FE4P20-35-SMS-001

Warning
Operators should read and understand
this manual and all warning labels on
the forklift before using the forklift!
Keep the manual for future reference!

Operation & Maintenance Manual

FE4P20-35 SERIES
Battery Counterbalanced Forklift Truck

ZheJiang Noblelift Equipment Joint Stock Co.,Ltd

 Table of Contents
Introduction…………………………………………………………………………………………… 4
Chapter 1 Precautions of using forklift…………………………………………………………… 5
Ⅰ. Forklift transportation ....................................................................................................... 5
Ⅱ. Forklift storage ................................................................................................................. 5
Ⅲ. Pre-use preparation......................................................................................................... 5
Ⅳ. Operation of the forklift .................................................................................................... 5
Ⅴ. Charging of accumulator cells ......................................................................................... 6
Chapter 2 Structure and main performance parameters of the forklift………………………… 7
Ⅰ. Overall Dimension and Technical Parameters ................................................................ 7
1. Overall dimension.......................................................................................................... 7
2 Technical Parameters..................................................................................................... 10
Ⅱ. Structure, principle and adjustment of the main components ......................................... 11
1. Transmission system..................................................................................................... 11
1.1 Overview.................................................................................................................... 11
1.2 Gearbox and differential ............................................................................................ 11
1.3 Drive axle................................................................................................................... 12
1.4 Installation of wheel hub............................................................................................ 13
1.5 Troubleshooting ......................................................................................................... 14
2. Braking system.............................................................................................................. 15
2.1 Overview.................................................................................................................... 15
2.2 Brake pedal ............................................................................................................... 15
2.3. Brake master cylinder............................................................................................... 15
2.4. Brake ........................................................................................................................ 16
2.5 Device for parking brake control ............................................................................... 18
2.6 Technical points for brake disassembly and adjustment......................................... 18
2.7 Adjustment of brake pedal ....................................................................................... 21
2.8 Troubleshooting ......................................................................................................... 22
2.9. Maintenance ............................................................................................................. 23
3 Steering system ........................................................................................................... 24
3.1 Overview.................................................................................................................... 24
3.2 Cycloid full hydraulic steering gear ........................................................................... 24
3.3 The steering axle ....................................................................................................... 25
3.4 Technical points for adjustment and repair................................................................ 28
3.5 Check of steering system after being re-installed ..................................................... 29
3.6 Trounble shooting ...................................................................................................... 29
4 DC electrical system .................................................................................................... 30
4.1 Overview .................................................................................................................. 30
4.2 Electronic control assembly....................................................................................... 31
4.3 Combination instrument ............................................................................................ 33
4.4 Trouble shooting ........................................................................................................ 34

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 5 AC electrical system(Curtis’ system) ......................................................................... 36
5.1 Overview .................................................................................................................. 36
5.2 Electronic control assembly ..................................................................................... 38
5.3 Combination instrument ............................................................................................ 40
5.4 Trouble shooting ........................................................................................................ 41
6 AC electrical system(Zapi’s system) .......................................................................... 43
6.1 Overview.................................................................................................................... 43
6.2 Electronic control assembly....................................................................................... 45
6.3 Combination instrument ............................................................................................ 46
6.4 Trouble shooting ........................................................................................................ 47
7．Accumulator…………………………………………………………………………………… 49
7.1 Accumulator safety precautions………………………………………………………… 49
7.2 Accumulator use precautions…………………………………………………………… 49
7.3 Charging of the accumulator……………………………………………………………… 50
7.4 Installation and replacement of the accumulator………………………………………… 52
8．Hydraulic system……………………………………………………………………………… 53
8.1 Overview…………………………………………………………………………………… 53
8.2 Oil pump…………………………………………………………………………………… 53
8.3 Multi-way valve…………………………………………………………………………… 53
8.4 Lifting cylinder and the lifting chain……………………………………………………… 56
8.5 Governor valve…………………………………………………………………………… 58
8.6 Tilt cylinder………………………………………………………………………………… 58
8.7 Hydraulic oil tank………………………………………………………………………… 59
8.8 Hydraulic pil pipe………………………………………………………………………… 60
8.9 Maintenance and adjustment…………………………………………………………… 61
8.10 Failure analysis………………………………………………………………………… 63
9．Lifting system………………………………………………………………………………… 64
9.1 Overview…………………………………………………………………………………… 64
9.2 Inner and outer main frame……………………………………………………………… 64
9.3 Fork frame………………………………………………………………………………… 65
9.4 Location of rollers………………………………………………………………………… 66
9.5 Maintenance and adjustment…………………………………………………………… 67
9.6 Installation of accessories………………………………………………………………… 68
10．Removal and installation…………………………………………………………………… 68
10.1 Precautions……………………………………………………………………………… 68
10.2 Lifting points of the detached parts…………………………………………………… 69
Chapter 3 0peration, use and safety of the forklift………………………………………………… 71
Ⅰ. Driving and operation ...................................................................................................... 71
1 Use of a new forklift........................................................................................................ 71
2 The relationship between forklift stability and load...................................................... 71
3 Load centre and load curve ......................................................................................... 71
4 Forklift stability ............................................................................................................. 71

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 5 Transportation and handling of the forklift ................................................................... 72
6 Preparation before driving ........................................................................................... 72
7 Driving.......................................................................................................................... 73
8 Parking and temporary parking ................................................................................... 74
9 Use method of the accumulator .................................................................................. 74
10 Stacking ..................................................................................................................... 76
11 Un-stacking ................................................................................................................ 76
12 Storage....................................................................................................................... 77
Ⅱ. Operation device and use method ............................................................................... 78
1. Diagram on forklift parts and operation device ............................................................. 78
2 Combination instrument ................................................................................................. 78
3 Switches....................................................................................................................... 78
4 Controllers.................................................................................................................... 79
5 Forklift body ................................................................................................................. 82
Ⅲ. About safety ..................................................................................................................... 83
1. Site and working environment of the forklift .................................................................. 83
2. Safety rules.................................................................................................................... 84
3 Handling of the forklift .................................................................................................. 94
4 How to avoid rollover and how to protect yourself from accidents.............................. 95
5 Safety issues during maintenance and protection ...................................................... 97
6 Safety during use of the accumulator.......................................................................... 98
7 Signs ............................................................................................................................ 100
Chapter IV Periodic inspection and maintenance of forklift................................................... 101
Ⅰ. Check before operation ................................................................................................... 101
1. Check points and contents............................................................................................ 101
2. Check procedures ......................................................................................................... 102
Ⅱ. Checking after operation............................................................................................... 106
Ⅲ. Clean the forklift............................................................................................................... 106
1. Clean the forklift surface................................................................................................ 106
2. Clean the chain ............................................................................................................. 106
3 Clean the electric system ............................................................................................ 106
4 . After the cleaning.......................................................................................................... 106
Ⅳ. Regular maintenance ...................................................................................................... 107
1. Regular maintenance schedule..................................................................................... 107
2. Replace critical safety components periodically ........................................................... 115
Ⅴ. Lubricating parts and recommended oils ........................................................................ 116
1. Lubricating parts ............................................................................................................ 116
2. Recommended oils........................................................................................................ 116

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 Introduction
This manual briefly describes the technical parameters of the counterbalanced accumulator
forklift made by our company, and the structure of its main components, working principle and
requirements on operation and maintenance. Please read this manual carefully before operation,
so as to achieve proper driving and maintenance, and to ensure safe and effective material
handling. Meanwhile, this manual aims to guide operators to use the forklift in an appropriate way
and to maximize its performance! We hope that operators and equipment managers could read it
carefully before use! Please strictly observe the provisions and cautions stipulated in this manual
and operate the forklift with caution and care, so that the forklift can be maintained in its best
status and optimal performance can be ensured. When you lease or transfer your forklift, always
keep this manual with it.
For highlighting purpose, the following icons are used in this manual:


1. ----refers to a potential danger; if not avoided, it may cause serious human injury, vehicle
damage or fire.

2. ----refers to a potential danger; if not avoided，it may cause minor human injury, or local
damage to the vehicle.。

3. ----Refers to general cuations and instructions during use.

Most parts of the product are made from recyclable steel. The recycling and disposal of
cast-offs resulted during use, maintenance, cleaning and disassembling of the product has to
comply with local regulations without pollution to the environment. The recycling and disposal of
the cast-offs should only be operated by specialised personnel in the designated area. The
cast-offs, such as hydraulic oil, batteries and electronic units, if improperly disposed, may be
hazardous to the environment and human health.

Special Declaration:
1）This product is strictly prohibited for potentially explosive hazardous environments.
2）The Noise level of the normal use of this product is compliant with international
standards EN 12,053.
3）The vibration level of the normal use of the product is compliant with international
standards EN13059.
4）The normal use of the product's environmental requirements as follows: no more than
2000 meters above sea level and the temperature range of-5 ° C - +40 ° c, humidity should
no more than 90%.The wind speed is not more than 5m/s.
If you need to use in the freezer for a long time or in special environment, it is needed to
install special attachments. Please contact our technical staff.
5）Product recall serive is available when serial faulties occur.

Due to continuous product improvement, Noblelift reserves the right to make changes in product
designs and specifications without prior notice. For the latest product parameters, please feel free
to contact us. All parameters provided herein are as of the publication date of the Instruction
Manual.

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 Chapter 1 Precautions of using forklift
Forklift drivers and managers must remember the principle of "safety first", and carefully read
this maintenance manual. Operators shall be in strict accordance with this manual to ensure safe
and normal operation.

Ⅰ. Forklift transportation
The following shall be noted when transporting forklift by container or trucks:
(1) Apply the parking brake;
(2) Fix the main frame and counterweight with steel wires, and use pads to wedge the
corresponding positions at the front and rear tires;
(3) Start lifting from the positions indicated by the "Craning Label" on the forklift.

Ⅱ Storage of the forklift

(1) Reduce the main frame to the lowest position;
(2) Turn off the electric lock, place the lever rod to the "Nertral" position and unplug the power
cord;
(3) Tighten the hand brake;
(4) Use pads to wedge the front and rear tires ;
(5) If the forklift is to be left unused for a long time, its wheels should be elevated. The
accumulator should be recharged once a month.

Ⅲ Pre-use preparation
(1) Check if all instruments are normal;
(2) Check the tire pressure;
(3) Check the condition of the levers and pedals;
(4) Check if the accumulator voltage is within the working scope, and if the specific gracity of
the electrolyte and the height level of the liquid are appropriate;
(5) Check if the connectors and plug contacts of the electrical system are reliable;
(6) Check for leakage of the hydraulic fluid, electrolyte and brake fluid;
(7) Check the tightness of major fasteners;
(8) Check if the lighting and signal lamps are normal;
(9) Release the parking brake;
(10) Conduct test actions such as lifting and lowering the main frame, tilting forwards and
backwards, steering and braking;
(11) Contamination level of hydraulic oil shall not be greater than 12.

Ⅳ. Operation of the forklift

(1) Only trained and licensed drivers can drive the forklift;
(2) Operators shall wear security shoes, hats, clothing and gloves for protection purpose;
(3) Operators should note the performance and working conditions of mechanical, hydraulic,
electrical and MOSFET governor;
(4) Power on by switching on the key switch, choose the right position of direction switch, and
then rotate the steering wheel to see if the forklift can steer.
If ok, slowly depress the speed pedal and maintain an appropriate speed;
(5) Observe the voltage meter, if the voltage indicated by the voltage meter is below 41V
during working, immediately stop operation, and recharge the accumulator or replace with another
fully charged accumulator;
(6) Weight of loads handled should not exceed the specified value and fork spacing and
location should be appropriate. The fork should be fully inserted below all the goods, which shall
be uniformly distributed on the fork. Uneven loading shall be avoided;
(7) If the distance between loads‘ center of gravity and the fork arm is no more than 500mm, the
maximum load shall be the rated capacity. If the distance between loads‘ center of gravity and the fork

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arm is more than 500mm, the maximum load shall be less than the rated capacity;
(8) When carrying loads, the main frame should tit backwards to the maximum extent and the
fork arm should be in contact with the goods. Raise the fork to about 200mm away from the
ground before driving;
(9) Standing under the fork and on the lifting fork are forbidden;
(10) The initial velocity should not be too fast when lifting and lowering goods;
(11) Never operate the forklift and accessories at places other than the driver's seat;
(12) When the main frame is moving forwards and backwards to the maximum extent, or
when the fork is lifted to its maximum height, the operator must rapidly set the lever to the neutral
position;
(13) When the main frame is lifting, driving or turning of the forklift is not allowed;
(14) When driving the forklift, drivers should pay attention to pedestrians, road obstacles and
potholes, and also note the gap above the forklift;
(15) Drivers should be very careful when driving on ramps. When driving on a ramp with slope
gradient more than one-tenth, do move forward for up-hilling and backward for down-hilling.
Never perform steering during up-hilling ad down-hilling process. And avoid loading and unloading
when the forklift is down-hilling;
(16) Slow down when steering on wet or slippery road surfaces; be very careful and drive
slowly when driving on docks or temporary boards;
(17) For forklifts with lifting height greater than 3 meters, users shall be careful to guard
against falling down of the goods overhead and take protective measures if necessary;
(18) Do not carry unfixed or loosely stacked goods and be careful when handling goods with
large size;
(19) When driving the forklift with load, emergency braking should be avoided;
(20) Before leaving the forklift, lower the fork down to the ground, set the lever at neutral
position and disconnect power. In case of parking on a ramp,
apply the parking brake. Use wedge pads to fix the wheels if you need to park for a long time;
(21) The safety valve pressures of multiple unit valve and steering device have been tuned up
before leaving the factory. During use, users
shall not adjust it, because excessive pressure may cause damage to the entire hydraulic system
or its components ,and the motor;
(22) Tire inflation pressure shall be in line with that stipulated on the "Air pressure" plate;
(23) When moving with no load, forklift with accessories shall be operated in a way as if
carrying a load.

Ⅴ. Charging of accumulator cells

(1) When charging the accumulator cells for the first time and further charging, users should
be in strict compliance with the instructions;
(2) When operating the forklift, if the accumulator voltage decreases to 41V, or that of its
single cell drops below l.7V , or the instrument alarms, users shall immediately stop using the
forklift and replace the accumulator or recharge it before further use;
(3) Check the specific gravity, liquid level and temperature of the electrolyte from time to time
during the charging process;
(4) Forklift must be recharged as soon as possible after use. Never leave the forklift
uncharged longer than 24 hours. When charging, pay attention to prevent
insufficient charging and over-charging, so as not to damage the battery;
(5) Users should conduct balanced recharging to the forklift in normal use once a month, so
as to adjust the proportion among the accumulator units.
Please refer to the relevant sections of this Mannual for detailed charging and maintenance
methods.

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 Chapter 2 Structure and main parameters of the forklift

Ⅰ. Overall size and performance parameters of the forklift

1. Overall dimensions (as shown in Figure 1-1 )

Figure 1-1 Overall dimension

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2. Technical parameters (Table 1-1)
2.1 FE4P20-35 parameter table（table 1-1）
Model FE4P20 FE4P25 FE4P30 FE4P35
Drive mode: Electric
Operation mode: Sit-down
Rated loading capacity Q(Kg) 2000 2500 3000 3500
Load centre distance C(mm) 500
Front overhang distance x(mm) 473 488
Wheelbase y (mm) 1520 1720 1720
Weight with accumulator Kg 4040 4190 5200 5400
Axle load with full load, front/rear Kg 5200/840 5750/940 7050/1150 7870//1005
Axle load with no load, front/rear Kg 1650/2390 1720/2470 2390/2810 2400/2975
Specification of Front wheel 7.00-12-12PR 28×9-15-12PR
Specification of rear wheel 18×7-8-14PR
Front wheelbase b10(mm) 960 1000
Rear wheelbase b11(mm) 950 980
Tilt angle of main frame, forward/backward
6/8
α/β(°)
Height of main frame when retracted
2010 2080
h1(mm)
Free lifting height h2(mm) 115 145
Lifting height h3(mm) 3000
Height of main frame when stretched
4040 4255
h4(mm)
Height of overhead guard h6(mm) 2150 2180
Seat height h7(mm) 1100 1100
Traction pin height h10(mm) 220 200
Total length l1(mm) 3453 3487 3692 3751
Length of forklift body (Fork surface)
2383 2417 2622 2681
l2( mm )
Total width b1(mm) 1150 1255
Fork dimension s/e/l(mm) 40×122×1070 45×125×1070
Fork frame width b3(mm) 1040 1100
Distance from wheel base centre to ground
110 145
m2(mm)
Turning radius Wa(mm) 2150 2180 2410 2440
Driving speed, full load/no load km/h 12/14 12/14 12/13 12/13
Lifting speed， full load/no load m/s 0.24/0.40 0.25/0.39 0.24/0.36
Lowering speed full load/no load m/s 0.50/0.40
Climbing ability, full load/no load S2 5 min % 12/15 12/15 10/13 10/13
Drive motor power S2 60min Kw 11 11 12 12
Lifting motor power S3 15% Kw 10 12 12 12
Accumulator voltage/capacity K5 V/Ah 48/600 80/560 80/600
Accumulator weight kg 980 1450 1500
Working pressure of accessories MPa 17.5
Oil volume of accessories l / min 36

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2.2 FE4P20-35AC parameter table（table 1-2）

Model FE4P20AC FE4P25AC FE4P30AC FE4P35AC

Drive mode: Electric
Operation mode: Sit-down
Rated loading capacity Q(Kg) 2000 2500 3000 3500
Load centre distance C(mm) 500
Front overhang distance x(mm) 473 488
Wheelbase y (mm) 1520 1720 1720
Weight with accumulator Kg 4040 4190 5200 5400
Axle load with full load, front/rear Kg 5200/840 5750/940 7050/1150 7870//1005
Axle load with no load, front/rear Kg 1650/2390 1720/2470 2390/2810 2400/2975
Specification of Front wheel 7.00-12-12PR 28×9-15-12PR
Specification of rear wheel 18×7-8-14PR
Front wheelbase b10(mm) 960 1000
Rear wheelbase b11(mm) 950 980
Tilt angle of main frame, forward/backward
6/8
α/β(°)
Height of main frame when retracted
2010 2080
h1(mm)
Free lifting height h2(mm) 115 145
Lifting height h3(mm) 3000
Height of main frame when stretched
4040 4255
h4(mm)
Height of overhead guard h6(mm) 2150 2180
Seat height h7(mm) 1100 1100
Traction pin height h10(mm) 220 200
Total length l1(mm) 3453 3487 3692 3751
Length of forklift body (Fork surface)
2383 2417 2622 2681
l2( mm )
Total width b1(mm) 1150 1255
Fork dimension s/e/l(mm) 40×122×1070 45×125×1070
Fork frame width b3(mm) 1040 1100
Distance from wheel base centre to ground
110 145
m2(mm)
Turning radius Wa(mm) 2150 2180 2410 2440
Driving speed, full load/no load km/h 12/14 12/14 12/13 12/13
Lifting speed， full load/no load m/s 0.24/0.40 0.25/0.39 0.24/0.36
Lowering speed full load/no load m/s 0.50/0.40
Climbing ability, full load/no load S2 5 min % 12/15 12/15 10/13 10/13
Drive motor power S2 60min Kw 11 11 12 12
Lifting motor power S3 15% Kw 10 12 12 12
Accumulator voltage/capacity K5 V/Ah 48/600 80/560 80/600
Accumulator weight kg 980 1450 1500
Working pressure of accessories MPa 17.5
Oil volume of accessories l / min 36

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2.2 FE4P20-35AC2 parameter table（table 1-3）

Model FE4P20AC2 FE4P25AC2 FE4P30AC2 FE4P35AC2

Drive mode: Electric
Operation mode: Sit-down
Rated loading capacity Q(Kg) 2000 2500 3000 3500
Load centre distance C(mm) 500
Front overhang distance x(mm) 473 488
Wheelbase y (mm) 1520 1720 1720
Weight with accumulator Kg 4040 4190 5200 5400
Axle load with full load, front/rear Kg 5200/840 5750/940 7050/1150 7870//1005
Axle load with no load, front/rear Kg 1650/2390 1720/2470 2390/2810 2400/2975
Specification of Front wheel 7.00-12-12PR 28×9-15-12PR
Specification of rear wheel 18×7-8-14PR
Front wheelbase b10(mm) 960 1000
Rear wheelbase b11(mm) 950 980
Tilt angle of main frame, forward/backward
6/8
α/β(°)
Height of main frame when retracted
2010 2080
h1(mm)
Free lifting height h2(mm) 115 145
Lifting height h3(mm) 3000
Height of main frame when stretched
4040 4255
h4(mm)
Height of overhead guard h6(mm) 2150 2180
Seat height h7(mm) 1100 1100
Traction pin height h10(mm) 220 200
Total length l1(mm) 3453 3487 3692 3751
Length of forklift body (Fork surface)
2383 2417 2622 2681
l2( mm )
Total width b1(mm) 1150 1255
Fork dimension s/e/l(mm) 40×122×1070 45×125×1070
Fork frame width b3(mm) 1040 1100
Distance from wheel base centre to ground
110 145
m2(mm)
Turning radius Wa(mm) 2150 2180 2410 2440
Driving speed, full load/no load km/h 12/14 12/14 12/13 12/13
Lifting speed， full load/no load m/s 0.24/0.40 0.25/0.39 0.24/0.36
Lowering speed full load/no load m/s 0.50/0.40
Climbing ability, full load/no load S2 5 min % 12/15 12/15 10/13 10/13
Drive motor power S2 60min Kw 11 11 12 12
Lifting motor power S3 15% Kw 14 14 14 14
Accumulator voltage/capacity K5 V/Ah 48/600 80/560 80/600
Accumulator weight kg 980 1450 1500
Working pressure of accessories MPa 17.5
Oil volume of accessories l / min 36

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 Ⅱ.Structure, principle and adjustment of the forklift’s main components
1. Transmission system
1.1 Overview
The transmission system of forklift is composed of reduction gearbox assembly, differential
assembly and drive axle. Driving gear of decelerator is connected directly with the travel motor, so the
driving speed of forklift increases with the increase of motor speed and the driving direction can be
changed by changing the direction of motor rotation.
1.2 Reduction gearbox and differential
Located between the drive axle and the travel motor, the reduction gearbox uses two pairs of
helical gear to reduce rotation speed of the output shaft in travel motor. It also increases the torque
transmitted by the output shaft, and then pass this torque to the differential. See figure 2-1

1. O ring 2.Bolt 3.Ball bearing 4. O ring 5. Bolt

6. Spring 7. Bearing 8. Gearbox 9. Washer 10. Spring
washer cover shell washer
11. Bolt 12. Framework 13. Bearing 14.Ball bearing 15. Washer
oil seal
16. Spring 17.Bolt 18. Pin 19. Gear shaft 20. Duplicate
washer gear
21. Shaft 22. Paper pad 23. Case 24. Lock plate 25.Bolt
26. Input shaft 27.Ball bearing 28. Pad 29. Pad 30. Pad
31. Pad

Figure 2-1 Decelerator

Differential is mounted on the first half of the shell through the bearings at each end, with its
front-end connected with the axle housing. Differential shell is made of two splited parts, with two
half axle gears and four planet gears. See figure 2-2

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 1. Left differential shell 2. Bearing block 3. Bolt 4. Locking plate
5. Half axle gear 6. Pinion shaft 7. Washer 8. Cross axle
9. Planet gear 10. Right differential 11. Ring gear 12. Ring gear bolt
shell
13. Locking plate 14. Bolt 15. Locking washer 16. Cylindrical pin 6×30
17. Nut M10×1.25 18. Deep groove ball 19. Thrust washer
bearing 6213

Figure 2-2 Differential

1.3 Drive axle

Drive axle, which is composed of the axle shell, wheel hub and brake, is installed in the front
of forklift frame.
Axle shell is a overall casting structure. Tires are fixed on the wheel hub by studs and nuts
through the rim. The wheel hub is supported by the tapered roller bearings and is fixed on the axle
shell. Power is transmitted through the differential to the half axle, which drive the wheel hub, and
cause the front wheel to rotate. The half axle only bear the torque transmitted to the wheel hub. Oil
seals are installed within the left wheel hub, so as to prevent incoming water and dust, and to
avoid oil leaking. See figure 2-3

1. Axle shell 2. Retainer ring for oil 3. Oil seal 100×125×12 4. Oil baffle
seal
5. Spare pad 6. Bearing 7214E 7. Cylindrical pin D10×30 8. Brake drum
9. Wheel hub 10. Oil seal assembly 11. Pad 12. Small round nut
33012A M60×2
13. Stop washer 60 14. Half axle 15. Half axle pad 16. Hexagon headed
bolt

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 17. Breather plug 18. Blocking plug 19. Hexagon headed bolt 20. Hexagon headed
assembly bolt
21. Nut M20×1.5 22. Stud bolt 23. Ball nut 24.Brake
25. Stud nut 26. Twin stud bolt 27. Twin ball nut
Figure 2-3 Drive Axle
The drive axle has advantages such as reasonable design structure, reliable performance
and long service life. Axle shell is made of steel materials, which provides strong rigidity and high
load capacity. See Table 2-1 for the main technical parameters.
Table 2-1 Main technical parameters

Model FE4P20/25(AC) FE4P30/35(AC)

Drive axle structure Front wheel drive, fixation of axle and frame, floating type

Brake type Front dual-wheel brake, internal expansion, hydraulic type

Tire installation distance
mm
960 1000
Dimension of the friction disk in
brake (length×width×thickness) 348×60×8 348×76×8
mm×mm×mm
Area of friction disk
cm
2 209×4 264×4
Inner diameter of brake drum
mm
310 314
Outer diameter of brake
mm
348 349
Cylinder diameter
mm
28.58 28.58

1.4 Installation of wheel hub

(1) Fill 100ml lubricating grease into the wheel hub, and then mount the hub onto the shaft.
（Figure 2-4）
(2) Use a torque of about 9.8N • m to tighten the adjustment nut and then rotate back for 1 / 2
cycle.
(3) Attach a spring scale on the bolt to measure the pickup torque of wheel hub. When the
specified value is reached, slowly tighten the nut.
Pickup torque: 49N·m－147N·m. （Figure 2-5）

Figure 2-4 Filling lubrication grease Figure 2-5 Measuring pickup torque

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 (4) Mount locking plate and locking nut, and then tilt up the locking plate to lock the stopping
function.
(5) Tire assembly (Figure 2-6)
Mount the air intake rod and cap onto the tire and conduct rim assembling. Pay attention to
the following:
Note: (a) Place the air valve stem at the rim gap, facing outwards;
(b) Rim bolt head should be mounted facing outside of the forklift.

1. Outer rim 2. Inner rim 3. Hexagon nut M16

4. Spring washer 16 5. Rim bolt 6. Tire
Figure 2-6 Tire assembly

1.5 Failure Analysis

Table 2-2 Failure Diagnosis and Correction
Failures Possible causes Correction methods
High Looseness of fastening bolts at the installation
Tighten the bolts
vibration and connection points
Deterioration of gear oil Replace
Excessive
oil Abnormal oil level Add or reduce oil
temperature
Jamming of moving parts Adjustment
Looseness of bolts at the combining surfaces Tighten the bolts
Oil leakage
Damaged seals Replace
Damaged rotary gear Replace
Noise
Damaged bearing Replace

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 2. Braking system
2.1 Overview
The braking system consists of the brake pedal, brake master cylinder and wheel brakes. The
two wheel brakes in the front are hydraulic internal expansion brakes.
2.2 Brake pedal
The structure of brake pedal is shown in Figure 2-7. The pedal would transfer the pedal force
into brake oil pressure through the push rod on the brake master cylinder.

1 Brake pedal 2. Brake oil cup 3. Brake master cylinder

4. Brake support 5. Brake sensor 6. Spacing bolt
Figure 2-7 Brake pedal assembly

2.3 Brake master cylinder (Figure 2-8)

The master cylinder includes a valve seat, a check valve, a return spring, the main cup, piston
and auxiliary cup. Stop washer and stop steel wire are used to fix the ends of the cylinder and
rubber dust cover is applied to protect its external surface. Master cylinder piston works by
depressed the brake pedal to touch the push rod. When the brake pedal is depressed, the push
rod will push the piston forward, and the brake fluid in the cylinder will flow back to the storage tank
through the oil return hole until the main cup block the oil return hole. When the main cup block the
oil return hole, the brake fluid in front cavity of the master cylinder is compressed and the check
valve is opened. The fluid will flow to the wheel cylinder through the brake pipelines. Thus, each
wheel cylinder piston will protrude and the friction disk of the brake shoe will contact the brake
drum to achieve slowing down or braking. At this point, the back cavity of piston will be filled with
brake fluid from the oil return hole and the oil inlet. When the brake pedal is released, the piston
will be pressed backwards by the return spring, and at the same time the brake fluid in each brake
cylinder is also compressed by the return spring of the brake shoe, so that the brake fluid will flow
back to the master cylinder (front cavity of the piston ) through the check valve. Then the piston
will return to its normal position, while the brake fluid in the master cylinder flows back to the
storage tank through the oil returning hole. The pressure of the check valve will be adjusted to be
in certain proportional of the remaining pressures in the brake pipeline and the brake cylinder, so
that the cylinder cup will be correctly placed to prevent oil spilling and to eliminate air resistance
that may occur during emergency brake.

15
 1. Locking nut 2. Pushing rod 3. Dust cover 4. Stop steel
wire
5. Stop washer 6. Auxiliary cup 7. Piston 8. Main cup
9. Spring 10. Check valve 11. Valve seat 12. Pump body
Figure 2-8 Brake Master Cylinder
2.4 Brake
The brake is a dual-shoe brake installed on both sides of the drive axle. The brake consists of
two groups of brake shoes, brake cylinders and regulators. One end of the brake shoe
contacts the fixed pin and the other end contacts the regulating device. The return spring and the
compression spring bar hold the parking brake. In addition, the parking brake mechanism and
automatic regulating device are also assembled onto the brake. See figure 2-9

1. Brake backing plate 2. Clearance adjuster 3. Friction disk assembly 4. Flexible washer
assembly
5. Hand brake lever 6. Return spring 7. Pad 8. Ejector Pin
9. Return spring 10. Hand brake push 11. Compression spring 12. Adjusting lever
lever
13. Compression spring 14. Spring 15. Compression spring 16. Spring
base cover
17. Compression spring 18. Compression 19. Support pin 20. Pad
base spring bar
21. Rubber plug 22. Brake steel wire 23. Bolt M8×16 24. Spring washer 8
assembly
25.Brake cylinder 26. Brake cylinder 27. Piston rod of brake 28. Piston
shield cylinder
29. Cylinder sleeve 30. Brake cylinder 31. Oil plug of brake 32. Bleeder screw of brake
spring cylinder cylinder
33. Bleeder screw shield 34.Dust cover
Figure 2-9 Brake

16
 (1) Brake action
Brake cylinder exerts the same force to the main brake shoe and auxiliary brake shoe to
suppress the brake drum, until the upper end of auxiliary brake shoe contacts against the fixed pin.
Then the brake shoe will move towards the rotation direction of the brake drum. After contact
against the fixed pin, the friction between friction disk and brake drum will increase. The main
brake shoe will exert a pressure larger than the brake cylinder pressure on the auxiliary brake
shoe, resulting in a large braking force. See Figure 2-10
When moving backwards, the brake action is in reverse to that of moving forwards. See
Figure 2-11

Driven brake shoe

Driving brake shoe
Driving brake shoe Driven brake shoe

Figure 2-10 Action when moving forwards Figure 2-11 Action when moving backwards

(2) Parking brake

Mounted in the wheel brake, the parking brake consists of the lever and push lever. The lever
is mounted on side of the main brake shoe by a pin,
and the pulling action spread through the push lever to the auxiliary brake shoe. See figure 2-12
(3) Clearance self-adjusting mechanism
The clearance self-adjusting mechanism can maintain appropriate clearance between the
friction disk and the brake drum. See Figure 2-13 for its structure. Clearance self-adjusting
mechanism works only when the forklift is moving in reverse.

1. Pin 2. lever 3. Driving brake 1. Regulating 2. Spring 3. Cable

shoe mechanism
4. Driven 5. Support rod 4. Guide groove 5. lever
brake shoe
Figure 2-12 Parking brake Figure 2-13 Clearance self-adjusting mechanism

(4) Action of the automatic clearance adjusting mechanism

If braking during reversing of the forklift, the auxiliary and main brake shoes contact with each
other and rotate together, so that the lever will rotate rightwards around A point as shown in Figure
2-13, and B point is then elevated. After the brake is released, the lever will rotate leftwards by the
spring force to lower B point. When the clearance between brake hub and friction disk is enlarged,
the vertical distance of B point’s rotation will increase. The regulator will be toggled for one more
tooth and the regulating lever lengthens (see Figure 2-14), so that the clearance shrinks.
Clearance adjustment range falls within 0.40mm ~ 0.45mm.

17
 2.5 Control device of parking brake (Figure 2-15)
The regulator located at the cam-type parking brake lever can be used to adjust the braking
force.
Braking force adjustment: Turn the regulator clockwise to increase the braking force; turn the
regulator counter-clockwise to reduce the braking force.
Pulling force：196N～294N

Parking Brake

Wire rope
Along this direction elong elongtion

Figure 2-14 Clearance Figure 2-15 Parking brake lever

self-adjusting mechanism

2.6 Technical points for brake disassembly and adjustment

Disassembly, assembly and adjustment of the brake and adjustment of brake pedal when the
wheel and wheel hub is removed.
2.6.1 Disassembly of the brake
(1) Remove the support pin, regulating bar, regulating device and spring on the auxiliary
brake shoe. See figure 2-16
(2) Remove the return spring on the shoe. See figure 2-17

Figure 2-16 Figure 2-17

(3) Remove the fixing spring on the main brake shoe. See figure 2-18

18
 (4) Remove the main and auxiliary brake shoes. And also remove the regulator and the
regulator spring. See figure 2-19

Figure 2-18 Figure 2-19

(5) Remove the brake pipe from the brake cylinder. Then remove the mounting bolt of the
brake cylinder, and remove the brake cylinder from the brake backing plate. See figure 2-20
6) Remove the E-shaped retaining ring used for fixing the brake cable on the brake backing
plate. Then remove the mounting bolt on the brake backing plate and dismount the brake backing
plate from the drive axle. See figure 2-21

Figure 2-20 Figure 2-21

(7) Disassemle the brake cylinder: Remove the dust-proof ring. Press on one end of the
piston to push out the other end and then press down the headed out end of piston with fingers.
See figure 2-22

Figure 2-22
2.6.2 Check of the brake
Inspect the parts and then repair or replace damaged ones.
(1) Check the surface of the brake cylinder and peripheral surface of the piston for rust; then
measure the clearance between the piston and the brake cylinder.
Standard size: 0.03mm-0.10mm; Maximum size: 0.15mm
(2) Conduct visual inspection of the piston cup for damage and deformation. Replace the cup
if there is any abnormality.
(3) Measure the free length of brake cylinder spring. Replace it if it exceeds the baseline.
(4) Measure the thickness of friction disk. Replace it if the wear degree exceeds limit. Figure
2-23 Standard thickness: 8.0mm; Minimum thickness: 2.0mm
(5) Conduct visual inspection on the inner surface of brake drum for damage and uneven
wear. Then grind the brake drum for correction purpose and replace it if it can’t be corrected.
Standard value: 314mm; Maximum value: 316mm. See Figure 2-24

19
 Figure 2-23 Figure 2-24
2.6.3 Brake assembly
(1) Coat the cup and piston on the brake cylinder with brake fluid and assemble the spring,
piston cup, piston and protection loop in sequence.
(2) Mount brake cylinder on the brake backing plate.
(3) Mount the brake backing plate on the drive axle.
(4) Coat all the positions as shown in Figure 2-25
with heat-resistant grease,
and be careful not to smear any oil on the friction disk.

(a) Contact surface of the brake backing plate and

brake shoe;
(b) Fixed pin;
(c) Contact surface of the brake shoe and spring
compression base;
(d) Support pin of the hand brake lever;
(e)Threads on the regulating mechanism and other rotating parts. Figure 2-25
(5) Use a E-shape retaining ring to seize the parking brake cable.
(6) Mount the brake shoe with a fixed spring. See figure 2-26
(7) Mount the compression spring on the push lever of hand brake, and then mount the push
lever onto the brake shoe.
See figure 2-27

Figure 2-26 Figure 2-27

(8) Mount the brake shoe guide plate to the support pin, and then mount the return spring of
the brake shoe. First install the main shoe and then install the auxiliary shoe. See figure 2-28
(9) Mount the regulator, the regulator spring, ejector Pin, return spring of the ejector Pin. The
following points shall be noted:
(a) The screw direction and mounting direction of the regulator;
(b) The direction of spring in the regulator (contact between regulator gear and spring is not
allowed);
(c) The direction of return spring in the ejector pin (the spring hook at the support pin side
should be fixed at the side opposite to the ejector pin);
(d) The lower end of the adjustment lever must contact with the regulator gear.
(10) Connect the brake pipelines with the wheel cylinders.
(11) Measure the inner diameter of brake drum and outer diameter of brake shoe, and then
use the regulator to set the difference between inner diameter of brake drum and outer diameter of
brake shoe at 0.3mm-0.5mm. See figure 2-29

20
 Figure 2-28 Figure 2-29
2.6.4 Operation test of the automatic clearance regulator as shown in Figure 2-30
(1) First, adjust the diameter of brake shoe to be close to the stipulated installation size; pull
the lever to rotate the regulator. When letting the lever go, the regulator lever will return to its
original position and the regulator gear won’t rotate.
Note: Even if the regulator gear and the lever both return after the lever is let go, the regulator
still works properly.
(2) If the regulator can not finish the above actions when the lever is pulled, carry out the
following checks:
(a) Securely mount the adjustment lever, ejector pin, spring of the ejector pin and
compression spring base;
(b) Check the return spring on ejector pin and the regulator spring for damage,and then
check the rotation of its regulator gear and its meshing parts to see if there is excessive wear or
damage. Check whether the pin contacts with the gear. Replace damaged parts.

Inflation direction
Figure 2-30
2.7 Adjusting the brake pedal as shown in Figure 2-31 (a)
(1) Shorten the push lever;
(2) Regulate the pedal spacing bolt and adjust the pedal height as shown in Figure 2-31 (b);
(3) Adjust the length of the push lever until its front end contacts with the piston of master
cylinder. Then turn back 1-2 circles to guarantee a free travel of the pedal between the
10mm-20mm;
(4) Lock the nuts of push lever and the pedal spacing bolt.

21
 Free stroke

Pedal
Brake pedal Push lever Spacing bolt

a b
Figure 2-31

(5) Adjust the brake switch as shown in Figure 2-32

(a) After the height of the brake pedal has been adjusted,
release the brake switch and lock the nut;
(b) Disconnect the plug to separate the wires; brake switch
(c) Rotate the switch to set the gap A at 1mm;
(d) Make sure the brake light be lit when depressing the
brake pedal;
Lock nut
(e) Finally lock the nuts.

Figure 2-32 Brake light switch

2.8 Troubleshooting and Failure Analysis(Table 2-3)

(Table 2-3)
Problems Causes analysis Solutions
1.Oil leaks in the brake system Repair it
2 The brake shoe clearance is not
Adjust the regulator
well-tuned
3 The brake is over-heated Check if the brake is slipping
Abnormal 4 Brake drum and friction disk are not
Readjust it
braking appropriately contacted
5 There are foreign matters attached to the
Repair or replace it
friction disk.
6 The brake fluid is contaminated Check the brake fluid
7 The brake pedal (micro-valve) hasn’t been
Adjustment
adjusted properly
1 The friction surface is hardened or with
Repair or replace it
foreign matters attached on it
2 The baking plate is deformed or the bolts
Repair or replace it
are loosen
Noise in 3 The brake shoe is deformed or is not
the brake Repair or replace it
installed correctly
4 Worn friction disk Replace
5 The wheel bearing is loosened Repair or replace it

22
 1 There are oil stain on the friction disk Repair or replace it
2 The brake shoe clearance is not
The Adjust the regulator
well-tuned
braking
3 The wheel cylinder fails Repair or replace it
is
uneven 4 The return spring of brake shoe is
Replace
damaged
5 The brake drum is deflected Repair or replace it
1.Oil leaks in the brake system Repair or replace it
The 2 The brake shoe clearance is not
Adjust the regulator
braking well-tuned
is 3 Air is mixed within the brake system Let out the air
not
enough 4 The brake pedal is not adjusted
Readjust it
appropriately

2.9 Care and maintenance

① Before conducting running-in test of a new drive axle, users shall fill in gear oil (gear oil
shall be selected in accordance with the instructions. Please refer to Table 2-1 for the specific
requirements). Fill oil into the hole at top of the axle shell until oil is spilled out of the oil level hole
in central axle.
② The thickness of friction disk on brake shoe is 8mm. The minimum thickness allowed is
2mm. These two are key components of the braking system and should be checked monthly. If
excessive wear is found, the components shall be timely replaced to avoid accidents.
③ Technical maintenance after each 50h:
Ⅰ. Change the gear oil if a new axle has been working for 50h along with the forklift. Clean
the axle before refilling new oil.
Ⅱ. Check all the fasteners. If any looseness is found, tighten it immediately.
Ⅲ. Check the wheel axle and wheel hub connection for any oil leakage. Re-apply sealant if
any leakage is found.
④ Monthly technical maintenance:
Ⅰ. Check the brake drum for any destructive wear.
Ⅱ. Check the wear condition of brake shoe. If wearing is so serious that the brake shoe fails
to meet requirements, the brake shoe should be replaced immediately.
Ⅲ. Check if the oil level in axle shell meets standards. If the oil level reduces, users should
promptly fill up.
⑤ Semi-annual technical maintenance: Change the gear oil within the axle once every six
months of working.
⑥ Annual technical maintenance: Disassemble the drive axle for inspection every year.
⑦ Check and debug requirements during the installation process:
When re-installing the wheel hub of the drive axle, users should regulate the clearance
adjuster of the brake, so as to set the gap between brake drum and friction disk at 0.3mm ~ 0.5mm.
Fill 100ml 3# lithium base grease into the tapered roller bearing on the wheel hub.
Adjustment of the bearing clearance on wheel hub: tighten the inner locking nut until the
wheel brake drum can barely turn up. Then rotate the inner locking nut in reverse for 1 / 8 circle. At
this moment wheel brake drum can be freely rotated without jamming, significant axial clearance
or deflection. Finally, assemble the washer pad and tighten the outside locking nut.

23
 3. Steering system
3.1 Overview
The steering system (Figure 2-33) mainly consists of the steering wheel, steering shaft,
steering gear, steering pump and steering axle. The steering shaft is connected with steering gear
through gimbal joints, while the connecting shaft is connected with steering wheel through gimbal
joints. The steering column can tilt backwards or forwards to an appropriate position. The steering
axle is bolted to the tailstock on the frame rear end, with each steering knuckle at its left and right
side. The cylinder piston rod will push the steering knuckle via the connection rod, so that the
steering wheel will deflect to achieve steering.

Fig. 2-33 Steering device

3.2 Cycloidal full hydraulic steering gear

The hydraulic steering gear (Figure 2-34) can, according to the rotation angle of the steering
wheel, transmit the oil from steering pump to the steering cylinder through the oil pipeline. When
the pump can not supply oil, the operator can rotate it manually.
The steering gear is composed of a general steering and a combination valve, on which there
is a hole serving as the safety valve of the system. Within the valve, there is a two-way overload
valve, which could protect the parts from unexpected damage. If accident external shocks cause
high pressure within the hydraulic system during the driving process of the forklift. The safety valve
and two-way overload valve has been tuned up by the manufacturer and users should not adjust it
without permmision.

24
 1. Limitation column 4. Couple shaft 7.Rotor
2.Valve body 5.Spring 8.Stator
3. Valve core 6.Connection block 9.Valve sleeve
Figure 2-34 Cycloidal full hydraulic steering gear

3.3 Steering axle

The steering axle is a welded structure with box cross section (Figure 2-35), which consists of
steering axle body, steering cylinder, connecting rod, steering knuckle, steering wheel, and other
component parts. The steering trapezium adopts slider-crank mechanism, in which the cylinder
piston rod will push the steering knuckle via the connection rod, so that the steering wheel will
deflect to achieve steering. The steering axle is bolted to the tailstock on the frame rear end by the
front and rear pins via the fixed plate, i.e. shock pad, so that the axle can swing around the pin.
There is a steering knuckle at each side of the steering axle and the rear wheel hub is mounted to
the steering knuckle by two tapered roller shaft bearings. The wheel is fixed to the hub by a wheel
rim. Oil seal is mounted onto inside of the bearing, so as to keep grease in the wheel hub and
steering knuckle cavity.

25
1. Steering axle 2. Connecting rod 3. Steering oil 4. Shock pad
body assembly cylinder
5. Fixing plate for 6. Right knuckle 7. Thrust bearing 8. Needle bearing
steering axle assembly 51208 943/32
9. Main pin of 10. Cylindrical pin 11.Adjustment pad 12. Rubber oil seal
knuckle 10×20
13. Knuckle 14. Nut M12 15. Dust shield 16. Bearing
adjusting washer
17. Bearing 18. Nut M30×2 19. Fat washer 30 20. Cylindrical pin
6.3×55
21. Wheel hub cover 22. Wheel hub 23. Fastening pin 24. Nut M10×1.25
25. Washer 10 26. Bush 27. Oil Cup M6 28. Left knuckle
assembly
29. Bolt M14×45 30. Spring washer 31. O ring 32. Oil seal
14
33. Bush 34. Bolt M12×35 35. Oil Cup ZG1/8 36. Bolt M8×18
37. Spring washer 8 38. Baffle plate 39. Link pin 40. Centripetal joint
bearing
41.Adjustment pad 42. Spring washer 43. Bolt M16×45 44. Nut M16
16
Figure 2-35 Steering axle

26
 (1) Knuckle
Knuckle refers to the main pin of knuckle, tapered bearing, dust shield and O ring mounted
between the upper and lower ends of the steering axle, with upper end of the main pin fixed on the
axle body with a bumper pin and the lower end fixed on the axle body with a cotter pin. The
tapered bearing which suppresses on the axle serves as the support. (See Figure 2-36)

1. Thrust bearing 4. Knuckle adjustment washer 7. Rubber sleeve

2. Knuckle 5. Main pin of knuckle 8. Fixing plate of steering axle
3.Fixed pin 6. Needle bearing
Figure 2-36
2. Steering oil cylinder
Steering oil cylinder is a double-acting piston cylinder, with both ends of the piston rod
connecting with the knuckle through the connecting rod. The pressure oil from the hydraulic
steering gear pushes the piston rod around move leftwards and rightwards through the steering
cylinder, so as to achieve steering. Piston sealings combine the support ring and the 0 ring, while
Yx axial seal is used between cylinder cover and piston ring. The cylinder is fixed on the steering
axle by the cylinder cover on both sides. (See Figure 2-37)

1. Piston rod assembly 2. Cylinder cover 3. Dust proof ring 50×72

4. U ring 50×60×8 5.O ring 63×3.55 6.O ring 60×3.55
7. Supporting ring 8. Cylinder barrel 9. Steel-backed bearing
assembly
Figure 2-37 Steering oil cylinder

27
 (3) Wheel hub
The wheel hub is mounted to the knuckle with two tapered roller bearings and the wheel is
fixed to the hub by a wheel rim. Oil seal is mounted onto inside of the bearing, so as to keep
grease in the wheel hub and steering knuckle cavity. Nuts can be used to adjust the bearing
tightness.
3.4 Technical points on adjustment and maintenance
(1) As shown in Figure 2-38, fill lubricating grease into the wheel hub, internal and external
bearings and the inner cavity of the wheel hub cover. And also apply some grease on the oil seal;
(2) Fix the bearing outer ring to the hub and mount the wheel hub to the knuckle;
(3) Put the washer in place and tighten the slotted nut with a torque of 206-235N.m
(21-24kgm). Loosen the slotted nut and then tighten it with a torque of 9.8Nm (1kgm);
(4) Tap the wheel hub with a wood hammer and then rotate the wheel hub for 3-4 cycles to
ensure that the wheel hub is not loosened;
(5) Tighten the slotted nut to align it to the cotter pin on the knuckle;
(6) And then tap gently on the wheel hub with a wood hammer and turn the wheel by hand for
3-4 cycles to ensure smooth rotation. Then measure the rotation torque of the wheel hub, which
should be 2.94-7.8N. m (0.3-0.8kgm);
(7) If the torque is larger than the specified value, rotate in reverse for 1 / 6 circle to
re-measure the torque;
(8) When the specified torque is reached, lock the slotted nut with a cotter pin.

Fill lubrication
grease

Figure 2-38 Preload adjustment

28
3.5 Check the steering system after reinstalling
(1) Turn the steering wheel leftwards and rightwards to the maximum extent to see whether
the rotation is uniform and smooth;
(2) Check if the layout of hydraulic piping is correct and if the left and right steering are
mounted reversely;
(3) Jack up rear wheels and slowly rotate the steering wheel leftwards and rightwards for
several times to remove air in the hydraulic pipelines and oil cylinder.
3.6 Failure analysis (Table 2-4)
(Table 2-4)

Problems Causes analysis Solutions

The steering The oil pump is damaged or faulted Replace
wheel gets The rubber hose or fitting is damaged or the
stuck Replace or clean it
pipe is blocked
The pressure of the safety valve is too low Adjust the pressure
There is air in the oil pipeline Remove the air
The steering The reset function of steering gear fails.
wheel is heavy Positioning spring is broken or lacks Replace the spring
elasticity
The inner leakage of steering cylinder is too
Check the piston seal
large
The forklift
moves
unsteadily or in The spring is broken or lose elasticity Replace
a snake-like
manner
It is noisy when The oil level in the oil tank is low Add oil
the forklift is
working The inlet tube or filter is blocked Replace or clean it
Guide sleeve seal of the steering cylinder is
Oil leakage damaged, or the joint or pipelines are Replace
damaged.

29
 4. DC Electric system

4.1 Overview
The electrical system mainly includes accumulator cells, traction motor, pump motor, traction
motor controller, pump motor controller, combination control switch, instrumentation and lighting
devices.
Schematic of electrical system See Figure 2-39

Figure 2-39 Schematic of electrical system (Table 2-5)

30
 (Table 2-5)
No. Name Remarks No. Name Remarks
QL1 Left front headlight JT Emergency stop switch
QL2 Right front headlight YK Key switch
HL1 Left front width lamp HDK Rear headlight switch
HL2 Right front width lamp FK Direction switch
KL Rear width lamp DK Light switch
SL Brake lamp ZYK Seat switch Seat belt
QL3 Rear headlight ZK Steering switch
DL Reversing lamp SK Foot brake switch
JSD Warning lamp SZ Hand brake switch
XL1 Left rear steering lamp LN Horn switch Steering wheel belt
XL2 Left front steering lamp QS Lifting switch
XL3 Right rear steering lamp QX Tilt switch
XL4 Right front steering lamp CY Side shifting switch
M1 Traction motor M Main contactor
M2 Auxiliary motor MP Auxiliary contactor
FU1 Fuse 500A LD Horn
FU2 Fuse 500A DF Back-up buzzer
FU4 Fuse SQ Flasher
FU5 Fuse B Accumulator cell 48V
FU6 Fuse JSQ Electric accelerator
FU7 Fuse DYK Power connector
FU8 Fuse

4.2 Electric control assembly

The electric control assembly mainly consists of PMC 1244-type motor controller and
EVC255 type hydraulic pump motor controller from the U.S. CURTIS Company. With the above
two controllers as the core components, the system is energy-saving and superior in performance
and reliable in quality.
Basic working principle:
PMC1244 motor controller adopts the pulse width modulation (PWM) technology and
MOSFET power circuit, which can control the current of traction motor for speed controlling
purpose. It could also avoid starting current impact of the traction motor.
Features of the electric control device:
1. The forklift features even speed regulation, easy steering and excellent performance during
driving. The steering is characterized by non-contact, non-sparking, no erosion and
maintenance-free as no reversing contactor is needed in the electric controller.

31
 2. During braking or sliding process of the forklift, the seperately excited electric controller can
achieve the regenerative braking function. At this time, the travel motor will automatically switch to
a generator, effectively shortening the braking distance, controlling the sliding speed, and charging
the accumulator to extend the working time of accumulator cells.
3. Equipping with the pump motor controller of the U.S. CURTIS Company, the hydraulic
system of the forklift features non-contact, non-sparking, no noise, smooth & reliable working
during start of the hydraulic lift motor. Such problems as the main contacts is easy to erode, short
service life, impact or damage to the accumulator cells and other defects frequently seen in the
traditional hoisting contactor are completely eliminated. Thus accumulator life can be extended
and maintenance costs can be reduced, greatly lowering the forklift’s operating cost.
4. Under-voltage protection of the hydraulic lifting motor is used in the control system to
ensure a long accumulator life in the forklift. When the discharge capacity of the accumulator cells
reaches 80%, the automatic protection will be activated and working of the hydraulic lifting system
will be disabled. Thus, there will be sufficient power for users to drive the forklift to the charging
station for timely charging.
5. The control system has the fault detection function, which could monitor the entire process
to see whether the forklift is under normal operation. If the control system fails, it will alarm timely
to alert the operator and maintenance staff to carry out timely repair and maintenance based on
the fault code displayed on the meter.
6. The storage device has a short time auto-release function and will not cause harm to
people.
7. The electric control device is equipped with a internal current sensor that automatically
monitors the motor current, so as to effectively control the overload current of the motor.
8. There is a seat switch under the driver's seat. The control device of the forklift will be
automatically shut down if the driver leaves the seat.
9. If the controller detects that the pedal input signal is greater than 25% when the forklift
starts, the controller protection (HPD) function will be triggered, namely, the controller will disable
the output to prevent runaway during start.
10. The microprocessor has a power-on self-test function and continuous diagnosis during
operation. If a fault occurs, the controller immediately stops output to ensure comprehensive
protection of the operator and the forklift.
11. Activate sequence protection (SRO) when starting the forklift.

Figure 2-40 CURTIS separately excited electronic control assembly

32
 4.3 Combination instrument
The accumulator forklift uses new combination instrument that provides auxiliary control
function and displays the forklift condition to the driver. It consists of control circuit, cumulative time
counter (on liquid crystal display), accumulator meter, fault code display and other display circuit.
In order to meet the current demand and requirements on electric forklift, the instrument adopts
new design on control circuit and display form featuring compact structure, elegant appearance,
high automation level and reliable quality.
(1)Description on the displayed icons:

1.Indicationon of 2.Indicationon of hand 3.Fault code of 4.Speed

locking braking traction control mode
5.Fault code of 6.Indication of oil filtering 7.Indication of 8.Fault
pump controller (disabled) maintenance time indication
9.Indication of 10.Buttons for mode switch 11. Capacity 12.Timing
turning right and parameter adjustment indicator of the indicator
accumulator
13. Operation menu 14.Indication of turning left
button
Figure 2-41 Instrument appearance
(2) Working process and use instructions
a．Timing indicator
It will display the accumulated working time. Timing starts when the key switch is turned on.
b. Capacity indicator of the accumulator
The current accumulator capacity will be indicated by a group of ten simulated colored grids.
The ten colored grids will be all lighted if the accumulator is fully charged and the grids lighted will
be reduced grid-by-grid from top to bottom when accumulator power is reduced.
c. Under-voltage protection
When the accumulator displayed is below 20%, the instrument determines that the
accumulator is under voltage, and the normally closed contact of internal control relay will be
disconnected to cut off the lifting control signal, disabling lifting and tilting operations and
reminding drivers to charge the accumulator in time for the purpose of protecting the battery.
d．Indication of hand braking
When the hand brake is used, the brake indicator lamp lights up; when the hand brake is
released, the brake lamp lights off.
e. Indication of steering
The steering direction of the forklift will be indicated and the steering lamp flashes when the
forklift is about to make a turn. The left turning light flashes when turning the steering wheel

33
forwards; the right turning light flashes when turning the steering wheel backwards.
4.4 Fault diagnosis (CURTIS Electronic Control)
The control system has the fault detection function, which could monitor the entire process to
see whether the forklift is under normal operation. The top of traction motor controller is equipped
with a state LED, which will steadily flash during normal operation of the forklift. If the controller
detects a failure, the two-digit indicator will blink continuously until the fault is eliminated, while the
instrument will display the fault code. Traction motor controller and pump motor controller can be
tested by the programmer. If the controller fails, the programmer will display the fault item. The
following is the fault code diagnosis of the traction motor controller: fault code diagnosis (Table
2-6)

(Table 2-6)
LED
Code Programmer display Explanation Possible causes
Code
HW FA I LSAFE Self-test function or
03 1，2 The controller is damaged.
1-2-3 watchdog fails
Internal short-circuit
M-SHORTED The controller is damaged.
from M- to B-
The motor field winding is
loosened
FIELD OPEN Field winding fails
Open-circuit of the motor
04 1，3
field winding
Armature current
ARM SENSOR The controller is damaged.
sensor fails
Excitation current
FLD SENSOR The controller is damaged.
sensor fails
Accelerator potentiometer
THROTTLE FAULT Slide end signal falls is damaged
1 beyond range
Accelerator circuit from B +
to B-
06 2，1 Accelerator potentiometer
is damaged
THROTTLE FAULT
Failure of potentiometer The wrong form of
2
accelerator has been
chosen
The wrong form of SRO
has been chosen
Open-circuit of interlock or
direction switch
07 2，2 SRO SRO Fault
Wrong sequence of KSI,
interlock and direction
Sequence delay is too
short
The wrong form of HPD
has been chosen
Direction and accelerator is
in the wrong order
08 2，3 HPD HPD Fault
Accelerator potentiometer
is not well adjusted
Sequence delay is too
short

34
 Open circuit of emergency
Error in wiring of reverse
09 2，4 BB WIRING CHECK
emergency reverse Test line of emergency
reverse is broken
Over-current output of Short circuit of contactor
10 3，1 CONT DRVR OC
the contactor driver coil
Jamming of the main
MAIN CONT The main contactor is contactor
11 3，2
WELDED welded Short circuit of the main
contactor driver
The controller is damaged.
PRECHARGE Internal voltage is too
12 3，3 Short circuit of external
FAULT low during start
B-to B + or current leakage
Open circuit or
MISSING The contactor is not
disconnection of any of the
CONTACTOR connected
13 3，4 contactor coils
Main contactor is not Main contactor coil is not
MAIN CONT DNC
closed connected or is off
Accumulator under-voltage
is cut off
LOW Corrosion of the
Low voltage of the
14 4，1 ACCUMULATOR accumulator connector
accumulator
VOLTAGE Looseness of the
accumulator or the
controller connector
Accumulator over-voltage
is cut off
The accumulator is
charged when the forklift is
15 4，2 OVER VOLTAGE Over-voltage
working
The accumulator is
disconnected during
regenerative braking
Temperature exceeds 85
℃ or below -25 ℃
THERMAL Cut off due to
16 4，3 Overloading of the forklift
CUTBACK over/under temperature
Working in extreme
environments
Short circuit of mode switch
Placed in mode 2 or 4 to B +
17 4，4 ANTI-TIEDOWN
when starting Mode switch is "tied" to 2 or
4

35
 5. AC Electric system(Curtis system)
5.1 Overview
The electrical system mainly consists of accumulator cells, traction motor, pump motor,
traction motor controller, pump motor controller, steering combination switch, multi-valve block
controller, display instruments, combination control switch, gauges and lighting devices.
Schematic of electrical system.See the figure below

Figure 2-42 Schematic of electrical system (Table 2-7)

36
(Table 2-7)
No. Name Remarks No. Name Remarks
M1 Traction motor LB Horn
M2 Oil pump motor DF Reversing buzzer
E3 DC converter DK Light switch
E2 Oil pump controller LN Horn switch
E1 Traction controller ZK Steering switch
FU2 Fuse JK Foot braking switch
FU1 Fuse FK Direction switch
KM2 Contactor KL3 Width lamp
KM1 Contactor XL2 Left steering lamp
DYK Power connector QL1 Headlight
GB Battery XL3 Right steering lamp
JSQ Accelerator KL2 Width lamp
ZYK Seat switch SL2 Braking lamp
YK Key switch DL2 Reversing lamp
JT Emergency stop button DL1 Reversing lamp
FU4 Fuse SL1 Braking lamp
FU6 Fuse KL1 Width lamp
FU7 Fuse XL1 Left steering lamp
FU8 Fuse CY Side shifting switch
P Instrument QX Tilting switch
K Relay QS Lifting switch
SK Hand braking switch KL4 Width lamp
FM1 Fan XL4 Right steering lamp
FM2 Fan QL2 Headlight
SQ Flasher HDK Single level Switch

37
 5.2 Electric control assembly
The electronic control assembly mainly consists of CURTIS Company's 1238 traction motor
controller and 1253 pump motor controller, which could provide superior performance,
energy-efficiency and reliable quality.

Figure 2-43 CURTIS separately excited electronic control assembly

Basic working principle:

Curtis 1238 motor speed controller adopts advanced control software to guarantee smooth
running of the motor in various modes, including regenerative braking, zero speed and torque
control under full speed or high torque. Plus, proprietary input / output ports and the corresponding
software are used to ensure that the controller controls the electromagnetic brake and hydraulic
system in an economic and efficient manner.
Features of the electric control device:
① Its main functions, operating method and the system itself are superior to DC systems.
The forklift can be operated in low noisy circumstance at a frequency range from 0 to 300 Hz.
With 24 to 80 V battery voltage system, current could rise to 350-650 amps in 2 minutes.
With powerful operating system, the forklift’s control program, motor control program, and
user program could run concurrently.
The advanced PWM technology ensures efficient usage of the battery, cuts down motor
power consumption and reduces the loss of torque converter.
The AC controller of Curtis can be adapted to different AC motors of any type.
Timer and battery charge status monitor are built-in.
With the built-in flash memory, users can download softwares for on-site commissioning and
programming whenever necessary.
② Excellent drive control
Combination of Curtis’ vector control technology and unique algorithms ensures consistent
peak torque and optimal efficiency of the controller.
Both the torque and speed work in a wide range, and the regeneration performance is perfect.
Speed and torque mode controlled by the internal closed loop could ensure optimum

38
 performance without any additional device.
The drive and braking performance can be adjusted to the best by setting the programmed
parameters.
Torque control mode provides uniquely excellent performance to ensure smooth transition
and quick response in any state.
With the unique pump control mode, the forklift could quickly respond to hydraulic changes.
③ Unmatched flexibility
Curtis's unique control language allows OEM manufacturers to design forklifts in an
unprecedentedly easy way. With decades of industry experience, Curtis can not only provide
you with various pre-setting functions, but also with the possibility of quickly and easily
customized settings and new algorithms, so as to differentiate your system with similar
products from your competitors.
VCL makes it possible for the controller to reflect and manage the system status of the forklift
without additional hardware, saving your cost and design time.
Being widely applicable to a variety of I / O interface, it can meet all the needs of system
control.
Through CAN BUS communication, it can be connected to other systems with a function of
CAN BUS connection. (CAN OPEN, or customized through VCL)
The controller can be used for lifting or traction. (The specific model of corresponding
software is built-in)
Users can easily perform programming by using the 1311 handheld programmer and 1314
PC programming station.
④ High security and reliability
Insulated metal base provides excellent heat dissipation, thus enhancing reliability of the
controller.
Failure-safe power device
Hardware watchdog
Electrode reversal protection
Short circuit protection of the output drive
Settings on overheat protection, warning and automatic shutdown can protect the motor and
the electronic controller.
Conforming to the IP65 protection standard, it could meet various harsh environmental
requirements.
⑤、 Equipping with the 1253 pump motor controller of the U.S. CURTIS Company, the
hydraulic system of the forklift features non-contact, non-sparking, no noise, smooth & reliable
working during start of the hydraulic lift motor. Such problems as the main contacts is easy to
erode, short service life, impact or damage to the accumulator cells and other defects
frequently seen in the traditional hoisting contactor are completely eliminated. Thus accumulator
life can be extended and maintenance costs can be reduced, greatly lowering the forklift’s
operating cost.

39
 5.3 Combination instrument
In order to meet the current demands and requirements on electric forklift, the instrument
adopts new design on control circuit and display form featuring compact structure, elegant
appearance, high automation level and reliable quality, providing drivers with intuitive
information of the forklift status.
5.3.1 Description of the displayed icons:

Figure 2-44 CURTIS instrument

"TRVAL" indicates travelling and "HYD" indicates lifting. If the travelling
controller fails, the fault code will display after "TRAVEL" appears; If the lifting
controller fails, the fault code will display after "HYD" appears;
 Mode selection

a) Three modes are available: " " ," " and " " , which
are M1, M2, M3 modes of the travelling controller correspondingly.

b) The “ " key is used for mode selection. If you keep on

pressing the button, the three modes will be chosen in turn and the cycle will be
repeated.
c) When fault code is displayed under "HYD" status, the instrument will automatically
switch the mode of the travelling controller to M4 and set M4 speed as 0 to stop the
forklift.

 Speed status
a) Speed Status: " ", this state is invalid for the DC controller system;
b) Speed meter: The speed display is invalid for the DC control system;

 Upgrade locking
a) a) If the battery is empty and the controlling cable of upgrade locking has been
connected to B +, the instrument will send a signal to the pump controller to activate

40
 the upgrade locking function and display " " on the screen.

 Alarm icon

a)
Parking
Conditions for displaying: connected to B +

b)
Seat switch
Conditions for displaying: connected to B - or is hanging in the mid-air

c)
Upgrade locking
Conditions for displaying: see the feature of "upgrade locking"

d)
Maintenance time
Conditions for displaying: time for maintenance

e)
Turn left
Conditions for displaying: connected to B +

f)
Turn right
Conditions for displaying: connected to B +
5.4 Fault diagnosis (CURTIS Electronic Controller)
Fault detection is available in the control system, enabling whole-process monitoring on the
forklift.Traction motor controller and pump motor controller can be tested by the programmer. If the
controller fails, the programmer and the instrument will display the fault item. The following is the
fault code diagnosis table of a controller: fault code diagnosis
Example of LED code : ☼ ☼ ☼ ☼ ☼ ☼ indicates that LED light first flashes twice, then pause a
few seconds and after that, flashes for 4 times.
LED is dark No power supply or controller fails
All lights are on Failure of controller or microprocessor
LED displays 0，1 The controller works mormally; trouble-free
Table 2-8 Fault table and diagnostic guidelines of the 1253 controller
Fault
Status light Explanation Possible causes
code
There is no voltage or the
controller does not work
The controller fails (such
as failure of MCU etc.)

41
 The controller is working
■ ¤ properly without any
known faults
1. Loss of EEPROM data
2.Error in EEPROM data
efficacy, which could be
1,1 ¤ ¤ Failure of EEPROM
eliminated by using 1311
programmer to change any
parameter of the controller.
1.Short-circuit of MOSFET
1,2 ¤ ¤¤ Hardware failure
2. Open circuit of the motor.
2,1 ¤¤ ¤ Deep under-voltage Battery voltage is too low
The upgrade locking function of
2,2 ¤¤ ¤¤ Upgrade locking
the controller has been triggered.
Any switch of the SS1-SS4
2,3 ¤¤ ¤¤¤ Fault in orders(Startup lockout) switches is turned off prior to that
of the KSI or INTERLOCK.
1. The main contactor gets stuck
2.Setting of the
3,2 ¤¤¤ ¤¤ Jamming of the contactor
parameter "CONTACT
CNTRL" is incorrect.
1.The circuit for pre-charging is
not working properly.
3,3 ¤¤¤ ¤¤¤ Pre-charging fails
2. Short circuit occurs to the
motor.
1.Coil connection of the
Contactor has not been
main contactor becomes loose.
3,4 ¤¤¤ ¤¤¤¤ installed or couldn't be
2.The main contactor is not
closed (DNC)
working properly.
The battery voltage is lower
4,1 ¤¤¤¤ ¤ Under-voltage protection than the pre-set value of
"LOVOLT CUTBACK".
4,2 ¤¤¤¤ ¤¤ Over-voltage protection Battery voltage is too high
1.The controller’s temperature is
Temperature protection
too high or too low
4,3 ¤¤¤¤ ¤¤¤ (over-temperature or under-te
2.Temperature sensor is not
mperature)
working properly.

42
 6. AC electrical system (Zapi system)
6.1 Overview
The electrical system mainly includes accumulator cells, traction motor, pump motor, traction
motor controller, pump motor controller, steering combination switch, multi-valve block controller,
display instruments, combination control switch, gauges and lighting devices.
Schematic of Zapi’s electrical system is shown below

Figure 2-45 Schematic of Zapi’s electrical system (Table 2-9)

43
(Table 2-9)
No. Name Remarks No. Name Remarks
M1 Traction motor LB Horn
M2 Pump motor DF Reversing buzzer
E3 DC converter DK Light switch
E2 Pump controller LN Horn switch
E1 Traction controller ZK Steering switch
FU2 Fuse JK Foot braking switch
FU1 Fuse FK Direction switch
HDK Single level Switch KL3 Width lamp
KM1 Contactor XL2 Left steering lamp
DYK Power connector QL1 Headlight
GB Battery XL3 Right steering lamp
JSQ Accelerator KL2 Width lamp
ZYK Seat switch SL2 Braking lamp
YK Key switch DL2 Reversing lamp
JT Emergency stop button DL1 Reversing lamp
FU4 Fuse SL1 Braking lamp
FU6 Fuse KL1 Width lamp
FU7 Fuse XL1 Left steering lamp
FU8 Fuse CY Side shifting switch
P Instrument QX Tilting switch
K Relay QS Lifting switch
SK Hand braking switch KL4 Width lamp
FM1 Fan XL4 Right front steering lamp
FM2 Fan QL2 Headlight
SQ Flasher

44
 6.2 Electric control assembly
The electronic control assembly mainly consists of FLASH's AC-2 traction motor controller
and ZAPI’s HP500 pump motor controller, which could provide superior performance,
energy-efficiency and reliable quality.

Figure 2-46 Zapi’s electronic control assembly

Basic working principle:
Among MOS Series products of Zapi Company, the AC2 inverter, which is specially designed
for 3.0kW-8.0kW motors, has been widely used in electric vehicles, golf carts and multi-purpose
utility vehicles for controlling purpose. The lifting force is generated in a way as follows: the DC
motor drive pump to generate oil pressure, and then the hydraulic pipes work on the hydraulic
cylinders on both sides of the frame to achieve lifting of the fork.
Features of the electric control device:
6.2.1 Overview
The electrical system of FE4P30AC three-wheel AC electric forklift is powered by an 80V
battery and traction is enabled by the AC motor. The lifting force is generated in a way as follows:
the DC motor drive pump to generate oil pressure, and then hydraulic pipes work on the hydraulic
cylinders on both sides of the frame to achieve lifting of the fork. The lighting system is powered by
a 24V voltage.
6.2.2 Characteristics of the Electric System:
The forklift’s AC frequency conversion traction motor, AC frequency conversion steering
motor controller, dashboard display, AC drives are all products from the Italian ZAPI Company, the
world's leading supplier of electric vehicle systems. The AC frequency conversion motor is efficient,
durable and essentially maintenance-free. As it does not contain any commutator seen in DC
motors, acceleration is faster (commutator limits acceleration and even limits braking torque
during high-speed driving). The controller is one universally used in electric vehicles that
communicate via CANopen protocol. With its analog and digital I / O and communication devices,
the controller is ideal for managing forklift movements, I / O, for controlling operation and for
displaying information. In addition, it can perform discharging and monitoring of the battery group
and offers a variety of protection. Dashboard display ECO-SMART can show a variety of data, and
can be set at factory or by users. Plus, other functions such as entering of user commands are
also avaliable.

45
 6.2.3 Main functions and settings
By properly setting the motor parameters, control parameters and corresponding functional
value of the controller, users can acheive safe and efficient performance as well as full operational
capabilities of the electric forklift.
1. The crawling speed of electric forklift can be regulated. By setting the crawling speed of the
controller, users can operate the electric forklift under low-speed in a long time.
2. Acceleration rate can be regulated. Under different acceleration rate, the "hardness and
softness" feel of the accelerator pedal varies. By setting of the acceleration rate, users can meet
various accelerating demands in different conditions.
3. Reverse braking and regenerative braking.When the direction lever is placed reversely
during moving of the forklift, a reverse braking signal will be created, and then the motor drive will
order the traction motor to generate a braking torque, so as achieve the purpose of deceleration.
Size of the braking force is controlled by the accelerator pedal.Regenerative braking refers to the
forklift’s braking force generated by the controller when the forklift’s speed is relatively higher than
the traction motor speed. The force can be transformed into electrical energy and returned to the
battery group. In order to reduce the speed of the forklift when moving downwards, users can
release the accelerator pedal to a certain extent to achieve regenerative braking, so as to extend
the driving distance enabled by a single battery charge.
4. Function of avoiding slipping backwards on a ramp. Electric forklift with AC traction motor
could excellently avoid downwards-moving of the forklift on a ramp.
5. The maximum driving speed could be regulated. By setting a reasonable vmaximum speed
of the electric forklift, users can avoid overload of traction motor due to excessive speed.
6. Static response off.If the seat switch or key switch is off, the control device will be turned off
either. Re-start is enabled only when the directional control lever is placed on the neutral position.If
the driver leaves the forklift and then return, he needs to place the directional control lever on the
neutral position to re-start the forklift.This feature eliminates accidental occurrence of unsafe
operation.A few seconds of latency have been set to the input end of seat switch, so as to realize
momentary disconnection of the seat switch in case of turbulence.
7. Function of security protection. If damage occurs to the controller's power components
when forklift is running, the controller will disconnect the main contactor in the shortest time; if the
controller’s temperature is too high, the controller will automatically limit armature current of the
motor; if the battery voltage is too low, the controller will stop working to ensure safety.
8. Both the traction motor controller and pump motor controller are equipped with a
self-diagnostic function. Fault code will show on the meter display and the controller will be
automatically disabled to ensure the operating system's security whenever controller fault occurs
during its working process.
9. The meter display will show the battery power and its cumulative work hours.
6.2.4 Maintenance of the electrical system
(1) Check wear status of contacts and change them if worn. Contactor contacts should be
inspected every 3 months.
(2) Check the micro-switch of pedal or handle and measure voltage drop at both ends of the
micro-switches. No resistance shall be found when the micro-switch is open or closed and
crackling sound shall be heard during release. Check once every 3 months.
(3) Check the main circuit: accumulator - controller - connection cable of motor. Ensure good
cable insulation and tight electrical connection. Check once every 3 months.
(4) .Check the mechanical movement of the pedal. See if spring deformation is normal and if
potentiometer spring is retractable within the maximum level or to a set level. Check once every 3
months.
(5) Check once every 3 months the mechanical movement of the contactor, which should move
freely without adhesion.
6.3 Combination instrument
The forklift uses new combination instrument that provides auxiliary control function and
displays the forklift condition to the driver. It consists of control circuit, cumulative time counter (on
LCD), accumulator meter, fault code display and other display circuit. In order to meet the current

46
demands and requirements on electric forklift, the instrument adopts new design on control circuit
and display form featuring compact structure, elegant appearance, high automation level and
reliable quality, providing drivers with intuitive information of the forklift status.
Smart Display monitor is equipped with six built-in red LCD displays, which could provide
basic information of the forklift’s operation status to the operator.See the Figure below.

1. Latency light 2 Failure alarm light 3. Battery level mark 4 Display of speed, time
and battery level
5 Temperature warning 6. Indication light of 7. Indication light of 8. Meter function keys
light hand braking seat
9. Function selection 10. Function selection 11. Parameter 12. Parameter
key (up) key (down) adjustment key (-) adjustment key (+)
13. Exist function key 14. Battery indicator
Figure 2-47 Instrument of Zapi
1) Battery
Battery indicator lights on – the measured battery capacity is less than or equal to 10% of
full battery power.
2) Lever
Malfunction indicator light flashes - the forklift is in alarm.
3) Temperature
Temperature indicator light flashes - the stacker is in alarm due to high temperature of IMS.
4）Seat
Seat indicator light flashes - the operator has left the seat.
5) Handbrake
Handbrake light flashes - handbrake function is activated
When the main switch is off, Eco Smart display will perform a comprehensive test, and turn
off all the LCDs in turn.
6.4 Meter fault code
Table 2-10 Fault code
Status code Diagnosis of fault Status code Diagnosis of fault status
status
00 NONE 42 DIR CONT. OPEN
01 CHOPPER RUNNING 43 RIGHT CON CLOSED
02 NO COMMUNICATION 44 RIGHT CONT. OPEN
03 UNKNOWN CHOPPER 45 LEFT CONT CLOSED
04 CONSOLE EEPROM 46 LEFT CONT. OPEN
05 SERIAL ERROR #2 47 MAIN CONT CLOSED
06 SERIAL ERROR #1 48 MAIN CONT. OPEN
07 CHOPPER NOT CONF 49 I=0 EVER

47
08 WATCHDOG 50 LEFT I=0 EVER
09 FIELD FF FAILURE 51 RIGHT I=0 EVER
10 EEPROM DATA KO 52 PUMP I=0 EVER
11 EEPROM PAR. KO 53 STBY I HIGH
12 EEPROM CONF. KO 54 LEFT STBY I HIGH
13 EEPROM KO 55 RGT STBY I HIGH
14 EEPROM OFFLINE 56 PUMP STBY I HIGH
15 LOGIC FAILURE #5 57 HIGH FIELD CUR.
16 LOGIC FAILURE #4 58 NO FIELD CUR.
17 LOGIC FAILURE #3 59 HIGH BRAKING I
18 LOGIC FAILURE #2 60 CAPACITOR CHARGE
19 LOGIC FAILURE #1 61 HIGH TEMPERATURE
20 FORW VMN LOW 62 TH. PROTECTION
21 FORW VMN HIGH 63 THERMIC LEVEL #2
22 BACK VMN LOW 64 PUMP TEMPERATURE
23 BACK VMN HIGH 65 MOTOR TEMPERAT.
24 LEFT VMN LOW 66 BATTERY LOW
25 LEFT VMN HIGH 67 BATTERY LEVEL #2
26 RIGHT VMN LOW 68 BATTERY LEVEL #1
27 RIGHT VMN HIGH 69 CURRENT SENS. KO
28 PUMP VMN LOW 70 HIGH CURRENT
29 PUMP VMN HIGH 71 POWER FAILURE #3
30 VMN LOW 72 POWER FAILURE #2
31 VMN HIGH 73 POWER FAILURE #1
32 VMN NOT OK 74 DRIVER SHORTED
33 NO FULL COND. 75 CONTACTOR DRIVER
34 RGT NO FULL COND 76 COIL SHORTED
35 LFT NO FULL COND 77 COIL INTERRUPTED
36 PU NO FULL COND 78 VACC NOT OK
37 CONTACTOR CLOSED 79 INCORRECT START
38 CONTACTOR OPEN 80 FORW + BACK
39 BRAKE CON CLOSED 81 BAD STEER 0-SET
40 BRAKE CONT. OPEN 82 ENCODER ERROR
41 DIR CONT. CLOSED 83 BAD ENCODER SIGN
84 STEER SENSOR KO 92 DRIVER 1 SIC. KO
85 STEER HAZARD 93 DRIVER 2 SIC. KO
86 PEDAL WIRE KO 94 INPUT ERROR #6
87 PEDAL FAILURE 95 INPUT ERROR #5
88 TRACTION BRUSHES 96 INVERTION
89 PUMP BRUSHES 97 POSITION HANDLE
90 DRIVER 1 KO 98 INPUT ERROR #2
91 DRIVER 2 KO 99 INPUT ERROR #1

48
 7．Accumulator
7.1 Accumulator safety precautions:
△ Appropriate ventilation measures shall be adopted because hydrogen and oxygen will be
generated at the end of the accumulator charging process. If spark occur during the process, explosion
may be caused.
△ Harmful acid mist will also be generated during charging. Remove the mist promptly after
charging and clean up the accumulator and the charging place promptly.
△ Please wear protective glasses and rubber gloves when charging the accumulator as it
contains sulfuric acid. Careless use may cause skin burns and loss of vision. If you splash electrolyte
(acid) in your eyes or skin, immediately wash with plenty of water and visit a doctor for treatment.
Electrolyte on clothes can be washed off with water.
△ People who are not familiar with the operating method of the accumulator and its
dangerousness shall not use the accumulator, so as to avoid harm to personnel caused by the dilute
sulfuric acid.
△ Never place any metal objects or tools on the accumulator to eliminate the danger of
short-circuit.
△ Unplug the power connector of the accumulator only when power is fully turned off. Hot
plugging is strictly prohibited.
△ Before installing the accumulator, please read the instruction manual carefully. After reading,
please keep it with you for future reference.

7.2 Accumulator use precautions

Service life of the accumulator is generally 2 to 3 years, or even 4 years if it can be properly used
and maintained. In case of the improper use and maintenance, it may suffer early damage in a few
months since initial use.
During use of the accumulator, users should regularly check the electrolyte level and the remaining
accumulator capacity. Recharge the accumulator if necessary. Accumulator maintenance is relatively
simple, but requires patience and meticulousness. Timely supplementing and density control of the
electrolyte as well as cleanup of accumulator and polarity terminals can effectively extend the service
life of accumulator.
Check if there is water in the accumulator box and drain the water immediately if any.
In addition, the accumulator should not be stored with electrolyte in it. In case of short-term storage
of a fully charged accumulator, please charge the it every month during the storage period to
compensate for self-discharge of the accumulator, preventing vulcanization of accumulator plate or
eliminating minor vulcanization of the accumulator plates. Plus, users shall check the accumulator
status frequently during the storage period.
If the accumulator is being used, please conduct a fully discharge together with a fully charge each
month. This could help maintain accumulator capacity and avoid plate salvation.
Please keep the external surface of the accumulator clean.
Check the accumulator and the fixing status of wire leads. There should be no looseness.
Check the accumulator case for cracking and damage and then check the pole and lead chuck to
see if they are burnt.
Wipe clean dust on the external surface of the accumulator with a cloth. If electrolyte overflows to
the surface, please wipe with a cloth or rinse with hot water and wipe it dry with a cloth. Remove dirt
and oxides on the post piling and wipe clean the external of lead cable and lead chuck. Unblock and
clean up the vent on the filler cap. During the installation process, apply a thin layer of industrial
Vaseline on the pole and lead chuck.

Check the accumulator fluid level:

Vertically insert a glass tube with a diameter of 6 ~ 8mm and length of 150mm into the filler until
reaching the upper edge of the plate. Then press the upper end of the tube with thumb and clip out the
glass tube with the index finger, middle finger and ring finger. The height of the electrolyte within the
tube is the height of electrolyte above the plate accumulator surface, which should be 15-25mm. Finally,
return the electrolyte to the original single-cell accumulator.

49
 Add electrolyte
If the electrolyte level is too low, distilled water should be promptly added other than tap water,
river water or well water, so as to avoid failure of self-discharge caused by impurities. Plus, do not add
electrolyte, otherwise the electrolyte concentration will increase, shortening the accumulator life. Note
that the electrolyte level can not be too high in order to prevent spill-over of the electrolyte during
charging and discharging process that may cause short circuit. After adjusting the electrolyte level,
charge the accumulator for 0.5 hours or more to well mix the added distilled water with the original
electrolyte. Otherwise, the interal parts of the accumulator tend to be frozen in winter.
Check the electrolyte density
The electrolyte density varies with the different degree of accumulator charging and discharging.
Drop of the electrolyte density is an indication of accumulator discharging. To measure the electrolyte
density in each cell is a manifestation of the accumulator discharge level.
(1) Measurement method: Remove the liquid filler cap in the single cells in the accumulator, and
draw the electrolyte from the liquid filler cap with a density meter, until the float of density meter floats
up. When observing the readings, you should raise the density meter to a position that flush with your
eye sight, and put the float in the center of the glass tube without touching the tube wall, so as not to
affect the accuracy of reading.
If the temperature is below 25 ℃ or higher than 25 ℃, a thermometer should be used to measure
the actual temperature of the electrolyte for correcting the value of electrolyte density.
(2) Correction of electrolyte density: errors exist in the density of the electrolyte at different
temperatures, so the electrolyte density value shall be corrected accordingly. Electrolyte density at 25
℃ shall be used as the benchmark. Therefore, if the electrolyte temperature is higher than 25 ℃, you
should add 0.0007 to the actual measured value of density for an increase in temperature by 1 ℃; In
contrast, if the electrolyte temperature is lower than 25 ℃, subtract the density by 0.0007 when the
temperature decrease by 1 ℃; If the temperature difference is large, the density value shall be
corrected by the following formula:
Density of electrolyte under standard temperature (25 ℃) can be converted by the following
formula:
D25 = Dt + 0.0007(t - 25)
D25 — Electrolyte density when the temperature is 25 ℃
D25 — Measured electrolyte density when the temperature is t ℃
t — The electrolyte temperature when measuring the density

7.3 Charging of the accumulator

(1) Initial charge (generally initial charge has been conducted to the products before leaving the
factory, so users could omit this operation)
The quality of initial charge would greatly impact the future performance of accumulator. So initial
charge shall be conducted by experienced operators.
Initial charge should be carried out to new accumulators before use.
You should wipe clean the surface of the accumulator and check for damage before the initial
charge.
Open the cover on the liquid filler to ensure that the vent is unblocked.
When the charger is under normal working conditions, you could fill sulfuric acid electrolyte with
density of 1.26±0.005 (25 ℃) and temperature below 30 ℃ into the accumulator. In this case, liquid
level shall be 15 ～ 25mm higher than the protection plate.
Place the accumulator aside for 3 to 4 hours, but ensure the time will never be more than 8 hours.
Conduct initial charge only after liquid temperature is reduced to below 35 ℃. If the electrolyte level
reduces after standing down, you should add electrolyte to it original level.
Sulfuric acid electrolyte shall be prepared by mixing the accumulator acid and distilled water
according to national standard GB4554-84 (never use industrial sulfuric acid and tap water).

50
 During preparation, please slowly fill the concentrated sulfuric acid into the distilled water
by trickle and continuously stir with a acid-proof glass rod or with a lead covered wood stick.
Filling of distilled water into the sulfuric acid is not allowed, otherwise it will cause boiling and
splashing of solution, resulting in burning.
Connect the accumulator with the charger correctly in terms of polarity in a reliable manner,
namely, ensure ro connect positive to positive and negative to negative.
For the first phase of initial charge, please use 0.5I5A (60A for D-600 accumulator) until the
voltage of a single cell reaches 2.4V. Then we could shift to the second phase of initial charge;
For the second phase of the initial charge, you could use 0.25I5A (30A for D-600
accumulator) for charging；
The temperature of the electrolyte shall not exceed 45 ℃ during charging. Reduce the
charge current by half or suspend the charge when the temperature is close to 45 ℃. Continue
charging after the electrolyte temperature drops to below 35 ℃. In this case, the charging time
shall be extended appropriatly;
Evidence of fully charged: In the second stage of the initial charging, charging voltage will
be up to 2.6V and the voltage change shall be less than 0.005V; When electrolyte density is 1.28
± 0.005 (25 ℃) , if there is no significant change within 2 hours and fine bubbles emerges
intensely, the accumulator can be considered fully charged. The charging power is 4 to 5
times of the rated capacity and the charging time is about 70 hours;
In order to accurately control the content of sulfuric acid in the electrolyte, the density of
the electrolyte should be checked at the end of the charging process; In case of any
discrepancy, please use distilled water or sulfuric acid with density of 1.40 to adjust. Ensure the
electrolyte density and height level is adjusted to the specified value within 2 hours since the
charging starts;
Wipe clean the accumulator surface and cover the filler cap before putting into use.

（(2) General Charge

Do not use accumulator that is not fully charged. Users should pay close attention to the discharge
level of accumulator during use. If the discharge level exceeds the set value, conduct charge in time.
Excessive discharge is strictly forbidden. When the voltage drops o 1.7V / cell, electrolyte density
decreases to 1.17, stop discharge timely and conduct charge soon. Never delay charging for a long
time. Don’t stop halfway without reason during the charging process.
When conducting general charge, first open the flip cover on the filler cap cover and check whether
the electrolyte height meet requirements. If not, please fill distilled water to adjust the liquid level to the
required height.
Connect the output of the charger with the accumulator in accordance with the requirements.
Connect positive to positive and negative to negative. Pay attention not to connect it reversed.
The charger compatible with the accumulator could automatically regulate the charging current
according to the charging capacity and conduct charging until the accumulator is fully charged. (Please
refer to the manual of charger for details on observation of the charging state)
In order to keep the accumulator status updated, it is recommended to record each charge and
discharge conducted for each accumulator, so as to provide useful basis for determining whether or not
the accumulator in the future or not. During the charging process, measure and record the current, total
voltage, voltage of each single cell(the cells shall be numbered) , changes in the electrolyte density and
temperature (measure with a 0 ~ 100 ℃ mercury thermometer) every 1-2 hour .
If large quantities of even and fine bubbles come into being, voltage of single cell is stabilized at
2.5-2.7V and electrolyte density and terminal voltage stops rising in 2-3 hours, then it can be
determined that the accumulator is fully charged. If any cells have no or few bubbles, try to find out the
reasons and fix the problem. Then record it in your work log.
Electrolyte temperature shall not exceed 45 ℃ during the charging process. The temperature of
the electrolyte during charging shall not exceed 45℃. Suspend charging if the temperature is close to
45 ℃ and continue charging when the electrolyte temperature drops to below 35℃.
When the accumulator charging comes to end, the electrolyte density of the accumulator shall be
checked and adjusted. If the electrolyte density fails to meet the requirements, draw some electrolyte
from the original cells. If it is less denser than normal, fill concentrated electrolyte with density of 1.40

51
for adjustment; if it is denser than normal, dilute it by adding distilled water. After adjustment, the
difference of electrolyte density of cells should not exceed 0.01 and the liquid level should meet
relevant requirements. After adjusting the density, you could continue to charge with small current for
0.5 hours to mix the electrolyte. Then review the electrolyte density and adjust it if necessary. Finally,
wipe clean and mount the accumulator for future use.

3）Balanced recharging
Under normal circumstances, although all the accumulator cells run under the same situation, but
for some reasons, imbalance in the entire accumulator may occur. In such case, balanced recharging
should be conducted to eliminate the charge difference between the accumulator cells, so as to
achieve a balanced charging between all cells of the battery. Balanced recharging is simple and users
can operate according to the instructions.
Perform balanced recharging to the accumulator once every two or three months during normal
use. accumulators that are left unused for a long time should be charged before use.

7.4 Installation and replacement of the accumulator

Perform installation and replacement of batteries in a fixed and reliable manner to avoid tipping;
Beating on the polar column and lead chuck with a tool is strictly forbidden; in the handling process, pay
attention to avoid strong impact.

52
 8. Hydraulic system
8.1 Overview
The hydraulic system consists of working pump, multiple unit valve, lifting cylinder, tilting
cylinder, pipelines and other component parts. See figure 2-48
The hydraulic oil will be supplied by the oil pump directly connected with the motor. The
multiple unit valve will assign oil to each cylinder.

Multiple Directional Control Valve

Steering Cylinder tilting cylinder

lifting cylinder

Steering Gear

Prior Valve Governor valve

Gear Pump

Figure 2-48 Diagram of the hydraulic system

8.2 Oil pump
The oil pump is a gear pump.

8.3 Multiple unit valve

The multiple unit valve includes two four-piece valves. Controlled by the valve rod of the
multiple unit valve, the hydraulic oil from the work pump will assign high-pressure oil to the lifting
cylinder or tilting cylinder. Safety valve and self-locking valve are installed in the multiple unit valve.
Safety valve is located in the upper side of oil inlet in the multiple unit valve to control the system
pressure; self-locking valve is located in the tilt valve plate to prevent serious consequences due
to misoperation of control lever in case of no pressure source of the tilting cylinder. A check valve
is mounted between the oil inlet and the oil abortion hole of the lifting valve plate, as well as
between the oil inlet and the oil abortion hole of the lifting valve plate with check valve.

Please see Figure 2-49 for the shape of the multiple unit valve.

53
1. Safety valve 2. Microswitch bracket 3. Oil returning hole 4. Lifting speed sensor sets
Figure 2-49 Shape of multiple unit valve
(1) Operation of the slide valve (Take tilting slide valve as an example)
(a) Middle position (Figure 2-50)
At this time the high pressure oil discharged from the oil pump will return to the cylinder
through the middle position.
(b) Pull in the slide valve (Figure 2-51)
The middle channel is closed at this time, oil from the inlet hole openes the check valve and
flow into the cylinder interface B. Oil flows from interface A will flow to the cylinder through the low
pressure channel. Then the slide valve can return to the middle position with the help of the return
spring.

Inlet check Oil inlet

Oil inlet hole Oil inlet hole

Return

Slide
Low
Middle

Figure 2-50 Figure 2-51

(c) Pull out the slide valve (Figure 2-51)
The middle position is closed at this time, oil from the inlet hole openes the check valve and
flowes into the cylinder interface A. Oil flows from interface B will flow to the cylinder through the
low pressure channel. Then the slide valve can return to the middle position with the help of the
return spring.
(2) Action of safety overflow valve (Figure 2-52)
The overflow valve is installed between the "HP" interface of the oil pump and the
low-pressure channel "LP". The oil that flows through the lifting valve "C" will acts on the different
areas of diameter "A" and "B", so the check valve "K" and overflow lifting valve "D" all land on the
valve seat. The preset pressure in the oil pump "HP" channel will act on the spring of pilot valve
and the check valve "E" will open. Oil will flow around the valve into the low pressure "LP" side
through the open-end hole.
Once the pilot valve "E" is open, the pressure at the inside of valve "C" will decrease and the

54
valve "E" and valve "C" will both land on the valve seat. Liquid flow at back of the flow valve "D"
will be off, so the pressure inside is reduced. Pressure on pump "HP" channel side and the inside
pressure are different, the valve "D" will open under the pressure difference and the oil will directly
flow into the low pressure loop "LP".

Figure 2-52
(3) Action of the self-locking tilt valve
Self-locking tilt valve is mounted in the tilt cylinder valves. The self-locking valve could prevent
sudden fall of the main frame when negative pressure occurs in the cylinder and also eliminate
dangers if the valve rod is titled due to misuse. With this self-locking valve, when forklift motor
stops working, the main frame will not tilt forward even if the control lever is shoved. Oil flow
direction when valve core is pulled out is the same with that shown in Figure 2-52, at which time
the main frame is tilting backwards.

(a) When the valve core is inserted (pump is working), oil from the main pump will flow into
the tilt cylinder through interface "B", and the oil flowes back from the cylinder will be used to the
piston through the role of port A. Oil will return to the cylinder through the holes A and B on the
valve core. See Figure 2-53
(b) When the valve core is inserted (pump is not working), there will be no oil that flows into
interface "B" of the cylinder, so that the pressure in part P will not increase. Therefore, the piston
will not move and oil in the cylinder Interface "A" can not return to the oil cylinder, which won’t
move. See Figure 2-54
Oil inlet A Oil inlet B Oil inlet A Oil inlet B

○
A ○
A
○
B ○
B

Self-locki Self-locki
○
P

Figure 2-53 Figure 2-54

(4) Multiple unit valve control Figure 2-55

Multiple unit valve is controlled by the control levers, all of which are installed in a connecting
shaft and the shaft is fixed to the forklift body through a bracket.
The control lever controls the slide valve through the connecting rod.

55
 1.Tilting control lever 2. Lifting control lever 3. Attachment control lever
4.Connecting shaft 5. Connecting Rod 6. Bracket
(Figure 2-55) Multiple unit valve control
(4) Pressure adjustment of the safety valve
The pre-set pressure of the safety valve: 13.5/16.8MPa;

Pressure of the safety valve has been set by the manufacturer and users shall not
adjust it wilfully.

8.4 Lifting cylinder and lifting chain （ See figure 2-56）

The lifting cylinder is a single-acting piston cylinder, which consists of the cylinder, piston rod,
piston and cylinder head. For the series of forklifts, the two lifting cylinders are installed behind the
outer main frame, with the cylinder bottom fixed on the cylinder bearing with a pin and a bolt. And
the top of the cylinder (ie the top of the piston rod) is connected with the beam on the outer door
frame. The right lifting cylinder is equipped with a governor valve.

Piston is fixed to the piston rod with a elastic steel wire. Oil seal and support ring are mounted
to the outer ring of piston.
A shut-off valve is mounted at the bottom of the cylinder, which serves as a protection device
if the high pressure pipe suddenly burst in case of lifting of the main frame.
Cylinder head is fitted with steel bearing and oil seal to support the piston rod and to protect
the cylinder from dust.

56
 Left lifting cylinder Right lifting cylinder
1.Dust proof ring 2.Shaft seal 3. Steel 1. O ring 5.
cover Steel-backed
bearing
6. Left cylinder body 7. Piston rod 8.Adjustment 9. O ring 10. Spring
sleeve
11. Stell wire washer 12.Spring 13. Piston 14.Supporting 15.Buffer
for hole base ring for hole valve core
16.Retainer ring 17.Hole seal 18. Check 19.Spring washer 20.Shut-off
valve for hole valve
21. O ring 22. 23. O ring 24.Cotter pin 25. Chain
Governor joint
valve
26.Nut 27. Chain 28. Chain
wheel
Figure 2-56 Lifting cylinder and chain
■Working status of the shut-off valve
A shut-off valve is mounted at the bottom of the lifting cylinder (see Figure 2-57). When the
high pressure hose suddenly bursts, it could avoid sharp decline of the goods. Oil from the lifting
cylinder will flow through the shuut-off valve and slide valve. The oil hole around the slide valve will
generate pressure difference between the two cavities. If this pressure is less than
the spring force, the slide valve does not move. For example, if high pressure hose bursts, forming
a large pressure difference, the slide valve will move to block the holes around so that only a small
amount of oil will flow through the small hole at the slide valve end to slowly decline the fork.

57
 Normal status Shut-off status
1.Lifting cylinder 2. Pressure spring 3. Valve core
Figure 2-57 Shut-off valve
8.5 Governor valve
The governor valve is installed within the right lifting cylinder to control the decline speed of
fork and to ensure safety in case of rupture at high pressure and other unexpected situations.
See Figure 2-58 for the connection method.

1.Lifting cylinder 2. Valve core 3. Pressure spring 4.Screw plug

Figure 2-58 Built-in governor valve
8.6 Tilting Oil Cylinder
The tilting oil cylinder is double acting, with its piston rod end connected to the main frame
through the earrings. Bottom of the tilting oil cylinder is connected with the frame by pins.
and there is a tilted cylinder at each side of the forklift.

The tilting cylinder is mainly composed by piston, piston rod, cylinder, cylinder bottom, guide
sleeve and seals. The piston and piston rod adopt welded structure, with the piston outer surface
mounted with a bearing outer ring and two Yx seal rings. In the internal hole of guide sleeve there
mounts an axle sleeve, Yx seal ring, retaining ring and dust ring. The shaft sleeve support the
piston rod, seals, retaining ring and dust ring that protects from oil spills and dust, all of which are
mounted to the cylinder together with the 0-ring. See Figure 2-59
When the tilt sliding valve is pushed forward, the high-pressure oil will flow from the cylinder
bottom to push the piston, moving the main frame titling forward. When the slide valve is pulled
backwards, the high-pressure oil will flow into from the front end of the cylinder to pull the piston
backward, moving the main frame titling backward.

1. Ear ring 2.Dust proof ring 3. Retaining ring 4.Yx seal ring 5. Bearing
6. O ring 7. Guide sleeve 8. Piston rod 9. Cylinder 10.Yx seal ring
barrel
11. Bearing 12.Yx seal ring 13. Piston

Figure 2-59 Tilting oil cylinder

58
 8.7 Hydraulic oil cylinder
The hydraulic cylinder is installed at right rear of the frame. Meshy filter is mounted to the
cylinder and breather is mounted to the cylinder cover. See Figure 2-60

1. Oil cylinder 2. Breather 3. Oil cylinder cover 4. Cover plate of oil cylinder
5. Sealing plate 6. Meshy filter 7. Bonded washer 8.Oil drain plug

Figure 2-60

59
 8.8 Hydraulic piping
See Figure 2-61 for the oil pipelines in the hydraulic system

Cover plate of oil cylinder

1. Front tilting oil tube 2. Rear tilting tube 3. Oil return hose for 4. Steering
multiple unit valve device-multiple unit valve
hose
5. Right-angle connector 6. O ring 7. Delivery connection of 8. O ring
multiple unit valve
9. Right-angle connector 10. Double steel 11. Oil release hose of 12. Oil returning tube of
wire clamp pump steering device
13. Steering cylinder 14. Joint of 15. O ring 16. Oil outlet joint of pump
hose steering cylinder
17. O ring 18. Gear pump 19. Fat washer 20. Spring washer
21. Bolt 22. O ring 23. Oil suction joint of 24. Oil suction hose of
pump cylinder
25. Double steel wire 26. Bolt 27. Oil return rear tube for 28. Steel tube
clamp multiple unit valve
29. Six-way valve 30. Spring washer 31. Screw 32.Delivery connection of
multiple unit valve
33. Delivery connection 34. Bonded 35. Six-way valve-multiple 36. Six-way valve-multiple
of multiple unit valve I washer unit valve hose I unit valve hose II
Figure 2-61 Hydraulic piping

60
 8.9 Maintenance and adjustment
Maintenance of working oil pump

(1) Disassembling
Clean it thoroughly before disassembling. Removed parts should be placed on a clean paper
or cloth. Be careful not to make the parts dirty or damaged.
(a) Place the pump flange at the clamp table.
(b) Remove the connecting bolt 11, rear end cover 5 and pump 1.
(c) Remove the liner plate 6, drive gear 2 and passive gear 3.
(d) Remove the seal ring 7 and retaining ring 8 from the front and back end cover.
Note: If you do not plan to replace the seal ring, do not remove it from the front end.
(2) Check
Check the disassembled parts and clean them with gasoline (except rubber parts).
(a) Pump check
If the contact length of pump cavity and gear is greater than 1/2 of the circumference, replace
the pump.

Figure 2-62 Figure 2-63

(b) Check of liner plate
Check the contact surface of the lining plate and replace it if the surface is damaged or if the
lining thickness is less than the specified value. Specified value of the lining thickness:
4.94mm.

Liner plate Groove

Oil inlet hole
Oil inlet side

Oil outlet Oil

discharge

Figure 2-64 Figure 2-65

(c) Check of the front and rear pump cover
If the inner surface of the bush discolours (turn brown) exceeding the range of 150 °, replace
it.
(d) Check of the driving and passive gears
Replace a pair of gears in case of excessive wear. If size of D is less than the specified value,
replace in pairs.

61
 12.7 12.7
(0.5) (0.5)

D
Figure 2-66
(e) If necessary, replace the seal rings, bushing seal, retaining ring, oil seal, spring ring.
(3) Assembly
(a) Mount a new seal ring and a new retainer ring at the front end cover of the pump.
(b) Mount the upper liner plate at the front end cover trench. Be careful not to mis-distinguish
the oil abortion hole and the oil discharge hole.
(c) Mount the drive and passive gears on the front end cover.
(d) Mount the liner plate on the gear side to align the groove to the gear points. Be careful
not to mis-distinguish oil suction side and oil discharge side.
(e) Mount a new seal ring and a new retainer ring on the groove at the rear-end cover. See
Figure 2-65
(f) Mount the rear cover on the pump body and pay attention to distinguish the oil abortion
hole and the oil discharge hole.
(g) When all the parts have been installed, tighten the connecting bolts to the specified
torque of 9 ~ 10kg.m.

1. Pump body 2. Driving gear 3. Passive gear 4. Front-end cover

5. Rear-end cover 6. Liner plate 7. Seal ring 8. Retainer ring
9. Oil seal 10. Flexible ring 11. Bolt 12. Washer
Figure 2-67 Gear pump

62
 (4) (4) Test run
Conduct running-in of the pump to check if it functions properly. Then perform oil pump testing
on the test bench or test by the following steps on the forklift truck:
(If oil pump is subject to decomposition and maintenance due to serious wear and jamming
caused by the hydraulic oil, the hydraulic oil and filter should be replaced before test-running on
the forklift.)
(a) Mount the pump onto the forklift and mount the pressure gauge onto the test hole of the
multiple unit valve.
(b) Loosen the adjusting screw of the overflow valve to keep the pump working for
5001000-1000rpm for about 10 minutes. Ensure that the oil pressure is lower than 10kg/cm ².
(c) Increase the pump speed to 1500-2000rpm and keep it running for about 10 minutes.
(d) Set the pump operating speed at 1500-2000rpm. Perform pressure increment of
20-30kg/cm ² and keep it running for 5 minutes after each increase, until the pressure reaches
175kg/cm ². Then keep each oil line working for 5 minutes and replace the oil returning filter.
When increasing the oil pressure, pay attention to the oil temperature, pump surface
temperature and the operation sound. If the oil temperature or the pump surface temperature rises
excessively, reduce the load to lower the oil temperature before further testing.
(e) After testing, set the overflow pressure at 175kg/cm ² and measure the flow traffic.
Determine the flow traffic by measuring lifting speed.

8.10 Failure analysis

If the hydraulic system fails, please find out the causes according to the table below and
conduct necessary repairs.
（1）Failure analysis of the multiple unit valve (Table 2-11)
Table 2-11
Fault Cause Countermeasures
Pressure of the lifting oil line Jamming of the slide valve Clean it after disassembling
can’t be increased Oil hole is blocked Clean it after disassembling
Vibration Jamming of the slide valve Clean it after disassembling
Pressure rise is slow Inadequate exhaust of air Full exhaust
Steering oil pressure is Jamming of the slide valve Clean it after disassembling
greater than the specified
value Oil hole is blocked Clean it after disassembling
Less than the required oil Overflow valve is not well
Adjustment
volume adjusted
Overflow valve is not well
Adjustment
With noise adjusted
Wear of sliding surface Replace the overflow valve
Aging or damage of the O
Leakage (external) Replace the O seal ring
seal ring
The spring is damaged Replace the spring
The set pressure is low Damage of valve seat Adjust or replace the
surface overflow valve
Damage of valve seat
Leakage (internal) Fix the seat surface
surface
The set pressure is high Jamming of the valve Clean it after disassembling

63
 （2）Failure Analysis of the oil pump（Table 2-12）
Table 2-12
Fault Cause Countermeasures
The oil level in the oil tank is Add oil to the specified
Low volume of oil discharge low value
The tube or filter is blocked Clean or replace as needed
●Liner plate damage
●Bearing damage
●Poorly functioned seal ring,
Replace
bushing seal or retaining
ring
Adjust the pressure of
Low pressure of the pump Overflow valve is not well overflow valve to the
adjusted specified value with a
pressure gauge
●Re-tighten the side tubing
There is air within the of the oil inlet
system ●Add oil
●Replace the oil pump seal
The inlet tube is damaged or Check the tube or repair oil
the filter is blocked filter
Looseness or leakage of the
Tighten the loosened parts
oil inlet
Replace the oil with
With noise when running viscosity compatible with
Excessive oil viscosity
the pump operating
temperature
Find out the cause of
Bubbles in the oil bubbles and take measures
accordingly
The pump seal or seal ring
Replace
The pump leaks oil is damaged
Pump is damaged Replace

9. Lifting system
9.1 Overview
Composed by the inner and outer main frames as well as the forklift frame, the lifting system
is a roller vertical elevating system with two levels.
9.2 Outer and inner main frames (Figure 2-68)

Inner and outer main frames are welded structures. The bottom of the outer main frame is
installed onto the drive axle by supporting parts.
The central part of the outer main frame is connected with the frame by the tilting cylinder and
can tilt forward and backward under the action of the tilting cylinder.

64
1. Inner main frame 2. Guide plate 3.Adjustment 4. Outer main 5. Flat roller of outer
pad frame frame
6. Pin roll of tilting cylinder 7. Spring washer 8. Bolt 9. Oil cup 10. Bearing bush
11. Bracket cover 12. Spring washer 13. Bolt 14. Roller

Figure 2-68 Inner and outer main frame

9.3 Forklift frame (Figure 2-69)

Forklift frame will roll within the inner main frame through the main roller, which is mounted
onto the main roller shaft and fixed by elastic rings. The main roller shaft is welded onto the fork
frame and the side roller is integrated into the adjustable composite roller that rolls along the wing
plate of the inner main frame. Use two fixed side rollers to roll along the outside of the wing plate in
the inner main frame to eliminate rolling gap. The longitudinal load will be born by the main roller.
When the fork rises to its highest level, the top roller will be exposed from the main frame top.
Lateral load will be born by the side roller.

65
1. Back-rest 2. Fat washer 3. Spring 4. Bolt 5. Roller
washer
6. Spring washer for shaft 7. Composite roller 8. Fork frame 9. Fork assembly
Figure 2-69 Fork frame

9.4 Roller position (Figure 2-70)

There are two types of rollers: outer frame composite roller, composite roller of inner frame
and fork frame. The two rollers are installed in the outer door frame, inner door frame and fork rack.
Composite roller consists of the main roller () and the side roller, with the former bearing loads
from the front and rear sides and the latter bearing loads from the side to achieve free movement
of the inner door frame and fork frame.

1. Fork frame 2. Outter main frame 3. Composite roller of outer frame

4. Inner main frame 5. Inner frame and composite roller of fork frame
Figure 2-70 Roller position

66
Note: (a) adjust the clearance of side rollers at 0.5mm;
(b) Apply lubricant oil onto the main roller surface and the contact surface of main frame.

9.5 Maintenance and adjustment

9.5.1 Regulating the lifting cylinder. See Figure 2-71
After disassembling or replacing the lifting cylinder, inner main frame or outer main frame,
re-adjust the lifting cylinder stroke. Adjustment method is as follows:
(1) Mount the piston rod without adjusting pad onto the beams of inner main frame.
(2) Slowly lift the main frame to its maximum extent of stretching and check the
synchronization of two cylinders.
(3) Add the adjustment pad between the piston rod head of the cylinder and the beam on the
inner main frame. Thickness of the pad is 0.2mm or 0.5mm.
(4) Adjust the tightness of the chain.

1. Upper beam on the inner main frame 2. Adjustment pad of lifting cylinder 3. Lifting cylinder
Figure 2-71 Regulation of the lifting cylinder

9.5.2 Height adjustment of the fork frame (Figure 2-72)

(1) Park the forklift on level ground and set the main frame vertical.
(2）Lower the fork bottom to make it reach the ground. Then adjust the adjusting nuts on the
upper end joint of the chains, so that there will be a certain distance A between main roller and the
lower end of the inner main frame
(A=24～29)。

Inner main frame Tires

Fork frame

Main roller
Fork

Figure 2-72
(3) Lower the fork to the ground and tilts it backward in place. Adjust the upper end joints of
the chain and then regulate the nut to set tightness of the two chains at the same degree.
9.5.3 Change or replace the roller of the fork frame

67
 (1) Place a tray on the forklift and park it on level ground.
(2) Lower the fork and tray down to the ground.
(3) Remove the upper end joint of the chain and remove the chain from the chain wheel.
(4) Lift the inner main frame ( ① in Figure 2-73)
(5) Reverse the forklift after confirming that the fork frame has been separated from the outer
main frame (② in Figure 2-73).
(6) Replace the main roller
(a) Remove all of spring rings and remove the main roller with drawing tools. Pay attention
to the adjustment pad.
(b) Confirm that the new roller is the same with the newly replaced one. Mount the new
rollers to the fork frame and fix it with an flexible washer.

Figure 2-73 Figure2-74

9.5.4 Replace the roller of main frame as shown in Figure 2-74
(1) Accoding to the method of replacing fork frame roller as described in 9.5.3, remove the
fork frame from the main frame. 9.5.3
(2) Drive the forklift to a level ground and jack up the front wheels for 250-300mm.
(3) Apply the hand brake and put pads under the rear wheels.
(4) Remove the lifting cylinder and the mounting bolts of inner main frame. Lift the inner main
frame and be careful not to loose the adjustment pad at head of the piston rod.
(5) Remove the connecting bolts on the lifting cylinder and at the bottom of the outer main
frame, and then remove the lifting cylinder and the tubing between the two cylinders without
loosening the pipe joints.
(6) Lower the inner main frame and remove the main roller at the bottom of the inner main
frame. The main roller at the upper end of the outer main frame will be exposed out of the inner
main frame top.
(7) Replace the main roller.
(a) Remove the main roller at the upper end with drawing tools and keep the adjustment
pads appropriately.
(b) Install the new roller and the adjustment pads removed at the (a) step.
(8) Lift the inner main frame until all the rollers enter the main frame.
(9) Mount the lifting cylinder and the fork frame in reverse procedures of removing.
9.6 Installation instruction of accessories

If you need to install accessories, please contact our sales department and never
install by yourselves.

10 Removal and installation

10.1 Precautions
(1) Only qualified operator can remove or repair the forklift's parts.

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 2) Before disassembling and detection operations, park the forklift on a flat ground and
wedge the wheels, otherwise accidental movement of the forklift may occur. Meanwhile, set the
main switch at the off position and disconnect the accumulator plug.
(3) Before disassembling and testing operations, remove all the rings, watches and other
metal objects on your body to avoid accidental short circuit.
(4) Please use the right tools for the disassembling process, and use the specified tools if
required.
(5) Please choose an appropriate spreader according to the size and weight of the removed
parts, so as to avoid danger.
(6) Be sure to mount sling steadily before lifting to prevent falling of the cargo. Please keep
the sling tightened during the lifting process.
(7) When removing a heavy part from the forklift, be careful to keep balance and to avoid
damage.
10.2 Lifting points of the detached parts Lifting Hole
(1) Lifting description of the lifting system as shown in Figure 2-75
Overall Dimension L×W×H Weight
Model
(mm) (kg)
FE4P18-25(AC) 1543×1100×1895 700
FE4P30-35(AC) 1558×1200×1935 730

Figure 2-75

Lifting Hole
(2) Lifting description of the overhead guard as shown in Figure 2-76

Model Overall Dimension L×W×H Weight (kg)

(mm)
FE4P18-25(AC) 1538×1048×1375 71
FE4P30-35(AC) 1713×1080×1375 76

Figure 2-76

Lifting ring
(3) Lifting description of the counterbalance as shown in Figure 2-77

The lifting ring on the counterbalance can be used to lift the balance weight
only. Do not use it for lifting the whole forklift.
Overall Dimension
Model Weight (kg)
L×W×H (mm)
FE4P18-20(AC)(AC2) 440×1128×935 885
FE4P25(AC) (AC2) 474×1128×935 1075
FE4P30(AC) (AC2) 504×1160×935 1100

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 FE4P35(AC) (AC2) 544×1160×935 1310

Figure2-77

(4) Lifting description of the accumulator as shown in Figure 2-78 Lifting Hole
Overall Dimension
Model Weight (kg)
L×W×H (mm)
975×466×780 980
FE4P18-25(AC)(AC2)
975×530×780 1070
FE4P30-35(AC)(AC2) 1028×690×780 1450

Figure 2-78

The accumulator also functions as a counterbalance, so users shall not arbitrarily

change it; otherwise the overall balance and other features may be affected。
(5) Lifting description of the travel motor as shown in Figure 2-79 Lifting Hole
(6)

Overall Dimension L×W×H Weight

Model
(mm) (kg)
FE4P18-25(AC) 455×325×φ270 106
FE4P30-35(AC) 470×350×φ300 120

Figure 2-79

Lifting Hole

(6) Lifting description of the working motor as shown in Figure 2-80

Overall Dimension L×W×H Weight

Model
(mm) (kg)
FE4P18-20(AC)(AC2) 324.5×245×φ242 47
FE4P25(AC) 324.5×245×φ242 50
FE4P30-35(AC) 349.5×245×φ242 56

Figure 2-80

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 Chapter 3 0peration, use and safety of the forklift
Ⅰ. Driving and operation
In order to ensure good performance, safety operation and economic use of the forklift, we
specify the precautions below that should be noted during proper driving operation.
1. The use of a new forklift

•All the package materials removed from a new forklift shall be recycled according to
local regulations.
• Test run should be carried out before using a new forklift to see if the forklift parts
can work properly (see Ⅰ. Check before operation on page 75).
The service life of your forklift depends on your initial operation. When using it in the first 200
hours, please pay great attention to the following issues:

• Heat engine operation shall be conducted before use no matter what season it is.
• Conduct maintenance in a timely and through manner.
• Never operate it violently or rudely。
2. The relationship between forklift stability and load
In the load curve, the front wheel centre of the forklift is taken as the fulcrum to keep the
forklift body and load on the fork balanced. Pay attention to load quantity and load centre when
driving to maintain stability of the forklift.

·In case the load exceeds the load curve, rear wheels may be lifted and subject to
extreme cases, and the forklift may rolling over, causing serious accidents. If goods are
stacked at a place close to the sharp tip of fork, the risks above also exist. In this case,
decrease the load weight.
3. Load centre and load curve
Load centre refers to the distance between the front surface of the fork and the cargo’s centre
of gravity. Load curve label indicating the relationship between the load centre and the allowed
loading quantity (allowable load) is attached to the forklift. Replace the plate in case of damage or
loss.
 ·If the forklift is equipped with accessories for cargo handling, such as the side shifter,
bucket, or rotating fork, the allowable load shall be less than standard forklift (without
accessories) for the following reasons:
1) Reduce loads equal to the weight of the accessories.
2) Since adding of accessory will move the load centre forward, the allowable load will
be reduced accordingly.
The installation of accessory will cause load centre shift forward, which is known as
the "loss of load centre.”
Do not exceed the allowable load indicated by the load curve attached to the forklift or
the accessory.
4. Forklift stability
4. Standard of forklift stability is specified in IS0 or other standards. However, the stability
described in these standards does not apply to all the running status and the stability of forklift
varies with different operational status.
The maximum stability can be ensured under the following operating status:

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 1) The ground is flat and solid.
2) Operate under standard no-load or load.
Standard no-load status: fork or carrying accessories are 30cm away from the ground and the
main frame can tilt backwards to the specified position without load.
Standard load status: fork or carrying accessories are 30cm away from the ground,
allowable load capacity is carried at the standard load centre and the main frame can tilt
backwards to the specified position.

 ·When loading and unloading goods, try to minimize the tilting degree when tilting
forwards and backwards. Never tilt forwards unless the load is close to or fixed by steel
shelves or the lifting height is low.
5. Transportation and handling of the forklift
(1) Forklift transportation

• When transporting with a truck, stabilize the wheels and fix the forklift with ropes so
that the forklift won’t slide within the truck.
• During handling and road transportation, the full length, full width and full height of
the forklift shall be in compliance with relevant laws and regulations.
(2) Loading and unloading of the forklift

• Use a slab with sufficient length, width and intensity.

• Pull the parking brake in an effective and efficient way to stop the wheels.
• The slab shall be stably fixed to the truck centre and there shall be no oil and grease
on the slab.
• The height at the left and right side of the slab shall be the same so that the forklift
can move smoothly during loading and unloading process.
• To avoid dangers, please do not change direction or move laterally when driving on
a slab.
• Slowly reverse the forklift to achieve simultaneous boarding of the left and right tires
when loading the forklift onto a truck.
6. Preparation before driving
(1) Check the position of the direction switch lever ⑤
Place the switch lever in the middle position (N).

(2) Turn on the key switch

Seize lever ball of the steering wheel, and then turn the key switch t

• Even if the key switch is turned to the "0N" position, it will take about 1 second for
lever ball of the steering Steering wheel
wheel
the brake circuit to start off after it starts action.
• If the gear lever is placed at forward "F" or
reverse "R" position before turning the key switch to
the "0N" position, please shift the lever to the middle
position "N".
• If the accelerator pedal is rapidly depressed,
it is likely that the forklift will accelerate suddely, be
sure to pay attention.

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 (3) Tilting backward of main frame
Pull back the lever to lift the fork to 150 -
200mm away from the ground and pull back the lever to tilt the main frame backward.
(4) Operation of the direction switch lever ⑤
Use the direction switch lever to decide the driving direction
(forward - backward).
Forward F: push the direction switch lever forward.
Backward F: push the direction switch lever backward.
(5) Release the parking brake lever;
Depress the brake pedal.
Fully release the parking brake lever forward, seize the steering
wheel with your left hand and place your right hand gently on the
steering wheel.
7. Driving
(1) Starting
Release the brake pedal and gradually depress
the accelerator pedal, and the forklift will start moving.
Change in acceleration depends on how much
the accelerator pedal has been depressed.

·Do not suddenly start or stop, otherwise the

goods loaded may fall down.
(2) Deceleration
Slowly release the foot pedal. Depress the brake pedal if necessary. If it is not for an
emergency brake, slowly release the accelerator pedal
to decelerate until the forklift stops. But even if the accelerator pedal is released rapidly,
emergency brake won’t be activated. Under emergency situations, please press the brake pedal
to perform emergency braking.

• Slow down in the following cases:

a) When turning at a crossing;
b) When moving close to the goods or tray;
c) When moving close to the goods;
d) When staying in a narrow channel;
e) When the ground / road condition is bad.
• During reversing operation, you must watch the rear side directly and ensure safety
through visual confirmation. Relying only on the rear view mirror may cause dangerous.

(3) Turning
Unlike common cars, forklift adopts rear-wheel steering. So operators shall slow down and
watch the rear side when turning.

• In the case of steering, the faster the forklift moves, the smaller turning radius will be,
and more easily the forklift will overturn. Please be quite careful.
(4) Simultaneous operation of driving and lifting (micro-operation)
a) First drive the forklift until the front end of fork is 3-5m away from the goods.
b) Fully depress the brake pedal. (Travel stop)
c) Depress the accelerator pedal to obtain the right operation speed.
d) Operate the lifting lever to start lifting operation.

·Simultaneous operation of driving and lifting

(micro-operation) require high level of skills. The
operator must correctly understand the form, gravity

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centre and other features of the goods and ensure stability of the forklift before carrying
out low-speed lifting and lowering operations. Be extremely careful when conducting
simultaneous operation.
·Tilting operation involves high risk. Never conduct other operations than extending
or retracting of the fork on a cargo platform.
• To eliminate the danger of lifting during driving, conduct lifting only when the forklift
is close to the cargo platform.

8. Parking and temporary parking

·Park safely
• The parking place should be spacious and the ground shall be flat.
• If you have to park the forklift without load on a ramp, the main frame side shall be
placed down-hilling and fix the wheels to avoid sliding.
• Please park the forklift in a safe place other than the operation site or designated
parking places.
• When necessary pay attention to the sign and signal lights.
• Park on solid ground and try to avoid sliding and falling.
• If the fork can be lowered due to failures of the forklift, rap a cloth around the fork tip
and adjust it to face the direction where no people and vehicles will pass.
• Pay great attention to road conditions to see if it is slippery or have any collapse.
• Lower the fork after the forklift completely stops. Reducing the fork of the forklift
during driving could be quite dangerous.
• Do not jump from the forklift.
• When getting off, you shall face the direction of the forklift and step on the pedal for
de-boarding.
• For deceleration, depresses the brake pedal
to stop the forklift, and set the gear lever switch to
neutral position "N".
• Park the forklift in a place that would not
hinder operation of other vehicles according to the
following procedures.
a) Pull the parking brake lever to the specified
place to activate the parking brake.
b) Lower the fork until it reach the ground.
c) Turn the key switch to the "0FF" position.
d) Remove the key and keep it safe.
e) Be careful when boarding and de-boarding.
f) Park the forklift

·When leaving the forklift, fully pull the parking brake lever to slightly tilt forward the
main frame. Lower your fork to the ground. When parking the forklift on a ramp, place pads
under the wheels.
• Remove the keys when leaving the forklift.

9. Use of the accumulator

(1) Charging of the accumulator
Choose appropriate charger for charging of the accumulator and operate in strict accordance
with the "Maintenance Manual" of the charger.
a) Don’t maintain the electrolyte at a too low level.

• Maintain the electrolyte at the required level, otherwise the accumulator may be
overheated or burned.

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 • When the electrolyte level is low, the accumulator life will be shortened.
b) Add distilled water
c) Overcharge is not allowed
d) Charging should be carried out in a well ventilated place

• Charging should be carried out in a well ventilated and moisture proof place.
b) Open the accumulator cover.

• Hydrogen will be generated during the charging process. Open the accumulator
cover during charging.
f) Check the connecting terminal, cables and connectors.

• Users should check the connectors and cable lines for damage before charging.
·Never conduct charging in case of the following conditions:
- The connector electrode is damaged.
- Connection terminals and cable lines are corroded.
These conditions can result in sparks, burning, fire or explosion。
g) Conduct charging after the key switch is turned off
h) Check the specific gravity
Measure the specific gravity of electrolyte in all the single-cell accumulator before charging to
identify abnormality of the accumulator. Understanding the specific gravity before charging could help
eliminate the possibility of accidents.
i) When connecting and disconnecting the power connector, hold the plug or handle instead
of holding the cable.

• Do not pull out the cable.

• If the cable and power connectors are damaged, please contact our sales
department and replace the damaged cables and power connectors.
j) Disconnecting the charging

·Disconnect the charging in strict accordance with steps required by the

"Maintenance Manual" of the charger.
• Do not pull out the charger plug during charging, or else danger may be caused by
sparks.
(2) Replace the accumulator
If the accumulator on the forklift completely runs out of power, another fully charged
accumulator should be timely used to replace the original one. Then recharge the original
accumulator.

·Before replacing the accumulator, ensure the new accumulator match the forklift. If a
accumulator doesn’t match with the forklift used, working hours of the forklift will shorten or
may cause rolling of the forklift.
·Replacement of the accumulator should be carried out on a platform 。
Follow these steps to replace the accumulator:

• When using another forklift to lift the accumulator to be replaced, appropriate

spreader (accessory) should be used.
• Only experienced operators could lift the accumulator.
a) Disconnect the accumulator plug.
b) Open the accumulator top cover.
Take advantage of gas spring or other means to ensure that the accumulator top cover is locked,
because its faliing may cause physical injury or damage to the forklift.
c) When lifting the accumulator out of the forklift, be careful not to damage the steering wheel
or other forklift parts.
d) After a group of fully charged accumulator is well placed, securely connect the

75
 accumulator plug.
e) Cap the accumulator cover.

·When fitting on the accumulator cover, be

careful not to hurt your fingers.
• Be careful to keep it stable when lifting the
accumulator, so as not to cause collision damage to
the forklift body.
10. Stacking

• Check the following items prior to operation

of forklift:
a) Ensure the goods in the loading area will
not fall and be damaged.
b) Ensure that no obstruction for the goods or cargo in the way .
Conduct stacking according to the following procedures:
(1) Slow down when driving close to the stacking area.
(2) Park before the stacking area.
(3) Check the safety status around the stack area.
(4) Adjust the forklift position to place it in front of the
stacking area.
(5) The main frame shall be perpendicular to the ground and
the lifting fork shall be higher than the stacking height.
(6) Check the stacking position and driving forward to park in
the right place.
(7) Ensure that the goods is right above the stacking position,
and slowly lower the fork to put the goods in place.

·When the goods are not fully placed on the shelf or

bracket：
a) Lower the fork until it no longer carry any weight.
b) Reverse the forklift for 1 / 4 of the fork length.
c) Lift the fork for 50-100mm, move the forklift
forward and stack the goods in the right position.
(8) Observe the rear space of the forklift and reverse
the forklift to avoid collision of the fork with the pallet or cargo.
(9) After confirming that the front end of fork left the goods
or the pallet, lower the fork to facilitate moving. (l50-200mm
away from the ground )

11. Un-stacking
Conduct un-stacking according to the following procedures:
(1) Slow down when close to the goods to be handled.
(2) Park in front of the goods (distance between the goods
and fork tip is 30cm).
(3) Adjust forklift position in front of the goods.
(4) Ensure to avoid overloading.
(5) The main frame shall be perpendicular to the ground.
(6) Observe the fork position and move forward the forklift until
the fork is fully inserted into the pallet.

·When the fork can't be fully inserted into the pallet：

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 a) Insert 3 / 4 of the fork length and lift the pallet a little (for 50-100mm), then pull out
the pallet for about 100-200mm, and lower the pallet.
b) Fully insert the fork into the pallet.
(7) After inserting the fork into the pallet, lift the pallet (for
50-100mm)
(8) Observe the space around and drive the forklift
backwards until the goods have been lowered.
(9) Reduce the goods to 150-200mm away from the
ground.
(10) Tilt the main frame backward to ensure stability of the
goods.
(11) Handle the goods to the destination

12. Storage
(1) Before storage
Prior to storage, thoroughly clean the forklift and
conduct inspection according to the following procedure:
a) If needed, clean oil and grease attached to the
forklift body with a cloth and water.
b) When cleaning the forklift body, check the overall
condition of the forklift. In particular, check if there are dents
or damage on the forklift body and if the tires are worn out or
embedded with nails or stones.
c) Check for oil leakage.
d) Add lubrication grease if necessary.
e) Check if the wheel hub nuts and joints of the cylinder piston rod is loose, and if the rod
surface have bumps or pull marks.
f) Check if rollers of the main frame could rotate smoothly.
g) Raise the lifting cylinder to the highest level to make the cylinder full of oil.
·If you found that the forklift is in need of repair, or it fails or is unsafe, report to the
management staff and stop using it until it returns to safe state.
(2)Daily storage
a) Park the forklift in designated areas and use wedge pads to fix the wheels.
b) Place the shift lever in neutral position and pull the parking brake lever.
c) Remove the key and keep in a safe place.
(3) Long-term storage
Conduct the following maintenance and inspection based on "daily storage" maintenance:
a) Park the forklift on a high and solid ground to protect it from flood in rain seasons.
b) Remove the accumulator from the forklift. In humid environment, store the accumulator in
a dry and cool place and charge it monthly even if the forklift is parked indoor.
c) Apply rust-proof oil on exposed parts such as cylinder piston rod and shafts that may get
rusty.
d) Cover parts from moisure
e) Start the forklift at least once a week. Mount the accumulator, remove the oil and grease
on the piston rod and the axis, start the engine and fully warm up, slowly drive the forklift forwards
and backwards, and manipulate hydraulic controller for several times.
f) Don’t park the forklift on soft ground such as those paved with asphalt in summer.
(4) Operation of the forklift after long-term storage
a) Remove the moisture-proof covering.
b) Remove anti-rust oil on the exposed parts.
c) Remove foreign bodies and water in the hydraulic tank.
d) Mount the charged accumulator onto the forklift and connect the accumulator plugs.
e) Conduct pre-start check carefully .

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 Ⅱ. Operation device and use method
1. Diagram on forklift parts and operation device (see below)

1. Overhead guard 2. Rear view 3. Instrumentation 4. Rear grouped 5. Warning lamp

lamps
6. Seat 7. Accumulator 8. Right guard 9. Counterweight 10. Controller
case cover plate cover plate
11. Traction bolt 12. Rear tires 13.Left guard 14.Multiple unit 15.Accelerator
plate valve lever pedal
16.Foot brake pedal 17.Steering wheel 18.Combination 19.Hand brake 20.Front tires
switch
21. Tilting oil 22. Fork frame 23. Back-rest 24. Fork 25. Lifting
cylinder cylinder
26. Main frame 27. Steering lamp 28. Front 29. Chain
headlight assembly

2. Combination instrument
See4.3 Combination instrument (Page 28 ), See5.3 Combination instrument (Page 34 )
See6.3 Combination instrument (Page 40 )

3. Switch parts
(1) Emergency stop switch
In the event of an emergency, press the red
mushroom-shaped button to cut off the control power of the
Key
forklift, disabling the walking, turning and lifting operation of the switch
forklift. Rotate the button as indicated by the arrow above the
button to restore operation.
(2) Key switch Emergency
stop switch

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 Key switch can be turned on or off for power control
0FF : The switch is off at this position and keys can be inserted and pulled out.
0N: The switch can be connected and the forklift will start if you rotate forward from the OFF
position.

• Do not step on the accelerator pedal when turning on the key switch.
• When you leave the forklift, take out the keys to protect it from being misused.
• After parking the forklift or when recharging, take out the keys to protect it from
being misused.
(3) Combination switch
Combination switch is combined by the direction switch, steering lamp switch as well as the
switchs of small and big lamps.

1-Direction switch 2 – Steering lamp switch 3 - Switch of small and big lamps
Direction switch controls the direction the forklift and would convey the signal to the
instrument for display. Push the lever to move forwards and pull back it to move backwards. The
middle position is the neutral position. When the lever is pulled back for reverse purpose, the
reversing lamp and warning lamp will light up and the reversing buzzer sounds.
Steering lamp switch will specify the turning direction. When the switch lever is turned to the
steering position, the turning lamp flashes.

Push The left steering

forward lamp blinks
Middle Neutral position
Pull The right steering
backwards lamp blinks

The switch of small and big lamp controls the lighting and extinguishing of the lamps. The
switch has two gears: the small lamp lights up when rotating to the first gear and the small and big
lamps light up together when rotating to the second gear.
Gear First Second
OFF
Lamp gear gear
Width lamp × ○ ○
Tail lamp × ○ ○
Headlamp × × ○
○:lights ON ×:lights OFF
(4)Rear headlight switch
Rear lamp switch is a single gear switch that controls the lighting and extinguishing of the rear
lamp. Pull the switch to light the lamp and push it to distinguish the lamp.
4. Control parts
(1) steering wheel ① and lever ball② of the steering wheel
The steering wheel can be operated in usual way, namely, when rotating the steering wheel

79
rightwards, the forklift will turn right; Vice versa. Steering wheel is mounted at the rear side of the
forklift, enabling the forklift rear part to swing out during turning.
During turning, grasp the lever ball of steering wheel with your left hand while place the right
hand on control lever of the multiple unit valve or steering wheel.
Hydraulic steering system and tilt device of the steering wheel are standard equipments on the
forklift.

• Adjust the steering wheel to the best angle according to the driver's position.
• After adjusting the tilt steering wheel, lock steering column with star-shaped
lever③ .

(2) Horn button ④

Press the rubber cover in the centre of the steering wheel to make a buzzing sound. The horn
can sound even when the key switch is closed.

(3) Direction switch lever ⑤

Indicating the direction of travel.
Moving forward (F): push forward the lever and depress the accelerator pedal.
Moving backward (B): pull back the lever and depress the accelerator pedal.
When parking the forklift, place the direction switch lever in the neutral position (N).

80
 (4) Parking brake lever ⑥
To prevent moving of the forklift, fully pull back parking brake lever when parking the forklift.
Push forward the parking brake lever to its maximum level before driving.

• When operating the parking brake lever, depress the brake pedal.

(5) brake pedal ⑦ and accelerator pedal ⑧

• Do not slam on the accelerator pedal, otherwise the forklift will suddenly start or
accelerate.
•Before depressing brake pedal, make sure to remove the foot from the accelerator
pedal.
From left to right, respectively, the brake pedal⑦ and accelerator pedal⑧.
Depresses the accelerator pedal slowly and the speed of forklift depends on how much the
accelerating pedal has been depressed.

(6) Lifting lever ⑨

Pull back the fork lever to lift the fork and push forward the fork lever to lower the fork. Lifting and
lowering speed can be controlled by the tilting angle of the lever . The greater the angle is, the greater
the speed will be.

• If you push or pull the lever when turning on the key

switch, the fork will not lift.
• Do not suddenly reduce the fork or suddenly stop
lowering the fork.
(7) Tilt lever ⑩
The main frame will tilt backward when pulling the tilt lever
backward and tilt forward when push the lever forward. Speed of
titling forward and backward can be controlled by the tilting angle of
the lever . The greater the angle is, the greater the speed will be.

81
 • If you push or pull the lever when turning on the key switch, the fork will not tilt.
5. Forklift body
(1) Seat
By adjusting the lever , the operator can tune the seat position for greater comfort.
Pull the lever upwards to activate the adjustment function. After completing adjustment, try
to move the seat back and forth gently to confirm if the seat has been locked.
Adjustment range of seat position is within 120mm. When driving on dry concrete ground, the
seat will exert a vertical acceleration on the driver at the speed of 2.130m/s-2.237m/s and the
integrated acceleration is 2.252m/s-2.356m/s.

(2) Overhead guard

·Overhead guard is a import component that prevent falling of objects overhead and
protect the operator’s safety. The size of a opening in overhead guard is more than 150mm.
If the cargo size is less than 150×150mm, additional protective measures must be adopted
to prevent accident falling of the cargo. Unsteady installation, removal or transformation
before use are all dangerous actions that may lead to major
accidents.
(3) Back-rest

·Back-rest is an import security component that

prevents falling down of cargo on the fork to the operator.
Unsteady installation, removal or transformation before use
are all dangerous actions.
(4) Traction Pin
Traction pin is only applicable to the following occasions:
• When the forklift can not move (such as tires sank into a
side ditch, etc.);
• When the forklift is to be loaded or unloaded from a truck.

• Never use it for towing or towed operation.

(5) Locating pin of the fork
The locating pin can lock the fork in a certain position. To adjust the fork spacing, pull up the
location pin and turn it for l/4 cycle. Then, adjust the fork to the required position. Fork spacing
should be adjusted based on the goods to be loaded.

·Based on the principle that gravity center of goods shall be consistent that of the
fork, operators shall adjust the spacing until the spacing to left side and to the right side
are the same. After adjusting, fix the fork with the location pin to make it immovable.
·When adjusting the fork spacing, lean your body against the back-rest. Stand still and

82
push the fork with your feet. Never adjust spacing by hands.
(6) Foot pedal and handrail
The foot pedal is located at left side of the forklift and the
handrail
handrail is on the left front strut of the overhead guard. Use the
pedal and handrail when on-boarding and de-boarding the
forklift to ensure safety.
(7) Lighting
The front of the forklift is equipped with front headlights and
front combination lights (steering lamp, parking light, width light).
The rear of the forklift is equipped with combination lamps which
include taillight, steer lamp, brake light, parking light, reverse
light and flasher. foot pedal

• Check the working conditions of lights, if the lamps

are burned, damaged or dirty, replace or repaired immediately.
(8) Rear view
Rear view is installed at the right side of the front beam on the overhead guard.

• Keep rear view surface clean.

• The rear view can be adjusted to a position allowing complete rear view.
(9) Accumulator plug
Accumulator plug is used to connect or disconnect the accumulator and forklift’s electrical
components. Generally connection operation is more common。

• If you have to touch the internal electrical components, disconnect the accumulator
plug first to prevent danger.
• Voltage still exist in the main circuit even if the key switch at the "0FF" position. If
you want to cut off the main power, please pull the plug.
• If the accumulator plug is disconnected during driving process, steering will be
disabled. So never unplug the accumulator unless circumstance requires.

Ⅲ. About safety
Ensure safety is your business and responsibility. This section describes the basic safety
regulations and warnings during use of the forklift, but also applicable to forklifts with special
specifications and with the main frame and accessories.
1. Site and working environment of the forklift
(1) Ground conditions
The forklift should used on solid ground in well-ventilated environment.
Forklift performance depends on the road condition. Rear view
Running speed should be adjusted to an appropriate level. Headlamp
Be especially careful when driving on ramps or rough
roads. When driving on ramps or rough roads, the forklift
will speed up, increasing tire wear and the noise. Front
grouped
(2) Working environment lamps Rear grouped lamps
Ambient temperature for use of the forklift should be
within -20 °C ~ 40 °C and the ambient humidity shall be
Warning lamp
less than 80%.
(3) Weather conditions
In days of fog, rain, snow and strong winds, pre-assess
the safety of using the forklift. It’s better not to use it for
outdoor operations. If it is must be done, be extremely
cautious during driving and operation.

83
2.Safety rules

Safety Helmet

Safety glasses
Earmuff

Only trained personnel who owns

a driving license of forklift
could operate it!

Driving on highways are prohibited! Drivers shall wear working clothes before driving!

Alert: seek medical aid in case of injuries!

84
Don’t change forklift parts without permission! Please read the instructions before operating the
forklift!

Turn off the engine before maintenance! Understand the traffic rules!

Check the forklift before use! Do not move the overhead guard!

85
keep the cab clean! Do not drive an unsafe forklift!

The driver should be healthy! Make sure that your forklift is safe!

Work within the permitted scope! Do not drive damaged forklift!

Hold the handrail during on-boarding Start the forklift in a correct way!

86
 Adjust the seat before driving! Make sure that your forklift is under safe
working condition

Appropriately fasten the seat belt! Always pay attention to the height of the working
area of forklift!

Turn on the lights in dark areas! Do not expose your arm and body outside the
overhead guard!

Avoid driving on soft or unprepared ground . Keep the body under the overhead guard!
Drive on flat and solid surface!

87
 Avoid eccentric loading! Pay attention to keep the projecting fork clear
from goods ahead!

Check the position of the location pin! Check the safety of working areas!

Don’t drive on smooth or slippery ground! Ensure the lateral driving stability when the
forklift is running without load!

Be especially careful when handling Carrying passengers is absolutely

goods with relatively large length or width! prohibited!

88
During turning, please slow down and Use the appropriate pallets or sleeper
blow horns if you can’t see the roads clearly! when handling small objects!

Do not chase each other driving across the road! No one shall stand on the goods!

Looking around is not allowed while driving! Do not do stunt with the forklift!

If the loaded cargo is too high and blocks Obey the traffic rules and all warnings and signs!
your eyesight, drive reversely.
or under the guidance of other people!

89
When carrying load, move uphill facing the ramp During up-hilling process, pay attention to
and move down-hilling by driving in reverse! steep ramp and the lifting height of the
goods!

When carrying no load, move uphill by Perform braking when starting on the ramp!
driving in reverse the ramp and move
downhill facing the ramp!

Turning on the slope is not allowed! Blow the horn when there are people walking ahead!

Avoid collision with people or objects Keep clear of other persons during working
during turning! of the forklift!

90
High speed during turning will cause Pedestrians are forbidden within
workingoverturning due to unstable centre of gravity! area of the forklift!

Changes in the rated capacity of the forklift Always pay attention to the areas around
should be noted! when driving the forklift!

Please use the fork for loading! Slow down when loading!

Please do not move the forklift when there are No one shall walk or stand below the
people standing in front of it! elevated fork!

91
Never load cargo with a height higher than the For goods difficult to fixed, bundle them
back-rest! before loading!

Goods have not been loaded from the forklift Do not carry damaged goods cases by
shall not be handled! your shoulders!

Abuse of the fork is not allowed! Be careful when loading the goods onto
cars!

Never carry people! Do not abuse the forklift!

92
 Do not stretch any part of the body out of the Drive smoothly. Sudden acceleration and
forklift! slow down is not allowed!

Special safety equipment shall be used when Do not overload!

carry out manned operation

Lifting is not allowed when it is too windy! Operating in an explosive environment is

not allowed!

Damaged forklifts need to be placed in When not in use, the forklift shall be
designated areas! parked in designated areas!

93
 It is prohibited to park the forklift on a slope!

When you do not use the forklift:

—Brake
—Place the direction lever at the netural position
—Lower the fork to the ground.
— Tilt the main frame forward
— Remove the key

3. Transportation of the forklift

Lifting from the forklift top is prohibited! Lifting from the forklift frame is
prohibited!

94
 Lift the forklift correctly when handling goods!

Lift the forklift

·Fasten the steel wire to the holes at the two ends of the outer frame beam and to the
counterweight hook, and then hoist the fork by using the lifting equipment. And the steel wire
connected to counterweight shall pass through overhead guard notch and shall not exert force on
the overhead guard.

• When lifting the forklift, be sure the steel wire is not twisted around the overhead
guard.
• The steel wire and lifting devices shall be firm enough to support the forklift safely,
because the forklift is extremely heavy.
• Do not use the cab frame (overhead guard) to lift the forklift.
• When lifting the forklift, do not stay underneath the forklift.
4. How to avoid rollover and protect yourself

To avoid tipping, tilting forward to lift the load Tilted loading of the goods is
is forbidden! prohibited!

Eccentric loading of the goods is prohibited! Avoid driving on slippery surface!

95
Do not load or unload if the forklift is not on a Do not drive over trenches, other obstacles that
level ground! cause tipping!

During driving, the distance between fork and Avoid fast and wide turning no matter
the ground shall be within 150mm to 200mm! carrying load or not!

When the empty fork is lifting, please turn Be sure to fasten your seat belts!
within a narrow range to avoid tipping!

In the event of forklift tipping, please do not Please wear a helmet while driving!
jump!

96
 In case of tipping, it is safer when you stayed in the forklift with seat belt than jumping
out of the forklift. If the forklift begins to tip:
1. Step on the brake pedal and clench the steering wheel tightly.
2. Do not jump.
3. Bend your body to the opposite direction of tipping.
4. Tilt your body forward。
5. Safety issues during maintenance and protection
(1) Maintenance location

• The premise should be designated places that can provide enough equipment and
security facilities to the service organization.
• The site should be level ground.
• The site should be well ventilated.
• The site should have fire-fighting equipment.
2) Precautions before maintenance

• No smoking.
• Wear all kinds of protective equipments (helmets, shoes, glasses, gloves and boots)
and appropriate clothing.
• Timely and wipe out overflowed oil.
• Use a brush or cloth or clean dust or dirty oil before adding lubrication oil.
• Turn off the key switch and pull out the accumulator plug except for some certain
cases.
• Lower the fork to the ground before carrying out maintenance of forklift.
• Use compressed air to clean electrical components.

(3) Precautions on care and maintenance

• Take care not to put feet below the fork and not to be tripped by the fork.
• When upgrading the fork, use pads or other things as cushion below the main
frame to avoid sudden drop of the fork and main frame.
• Take care to open and close the front chassis and accumulator cover
plate, so as not to pinch fingers.
• When your job can’t be completed within a day, make a mark to
continue work next time.
• Use right tools and never use makeshift tools.
• Because of the high pressure of hydraulic circuit, never carry out
maintenance work before the internal pressure of oil circuit is reduced.
• When injured by high-voltage electricity, immediately seek medical
treatment.
• Do not use the main frame assembly as a ladder.
• Do not put your hands, feet and body between the forklift frame and the main frame
assembly.
(4) Inspection and replacement of tires

• Removal and installation of tires must be operated by professionals.

• Handling of high-pressure air shall be done by professionals
• Wear a goggle when using compressed air.
• During disassembling of tires, do not loose bolts and nuts at rim connection. As
there is high-pressure gas within the tires, looseness of bolts, nuts and rims could cause
danger.
• Before removing bolts and nuts at the rim connection, you must first exhaust the
high pressure gas within the tires with special tools.

97
 (5) Use of jack (replace the tires)

• When jacking up the forklift, do not keep any part of your body below the forklift.
• When jacking up the forklift, ensure that there are no one and no load in the forklift.
• When the forklift wheels are lifted off the ground, stop use the jack and place pads
below the forklift to protect it from falling down.
• Take measures to prevent the forklift from sliding before jacking up the forklift.
(6) Requirements on waste discharge (electrolyte liquid, oil, etc.)

·Waste parts on the forklift (plastic parts, electrical components, etc.) and waste liquid
(hydraulic oil, brake fluid, etc.) should be recycled according to the local regulations rather
than discharged。

6. Safety during accumulator use

(1) No smoking

·The accumulator can produce hydrogen. Spark will generate in case of short-circuit
and lit cigarette near the accumulator may cause explosion and fire.

(2) Prevent electric shock

• The accumulator has high voltage, so when you perform installation and maintenance,
do not touch the accumulator conductor, which can cause serious burns.
(3) Correct connection

• When the accumulator is charging, ensure the positive and negative poles are not
reversed, otherwise heat, fire, smoke or explosion may be caused.
(4) Never place metal objects on the accumulator

• Avoid reversed installing of the positive and negative bolts or tools, which may lead to
short-circuit occurs, causing injury and explosion.
(5) Avoid excessive discharge

· Do not keep using the forklift until it can not move, otherwise the accumulator life will be
shortened. If the accumulator capacity alarm indicator flashes continuously, it means that the
accumulator needs to be recharged.
(6) Keep clean

• Keep cleanness of accumulator surface

·Do not use a dry cloth or chemical fiber cloth to clean the accumulator surface. Do
not use polyethylene film to cover the battery.
• Static electricity can cause an explosion.
• Clean the uncovered parts at the top of the accumulator with a damp cloth.
(7) Wear protective clothing

• During maintenance of the battery, you should wear goggles, rubber gloves and
rubber boots.

98
 (8) Accumulator electrolyte could be harmful

• Accumulator electrolyte is made of dilute sulphuric acid. Be careful when handling.

• When the electrolyte adheres to skin and clothing or touch your eyes, it will result in
vision loss or serious burning.
(9) Emergency treatment

When an accident occurs, perform following emergency treatment and contact a

doctor immediately.
• spilled on skin: rinse with water for 10-15 minutes.
• spilled in eyes: rinse with water for 10-15 minutes.
• contamination in large area: use soda (sodium bicarbonate) or clean with water.
• Ingestion: Drink plenty of water or milk.
• spilled on clothing: immediately take off the clothes.
(10) Put on the accumulator top cover

• Put on accumulator top cover tightly to prevent electrolyte leakage.

• Do not add too much electrolyte, otherwise the electrolyte will overflow and cause
current leakage.
(11) Waterproof

• The accumulator can not be wet by rain or sea water, otherwise the accumulator will
be damaged, causing fire.
(12) Abnormality of accumulator

When the following problems occur to the battery, please contact our sales
department:
• Accumulator stinks.
• The electrolyte gets dirty.
• The electrolyte temperature gets higher.
• The electrolyte volumes reduce quicker than normal .
(13) Prohibiting disassembling

• Do not drain the electrolyte from the battery

• Do not disassemble the battery.
• Do not repair the battery.
(14) Storage

• When the accumulator is to be unused for a long time, it should be stored in

well-ventilated places with low possibility of fire.
(15) Disposal of waste battery

• Contact our sales department for disposal of waste battery.

99
7. Lables
Labels posted on the forklift are used to illustrate the use and precautions of it. They are
for the benefits of both you and the forklift. Immediately re-paste the labels if they fall off.

1、Nameplate 2、curve of load

3、Side shifter notice 4、reading the Operation & Maintenance Manual
5、No carrying people 6、Suspension point
7、Prohibit suspension poin 8、Watch Your Hands
9、Tyre pressure 10、Corporate logo
11、Strong point 12、hydraulic oil
13、Product Model 14、safety belt
15、No climbing 16、Warning labels

100
 Chapter IV Periodic inspection and maintenance

Conduct a comprehensive inspection of forklift to avoid failure and to extend its service life.
Service hours indicated in the Maintenance Procedures is based on the assumption that the forklift
works 8 hours a day and works 200 hours a month. In order to ensure safe operation, maintain the
forklift regularly according to the maintenance procedures.
Routine maintenance and repair work shall be carried out by the forklift driver and other
inspection and maintenance work shall be done by professional maintenance personnel.
Ⅰ. Check before operation
In order to ensure safe operation and to keep the forklift in good condition, please undertake
the statutory duty to conduct a comprehensive inspection of the forklift before operation. If any
problems are found, please contact the sales department of our company.

• A small fault will cause a major accident. Don’t operate or move the forklift before
the completion of repair and inspection work.
• Conduct checking the forklift on a platform.
• Before checking the electrical system of the forklift, turn the key switch off and
unplug the accumulator before check.
• Improper handling of waste oil (such as dumping into water pipes, soil, or burning
them) will cause pollution to the water, soil and air, thus are strictly prohibited.
1. Check points and contents
No. Check points Check contents
Travel distance and braking force of the
1 Brake pedal
foot brake pedal
Braking
2 Brake oil Quantity and cleanliness
system
Travel distance and braking force of the
3 Parking brake
parking brake lever
Manipulation of steering Tightness, rotation, forward and backward
4
Steering wheel movement
system Manipulation of
5 The operation of all components
hydraulic steering
6 Features Function, cracks and lubrication status
Hydraulic
7 Pipeline If the oil pipeline leaks
system
and main 8 Hydraulic Oil Appropriate oil volume
frame Tightness of the left and right chains
9 Lifting chain
should be the same
Pressure size and if there is any damage
10 Tires
Wheels or abnormality
11 Rim nut Firmly tighten it
Check the display status of accumulator
Accumulator 12 Charging capacity, the specific gravity and firm
connection of the plugs
Headlights, tail lamps,
Switch on and off the lamps to see if they
reversing lamp, steering
Lights, horn can light up. Press the horn button to see
13 lamps, horn and
and switches if the horn could sound and check if the
emergency power off
emergency power off switch is normal.
switch
Inspection
When the key switch is turned on, it
and 14 Features
should display "normal test state"
displaying

101
 lamps
Overhead guard,
15 If the bolts and nuts are tightened
backrest
Others 16 Nameplate and labels Completeness
16 Other parts If there is abnormality

2. Check the procedure

(1) Check the foot brake pedal ⑦
Check the braking status. Ensure that if the brake pedal is fully depressed, the travel distance
of the brake pedal
should be more than 50mm, and the braking distance of no-load forklift shall be about 2.5m.

(2) Check brake fluid

• Open the oil cup cover and check the quantity of brake oil and other conditions.

Brake oil cup cover

Brake oil cup

(3) Check the parking brake lever

Push forward the parking brake lever and check the following items:
• If the pull distance is appropriate.
• Degree of braking force.
• If the parts are injured .
If the operator find the manipulation force of the lever(standard force is 17-22kg ) approprate.
Operators can adjust the screw at the top of the lever.

Parking brake lever

102
 (4) Check the rotation of the steering wheel
Gently rotate the steering wheel clockwise and counterclockwise to check if rebound occurs.
The suitable travel length for rebound
shall be 50-100mm. The travel length of steering wheel when moving forwards and backwards are
about 7°.If the actual travel length falls within the scope, rotation of the steering wheel can be
deemed as Normal.

Rebound stroke
50—100mm

(5) Check the power steering feature

Rotate the steering wheel clockwise and counter-clockwise, and check the working condition
of the power steering.
(6) Check the hydraulic system and the function of main frame
Check if the operations of lifting, tilting forward and ackward are normal and smooth.

(7) Check the oil pipe

Check the lifting cylinder, tilting cylinder and all the piping for oil leakage.

(8) Check hydraulic oil

Lower the fork to the ground and check the oil level of hydraulic oil with a gauge. If the oil
level is within the range of H to L, the hydraulic oil volume is appropriate.

Model H L rebound travel

FE4P18-35(AC)(AC2) 40L 33L hydraulic oil Box

103
 (9) Check the lifting chain
Lift the fork to 200-300mm away from the ground and
ensure that the tightness of left and right chains are the
same. Check whether the finger lever is in the neutral Lifting chain
position. Adjust the chain joints in case of difference in
tightness. Chain joint

Double-nut
Cotter pin

• Double-nut should be tightened after this adjustment, .

(10) Check the tires (inflated tires)
Unplug the gas nozzle cap and measure the tire pressure with a tire barometer. After
checking the pressure, make sure no gas leakage will occur before fitting the cap of gas nozzle.

• Tire pressure of forklift is higher than that of the tires. And all theses air pressures
should not exceed the specified value.
FE4P18-25(AC)(AC2) FE4P30-35(AC)(AC2)
Air
Air
pressure
Model pressure Model
of the
of the tires
tires
Front
7.00-12-12PR 0.85 28×9-15-12PR 0.83
Rollers
Rear
18×7-8-14PR 0.90 18×7-8-14PR 0.90
wheel

Check the tires (solid tire)

Check tires and the side surfaces for damage or cracking, and then check the wheel rim and
the lock ring for deformation or damage.
(11) Check the rim nuts

·Looseness of rim nuts could be very dangerous as it may lead to falling off of wheels
and overturning of the forklift. Check all the rim nuts for looseness. Make sure they have
been tightened to the specified torque to avoid danger.
Tightening torque of the rim nuts:
Front wheel：7.00-12-12PR 280-320N．m
Rear wheel：18×7—8-14PR 130-150N．m

(12) Check the charging status

Measure the specific gravity of the battery. If the specific gravity of the accumulator is 1.275 to
1.285 when the accumulator is switched to 30 ℃, indicating that the accumulator is fully charged.

104
Check for loosening of terminals and check cables damage.

Handle

Battery Plug

(13) Check the front headlight, steering lamp and the horn
Check if these lamps could light up normally and if the horn can sounds normally (checking by
pressing the horn button).
Check the emergency stop switch.

Left steering
L
Horn button
lamp lights up
N Neutral position
Right steering
R
lamp lights up
emergency button

(14) Check instrument panel

Under normal circumstances, the instrument panel will displays as below within a few
seconds after turning on the key switch.

1.Indicationon of 2.Indicationon of hand 3.Fault code of 4.Speed

locking braking traction control mode
5.Fault code of 6.Indication of oil filtering 7.Indication on 8.Fault
pump controller (disabled) maintenance time indication
9.Indication of 10.Buttons for mode switch 11. Capacity 12.Timing
turning right and parameter adjustment indicator of the indicator
accumulator
13. Operation menu 14.Indication of turning left
button

105
 15) Check the overhead guard and backrest
Check the bolts or nuts for looseness.
16) Check the integrity of the labels
17) Others
Check for abnormalities on other components.

• In addition to checking of the lights and operating conditions, turn off key switch
and unplug the accumulator before check the electric system.

Ⅱ.Checking after operations

After work, remove dirt from the forklift and check the following items:
(1) Inspect all parts and components for damage or leakages.
(2) Check for deformation, distortion, damage or breakage.
(3) Add grease if necessary.
(4) Lift the fork to the maximum height for several times after operations are finished. (After
you do not lift the fork to its maximum height in daily work, this allows the oil flow through the
cylinder to prevent rusting.) )
(5) Replace abnormal components that cause failures during work.

• A small fault will cause a major accident. Do not operate or move the forklift before
completion of repair and inspection.
Ⅲ.Clean the forklift
• Park the forklift at the specified location.
• Pull the parking brake lever.
• Press the emergency stop switch.
• Turn off the key switch and remove the key.
• Disconnect the accumulator plug.
1. Clean the forklift surface

Do not use flammable liquids to clean the forklift and take safety measures to prevent
short circuits.
·Use water and soluble detergent to clean the forklift.
• Carefully clean the oil filler and the periphery of the lubricating port.

 Please conduct lubrication timely if you clean the forklift frequently.

2. Clean the chain

Do not use chemical detergents, acids and other corrosive liquids to clean the chain.
• Place a container under the main frame.
• Use gasoline and other petrochemical derivatives to clean the chain.
• Do not use any additives when cleaning with a steam nozzle.
• Wipe the chain pin and water on chain surface immediately after cleaning.
3. Clean the electric system

Do not use water to clean the pump control and the connectors, so as to avoid
damage to the electrical system.
Use non-metallic brush or low-power dryer to clean the electric system according to the
manufacturer's instructions. Do not move the protective cover.
4. After cleaning
• Thoroughly wipe off water stains on the forklift (compressed air could be used.)
• Start the forklift according to the procedures.

106
 If moisture penetrates into the motor, you should first remove the moisture to prevent
short circuits.
 Moisture will reduce brake performance, so you shall conduct braking to dry the
brake.

Ⅳ. Regular maintenance
• Regular inspection and maintenance of the forklift shall be conducted to keep it in good
performance status.
•Use spare parts made by Noblelift Machinery.
•Do not use different types of oil when replacing or refilling oil .
• The oil and accumulator being replaced shall be disposed according to local environmental
protection laws and regulations rather than being dumped and abandoned.
• Develop comprehensive maintenance and repair program.
• Keep detailed record of each maintenance and repair.
• Forklift repairing without training is prohibited.

•No smoking.
· Turn off the key switch and disconnect the accumulator plug before maintenance.
(Except for conducting some of the troubleshooting checks)
• Clean electrical parts with compressed air and do not use water for cleaning.
• Never stretch your hands, feet or any part of the body into the place between the
main frame and instrument rack.
• The charged capacitor within the controller may cause electrical injury even if the
key switch is off. Be careful when contacting the controller.

1. Regular maintenance schedule √ - Inspection, calibration, adjustment × - Replacement

(1) Accumulator

Every 3
Maintenance Maintenance Per day per week per month Every 6 months
Tools months
Item content (8 hours) (50 hours) (200 hours) (1200 hours)
(600 hours)
Electrolyte measure by
Accumulator √ √ √ √
levels sight
Specific
gravity of Hydrometer √ √ √ √
electrolyte
Accumulator
√ √ √ √ √
power
Looseness
√ √ √ √ √
of terminals
Looseness
of the
√ √ √ √ √
connection
lines
Cleanness of
accumulator √ √ √ √ √
surface

If there is

107
 placed on
accumulator
surface
If the
ventilation
cover is tight
and if the √ √ √ √
ventilation is
uncovered
Keep away
from √ √ √ √ √
fireworks

1. Regular maintenance schedule √ - Inspection, calibration, adjustment × - Replacement

(1) Accumulator

（2）Controller
Every
per Every 3
per 6
Maintenance Maintenance Per day month months
Tools week months
Item content (8 hours) (200 (600
(50 hours) (1200
hours) hours)
hours)
Check wear status
√ √
of contacts
Check if the
mechanical
movement of the √ √
contactors is good
Check if the
operation of micro
√ √
switch pedal is
Controller normal
Check the
connection
between the motor, √ √
accumulator and
the power units
Check if the
For the
troubleshooting
first 2
system of controller
years
is normal

(3) Motor
Every 3 Every 6
per month
Maintenance Maintenance Per day per week months months
Tools (200
Item content (8 hours) (50 hours) (600 (1200
hours)
hours) hours)
Remove foreign
Motor
body on the motor √ √ √
shell

108
 Replace or clean
√
the bearing
Check for wear of
carbon brushes
and commutator.
√ √ √
Also check if the
spring force is
normal
Check if the wiring
is correct and √ √ √
reliable
Clean up the
groove on
changeover plate
and add carbon √ √
powder on the
changeover

（4）Transmission system
Every Every
per per
3 6
Maintenance Per day week month
Maintenance content Tools months months
Item (8 hours) (50 (200
(600 (1200
hours) hours)
hours) hours)
If any noise √ √ √ √ √
Check for leakage √ √ √ √ √
Replace the oil ×
Check the working
Gearbox √ √ √ √ √
status of brake
and Check the gear
wheel √ √
operation
reduction Check looseness of
mechanism the bolts at the
√ √ √
connection with the
main frame
Check the tightening
Torque
torque of wheel hub √ √ √ √ √
Wrench
bolt

(5) Wheels (front and rear)

per Every 3 Every 6
per week
Maintenance Per day month months months
Maintenance content Tools (50
Item (8 hours) (200 (600 (1200
hours)
hours) hours) hours)
Wear, cracks or
√ √ √ √ √
damage
nails, stones or other
Tires foreign body on the √ √ √
tire
Damage of wheel rim √ √ √ √ √

109
（6）Steering system
per Every 3 Every 6
per week
Maintenance Maintenance Per day month months months
Tools (50
Item content (8 hours) (200 (600 (1200
hours)
hours) hours) hours)
Check the clearance √ √ √ √ √
Check the axial
Steering √ √ √ √ √
looseness
Wheel Check the radial
√ √ √ √ √
looseness
Check the operating
√ √ √ √ √
status
Check for looseness
of the mounting √ √ √
bolts
Steering
Check the leakage
gear
on contact surface
and
of valve block and √ √ √ √ √
Vavle
steering gear
block
Check the sealing
condition of the √ √ √ √ √
interface connectors
Check for looseness
of the mounting √ √ √
bolts on rear axle
Check bending,
deformation,
√ √ √
cracking and
damage
Check or replace the
lubrication on axle
√ √
supporting bearing
Check or replace the
Rear axle lubrication on
bearing of the √ √
steering wheel hub
Check the operating
conditions of √ √ √ √ √
steering cylinder
Check for leakage of
√ √ √ √ √
the steering cylinder
Check the meshing
√ √
of gear and rack
Sensor wiring and
√ √
working status

110
（7）Braking system
Every 3 Every 6
Per day per week per month
Maintenance Maintenance months months
Tools (8 (50 (200
Item content (600 (1200
hours) hours) hours)
hours) hours)
Graduated
Free travel √ √ √ √ √
scale
Pedal travel √ √ √ √ √
Operating
Brake pedal conditions √ √ √ √ √
If there is air within
√ √ √ √ √
the brake lines
If the brake control
is safe and reliable
Manipulation and with enough √ √ √ √ √
of parking travel
brake
control performance √ √ √ √ √
control performance √ √ √
Rod, cable Looseness of the √ √ √
and etc connection
Wear of the joints
√ √
with gearbox
Damage, leakage,
√ √ √
rupture
Connection,
Pipelines
clamping parts and √ √ √
looseness status
Leakage √ √ √ √ √
Check the oil level
√ √ √ ×
and replace oil
Action of master
cylinder and wheel √ √
cylinders
Braking Leakage and
Master damage of master
cylinder √ √
cylinder and wheel
and cylinders
Wheel Check wear and
Cylinders damage of master
cylinder, wheel
cylinder piston cups
×
and check valve.
Replace if
necessary.

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（8）Hydraulic system
Every 3
Every 6
Maintenance Maintenanc Per day per week per month months
Tools months
Item e content (8 hours) (50 hours) (200 hours) (600
(1200 hours)
hours)
Oil volume
check and
√ √ √ √ ×
replacemen
t of oil
Clean the
Hydraulic
oil
cylinder √
absorption
filter
Exclude
foreign √
body
Looseness
of the √ √ √ √ √
The control
connection
valve rod
Operating
√ √ √ √ √
conditions
Oil leakage √ √ √ √ √
Operating
conditions
of the safety
√ √ √
Multiple valve and
unit self-locking
vavle tilt valve
Measure
the Oil
pressure of pressure √
the safety gauge
valve
Leakage,
looseness,
crack,
Pipe √ √ √
deformation
line
and
joints
damage
Replace the ×
tube 1 to 2 years
Oil leaks or
noise of
√ √ √ √ √
hydraulic
Hydraulic
pump
Pump
Wear of the
Cylinders
driving gear
√ √ √
of hydraulic
pump

112
（9）Lifting system
Per
per per Every 3 Every 6
Maintenance Maintenance day
Tools week month months months
Item content (8
(50 hours) (200 hours) (600 hours) (1200 hours)
hours)
Check the
tightness of
the chain and
see if there is
√ √ √ √ √
any
deformation,
damage and
corrosion
Lubricate the
Chain √ √ √
chain
sprocket
Riveting pin
and its √ √ √
looseness
Deformation
and damage of √ √ √
chain wheel
If the sprocket
of bearings are √ √ √
loose
Check if it is in
Accessories √ √ √
normal state
Looseness,
deformation,
damage of
piston rod,
√ √ √ √ √
threaded rod
and their
connection
Lifting
parts
cylinder and
Operating
tilt cylinder √ √ √ √ √
conditions
Leakage √ √ √ √ √
Wear and
damage of
pins and steel √ √ √
backed
bearing
Damage,
deformation
√ √ √
and wear of
the fork
Damage, wear
Fork of the location √ √
pin
Cracking and
wear on the
√ √ √
welding parts
at the root of

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 the fork

Crack or
damage on the
inner main
frame, outer
√ √ √
main frame
and welded
parts on the
beam
Bad welding,
cracking,
damage on the
welded parts
√ √ √
between tilt
cylinder
bracket and
the main frame
Bad welding,
cracking or
damage of the √ √ √
inner and outer
main frame
Bad welding,
Main cracking or
√ √ √
Frame damage of the
Fork fork frame
frame Looseness of
√ √ √
rollers
Wear and
damage of the
support √
bearing of the
main frame
Looseness of √
Test
bolts on the (Only for
hamm √
main frame the first
er
bearing cap time)
Looseness of
bolts on the
√
piston rod Test
(Only for
head of the hamm √
the first
lifting cylinder er
time)
and the plate
bending bolts
Cracking and
damage of
√
roller, roller √ √
axle and
welding parts

114
 (10) Others
Every
Per per per Every
3
Maintenance Maintenance day week month 6 months
Tools months
Item content (8 (50 (200 (1200
(600
hours) hours) hours) hours)
hours)
are firmly Test
√ √ √ √ √
installed hammer
Overhead
Check the
guard and
deformation,
backrest √ √ √ √ √
cracking and
damage
Working and
Steering
installation √ √ √ √ √
lamp
status
Working and
Horn installation √ √ √ √ √
status
Working and
Lamps and
installation √ √ √ √ √
light bulbs
status
Working and
Back-up
installation √ √ √ √ √
buzzer
status
Working
Instrument status of √ √ √ √ √
instrument
Damage and
loosening of √ √ √ √
harness
Wiring
Loosening of
circuit √ √ √
connection

2. Replace critical safety components periodically

If injury or damage of some parts is difficult to find through regular maintenance, users shall
conduct periodic replacement of parts given in the following table to further improve security.
If these parts are abnormal before the due replacement time, replace them immediately.

Name of key safety components Service life (years)

Brake hose or tube l～2
Hydraulic hose for the lifting system l～2
Lifting chain 2～4
High pressure hose and tube for the 2
hydraulic system
Oil cup of the brake fluid 2～4
Brake master cylinder cover and dust proof 1
cover
Internal seals and rubber parts of the 2
hydraulic system

115
Ⅴ. Lubricating parts and recommended oil
1. Lubricating parts
○: Replacement FO: Hydraulic oil
○: adding GO: Gear oil
□: Check and adjustment CG: Lubricant grease
BO: Brake oil W: Distilled water

Lifting chain CG

Direction column CG

Tilt cylinder shaft CG

Accumulator□W

Main frame support

CG

Drive axle□CG

Brake pedalCG

Brake oil tank BO

Steering device□CG

2. Recommended oil

Volume
Name Nameplate, code Remarks
( liters) )
L-HM32 Winter
Hydraulic Oil 40
L-HM46 Summer
Gear oil AFT DEXRONⅡ 4.5
Hydraulic fluid Caltex DOT3 0.2
accumulator
Industrial
2# electrode
Vaseline
column
Lubricant Universal lithium grease
grease for automobiles

116
ZheJiang Noblelift Equipment Joint Stock Co.,Ltd
Tel: 86-572-6210776 6210788
Fax: 86-572-6210777 6128612
PC: 313100
Email: [email protected]
URL: www.noblelift.com www.noblelift.cn
Add: 528 Changzhou Road, Taihu Sub-district, Changxing, Zhejiang 313100 China

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