DC Motor fault diagnosis

Fault Probable cause Correctives

Small brush contact surface Grind brush

Over brush wear Replace new brush

Oil stain on commutator surface Clean commutator surface

Commutator decentration or commutator
Process commutator outer circle
segment extrusion
Large spark
Motor overload Motor overload

Large mechanical vibration Eliminate vibration source

The welding of armature coils is not good
Repair welding
or open weld
Short circuit armature coils or
Eliminate short circuit.
commutator segment

Abnormal Large loading moment Reduce loading moment

speed Brush is not in neutral position Adjust brush to neutral position

Overload run Reduce overload

Coil overheat Eliminate short circuit and
Armature coils short circuit
reinforce insulation
Basis unstable or motor fixed on the Reinforce basis firmness and fix
basis unstable the motor.
Decentraction of axis Adjust concentricity
Large vibration
Armature imbalance Re-adjust armature balance
Reduce loading moment or
Overload or overspeed
reduce speed

80
1.3 Electromagnetic brake
The adopted brake of this truck is spring weighted electromagnetic brake. This brake is one-chip

brake, owns two friction surfaces. It can generate strong brake torque through compressed spring

in the state of power off, and electromagnetic induction realizes brake release.

6
5
4
3

1. Mounting screw 2.Stator

3. Friction disk assembly 4.Shaftsleeve

5. Friction disk 6.Dust cover

Fig. 2-1 Parts of electromagnetic brake

81
1.3.1 Working principle
Shaft(9) connects shaft sleeve(4)through flat key; shaft sleeve(4) connects friction disk

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

on the armature(8), friction disk assembly(3) that drives the shaft(9) to rotate, grips between

armature(8) and friction disk(5), thus generates braking torque. For this moment, there will be a

gap “Z” between armature(8) and friction disk assembly(3) . When need to release the brake,

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

stator(11), spring(10) is compressed when armature(8) moves, at this time, friction disk assembly

(3) is loosened, brake is released.

6 1. Mounting screw

3. Friction disk assembly

4. Shaft sleeve
1
5. Friction disk
7

5
6. Dust cover

3 7. Hollow screw
8 8. Armature
9
9. Motor shaft
4
10 10. Spring
11
11. Stator

Z Z. Air gap
Fig.2-5 Structure chart of electromagnetic brake

82
1.3.2 Brake installment
13
– Place flat key(12) to the key groove of motor shaft(9), press
4 12
shaft sleeve(4) to the shaft(9), and fix with inner snap 9

ring(13).

– Place friction disc(5) on the end face of motor.

– Cover friction brake disc(3) to the shaft sleeve.

– Install stator module(2) and three mounting screws(1). Note:

remove three fixed rubber gasket on the stator module(2)

before install.

– Screw down three mounting screws(1) with spanner, and

6
check air gap ”Z”.

– Put dust cover（6）.

– Connect brake wiring.

83
 WARNING
 No damage on the outer of wire to avoid circuit damage.

 Never process the locating face and hold of the product to avoid magnetic return

path.

 Mount on the motor shaft lightly, no damage the friction surface, get rid of burr from

mounting hold and face, install shaft sleeve on the shaft, and fix with snap spring.

 Measure brake connected DC voltage and compare it with the voltage given on the

nameplate. Deviation within 10% is allowable.

 During brake install and use, do not stain oil.

U=x V DC±10%

OIL

84
1.3.3 Brake air gap adjustment
Rated air gap ”Z” will be large for wear. Make sure the brake get enough brake torque, readjust air

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

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

specification table), replace the friction disk assembly.

When the air gas exceeds maximum air gas value, it may cause the brake unable to release,

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

cause severe accident. So it needs periodic check and re-adjust the air gap, and it must cut off the

truck general power.

Specifications
Rated Rated Rated air Max. air Rotor min. Tightening torque of
torque power gap gap thickness mounting screw

16 N.m 30 W 0.2 mm 0.5 mm 8.1mm 9.0 N.m

When the brake is off power, adjust three hollow screw(7), with the help of feeler gauge, adjust the

air gap between armature and friction plate to rated value “Z”, ensure that air gap of each direction

is the same. Here follows the adjusting procedure:

– Screw off three mounting screws（1）.

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

– Screw down three mounting screws（1）.

– Use feeler gauge to check if air gap ”Z” is rated air gap value. Repeatedly adjust “Z” to

specified value.

7
Z
-
+

In general working condition, the first air gap adjustment should proceed after brake working for

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

like frequently brake, repeatedly sudden brake, the first adjustment can be shortened and adjust

the interval.

85
1.3.4 Maintenance
– If work in high temperature environment for long time, please prevent rust, it may influence

use if there is rust on the suction surface.

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

maximum torque.

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

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

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

clearance of friction part is proper, exciting voltage normal.

86
1.3.5 Common fault and troubleshooting

Fault Probable cause Corrective action

Power is obstructed Connect

Too low exciting voltage Check voltage and adjust.

Brake does not work Improper air gap Adjust air gap

Stator coil breaks Replace stator

Oil dirt mixed in Clean oil dirt

Install the switch to the DC circuit
Switch installed to AC circuit
after rectifying
Long brake time Improper air gap Adjust air gap

Oil dirt mixed in Clean oil dirt

Unstable operation in previous Running-in for a while
use
Oil dirt mixed in Clean oil dirt
Slipping Reduce load or replace large
Large load
specification
Adjust load peak or large the
Large load change
specification
Too high exciting voltage Check voltage and adjust.
Clutch or motor interfere to the Check control circuit, eliminate
brake interference
High temperature High environment temperature Set ventilation

High operating frequency Adjust to proper frequency

Over large load Reduce load

Product service environment
Silence design
needs silence
Impurity mixed in. Clear away the impurity
Large noise
Bad mounting Replace mounting surface or shaft
Large rotational inertia or Reduce rotational inertia or
dynamic unbalance value dynamic unbalance value

87
2 Hydraulic system
Hydraulic system is mainly composed of hydraulic unit, lifting cylinder and rubber tube etc.

1. Hydraulic unit
4
2. Rubber tube assembly

3. Rubber tube assembly

1 4. Pipeline assembly

5. Left lifting cylinder

6. Right lifting cylinder

Fig. 2-1 Hydraulic system

88
2.1 Hydraulic system working principle
Brief introduction to the working principle of hydraulic system：
When press the lifting button of the control handle, lifting motor works, drive the hydraulic pump
through coupling device, hydraulic oil enters lifting cylinder through one-way valve, and forks lift.
When press the lowering button of the control handle, lifting motor does not rotate, the solenoid

valve open by this time, hydraulic oil in the lifting cylinder through solenoid valve and governor

valve returns to the oil tank, and the forks drop.

89
2.2 Hydraulic unit
The truck adopts combined hydraulic unit, and is composed of DC motor, relay, coupling, valve

seat and valves (solenoid directional valve, safety valve, one-way valve, governor valve and oil

blockage), gear pump, pipeline, oil filter and fuel tank etc.

Data

Rated power 2.2 kW /3.0 kW

Rated voltage 24 VDC

Rated current 180 A

Motor Rated speed 3500 r/min

Working system S2=3.5min

Working system S3=15%ED

Rotation direction Rotate in counterclockwise

Rated voltage 24 VDC

Relay
Rated current 150 A

Gear pump Certified capacity 2.6 ml/r / 3.15 ml/r

24V DC normally-closed valve element with

Solenoid valve
mergency unloading

Drop throttle valve 15 L/min

Thread G1/4

Safety valve(overflow valve) Set pressure 16.3MPa /18.5MPa /16.5MPa /20MPa

Type L-HM32 or L-HV32

Hydraulic oil
Oil temperature -10℃～+70℃

90
Pressure adjustment of safety valve

Set pressure of safety valve a is 20.0MPa. The pressure has been adjusted before sold, and

users do not need adjust under in general conditions. If needed, user can adjust the pressure

through pressure regulating valve knob according to the actual condition, but should not exceed

the nominal pressure.

– Take apart the cover.

– Connect oil pressure gauge to the pressure mouth

– Loosen main safety valve locking nut, screw the adjusting screw in clockwise, and increase

the main safety valve pressure. Screw the adjusting screw in counterclockwise, and reduce

the main safety valve pressure.

– Adjust to meet the requirement.

– Re-lock the locknut, and install into the cover.

3
2

91
Manually Lowering the Unloading
When the battery runs out or the electromagnetic valve fails to work , and the loading can not be

lowered mechanically, the emergency lowering device of the hydraulic unit can be applied

manually to lower the loading.

Procedure:

– Park the truck securely.

– Take down the hood.

– Screw out the bolts of the valve counterclockwise which can make the hydraulic oil flow back

to the fuel tank.

– After emergency lowering of the forks, screw up the bolts of valve clockwise and assemble

the engine hood back.

92
Notice
– Examine motor and solenoid valve wiring, virtual earth is prohibited.

– When install for the first time, notice inner oil in the oil tank, add enough oil after one working

cycle

– When wiring motor and solenoid valve, notice the power voltage is in accordance with the

marked one. AC motor shell should ground reliably and never run un-grounded. Prevent water

and humidity to motor connection box. When connect for the first time, start motor and check

motor direction, it rotates in counterclockwise seen from the rear motor. It is strictly prohibited

motor reverse rotation and no oil rotation.

– When add oil, hydraulic oil must be filtered and the filter fineness is no lower than 25µm.

– Power unit cannot filter out the impurity in the inner cylinder, so the inner cylinder should keep

clean to avoid control valve invalid. Pipeline should also be clean.

Maintenance
– Keep clean on the element and the pipeline, avoid dirty go into the system.

– Keep the oil level in the oil tank, add oil after certain working cycle. If pump absorbs air, it may

damage the pump and the sealer.

– Replace new oil after truck adds hydraulic oil for the first time and travel 100 hours. And then

replace new oil every year(about 1500hrs).

– Hydraulic oil viscosity is 22～46mm2/s.

– Working temperature with high temperature needs oil with high viscosity and low temperature

needs oil with low viscosity

93
2.3 Hydraulic unit dismantle
– Dismantle the hood.

– Dismantle the connector of the hydraulic unit

and the cylinder.

– Remove the wiring on the motor, contactor and

control valve.

– Remove the tightening bolt that fix hydraulic

unit.

– Take out hydraulic unit.

Assembling order is opposite to the disassembling order.

94
2.4 Hydraulic system fault diagnosis and correction

Fault Probable cause Corrective action

No oil Low oil level Fill to the specified oil level

pumps from
Clean oil pipe and oil tank. If hydraulic oil is
the pump Blocking of strainer
dirty, please change it.
Bearing worn; retainer, O-ring
Change the bad spare parts
Low oil damage
pressure of Adjustment failure of safety
Rise pressure with pressure gage
oil pump valve
output Fill hydraulic oil to the oil tank, use the pump
Air in the oil pump
after bubble vanishing
Cavitation arising from the Adjust or replace soft tube and clean the
strainer blocking strainer
Replace new hydraulic oil, whose viscosity
Noise of oil Cavity caused by the high
suits pump running speed. Work only when the
pump viscosity of hydraulic oil
oil temperature is normal
Check the reason for the bubble and then take
Bubble in the hydraulic oil
measures
Gear
pump Oil way block or damage Repair or replace
Forks can’t lift

works
Lifting inching switch loosen or
Gear Re-fix or replace
damage
pump
no work Motor or circuit fault Repair

Forks do not Solenoid valve block or

Repair or replace
drop down damage
Pressure adjusting screw
Re-adjust and lock.
loosen
Pressure of
Pressure adjusting spring
safety valve Replace
deformation or damage.
is unstable
Safety valve spool wear or
or can’t be Replace or clean to reassemble.
sticking
adjusted
Pump failure Repair pump

95
3 Electric system
Electric system of this truck is double wire system, all circuits do not ground. Working voltage is

DC24V.

3.1 Principles of electrical system

96
97
98
99
3.2 AC motor controller
3.2.1 Maintenance
AC motor controller, fuse protector and fuse are installed on the electronic control mounting
bracket, when mounting the controller, apply heat conduction silicon grease to its bottom.
Maintenance
Controller has no user repair parts. Do not try to open, repair or alter the controller. Otherwise it
may damage the controller and also invalid the guarantee.
It’s suggested to keep the controller clean and dry, periodically check and get rid of diagnose

historical files.

Cleaning
Periodically clean the outside controller is good for preventing corrosion or other controller fault

from dirty, dust and chemical, which is part of the environment and always exist in battery power

supply system.

Be careful when operating the truck power supplied by battery. Including but not limit to the

following: correct training, wear goggles, do not wear loose clothing and jewelry.

Carry out maintenance according to the following cleaning procedure. Never clean the controller

with high pressure washer.

– Remove battery to disconnect power.

– Connect load(like contactor coil or horn) between controller B+ and B- to discharge

controller capacity.

– Clean dirt or corrosive on the power and signal binding post. Wipe the controller with wet

cloth, dry the controller before connecting the battery. Controller can’t suffer the water

impact with pressure.

– Make sure the wiring is correct and fastened.

WARNING
 Strictly prohibit water in the product. Strictly prohibit operating with electricity.

Strictly prohibit reverse polarity. Strictly prohibit motor short circuit.

100
 3.2.2 Diagnosis and troubleshooting
Diagnosis procedure

Truck cannot travel

Check if the controller

LED light flashes

Flash
Light is off

If normally flashes

Switch in encoder Normal flashing way Fault flashing way

If battery has electricity If motor is normal

Display No display

Check if Check if If If other Use Refer to

input the output contactor external encoder instructi
signal signal absorbs facility to check ons to
Check if the input normal(us from normally is fault check
end signal of the able controller normal reason the
key switch is encoder) to motor is correspo
normal. normal (if nding
two fault
terminals code of
output LED
after flash.
accelerato
r input)
Normal Abnormal

Input Relevant
normal, part fault Eliminate
Eliminate external fault
key switch facility
fault normal,
output
abnormal

Controller Controller
fault fault Controller
fault

101
Get the fault information from three ways：

– Get fault information from the instrument: When the truck has fault, the LED3(RED) indicator

light is on, LCD displays fault type and code.

– Get fault information by switching in handheld programmer. Refer to Handheld Programmer.

– Get fault information by observe controller built-in LED indicator lights. Refer to LED Status

Indicator.

102
1311 Handheld Programmer
1311Handheld Programmer is a handheld tool that allows user programming, testing and

diagnosing the traction motor controller, refer to the following picture. Program setting handheld

terminal owns one menu navigation key, one data Inc/Dec key and three bookmark keys to control

all programmable functions.

Display window includes a seven-line 128 × 64 pixel LCD screen, this screen can show the test

and pictures at the same time, visible in the lightest condition, and adjust program to set menu.

Program is driven by the menu, and enters the next menu by pressing menu navigation button.

When the program is connected to motor controller, all motor controller information uploads to the

handheld programmer.

DISPLAY
SCREEN

MENU
NAVIGATION
KEY DATA
INC/DEC
KEY

1 3
2

BOOKMARK
KEYS

Display screen：It can show seven-line test and pictures at the same time.

Menu navigation key： Move the cursor on the screen up or down to pass the menu list(up or

down arrow),open or close submenu(right or left arrow)

Data Inc/Sec key： Alter data values by display cursor.

Bookmark key：Three bookmark keys allow you to return fast or reach your favor or often use

menu interface without through the menu navigation. Press on the relevant bookmark button for 4

seconds, it can store relevant menu interface to this button. Press the relevant bookmark key, it

103
can skip to the corresponding menu interface of your chosen bookmark. After close the

programmer, the bookmark button will not be kept.

104
3.2.3 LED Status Indicator
Controller built in one LED status indicator light(display red or yellow)

Display Information
Controller power is not on; or vehicle has dead battery; or other
LED light is off
severe damage.
LED light flashes yellow Controller is in normal working status.

Controller failed to supervise or did not load software. Restart KSI

LED light is often red
cycle, load software if necessary.
LED flashes yellow or red
Controller has detected a fault.
alternately

Red and yellow lights flash alternately in a repeated interval when there detects fault. Each code

consists of two digits. The red LED flashes once to indicate that the first digit of the code will

follow; the yellow LED then flashes the appropriate number of times for the first digit. The red LED

flashes twice to indicate that the second digit of the code will follow; the yellow LED flashes the

appropriate number of times for the second digit.

Example，fault code“23”LED status indicator light shows as follows：

Red Yellow Red Yellow

✱ ✲✲ ✱✱ ✲✲✲
（the first digit）（2） （the second digit）
（3）

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3.2.4 Fault code table
This fault codes provide the following information:
– Fault code

– Display fault name on the Curtis programmer

– Display caused by the fault

– Probable fault reason

– Fault deep reason

– Troubleshooting
When there is fault, if it’s affirmed not the wiring error or truck malfunction, you can try to restart
through key switch. If fault still exists, please turn down key switch, check if the connector of pin 35
connects right or gets dirt, after repair and clean , reconnect, and then start again.
Fault code table
Programmer display Deep fault
Code Probable fault reason
Fault display reason/troubleshooting
12 Controller Overcurrent 1. External short of phase U,V,W Reason：Phase current exceeds
Motor stops working motor connections limited current
Main connector disconnects 2. Motor parameters do not Troubleshooting：restart the key
EM brake shutdown match.。 switch
Throttle invalid 3. Controller malfunction
Brake
Pump stops working
13 Current Sensor Fault 1. Leakage to vehicle frame from Reason：Deviation reads out to
Motor stops working phase U,V, or W controller current sensor.
Main connector disconnects 2. Controller malfunction Troubleshooting：restart the key
Electromagnetic brake disconnects switch
Throttle invalid
Brake, Pump stops working
14 Precharge Failed 1. External load on positive Reason：Key switch input voltage
Motor stops working terminal of the capacitor that failed to charge the capacitor.
Main connector disconnects prevents the capacitor from Troubleshooting ： Reset or
Electromagnetic brake disconnects charging. re-input interlock switch through
Throttle invalid VCL function precharge().
Brake
Pump stops working
15 Controller Severe Undertemp 1. Severe controller working Reason：Radiator temperature is
Motor stops working environment. lower than -40℃.
Main contactor disconnects Troubleshooting：Raise the temp
Electromagnetic brake disconnects above -40℃, restart the key
Throttle failure switch or interlock switch.
Brake

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 Programmer display Deep fault
Code Probable fault reason
Fault display reason/troubleshooting
Pump stops working

16 Controller Severe Overtemp 1. Severe controller working Reason：Radiator temperature is

Motor stops working environment. higher than 95℃.
Main contactor disconnects 2. Truck overloads. Troubleshooting：Drop the temp
Electromagnetic brake disconnects 3. Incorrect controller mounting below 95℃. Restart the key
Throttle failure switch or interlock switch.
Brake, pump stops working
17 Severe Undervoltage 1. Setup error of battery parameter. Reason： When MOSFEET axle
Driving torque reduce 2. Power consumption of non working, capacitor voltage is
controller system. lower than the minimum voltage
3. Too large battery impedance. limit.
4. Battery disconnects. Troubleshooting ： Raise the
5. Fuse protector disconnect, or the capacitor voltage.
main contactor disconnect.
18 Severe Overvoltage 1. Setup error of battery parameter. Reason：When MOSFEET axle
Motor stops working 2. High battery impedance. working, capacitor voltage
Main contactor disconnects 3. Battery disconnects when exceeds the minimum voltage
Electromagnetic brake disconnects regenerative breaking. limit.
Throttle invalid Troubleshooting ： Reduce the
Brake voltage and then restart the key
Pump stops working switch.
21 Controller Undertemp Cutback 1. Controller works in limited Reason：Radiator temperature is
No fault(unless VCL set the condition. lower than-25℃.
incurred fault) 2. Severe controller working Troubleshooting ： Make the
environment. radiator temperature higher than
-25℃.
22 Controller Overtemp Cutback 1. Severe controller working Reason： Radiator temperature
Drive or regenerative braking environment. exceeds 85℃.
torque reduces. 2. Truck overloads. Troubleshooting ： Reduce the
3. Incorrect controller mounting temperature.
23 Undervoltage Cutback 1. Insufficient battery power. Reason ： Too low capacitor
Driving torque reduces 2. Setup error of battery parameter. voltage.
3. Power consumption of non Troubleshooting：Raise capacitor
controller system. voltage.
4. Too large battery impedance.
5. Battery disconnects.
6. Fuse protector disconnects or
main contactor disconnects.
24 Overvoltage Cutback 1. During regenerative braking, Reason：When MOSFEET axle
Regenerative braking torque regenerative braking current cause working, capacitor voltage
reduces. the raising of battery voltage. exceeds the maximum voltage
2. Setup error of battery parameter. limit.

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 Programmer display Deep fault
Code Probable fault reason
Fault display reason/troubleshooting
3. Too large battery impedance. Troubleshooting ： Reduce
4. When regenerating braking, capacitor voltage.
battery disconnects.
25 +5V Supply Failure 1. External load impedance is too Reason： 5V supply outside the
No fault(unless VCL set the low. 5V±10% range
incurred fault) Troubleshooting ： Bring voltage
within range.
26 Digital Out 6 Failure 1. External load impedance is too Reason： Digital Output 6 current
Digital Out 6 driver is not active. low. exceeds15mA.
Troubleshooting：Adjust load, set
“set_digout()” by VCL, and restart.
27 Digital Out 7 Overcurrent 1. External load impedance is too Reason：Digital Output 7 current
The Digital Out 7 driver is not low. exceeds15mA.
active Troubleshooting：Adjust load, set
“set_digout()” by VCL, and restart.
28 Motor Temp Hot Cutback 1. Motor temperature reaches or Reason：Input voltage value of
Driving torque reduced. exceeds parameter limit, thus motor temperature sensor is 0 or
cause current output reduce. larger than 10V.
2. Motor temperature parameters Troubleshooting ： Return the
incorrect. motor temperature to be within
3. If motor does not apply the permitted limits.
temperature sensor, programming
parameter “Temp compensation”
and “Temp cutback” must set
“OFF”.
29 Motor Temp Sensor Fault 1. Motor temperature sensor is Reason：Input voltage value of
Max. speed drops to LOS status connected wrongly. motor temperature sensor is 0 or
and motor temperature cutback 2. If motor does not apply larger than 10V.
invalid. temperature sensor, programming Troubleshooting: Adjust input
parameter “Temp compensation” voltage value of motor
and “Temp cutback” must set temperature sensor to the normal
“OFF”. scope.
31 Coil 1 Driver Open/Short 1. Connected load open or short. Reason： Driver 1 (pin 6) is either
Driver 1 output shut 2. Connecting pin stained. open or shorted. This fault can be
3. Wrong wiring. set only when “Main Enable” set
to “OFF”.
Troubleshooting：Correct open or
short circuit, restart output.
31 Main Contactor Coil Open/Short 1. Connected load open or short. Reason： Main contactor driver
Motor stops working 2. Connecting pin stained. (pin 6) is either open or shorted.
Main contactor disconnects 3. Wrong wiring. This fault can be set only when
Electromagnetic brake disconnects “Main Enable” set to “ON”.

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 Programmer display Deep fault
Code Probable fault reason
Fault display reason/troubleshooting
Throttle invalid Troubleshooting：Correct open
Brake circuit/short circuit, restart output.
Pump stops working
32 Coil2 Driver Open/Short 1. Connected load open or short. Reason： Driver 2 output(pin 5) is
Driver 2 output shut 2. Connecting pin stained. either open or shorted. This fault
3. Wrong wiring. can be set only when “EM brake
Type” set to 0.
Troubleshooting：Correct open or
short circuit, restart output.
32 EM Brake Open/Short 1. Connected load open or short. Reason： EM Brake output(pin 5)
Electromagnetic brake disconnects 2. Connecting pin stained. is either open or shorted. This
Throttle invalid 3. Wrong wiring. fault only occurs when “EM brake
Brake Type” set to 0.
Troubleshooting：Correct open or
short circuit, restart output.
33 Coil3 Driver Open/Short 1. Connected load open or short. Reason：Driver 3 output (pin 4) is
Driver 3 output shut 2. Connecting pin stained. either open or shorted
3. Wrong wiring. Troubleshooting：Correct open or
short circuit, restart output.
34 Coil4 Driver Open/Short 1. Connected load open or short. Reason： Driver 3 output (pin 3) is
Driver 4 output shut 2. Connecting pin stained. either open or shorted
3. Wrong wiring. Troubleshooting：Correct open or
short circuit, restart output.
35 PD Open/Short 1. Connected load open or short. Reason：PD(pin 2) is either open
PD shut 2. Connecting pin stained. or shorted
3. Wrong wiring. Troubleshooting：Correct open or
short circuit, restart output.
36 Encoder Fault 1. Motor encoder error. Reason：Encoder fault
Electromagnetic brake disconnects 2. Wrong wiring. Troubleshooting：Restart key
switch.
37 Motor Open 1. Motor phase is open. Reason：Motor phase, U,V,W
Motor stops working 2. Wrong wiring. detected open
Main contactor disconnects Troubleshooting：Check phase
Electromagnetic brake disconnects and restart the key switch.
Throttle invalid
Brake
Pump stops working
38 Main Contactor Welded 1. Main contactor tips are welded. Reason：Main contactor keep too
Motor stops working 2. Motor phases U and V is much connecting, capacitor
Main contactor disconnects disconnected or open. voltage can’t discharge.
Electromagnetic brake disconnects 3. An alternate voltage path is Troubleshooting：Restart the key
Throttle invalid providing a current to capacitor( B+ switch

109
 Programmer display Deep fault
Code Probable fault reason
Fault display reason/troubleshooting
Brake connection terminal)
Pump stops working
39 Main Contactor Did Not Close 1. Main contactor does not close Reason：When the main contactor
Motor stops working 2. Contactor contacts have is closed, capacitor voltage does
Main contactor disconnects oxidized, melted, or connection not charge B+ voltage.
Electromagnetic brake disconnects status is unstable. Troubleshooting：Check the
Throttle invalid 3. External load on the capacitor. contactor, restart the key switch.
Brake 4. Fuse protector disconnects.
Pump stops working
41 Throttle Wiper High 1. Throttle pot wiper voltage too Reason： Throttle pot wiper(pin
Throttle invalid high 16) voltage is higher than the high
fault threshold(can be changed
with the VCL function
setup_pot_faults()）
Troubleshooting： Reduce the
throttle pot wiper voltage
42 Throttle Wiper Low 1. Throttle pot wiper voltage too low Reason： Throttle pot wiper(pin
Throttle invalid 16) voltage is lower than the low
fault threshold(can be changed
with the VCL function
setup_pot_faults()）
Troubleshooting： Raise the
throttle pot wiper voltage
43 Pot 2 Wiper High 1. Pot 2 wiper voltage too high Reason：Pot 2 wiper(pin 17)
Full brake voltage is higher than the high
fault threshold(can be changed
with the VCL function
setup_pot_faults()）
Troubleshooting： Reduce the pot
wiper voltage
44 Pot2 Wiper Low 1. Pot 2 wiper voltage too low. Reason： Pot 2 wiper(pin 17)
Full brake voltage is lower than the low fault
threshold(can be changed with
the VCL function
setup_pot_faults()）
Troubleshooting：Increase the pot
wiper voltage
45 Pot Low Overcurrent 1. Potentiometer impedance is too Reason： Pot low end (pin 18)
Throttle invalid low. exceeds 10mA.
Full brake Troubleshooting: Reduce low end
current, restart the key switch
46 EEPROM Failure 1. Error writing to the EEPROM. It Reason：Controller system tries to

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 Programmer display Deep fault
Code Probable fault reason
Fault display reason/troubleshooting
Motor stops may be caused by VCL writing to write into EEPROM but failed.
Main contractor stops. EEPROM, or CANBUS, or Troubleshooting：Download
EM brake stops incorrect parameter editing. correct software(OS), set correct
Throttle stops parameter, and then restart the
Interlock stops key switch.
Driver1-4 stop
PD stops
Brake
Pump stops
47 HPD/Sequencing Fault 1. Wrong sequence setting of key Reason：The wrong input of key
Throttle invalid start, interlock, direction and start, interlock, direction and
throttle input sequence setting. throttle cause HPD and
2. Wiring, switch key, interlock, sequencing fault.
direction or throttle input fault. Troubleshooting ： Re-input
according to correct sequence.
47 Emer Rev HPD 1. Emer Rev already finished, but Reason：After Emer Rev finishes,
Throttle invalid the throttle, forward or reverse each input does not return to
input and interlock do not return to neutral, that cause the fault.
neutral. Troubleshooting ： Re-input
according to correct sequence.
49 Parameter Change Fault 1. In order to protect truck safety, Reason：Parameter change
Motor stops working change of certain special needs restart of the key switch.
Main contractor stops working parameter is only valid after restart Troubleshooting：Restart the key
EM brake stops working the key switch. switch
Throttle invalid
Brake
Pump stops working
52 TH PDO Timeout 1. Communication failures. Handle damaged or poor contact
Motor stops communication circuit。
Pump stops
Handle control button all failure
68 VCL RunTime Error 1. VCL runtime. Reason：VCL runtime error.
Motor stops Troubleshooting：Edit VCL
Main contactor stops software and correct, check new
EM brake stops software to make correct
Accelerator stops parameter matching; restart the
Interlock stops key switch.
Driver 1-4 stop
PD stops
Brake
Pump stops
69 External Supply Out of Range 1. External load on 5V and 12V Reason：Upper limit of external

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 Programmer display Deep fault
Code Probable fault reason
Fault display reason/troubleshooting
supplies too high or too low. power supply(total current: 5V(pin
2. Parameter error in the Checking 26) and 12V(pin 25) is defined by
Menu, like “ExtSupply Max”，,“Ext External Supply Max and lower
Supply Min” limit is defined by External Supply
Min
Troubleshooting：Adjust external
current.
71 OS General 1. Inner controller invalid. Reason：Inner controller invalid.
Motor stops Troubleshooting：Restart the key
Main contactor stops switch.
EM brake stops
Accelerator stops
Interlock stops
Driver 1-4 stop
PD stops
Brake
Pump stops
72 PDO Timeout 1. Time between CAN PDO Reason：Time between CAN PDO
Interlock stops messages received exceeds PDO messages received exceeds PDO
CAN NMT State set to Timeout Period Timeout Period
Preoperational Troubleshooting：Restart the key
switch, or accept CAN NMT
message
73 Stall Detected 1. Motor is stalled. Reason：No motor encoder is
EM brake stops 2. Motor encoder fault. detected.
Switch the control mode to 3. Wiring damaged. Troubleshooting：Throttle
LOS(Limited operation status) 4. Problem with power supply for Command=0,Motor RPM=0
motor encoder. Restart the key switch, or detect
the effective signal of motor
encoder in LOS mode, and set
the parameter to Throttle
Command=0,Motor RPM=0.
87 Motor Characterization Fault 1. Refer to the following code Reason： Motor matching
Motor stops during motor matching： process failure.
Main contactor stops 0=Normal Troubleshooting：Correct the fault
EM brake stops 1= Controller receives encoder and restart the key switch.
Accelerator stops signal, but pulse value not defined.
Brake Set pulse value manually
Pump stops 2= Motor temperature sensor
failure
3= Motor high temperature cutback
failure

112
 Programmer display Deep fault
Code Probable fault reason
Fault display reason/troubleshooting
4= Motor overtemp cutback failure
5= Motor low temperature cutback
failure
6= Low voltage cutback failure
7= High pressure cutback f failure
8= Controller can’t detect encoder
signal and passage signal
disappears.
9= Motor parameter setting
exceeds the scope.
89 Motor Type Fault 1. Motor type parameter values Reason：Motor Type parameter
exceed the range setting value is an illegal value.
Troubleshooting：Reset and
restart the key switch.
91 VCl/OS Mismatch 1. The controller VCL does not Reason：The controller VCL does
Motor stops match OS. not match OS.
Main contactor stops Troubleshooting：Update new
EM brake stops VCL and OS.
Accelerator stops
Interlock stops
1-4 output stops
PD stops
Brake
Pump stops
92 EM Brake Failed to Set 1. Truck continues to move after Reason：After EM brake locks, the
EM Brake failure the EM brake has been truck still moves.
Throttle invalid commanded to set Troubleshooting：Check if the
2. Small EM braking force. throttle works normal.
93 Encoder LOS (Limited Operating 1. LOS activated due to motor Reason：LOS activated due to
Strategy) installing or encoder fault. motor installing or encoder fault.
2. Wrong wiring. Troubleshooting：Restart the key
3. Truck is stalled switch，if it is caused by motor
installing, make sure encoder
work under normal condition,
Throttle Command=0,Motor
RPM=0.
94 Emer Rev Timeout 1. Emer Rev timeout activated due Reason：Emer Rev function
EM Brake failure to EMR Timer overdue activated to operate until Emer
Throttle invalid 2. Emer Rev switch is always at Rev timing end.
ON position. Troubleshooting：Check Emer
Rev switch.
98 Illegal Model Number 1. Controller model can’t be Reason：Controller model can’t be

113
 Programmer display Deep fault
Code Probable fault reason
Fault display reason/troubleshooting
Motor stops identified. identified
Main contactor stops 2. Software and hardware do not Troubleshooting：Choose correct
EM brake stops match. controller, and download correct
Throttle stops 3. Controller damage. controller software.
Brake
Pump stops
99 Dualmotor Parameter Mismatch Enable parameter of dualmotor is Reason：When the dual drive
Close main contactor set as ON, and control mode software enabled, control mode
Close EM brake selecting parameter not set as 0 should set as 0（Speed Mode
Close accelerator （Speed Mode Express) or 1 Express) or 1（Speed Mode）,
Brake and close the pump （Speed Mode） otherwise there will be fault.
Troubleshooting：Adjust to proper
value and switch KSI.

114
Curtis controller 1220 diagnosis and troubleshooting
1220 controller is capable of detecting faults of various kinds of cases.As shown in
troubleshooting table, steering controller failure usually affect the traction controller.
You can get controller fault information in two ways: ① through the instrument display on two two
fault code to obtain the fault information (the first two fault code for walking controller, the second
two fault code for steering controller); ②by reading the display of information on the handheld
programmer.
Handheld programmer will be cleared after shows that since the last time to now all the history of
the fault information.The programmer shows wrong name.
For example, the Command Analog1 Out of Range (41) code.
In the handheld programmer error menu will display the word "Command Analog1 Out of
Range".Actual voltage according to the monitor menu (the Command Input » Analog Input »
Analog to 1).
1220 controller fault code table
Programmer display
Code Probable fault reason
Fault display
23 Motor Polarity Fault
1.Steering motor is the cathode.
Steering stops
2.The encoder phase sequence counter.
Drive stops
36 Motor Stalled 1.Steering system resistance is too large.
Steering stops 2.To meet the mechanical limit.
Drive stops 3.The median detection switch failure.
37 Motor Open
1.Steering motor cable connector contact is not good.
Steering stops
2.The steering motor carbon brush poor contact.
Drive stops
41 Command Analog1 Out Of Range
1.Direction Angle sensor connection line open circuit
Steering stops
2.Direction Angle sensor is damaged
Drive stops
42 Command Analog2out Of Range
1.Direction Angle sensor connection line open circuit.
Steering stops
2.Direction Angle sensor is damaged.
Drive stops
47 Encoder Fault 1.The encoder connection line open circuit.
Steering stops 2.To encoder interference.
Drive stops 3.To damage of the encoder.
53 Home Position Not Found
1.Home switch in the distance detection distance too far.
Steering stops
2.The damage of a switch
Drive stops
73 Following Error
1.Steering resistance is too large.
Steering stops
2.The steering motor fault.
Drive stops

115
Attachment：Table for bolt’s tightening torque
Unit：N·m
Grade
Bolt’s diameter
4.6 5.6 6.6 8.8
6 4～5 5～7 6～8 9～12

8 10～12 12～15 14～18 22～29

10 20～25 25～31 29～39 44～58

12 35～44 44～54 49～64 76～107

14 54～69 69～88 83～98 121～162

16 88～108 108～137 127～157 189～252

18 118～147 147～186 176～216 260～347

20 167～206 206～265 245～314 369～492

22 225～284 284～343 343～431 502～669

24 294～370 370～441 441～539 638～850

27 441～519 539～686 637～784 933～1244

Note：·Use entirely 8.8 grade bolt in the important joint position.
·Bolt’s grade can be found in the head of the bolt, if it can’t be found, the grade is 8.8.

116
 Maintenance Record

Date Repair, maintenance content Serviceman

117
HANGCHA GROUP CO. , LTD.

■ Address For: OVERSEAS USERS

■ Address: 88 Donghuan Road, Lin'an Economic Development Zone,Zhejiang, China
■ Fax: 0086-571-88926789 0086-571-88132890 ■ ZIP:311305
■ Web: http://www.hcforklift.com ■ E-mail: [email protected]