X Series

ELECTRIC FORKLIFT TRUCK CPD60/70/80/90/100-XC4(-I)

CPD60/70/80/90/100-XC5(-I)
CPD60/70/80/90/100-XD3(-I)
CPD80-XLC4(-I)
CPD80-XLC5(-I)
CPD80-XLD3(-I)

OPERATION AND MAINTENANCE MANUAL

Original Instruction

HANGCHA GROUP CO., LTD

03/2023
 Foreword
Thanks for purchasing Hangcha J series four-wheel Electric Counterbalanced Forklift Truck
X series four-wheel electric forklift truck is a new product with a small turning radius, an attractive
design, a small and compact structure, a low centre of gravity, good stability and superior
performance.
This manual is brief introduction and correct use to X series four-wheel Electric Counterbalanced
Forklift Truck, which guides you how to safely operate and right maintain. Relevant people should
read and comprehend this manual well.
Due to the continuous updating and improvement of our products, there may be minor
discrepancies between your forklift truck and this manual.
For any questions, please contact Hangcha or your nearest dealer.

○
C 11/2022 HANGCHA GROUP CO., LTD
 Content
1. Appearance and Main Components ........................................................................................1
2. Displays and controls ............................................................................................................... 2
Multi-function display .................................................................................................................. 3
Controls ....................................................................................................................................... 9
Others ........................................................................................................................................14
Seat ........................................................................................................................................... 15
OPS system（optional） .......................................................................................................... 17
3. Labels ........................................................................................................................................19
4. Technical Specifications ........................................................................................................ 20
5. Safety instructions .................................................................................................................. 32
6. Truck Lifting, Carrying and Towing ...................................................................................... 38
Lifting .........................................................................................................................................38
Carrying .....................................................................................................................................39
Towing .......................................................................................................................................40
7. The structure and stability of truck .......................................................................................41
8. During running-in .................................................................................................................... 45
9. Routine Maintenance .............................................................................................................. 46
10. Starting and Operation ............................................................................................................ 52
Starting ...................................................................................................................................... 52
Driving ....................................................................................................................................... 52
Decelerating .............................................................................................................................. 52
Steering ..................................................................................................................................... 52
Parking ...................................................................................................................................... 53
Loading ......................................................................................................................................53
Stacking .....................................................................................................................................53
Unstacking ................................................................................................................................ 54
Post-operation checks .............................................................................................................. 54
11. Storage ...................................................................................................................................... 55
12. Battery ....................................................................................................................................... 56
Battery maintenance ................................................................................................................. 56
Specific gravity detection and conversion ................................................................................56
Check the electrolyte level and add distilled water .................................................................. 58
Battery charging ........................................................................................................................59
Battery specification ..................................................................................................................62
Battery charging ........................................................................................................................63
13. Lithium battery ......................................................................................................................... 68
 Lithium battery parameter （CATL） ...................................................................................... 68
Safety instructions .....................................................................................................................69
Installation instructions ............................................................................................................. 69
Basic terms for lithium ion battery ............................................................................................ 69
Instructions for Use ................................................................................................................... 70
Maintenance ..............................................................................................................................71
Emergency plan ........................................................................................................................ 71
SLC-96250 Operation instructions for intelligent charger (CATL battery charger) ................. 72
Lithium battery charging ........................................................................................................... 79
Daily battery maintenance and care .........................................................................................80
Chapter VI Common failures of batteries and their Solutions ................................................. 80
Chapter VIII Emergency Preparedness ................................................................................... 81
14. Maintenance Summary ............................................................................................................83
Periodic maintenance schedule ............................................................................................... 85
Forklift used oil and lubrication ................................................................................................. 92
Periodic replacement of safety-critical parts ............................................................................ 94
Bolt tightening torque table .......................................................................................................95
15. The use, install and safety rules of attachment ................................................................... 96
Attachment install ......................................................................................................................96
Attachment use ......................................................................................................................... 96
Attachment check and maintenance ........................................................................................ 98
16. Battery automatic filling water system(Option) ................................................................... 99
1. Appearance and Main Components
3
6

15
5
13
2
1

11

14
7 8
9 12

10

Item Description Item Description

1 Fork 9 Left side plate

2 Load bracket 10 Rear wheel

3 Mast 11 Counterweight

4 Lift cylinder 12 Towing pin

5 Tilt cylinder 13 Rear cover

6 Overhead guard 14 Front cover

7 Front wheel 15 Seat

8 Left side door

1
2. Displays and controls
4
12 7 8 9
10
3
5 6

2 17

1 15 16

11 13 14

Item Description Item Description

1 Emergency power off 10 Attachment lever

Steering column positioning
2 Parking brake 11
device
3 Forward/Reverse selector switch 12 Horn

4 Steering wheel 13 Brake pedal

5 Combination light switch 14 Accelerator pedal

6 Key switch 15 Rocker switch

7 Lifting lever 16 Cup holder

8 Tilting lever 17 Multi-function display

9 Sideshift lever

2
Multi-function display
Curtis electric-controlled model
The multi-function display shows the battery capacity, the service hours, the operating mode, the
travel speed and fault code information. Graphic illustrations on the multi-function display act as
warning indicators. Through the multi-function display on the right button can also check fault code
and parameter setting.

Enter/exit the operation menu; when the meter is in the password input interface, press F1
F1 to enter the number "1".

Enter/exit the meter menu; when the meter is in the password input interface, press F2 to
F2 enter the number "2".

Enter/exit the controller menu; when the meter is in the password input interface, press F3
F3 to enter the number "3".

Enter/exit the controller menu; when the meter is in the password input interface, press F4
to enter the number "4". When the meter is in the menu interface and the menu option is a
F4 modifiable parameter, press F4 to adjust the parameter change.The step size can be set to
change the single digit, tens, hundred or thousand digits of the parameter.

The setting mode is super mode; when the meter is in the password interface, press ▲ to
switch the user password or OEM password input setting; when the meter is in the menu

3
interface, press ▲ to move the menu option up.

The setting mode is slow mode; when the meter is in the password interface, press ▼ to
switch the user password or OEM password input setting; when the meter is in the menu
interface, press ▼ to move the menu option down.

The setting mode is power mode; when the meter is in the password interface, press the
key to switch the user password or OEM password input setting; when the meter is in the
menu interface, press the key to return to the previous menu.

The setting mode is economic mode; when the meter is in the password interface, press
the key to switch the user password or OEM password input setting; when the meter is in
the menu interface, press the key to enter the next level menu.

When the meter is in the password interface, it is used to delete the entered password;
when the meter is in the menu interface, it is used to reduce the parameter setting value or
return to the previous menu.

Enter the fault interface; when the meter is in the password interface, it is used to check
the input password; when the meter is in the menu interface, it is used to increase the
parameter setting value or enter the next level menu.

4
Main display interface

A Battery level display H Left turn indication

B Travel speed display I Right turn indication

C Operating mode display J Turtle speed mode indication

D Traction controller running hours display K Fault repair indication

E Vehicle running hours display L Battery below 10%, lift lock indication

F Pump controller operating hours display M Seat indication

G Vehicle steering angle display N Park indication

5
Battery level display [A] work in this mode in normal work-time.
SPE mode: The truck is in Safety Mode. In
this mode, maximum traveling speed is limited
to 7km/h. it is very good for working in a crowd
Shows the remaining capacity of the warehouse or other compact space. In this
battery.
As shown in the above figure, when the mode, the slow indicator[F] will be on.
battery power is less than 20%, the entire
battery indicator will flash. At this time, please CAUTION
stop working and charge immediately. It is
recommended to charge when two grids  The default mode is mode E. after
remain (the remaining battery is about 30%), power cutting every time, the work
otherwise the battery life will be greatly mode resets to mode E no matter
shortened. which mode it is before power
cutting, but the switch key is still in
CAUTION the mode before turn off.
 Charging in time is very important,
otherwise it will affect the lift-span Traction controller running hours display
of battery！ [D]

Travel speed display [B]

The hourglass icon indicates the hour meter
function.
Display the cumulative working time of the
Normal work, display the truck travel speed. traction controller

Vehicle running hours display [E]

Operating mode display [C]

The hourglass icon indicates the hour meter

function.
As the diagram shows When the vehicle key switch is turned on, the
S mode is super mode, thus the truck’s hour meter starts counting, and the minimum
acceleration, deceleration rate, max climbing resolution is 0.1 hour.
gradient and so on is much higher. It is applied
for transporting mass of good in short time and Pump controller operating hours display
[F]
climbing big gradient slop ， but it costs more The hourglass icon indicates the hour meter
energy，so the mode will not be used in normal function.
Display pump controller cumulative working
state except emergency. time.
P mode is power mode. All kinds of index are
Vehicle steering angle display [G]
lower than that of super mode. It is applied for
the case of long distance transporting and
needing higher power or speed.
E mode is economical mode. All the Steering wheel (rear wheel) steering angle and

parameters are optimized. Working in this steering direction display.

mode can save power so it is applied for a long As the steering wheel turns, the centered
arrow symbol rotates around the center of the
time work after charging, and it is suggested to circle.

6
1.Steering direction display: the arrow is
turned to the left around the center of the circle,
then it is turned left; when it is deflected to the
right, it is turned right. When parking brake applied, the light up.
2.Steering angle display: The larger the
deflection angle, the larger the turning angle. Battery low capacity indicator

Left turn indication [H]

This indicator lights up when the power is less

When the vehicle turns left, turn on the left turn than 20%.
signal and the indicator lights up.
Menu password interface
When the meter is in the main interface, press
Right turn indication [I]
F2 or F3, the meter will enter the password
interface before entering the corresponding
meter or controller menu. Only when the user
When the vehicle turns right, turn on the right inputs the correct password, the meter will
turn signal and the indicator lights up. enter the corresponding menu interface. The
password interface is displayed as follows:
Crawl speed indicator[J]

When the truck in SPE mode, the crawl speed

indicator light up.

Fault indicator[K]
OEM password
The meter sets menu options at different
permission levels for the users. As shown in
The light up when the controller is wrong or the figure above, when “User
operation mistake, and the fault code shows in Password/USER” is selected and the
corresponding user password is entered, the
the main display screen. meter enters the user level menu; after “OEM
password/ OEM is selected, enter the
Lifting low speed indicator[L] corresponding OEM password, the meter
enters the OEM level menu. If the password is
entered incorrectly, the meter will prompt the
password error and you need to re-enter the
When there is 10% power, the indicator is on, correct password.
and the mast lifting speed drops, to remind
Password interface button function
user to charge the battery as soon as possible.
When the meter is in the password input
interface, the function of each button is as
Seat switch indicator[M] follows:
When operator leaves the seat, the light will be
on, and the truck will be unable to travel or lift.
This function needs the seat to equip with seat
switch.

Parking brake applied indicator[K]

7
 Enter the number "1" for the
F1
password.

Enter the number "2" for the

F2
password.

Enter the number "3" for the

F3
password.

Enter the number "4" for the When the meter is in the fault interface,
F4
password. press again and the meter will return to
the main interface display.
Switch user password/OEM
password.
Key function
Switch user password/OEM When the meter is in the main interface, you
password. can enter the following 4 menu interfaces by
pressing F1~F4.
Switch user password/OEM F1 Enter/exit the operation menu.
password.
F2 Enter/exit the meter menu.
Switch user password/OEM
password. F3 Enter/exit the controller menu.
Delete the entered password; if the Enter/exit the controller monitoring
password has been deleted, press menu; when the meter is in the meter
the C/- button to return the meter to menu or controller menu interface, if
the main interface. the current menu option is a modifiable
F4
When the 4-digit password is all parameter, press F4 to adjust the
parameter change step size to set the
entered, press and the meter
single digit, tens, hundreds, or kilobyte
will automatically verify that the
value of the parameter separately.
password is entered correctly. If the
password is correct, the meter
enters the corresponding menu. If Move the menu option up.
the password is entered incorrectly,
the meter prompts the password Move the menu option down.
error. Note: When the password
input is less than 4 digits, is
Return to the previous menu.
invalid pressed.

Enter the next level menu.

Fault interface When the current menu option is a

When the meter is in the main interface, press modifiable parameter, it is used to
/+ to enter the fault interface. The fault code reduce the parameter setting value,
and the corresponding fault name are otherwise it will be returned to the
displayed according to the currently received previous menu.
controller fault code. The fault interface is
displayed as follows: When the current menu option is a
modifiable parameter, it is used to
increase the parameter setting value,
otherwise it will enter the next level
menu.

8
INMOTION electric-controlled model
The multi-function display shows the battery capacity, the service hours, the operating mode, the
travel speed and fault code information. Graphic illustrations on the multi-function display act as
warning indicators. Through the multi-function display on the right button can also check fault code
and parameter setting.

A B C D E L

S P E Mode -90
°
P
S

0
°
0

°
90
km/h

0h

F G H I J K N M

Item Display Item Display

A Battery capacity display H Battery low capacity indicator
B Service hours display I Lifting low speed indicator
C Operating mode display J Safety switch indicator
D Travel speed or fault code display K Parking brake applied indicator
Mode settings or direction choosing
E Steering wheel angle display L
button
F Crawl speed indicator M return key
G Fault indicator N Menu key

9
Main display interface hour.

Operating mode display[C]

S P ES P E
As the diagram shows, the pictures from the

left to the right represent the mode of S

mode→ P mode → E mode → SPE mode.

S mode is super mode, thus the truck’s

Battery capacity display[A]
acceleration, deceleration rate, max climbing

gradient and so on is much higher. It is applied

for transporting mass of good in short time and

climbing big gradient slop ， but it costs more

energy，so the mode will not be used in normal

Indicates the available residual capacity.
state except emergency.
As the following diagram shows, from the left
P mode is power mode. All kinds of index are
to the right, the battery decreases from full
lower than that of super mode. It is applied for
state to the only one case, which represents
the case of long distance transporting and
that the battery leaves only 20%. Thus the
needing higher power or speed.
whole battery indicator bar will twinkle, and the
E mode is economical mode. All the
state indicator lamp will be bright, now please
parameters are optimized. Working in this
stop working and charge immediately.
mode can save power so it is applied for a long
CAUTION
time work after charging, and it is suggested to
 Charging in time is very important,
work in this mode in normal work-time.
otherwise it will affect the lift-span
SPE mode: The truck is in Safety Mode. In
of battery！
this mode, maximum traveling speed is limited
Service hours display[B]
to 7km/h. it is very good for working in a crowd

0h warehouse or other compact space. In this

Hourglass icon indicates that timing function. mode, the slow indicator[F] will be on.

When you turn off the key switch, the hour CAUTION

meter will works and the minimum unit is 0.1  The default mode is mode E. after

10
 power cutting every time, the work Battery low capacity indicator[H](Red)

mode resets to mode E no matter

which mode it is before power

cutting, but the switch key is still in When there is only one line for the power, the

the mode before turn off. indicator will be on to remind the user to

charge the battery.

Travel speed or fault code display[D]
Lifting low speed indicator[I](Red)
Travel speed display

0 km/h
When there is 10% power, the indicator is on,

Normal work, display the truck travel speed. and the mast lifting speed drops, to remind

Fault code display user to charge the battery as soon as possible.

Seat switch indicator[J](Red)

Failure occurs, display the controller’s fault

When operator leaves the seat, the light will be
code.
on, and the truck will be unable to travel or lift.
Indicator light This function needs the seat to equip with seat

switch (optional).

Crawl speed indicator[F](Green) Parking brake applied indicator[K]

When parking brake applied, the light up.

When the truck in SPE mode, the crawl speed
Button
indicator light up.
Mode settings or direction choosing
Fault indicator[G](Red)
button[L]

The light up when the controller is wrong or P E

operation mistake, and the fault code shows in

the main display screen.

11
Mode settings

S
In the main display interface, the button 、

P E
、 、 , corresponding S mode、

P mode、E mode、SPE mode.

For example: In the main display interface, (2) Language switch setting: This instrument

supports two languages, Chinese and English,

press the button , the screen shows as
which will be adjusted to the language you need
follows:
when leaving the factory.If you need to switch the

S P E Mode -90
°
language,please refer to the following example for

operation.

0
0
°
For example: The language from English

°
90
switch to Chinese.
km/h
①On the main page, press the menu key ( )
0h
to enter the main menu. The main menu display is
Direction choosing
as follows:
S P
In the menu interface, the button 、 、

E
、 , corresponding up、left、right、

down four direction choosing button keys.

Menu button[M]

（1）In the main interface, press the menu key S

②Use the up key ( ) or down key ( ) to
[N], enter the password, and then press the menu
select "other settings".
key to enter the main menu page.
③ Press the menu key () to enter other setting

menus.

12
④ Select the "Language" option by moving up

S
( ) or down ( ).

Press the menu key ( ) to enter the language

setting state.

S
⑥ Use the up key ( ) or down key ( ) to

select the Chinese language.

⑦ Refer to steps ⑤ ④ ③ ② ①, press the return

key ( ) to return to the main interface.

13
Controls forward.
The hand brake is equipped with a
Emergency power off [1]
micro-switch on the left side that stops the
forklift from moving when the brake lever is
engaged.

WARNING
 If parking on the slope is
unavoidable, block the wheels with
solid wedge.
Forward/Reverse selector switch [3]

Turn on or off the power.

In an emergency, press the red mushroom
head button to cut off the vehicle's main power
supply. The vehicle will not be able to move,
turn or lift.

CAUTION Set truck moving direction according to need.

 Do not use the emergency power off When the direction lever is pushed forward
switch to stop the truck under and the accelerator pedal is depressed, the
normal circumstances as the key forklift truck will travel forward. When the
switch. direction lever is pulled back and the
accelerator pedal is depressed, the forklift will
Parking brake [2]
travel in reverse.
Loosen
CAUTION
Button
Lock  When the forklift is moving and the
direction lever is operated, the
electrical brake will be applied and
the forklift will decelerate to a
standstill before gradually moving
off in the opposite direction.

WARNING
Secure the stopping truck.  If the direction lever is not in neutral
When braking, pulling on the brake lever or the accelerator pedal is
generates a braking force on the front wheels. depressed, the forklift will not start
To release the brake, simply push the lever

14
 when the key switch is turned to ON.
In this situation, return the direction
lever to the neutral position and take
your foot off the accelerator pedal
before attempting to start the forklift.

Steering wheel [4]

Control turn light, headlight and front signal

light.
The turn signal light switch indicates the
turning direction of the forklift. Push forward,
left turn light flashes; push backward, right turn
light flashes.
The head/signal light switch has two settings:
signal light on; head light + signal light on.
Control truck direction.
When the steering wheel is turned right, the CAUTION
 The turn signal lever does not
forklift will turn to the right; when the steering
automatically return to the neutral
wheel is turned left, the forklift will turn to the
position. Reset it by hand.
left. The rear end of the forklift swings out
when turning. Key switch[6]

WARNING
 This forklift truck adopts a fully
hydraulic steering system.
Therefore, steering will be impaired
when the oil pump motor stops
running. Immediately restart the oil
pump motor before turning again.
Connect and interrupt control current. Remove
Combination light switch [5] the key and make sure that the truck does not
move suddenly.
The key switch has two positions: ON and
OFF. First set the direction lever to the neutral
position, take your foot off the accelerator
pedal, then turn the key clockwise to the ON
position.

15
 Control the forks’ forward and backward tilting.
CAUTION
The tilt lever is used to tilt the mast forward
 If the direction lever is not in neutral
and backward. Push forward to tilt forward,
or the accelerator pedal is
pull backward to tilt back. The tilting speed is
depressed, the forklift will not start
determined by the distance that the lever is
when the key switch is turned to ON.
moved.
 At this point a fault code will be
displayed, which is perfectly normal.
 Return the direction lever to the CAUTION
neutral position and take your foot  The multi-way valve is equipped with
off the accelerator pedal before a front tilt self-locking valve. When
attempting to start the forklift the circuit is cut off, the mast cannot
 The fault code will then disappear. tilt forward even if the lever is
pushed forward.
Lift lever [7]
Sideshifter lever [9]

Control the forks’ up or down.

Pull back to raise the forks. Push forward to
Control the fork to move to left or right.
lower the forks. The lifting speed is controlled
Push or pull this lever can realize the left/right
by the distance that the lever is moved
movement of the mast.
backward. The lowering speed is controlled by
Attachment lever [10]
the distance that the lever is moved forward.
Tilt lever [8]

16
It is used when installing attachment like paper
roll clamp or rotator.
Steering column positioning device [11]
Adjust and fix steering column according to
needed distance.
In order to meet operator’s need, the tilting
angle of steering column is adjustable. Pull the
lever upward, the steering column is released;
push downward and locked.

Stepless regulation of truck travelling speed.

Slowly depress the accelerator pedal, the drive
motor will start running and the forklift will
move off. The travel speed can be increased
gradually based on the force applied to the
pedal.

CAUTION
 Release the accelerator pedal while
driving to perform soft braking.

Brake pedal [13]

WARNING
 Do not depress the accelerator pedal
before turning on the key switch,
otherwise the meter display will
display a fault. Keep your foot off the
accelerator pedal when turning the
key switch on.

Front cover lock catch[20]

Carry out brake operation.

Depressing the brake pedal will slow down or
stop the forklift and activate the brake lights.

CAUTION
 Do not depress the accelerator and
brake pedals at the same time, as
this will damage the drive motor.

Accelerator pedal [14] Fix the front cover.

17
Fork stopper fork position.

Used when adjusting the spacing of the forks.

Pull up the fork stopper and rotate it 90°, then
adjust the forks to the desired positions
according to the load to be handled.

WARNING
 Fork spacing should be adjusted
symmetrically to the truck
centreline. After adjustment, make
sure that the fork stoppers are
securely locked.
 The lower crossbar of the fork
carriage has an opening for fitting
and removing the forks.
 Do not secure forks at the opening
position, in order to prevent them
falling through the opening.
 There installs one bolt in the middle
of upper beam to avoid forks
working here. If bolt damaged,
replace new one.
Replace forks
Remove old forks: place the forks in middle,
drop to the ground, tilt forward the mast, then
the forks are off the fork carriage and reverse
the truck.
Assemble new forks: place forks on the
ground facing the truck, lower the fork carriage
to the lowest, truck travels slowly, aim the fork
slot to the top-bottom beam and gag of fork
carriage, then lift the fork carriage and adjust

18
Others
Overhead guard
The overhead guard protects the operator
against injury from falling objects. It must have
sufficient impact strength. Loose installation,
dismantlement or remould of the overhead
guard is dangerous, and may cause major
accident. The gap on it is used to lift the
battery.

A safety step is provided on both sides of the

forklift body and a handrail is located on the
left pillar of the overhead guard. Use the step
and handrail to safely get on /off the forklift.

WARNING
 Do not use the forklift without the
overhead guard.

Front/rear cover
The wide-opening cover facilitates inspection
and battery maintenance.
The gas spring on the inside enables the cover
to be fully opened by lightly pulling it upwards.
To close the cover, release the gas spring
safety and push the cover head down.

CAUTION
 To close the cover, press the gas
spring safety and then press the
hood head down.
 Prevent the cover from clamping
your finger when closing the cover.

Safety step and handrail

19
Seat
The seat design satisfies the maximum comfort, and can adjust as follows:

①Weight adjusting lever

②Seat forward-backward adjusting lever
1
③Backrest adjusting lever
3
④ Safety belt
2 ⑤ Document box
Adjust driver seat according to weight：
In order to get ideal damping effect, adjust the seat according to driver’s weight
– Driver sits on. If it is set correctly, seat adjusting lever① should match with driver weight mark.
If the seat adjusting lever deviates to left or right too much, adjust the seat according to
driver’s weight.
– If driver is light, pull the seat adjusting lever① to left.
– If driver is heavy, pull the seat adjusting lever① to right.
Adjust seat position：
– Pull the driver seat forward-backward adjusting lever② upward, and move the seat forward or
backward to proper position.
– Lock driver seat forward-backward adjusting lever②.

WARNING
 Lock the driver seat forward-backward adjusting lever on the set position. Never
adjust seat when driving.

Adjust seat back：

– Driver sits on.
– Press the seat back adjusting button③, and adjust back inclination.
– Release the seat back adjusting button③ and lock the seat back.

20
 Safety belt
Fasten safety belt④ before driving. It protects driver when accidents happen. Regularly clean and
check safety belt, avoid dirt.
Correctly use safety belt：
– Sit on the seat correctly.
– Check if the safety belt twisted.
– Place the safety belt on the hip.
– Fasten the safety belt and check safety belt lock.
– Adjust safety belt until it reaches the state that it does not squeeze hip or is unable to fix due to
loosen too much.
Regular verification of seat belt related to:
– Cut or frayed straps.
– Worn or damaged hardware, including anchor points.
– Buckle or retractor malfunction.
– Loose stitching.

WARNING
 In any case, if there is damage or flaw(insecure lock, damage, wet light) on the safety
bet, please repair or replace immediately.
 Never do any change to the safety belt. Replace new one after each accident.

Adopted measure when special condition incurred：

– Fasten the safety belt and sit on.

– Never jump from the truck.

– Lean forward, hold the steering wheel with

both hands, and support with feet.

– Lean yourself in the opposite direction to

truck tipping over.

WARNING
 When there is danger of tipping over, do no unfasten the safety belt to escape. It may
cause severe bodily injury.

21
OPS system（optional）
OPS (Operator Presence Sensing) system is a safeguard system that installs a sensor in the
driver seat to sense if the driver sits on the seat correctly. If the driver does not sit on the seat
correctly, driving force is cut off, meanwhile, all loading and unloading operations will be stopped.
It helps to reduce accident when the driver leaves. When the driver does not sit correctly, the
driver cannot drive the truck or operate the loading and unloading, thus the accidents by
maloperation will be reduced.
Driving protection function
When the vehicle is travelling, the driver leaves the seat or the safety belt is released (if equip with
safety belt protection switch) over 1 second, truck stops automatically, and the instrument

displayed seat indicator light lights up, meanwhile the buzzer sends out continuous alarm
signal. Only when pulling up the hand brake or the driver sits on the seat correctly and the

direction switch returns to neutral, the seat indicator light goes out, travelling OPS status is
released.
Working protection function
When the vehicle is under working condition, the driver leaves the seat or the safety belt is
released (if equip with safety belt protection switch) over 1 second, working stops automatically,

and the instrument displayed seat indicator light lights up, meanwhile the buzzer sends out
continuous alarm signal. OPS light comes on, buzzer sends out alarm signal, transportation

operation stops automatically. When the driver sits down again, the seat indicator light goes
out, working OPS status is released.
Warning function
Once the seat sensor detects the seat switch is turned off, within 1 second, the buzzer sends out

continuous alarm signal, and the seat indicator light lights up. If the seat indicator light

keeps on when the seat switch is off, it means the OPS in the startup state.
Resume neutral function
If the direction switch does not return to neutral and the seat switch is turned on. The buzzer will
send out continuous alarm signal to remind the driver that the OPS in the startup state.
OPS abnormal function handling
Park the truck in safe place and contact Hangcha agency to check if any below condition is

occurred. a. after the driver leaves the seat, the seat indicator light does not light up; b. when

the driver sits down, the seat indicator light does not go out.

22
 Caution
 As to forklift equipped with safety belt protection switch, after driver sits on the seat
correctly, it also needs fasten safety belt, then can operate the truck normally. When
driving on the uphill, starting the OPS will cut off the drive power and make the truck
slip. In order to avoid this accident, the driver must sit correctly when operating on
the uphill.
Fork locking function after power off
This function means: forks are locked when starting switch is closed or power failure, forks will
not lower down even operate the control lever.

23
3. Labels
Labels, like warning label, load curve and nameplate, must be clear and readable. Replace when
necessary.

起吊方法

3
5
4
警 告
不遵守以下规则会使自己或他人受到严重伤害
未经正规培训的人员不得操作此叉车
仔细阅读操作指南和所有的标示，熟悉此叉车，操作指南随此叉车一起提供
每次使用前后都必须对叉车进行常规检查，不得操作有故障或损坏的叉车
只有经过正规培训的修理人员方可修理此叉车
一定要安装好护顶架和挡货架以防重物砸下
叉车工作前应保证蓄电池电量充足，各类开关、插接件、操作手柄、踏板、轮胎气压及紧固件处于正常状态；
车辆的起动过程如下：松开刹车手柄，开启电门开关，置方向开关手柄于前进或后退档，踩下加速踏板即可 ；
在狭小场地或恶劣路面作业时，应注意间距，避免碰撞
MEETS DESIGN SPECIFICATIONS OF ANSI / ITSDF B56.1 STANDARD IN EFFECT AT TIME OF MANUFACTURE 载货时，货物重量及尺寸应符合载荷曲线图规定，并使货物重心处于门架中心位置，切勿超载或偏位
载货行驶时，货叉离地300mm左右，门架最大后倾，使货物贴紧后壁，载货行驶中禁止急速制动和急转弯；
工作结束后，停好叉车，方向开关置"中档"，货叉下降着地，关闭电门开关，拉紧手制动，断开总电源插头
蓄电池电量不足时应及时充电，按说明书要求充电，避免过放电及过充电

6
叉车行驶时，如电控器失控，应立刻拉动总电源插头手柄及时断开总电源
吊装蓄电池箱时，箱体两侧的四个挂钩孔应同时挂钩起吊，严禁只用两只挂钩起吊，以免箱体变形挤伤蓄电池

warning

10

7
WARNING WARNING

No. Description
1 Product nameplate
Danger label ： Loading part is not allowed to carry people. Never stay under the
2
loading part
3 Lifting label：The fixing point when using crane to load and unload.
4 Danger label：When the forklift rollover ,Don't jump forklift
5 Load curve label
6 Warning label：Obey safety regulation.
7 Danger label：Be careful when lifting the mast，No climbing
8 Tonnage label
9 Brand label
10 Brand label

24
4. Technical Specifications
序号 项 目 CPD60-XC4 CPD70-XC4

1 Rated lifting capacity kg 6000 7000

2 Load center distance mm 600 600

3 Standard mast lift height mm 3000 3000

4 Free lift height mm 160 160

5 Mast Tilt angle (front/back) (°) 5 / 10 5 / 10

6 Maximum travel speed(full load) km/h 15 15

7 Maximum lifting speed (full load) mm/s 340 320

8 Maximum grade ability (full load) % 16 15

9 Minimum outside turning radius mm 3050 3050

10 Minimum ground clearance mm 183 183

11 Maximum braking distance m 2.5 2.5

Length(to fork
mm 3195 3200
face)

12 Dimensions Width mm 1870 1870

Height to
overhead mm 2565 2565
guard
Include battery
13 Service weight kg 9600 10280
box

Model 9PZS720 9PZS810

14 Battery
Standard V/Ah 96 / 720 96 / 810

Driven Motor kW 35 35
15 Motor
Pump Motor kW 40 40

Front/number 355/65-15/2 355/65-15/2

16 Tire
Rear/number 250-15/2 250-15/2

25
序号 项 目 CPD80-XC4 CPD90-XC4

1 Rated lifting capacity kg 8000 9000

2 Load center distance mm 600 600

3 Standard mast lift height mm 3000 3000

4 Free lift height mm 175 200

5 Mast Tilt angle (front/back) (°) 5 / 10 5 / 10

6 Maximum travel speed(full load) km/h 14.5 13.5

7 Maximum lifting speed (full load) mm/s 300 280

8 Maximum grade ability (full load) % 14 12

9 Minimum outside turning radius mm 3050 3350

10 Minimum ground clearance mm 183 183

11 Maximum braking distance m 2.5 2.5

Length(to fork
mm 3220 3755
face)

12 Dimensions Width mm 1945 1970

Height to
mm 2565 2565
overhead guard
Include battery
13 Service weight kg 12180 12960
box

Model 9PZS945 12PZS1104

14 Battery
Standard V/Ah 96 / 945 96/1104

Driven Motor kW 35 35
15 Motor
Pump Motor kW 40 52

Front/number 355/50-20/2 8.25-15/4

16 Tire
Rear/number 250-15/2 250-15/2

26
序号 项 目 CPD100-XC4 CPD100-XC4-I

1 Rated lifting capacity kg 10000 10000

2 Load center distance mm 600 600

3 Standard mast lift height mm 3000 3000

4 Free lift height mm 175 175

5 Mast Tilt angle (front/back) (°) 5 / 10 5 / 10

6 Maximum travel speed(full load) km/h 13 13.5

7 Maximum lifting speed (full load) mm/s 260 250

8 Maximum grade ability (full load) % 12 12

9 Minimum outside turning radius mm 3350 3350

10 Minimum ground clearance mm 183 183

11 Maximum braking distance m 2.5 2.5

Length(to fork
mm 3755 3755
face)

12 Dimensions Width mm 2038 2038

Height to
overhead mm 2565 2565
guard
Include battery
13 Service weight kg 13780 13180
box

Model 12PZS1260 CATL

14 Battery
Standard V/Ah 96 / 1260 96 / 606

Driven Motor kW 35 35
15 Motor
Pump Motor kW 52 52

Front/number 300-15/4 300-15/4

16 Tire
Rear/number 250-15/2 250-15/2

27
序号 项 目 CPD90-XC4-I CPD80-XC4-I

1 Rated lifting capacity kg 9000 8000

2 Load center distance mm 600 600

3 Standard mast lift height mm 3000 3000

4 Free lift height mm 200 175

5 Mast Tilt angle (front/back) (°) 5 / 10 5 / 10

6 Maximum travel speed(full load km/h 13.5 14.5

7 Maximum lifting speed (full load) mm/s 280 300

8 Maximum grade ability (full load) % 12 14

9 Minimum outside turning radius mm 3350 3050

10 Minimum ground clearance mm 183 183

11 Maximum braking distance m 2.5 2.5

Length(to fork
mm 3755 3220
face)

12 Dimensions Width mm 1970 1945

Height to
mm 2565 2565
overhead guard
Include battery
13 Service weight kg 11750 11230
box

Model CATL CATL

14 Battery
Standard V/Ah 96/606 96/542

Driven Motor kW 35 35
15 Motor
Pump Motor kW 52 40

Front/number 8.25-15/4 355/50-20SE/2

16 Tire
Rear/number 250-15/2 250-15/2

28
序号 项 目 CPD70-XC4-I CPD60-XC4-I

1 Rated lifting capacity kg 7000 6000

2 Load center distance mm 600 600

3 Standard mast lift height mm 3000 3000

4 Free lift height mm 160 160

5 Mast Tilt angle (front/back) (°) 5 / 10 5 / 10

6 Maximum travel speed(full load) km/h 15 15

7 Maximum lifting speed (full load) mm/s 320 340

8 Maximum grade ability (full load) % 15 16

9 Minimum outside turning radius mm 3050 3050

10 Minimum ground clearance mm 183 183

11 Maximum braking distance m 2.5 2.5

Length(to fork
mm 3200 3195
face)

12 Dimensions Width mm 1870 1870

Height to
mm 2565 2565
overhead guard
Include battery
13 Service weight kg 9400 9030
box

Model CATL CATL

14 Battery
Standard V/Ah 96/542 96/542

Driven Motor kW 35 35
15 Motor
Pump Motor kW 40 40

Front/number 355/65-15/2 355/65-15/2

16 Tire
Rear/number 250-15/2 250-15/2

29
序号 项 目 CPD80-XLC4 CPD80-XLC4-I

1 Rated lifting capacity kg 8000 8000

2 Load center distance mm 900 900

3 Standard mast lift height mm 3000 3000

4 Free lift height mm 200 200

5 Mast Tilt angle (front/back) (°) 5 / 10 5 / 10

6 Maximum travel speed(full load) km/h 14.5 14.5

7 Maximum lifting speed (full load) mm/s 300 300

8 Maximum grade ability (full load) % 13 13

9 Minimum outside turning radius mm 3350 3350

10 Minimum ground clearance mm 183 183

11 Maximum braking distance m 2.5 2.5

Length(to fork
mm 3745 3745
face)

12 Dimensions Width mm 1970 1970

Height to
mm 2565 2565
overhead guard
Include battery
13 Service weight kg 13530 12480
box

Model 9PZS945 CATL

14 Battery
Standard V/Ah 96/945 96/606

Driven Motor kW 35 35
15 Motor
Pump Motor kW 52 52

Front/number 8.25-15/4 8.25-15/4

16 Tire
Rear/number 250-15/2 250-15/2

30
序号 项 目 CPD60-XC5 CPD70-XC5

1 Rated lifting capacity kg 6000 7000

2 Load center distance mm 600 600

3 Standard mast lift height mm 3000 300

4 Free lift height mm 600 160

5 Mast Tilt angle (front/back) (°) 5/10 5/10

6 Maximum travel speed(full load) km/h 15 15

7 Maximum lifting speed (full load) mm/s 340 320

8 Maximum grade ability (full load) % 16 15

9 Minimum outside turning radius mm 3050 3050

10 Minimum ground clearance mm 183 183

11 Maximum braking distance m 5.8 5.8

Length(to fork
mm 3195 3200
face)

12 Dimensions Width mm 1870 1870

Height to
mm 2565 2565
overhead guard
Include battery
13 Service weight kg 9600 10280
box

Model 9TTM435 9TTM500

14 Battery
Standard V/Ah 96/720 96/810

Driven Motor kW 35 35
15 Motor
Pump Motor kW 40 40

Front/number 355/65-15/2 355/65-15/2

16 Tire
Rear/number 20-15/2 20-15/2

31
序号 项 目 CPD80-XC5 CPD90-XC5

1 Rated lifting capacity kg 8000 9000

2 Load center distance mm 600 600

3 Standard mast lift height mm 3000 3000

4 Free lift height mm 175 200

5 Mast Tilt angle (front/back) (°) 5/10 5/10

6 Maximum travel speed(full load) km/h 14.5 13.5

7 Maximum lifting speed (full load) mm/s 300 280

8 Maximum grade ability (full load) % 14 12

9 Minimum outside turning radius mm 3050 3350

10 Minimum ground clearance mm 183 183

11 Maximum braking distance m 5.8 6

Length(to fork
mm 3220 3695
face)

12 Dimensions Width mm 1945 1969

Height to
mm 2565 2565
overhead guard
Include battery
13 Service weight kg 12180 12960
box

Model 9PZS945 12PZS1104

14 Battery
Standard V/Ah 96/985 96/1104

Driven Motor kW 35 35
15 Motor
Pump Motor kW 40 52

Front/number 355/50-20/2 8.25-15/4

16 Tire
Rear/number 250-15/2 250-15/2

32
序号 项 目 CPD100-XC5 CPD60-XC5-I

1 Rated lifting capacity kg 10000 6000

2 Load center distance mm 600 600

3 Standard mast lift height mm 3000 3000

4 Free lift height mm 200 160

5 Mast Tilt angle (front/back) (°) 5/10 5/10

6 Maximum travel speed(full load) km/h 13.5 15

7 Maximum lifting speed (full load) mm/s 250 340

8 Maximum grade ability (full load) % 12 16

9 Minimum outside turning radius mm 3350 3050

10 Minimum ground clearance mm 183 183

11 Maximum braking distance m 6 2.5

Length(to fork
mm 3705 3195
face)

12 Dimensions Width mm 2038 1870

Height to
mm 2565 2565
overhead guard
Include battery
13 Service weight kg 13780 9030
box

Model 12PZS1260 CATL

14 Battery
Standard V/Ah 96/1260 96/542

Driven Motor kW 35 35
15 Motor
Pump Motor kW 52 40

Front/number 300-15/4 355/65-15/2

16 Tire
Rear/number 250-15/2 250-15/2

33
序号 项 目 CPD70-XC5-I CPD80-XC5-I

1 Rated lifting capacity kg 7000 8000

2 Load center distance mm 600 600

3 Standard mast lift height mm 3000 3000

4 Free lift height mm 160 175

5 Mast Tilt angle (front/back) (°) 5/10 5/10

6 Maximum travel speed(full load) km/h 15 14.5

7 Maximum lifting speed (full load) mm/s 320 300

8 Maximum grade ability (full load) % 15 14

9 Minimum outside turning radius mm 3050 3050

10 Minimum ground clearance mm 183 183

11 Maximum braking distance m 2.5 2.5

Length(to fork
mm 3200 3220
face)

12 Dimensions Width mm 1870 1945

Height to
mm 2565 2565
overhead guard
Include battery
13 Service weight kg 9400 11100
box

Model CATL CATL

14 Battery
Standard V/Ah 96/542 96/542

Driven Motor kW 35 35
15 Motor
Pump Motor kW 40 40

Front/number 355/65-15/2 355/50-20SE/2

16 Tire
Rear/number 250-15/2 250-15/2

34
序号 项 目 CPD90-XC5-I CPD100-XC5-I

1 Rated lifting capacity kg 9000 10000

2 Load center distance mm 600 600

3 Standard mast lift height mm 3000 3000

4 Free lift height mm 200 200

5 Mast Tilt angle (front/back) (°) 5/10 5/10

6 Maximum travel speed(full load) km/h 13.5 13.5

7 Maximum lifting speed (full load) mm/s 280 250

8 Maximum grade ability (full load) % 12 12

9 Minimum outside turning radius mm 3350 3350

10 Minimum ground clearance mm 183 183

11 Maximum braking distance m 6 6

Length(to fork
mm 3695 3705
face)

12 Dimensions Width mm 1969 2038

Height to
mm 2565 2565
overhead guard
Include battery
13 Service weight kg 11750 13180
box

Model CATL CATL

14 Battery
Standard V/Ah 96/606 96/606

Driven Motor kW 35 35
15 Motor
Pump Motor kW 52 52

Front/number 8.75-15/4 300-15/4

16 Tire
Rear/number 250-15/2 250-15/2

35
序号 项 目 CPD80-XLC5-I CPD80-XLC5

1 Rated lifting capacity kg 8000 8000

2 Load center distance mm 900 900

3 Standard mast lift height mm 3000 3000

4 Free lift height mm 200 200

5 Mast Tilt angle (front/back) (°) 5/10 5/10

6 Maximum travel speed(full load) km/h 14.5 14.5

7 Maximum lifting speed (full load) mm/s 300 300

8 Maximum grade ability (full load) % 13 13

9 Minimum outside turning radius mm 3350 3350

10 Minimum ground clearance mm 183 183

11 Maximum braking distance m 6 6

Length(to fork
mm 3705 3705
face)

12 Dimensions Width mm 1969 1969

Height to
mm 2565 2565
overhead guard
Include battery
13 Service weight kg 12480 13530
box

Model CATL 9PZS945

14 Battery
Standard V/Ah 96/606 96/945

Driven Motor kW 35 35
15 Motor
Pump Motor kW 52 52

Front/number 8.75-15/4 8.75-15/4

16 Tire
Rear/number 250-15/2 250-15/2

36
序号 项 目 CPD60-XD3 CPD60-XD3-I

1 Rated lifting capacity kg 6000 6000

2 Load center distance mm 600 600

3 Mast maximum lift height mm 3000 3000

4 Free lift height mm 160 160

5 Mast Tilt angle (front/back) (°) 5/10 5/10

6 Maximum travel speed(full load) km/h 15 15

7 Maximum lifting speed (full load) mm/s 340 340

8 Maximum grade ability (full load) % 15 16

9 Minimum outside turning radius mm 3050 3050

10 Minimum ground clearance mm 183 183

11 Maximum braking distance m 2.5 2.5

Length(to fork
mm 3195 3195
face)

12 Dimensions Width mm 1870 1870

Height to
mm 2565 2565
overhead guard
Include battery
13 Service weight kg 9600 9030
box

Model 9PZS750 CATL

14 Battery
Standard V/Ah 96/720 96/542

Driven Motor kW 35 35
15 Motor
Pump Motor kW 40 40

Front/number 355/62-15/2 355/62-15/2

16 Tire
Rear/number 250-15/2 250-15/2

37
序号 项 目 CPD70-XD3 CPD70-XD3-I

1 Rated lifting capacity kg 7000 7000

2 Load center distance mm 600 600

3 Mast maximum lift height mm 3000 3000

4 Free lift height mm 160 160

5 Mast Tilt angle (front/back) (°) 5/10 5/10

6 Maximum travel speed(full load) km/h 15 15

7 Maximum lifting speed (full load) mm/s 320 320

8 Maximum grade ability (full load) % 15 15

9 Minimum outside turning radius mm 3050 3050

10 Minimum ground clearance mm 183 183

11 Maximum braking distance m 2.5 2.5

Length(to fork
mm 3200 3200
face)

12 Dimensions Width mm 1870 1870

Height to
mm 2565 2565
overhead guard
Include battery
13 Service weight kg 10280 9400
box

Model 9PZS810 CATL

14 Battery
Standard V/Ah 96/810 96/542

Driven Motor kW 35 35
15 Motor
Pump Motor kW 40 40

Front/number 355/62-15/2 355/62-15/2

16 Tire
Rear/number 250-15/2 250-15/2

38
序号 项 目 CPD80-XD3 CPD80-XD3-I

1 Rated lifting capacity kg 8000 8000

2 Load center distance mm 600 600

3 Mast maximum lift height mm 3000 3000

4 Free lift height mm 175 175

5 Mast Tilt angle (front/back) (°) 5/10 5/10

6 Maximum travel speed(full load) km/h 14.5 14.5

7 Maximum lifting speed (full load) mm/s 300 300

8 Maximum grade ability (full load) % 14 14

9 Minimum outside turning radius mm 3050 3050

10 Minimum ground clearance mm 183 183

11 Maximum braking distance m 2.5 2.5

Length(to fork
mm 3220 3220
face)

12 Dimensions Width mm 1945 1495

Height to
mm 2565 2565
overhead guard
Include battery
13 Service weight kg 12180 11230
box

Model 9PZS945 CATL

14 Battery
Standard V/Ah 96/945 96/542

Driven Motor kW 35 35
15 Motor
Pump Motor kW 40 40

Front/number 355/50-20/2 355/50-15SE/2

16 Tire
Rear/number 250-15/2 250-15/2

39
序号 项 目 CPD90-XD3 CPD90-XD3-I

1 Rated lifting capacity kg 9000 9000

2 Load center distance mm 600 600

3 Mast maximum lift height mm 3000 3000

4 Free lift height mm 200 200

5 Mast Tilt angle (front/back) (°) 5/10 5/10

6 Maximum travel speed(full load) km/h 13.5 13.5

7 Maximum lifting speed (full load) mm/s 280 280

8 Maximum grade ability (full load) % 12 12

9 Minimum outside turning radius mm 3350 3350

10 Minimum ground clearance mm 183 183

11 Maximum braking distance m 6 6

Length(to fork
mm 3695 3695
face)

12 Dimensions Width mm 1969 1969

Height to
mm 2565 2565
overhead guard
Include battery
13 Service weight kg 12960 11750
box

Model 12PZS1104 CATL

14 Battery
Standard V/Ah 96/1104 96/606

Driven Motor kW 35 35
15 Motor
Pump Motor kW 52 52

Front/number 8.25-15/4 8.25-15/4

16 Tire
Rear/number 250-15/2 250-15/2

40
序号 项 目 CPD100-XD3 CPD100-XD3-I

1 Rated lifting capacity kg 10000 10000

2 Load center distance mm 600 600

3 Mast maximum lift height mm 3000 3000

4 Free lift height mm 200 200

5 Mast Tilt angle (front/back) (°) 5/10 5/10

6 Maximum travel speed(full load) km/h 13.5 13.5

7 Maximum lifting speed (full load) mm/s 250 250

8 Maximum grade ability (full load) % 12 12

9 Minimum outside turning radius mm 3350 3350

10 Minimum ground clearance mm 183 183

11 Maximum braking distance m 6 6

Length(to fork
mm 3705 3705
face)

12 Dimensions Width mm 2038 2038

Height to
mm 2565 2565
overhead guard
Include battery
13 Service weight kg 13780 13180
box

Model 12PZS1260 CATL

14 Battery
Standard V/Ah 96/1260 96/606

Driven Motor kW 35 35
15 Motor
Pump Motor kW 52 52

Front/number 300-15/4 300-15/4

16 Tire
Rear/number 250-15/2 250-15/2

41
序号 项 目 CPD80-XLD3 CPD80-XLD3-I

1 Rated lifting capacity kg 8000 8000

2 Load center distance mm 900 900

3 Mast maximum lift height mm 3000 3000

4 Free lift height mm 200 200

5 Mast Tilt angle (front/back) (°) 5/10 5/10

6 Maximum travel speed(full load) km/h 14.5 14.5

7 Maximum lifting speed (full load) mm/s 300 300

8 Maximum grade ability (full load) % 13 13

9 Minimum outside turning radius mm 3350 3350

10 Minimum ground clearance mm 183 183

11 Maximum braking distance m 6 6

Length(to fork
mm 3705 3705
face)

12 Dimensions Width mm 1969 1969

Height to
mm 2565 2565
overhead guard
Include battery
13 Service weight kg 13530 12480
box

Model 9PZS945 CATL

14 Battery
Standard V/Ah 96/945 96/606

Driven Motor kW 35 35
15 Motor
Pump Motor kW 52 52

Front/number 8.25-15/4 8.25-15/4

16 Tire
Rear/number 250-15/2 250-15/2

42
5. Safety instructions places, be safely secured and take care
not to slip.
1. Only trained and accredited operators are
– Be careful do not be scalded when
permitted to operate the forklift truck.
inspecting the motor, controller and etc.
5. Whenever you discover a fault, stop the
forklift, hang a "DANGER" or "OUT OF
ORDER" sign on it, remove the ignition key
and notify a manager. The truck may only be
used after the fault has been eliminated.
– Arrange for immediate repair in the event
2. Operators must wear a helmet, work of a fault when lifting or driving uphill or
shoes and overalls. downhill, or a leakage of battery
electrolyte, hydraulic oil or brake fluid.

3. Never carry people.

6. Batteries generate explosive gases. Keep

sparks and open flames away from the
battery.
– Keep tools away from the battery
terminals to prevent sparks or
4. Inspect the truck at periodic intervals for
short-circuits.
leaks, deformation, defects, etc. the life of the
7. The truck is designed to operate on solid
truck will be shortened or an accident could
and flat cement, asphalt or concrete surfaces.
occur.
Check the road condition in advance.
– Make sure to replace the “key safety
– The truck is designed to operate in the
parts” during periodical inspection.
following climatic conditions: temperature
– Wipe off oil, grease or water from the floor
range -20 ℃ to 50 ℃; maximum wind
board and foot and hand controls.
speed 5 m/s; maximum relative air
– Strictly prohibit smoking and spark near
humidity 90% (at 20°C).
the storage battery when checking it.
– The truck is not suitable for use in
– When performing maintenance on the
flammable or explosive working
mast, front and rear lights, or other high
environments.

43
– Altitude not exceeds 2000m. 14. Select appropriate attachments and tools
8. Never mount or dismount the forklift while according to the shape and material of the
it is in motion. Always use the safety step and loads to be handled.
safety handgrip when mounting and – Do not lift loads by suspending ropes from
dismounting. the forks or attachment, as the ropes may
slip off. If necessary, arrange for a lifting
hook or jib to be attached by someone
qualified to perform heavy lifting tasks.
– Be careful not to let the forks touch the
floor, so as to avoid damaging the fork tips
or driving surface.
15. Know the load capacity of the forklift and

9. Never attempt to work the controls unless attachments, and never exceed it. Do not use

property seated. people as an additional counterweight.

– Before starting the vehicle, adjust the seat

position to facilitate hand and foot control.
10. Before starting up, make sure that:
– The seat belt is fastened;
– The hand brake is released;
– The direction lever is in neutral;
– No person near the forklift.
– Before turning on the power, do not 16. During driving, mobile phones and other
depress the accelerator pedal or operate electronic products cannot be used, and the
the lift or tilt levers focus is on work.
– Operate the controls smoothly and do not 17. Keep your head, hands, arms, feet and
jerk the steering wheel. Avoid sudden legs within the confines of the forklift at all
stops, starts or turns. Sudden braking times.
may cause the vehicle to tip over.
11. Operate stably and correctly, no sudden
brake or turn.
-- Emergency brake has the danger of tipping
over.
12. Always look in the direction of travel and
keep a clear view of the travel path. 18. Pallets and skids should be strong
– It is especially important to look in the enough to bear the weight of the load. Never
direction of travel when reversing. use damaged or deformed pallets.
13. Other person is not allowed to sit on the fork, 19. Hangcha can provide users with a variety
tray or forklift. of attachments including rotating clamps, flat

44
clamps, side-shift forks, jibs, etc. Such height. If unavoidable, make the load stable
attachments are for special uses only. and secure. When handling bulky loads which
Modifications to attachments must be restrict your vision, operate the forklift in
authorized by the manufacturer. Do not reverse or have a guide. When using a guide,
attempt to modify attachments yourself. make sure you know and understand the
20. The overhead guard prevents cargo from meaning of all hand, flag, whistle or other
falling onto the operator. The load backrest signals being used. When transporting long
ensures the stability of loads. Do not use a loads such as lumber, piping and oversized
forklift without the overhead guard and load cargo, or operating vehicles with elongated
backrest. attachments, pay close attention to the front
21. Never permit anyone to walk or stand end when driving around corners or along
under upraised forks or attachments. Do not narrow aisles and be aware of other people.
allow anyone to stand on the forks. 25. Use minimum forward and reverse tilt
when stacking and unstacking loads. Never tilt
forward unless the load is slightly above the
stack or at low lift height.
– When stacking loads on a high place,
make the mast vertical at a height of
15–20 cm above the ground and then lift
the load. Never attempt to tilt the mast
beyond vertical when the load is raised
22. Never place your head or body in high.
between the mast and overhead guard. Risk of – To remove loads from high places, insert
serious injury or death due to entrapment. forks into the pallet, lift slightly and drive
– Never place your hands in between the backwards, then lower the load. Tilt the
inner and outer masts. mast backwards after lowering. Never
attempt to tilt the mast with the load
elevated.
26. It is dangerous to travel with the forks
elevated, regardless of whether loaded or not.
When travelling, the forks should be 15–30 cm
from the ground with the mast tilted backward.
23. Off-center loads may fall easily when Do not operate a sideshift mechanism when
turning corners or driving on uneven surfaces the forks are raised and loaded. This will
and increase the risk of the vehicle tipping cause the forklift to be unbalanced.
over. 27. When operating in congested areas, be
24. Do not stack loads on forks in such a way aware of intersections, trailing ropes,
that the top of the load exceeds the backrest entrances/exits and hanging objects.

45
– Slow down and sound the horn at cross
aisles and other locations where vision is
obstructed.
– Turning speed should be limited to 1/3 of
the vehicle's top speed.

28. Make sure to keep your distance from the

roadside or platform edge.
29. When driving over a ship's gangway or a 31. Do not allow cargo to move away from the

bridge, make sure that it is properly secured centre of the forks. Off-centre loads may fall

and strong enough to withstand the weight of easily when turning corners or driving on

the forklift. uneven surfaces and increase the risk of the

30. When operating a loaded forklift, climb vehicle tipping over.

inclines with the front end of the machine

pointing uphill.
– When operating an unloaded forklift,
descend inclines with the front end of the
machine pointing downhill.
– Never turn sideways on an incline
because of the danger of the forklift
turning over. 32. Never lift loads with the truck inclined.
Avoid loading and unloading work on a grade.
33. Never permit anyone to stand or walk
under upraised forks or attachments. If
unavoidable, choose a safe place and support
forks with wooden blocks to prevent the
possibility of them dropping or moving
unexpectedly.
34. Inspect the surface over which you will
run. Look for holes, drop-offs, obstacles,
protrusions and anything that might cause loss
of control or bumps.
– Clear away rubbish and debris and pick
up items that might puncture a tire or

46
 unbalance the load. 38. The labels and signs on the vehicle
– Slow down on wet/slippery areas. Do not provide warnings and operating instructions.
drive near the edge of the travel path; if During operation, adhere to the requirements
unavoidable, be extra cautious. of the manual as well as the labels and signs
– Do not use the forklift during sandstorms, on the vehicle. Inspect the labels and signs,
snowfall, lightning, torrential rain, and replace any that are damaged or missing.
typhoons or other harsh weather 39. The workplace should be equipped with
conditions. Above all, avoid using the fire extinguishers. Users can also select a
forklift where wind speeds are greater vehicle equipped with fire extinguisher. The
than 5 m/s. fire extinguisher is generally installed on the
35. Controller is equipped with accumulator. rear leg of the safety frame and is easily
Forbid to touch within B+ and B- to prevent accessible.
from wounding by electricity. Before checking – Drivers and managers need to be familiar
or cleaning, please connect loads (contactor with the location and use of fire
circuit or horn for example) between B+ and B- extinguishers.
first to discharge for capacitor of controller.

40. Small loads should be carried on a pallet

and not placed directly onto the forks.
41. Refrigerator type truck is not allowed to
36. Park the forklift on a level surface and
store in the refrigerator when power off
apply the handbrake securely. If parking on an
42. Never wash the forklift with water.
incline is unavoidable, be sure to block the
43. If fork arms/locking pins joint imperfectly，
wheels.
unexpected drop may occur.
– Lower the forks to the floor and tilt slightly
44. Forklift operator to ensure compliance
forward. Turn off the key switch and
with the requirements of the scene illumination,
remove the key.
forklift operation at night, you should open the
– Disconnect the battery plug.
truck lighting.
– Park the forklift away from naked flames
45. Only in the event that the truck
and sparks.
manufacturer is no longer in business and
37. When the truck is unable to drive, drag the
there is no successor in the interest to the
truck to safe place. Do not tow a truck whose
business, may the user arrange for a
steering system or braking system has been
modification or alteration to a powered
damaged.

47
industrial truck, provided, however, that the
user.
a) Arranges for the modification or alteration
to be designed, tested and implemented
by an engineer(s) expert in industrial
trucks and their safety,
b) Maintains a permanent record of the
design, test(s) and implementation of the
modification or alteration,
c) Approves and makes appropriate
changes to the capacity plate(s), decals,
tags and instruction handbook, and
d) Affixes a permanent and readily visible
label to the truck stating the manner in
which the truck has been modified or
altered, together with the date of the
modification or alteration and the name
and address of the organization that
accomplished those tasks.

48
6. Truck Lifting, Carrying and Towing
Lifting
Securely fasten wire ropes to the lifting holes in both ends of the outer mast crossbar and to the
counterweight hook, and then hoist the forklift with a lifting device. The wire rope fastened to the
counterweight end must pass through the gap in the overhead guard, without putting stress on the
overhead guard.

WARNING
 Only use the lifting tools with enough load.
 Fully tilt the mast backward when lifting.
 When assembling lifting tool, notice that the lifting tool will not touch forklift part or
overhead guard when lifting.
 Do not lift a forklift by its cab frame (overhead guard).
 Never walk under a forklift when it is being lifted.

49
Carrying
Forklift trucks are generally used for loading, unloading and short-distance transportation. They
are not designed to be a long-distance mode of transport. A forklift that needs to be transported
over a long distance should be transported in a ship, train or a truck having a load capacity over
13T.
Procedures：
– Park the forklift on the lorry or trailer, and pull up the parking brake.
– Tie the tension belt on the mast upper beam and counterweight, and use clamping
device to strain the tension belt.
– Block the front and rear wheel of the forklift with wedge wood.

WARNING
 When fixing forklift, take effective measures according to specific condition to
guarantee the safety of transportation.
 Correctly fix the forklift when transporting by lorry or trailer.
 Chock the forklift to avoid accident movement.
 Only use tension belt with big enough nominal strength or fasten the belt to fix the
truck.

50
Towing
Forklift is not permitted to use for daily traction or traction task
Towing pin in the lower counterweight is only used for the following occasions:
– Forklift malfunctions on the working road and move the truck urgently.
– Use when forklift gets into trouble and cannot drive(wheels get stuck in pits etc.)

Procedures：
– Turn off the key switch and disconnect the power plug.
– Release the parking brake.
– Put the direction lever in neutral.
– Fasten the wire rope for traction.
It can drag forklift.

WARNING
 Don’t tie the steel wire ropes on the unfixed position.
 Don’t carry a load to steel wire ropes suddenly.
 The truck would be damaged if you tow it with the electric lock working.

51
7. The structure and stability of truck
Prevent the forklift to turn over! It is very important for operator to know the truck’s
structure and relationship between load and stability.
The structure
CAUTION of the truck

The forklift truck essentially consists of the lifting device (forks

and mast) and the truck itself (with tires).
The front wheels are the fulcrum of the forklift and keep the
centre of gravity of the forklift and load balanced.
The relationship between the forklift's centre of gravity and
the load's centre of gravity is very important to maintaining
the operation of the forklift.

CAUTION Load center

The forklift handles loads of different shapes, from crates to

boards and elongated objects. In order to assess the forklift
and its stability, it is very important to distinguish between the
centres of gravity of different-shaped loads.

WARNING
If the forklift begins to tip over, do not attempt to jump off. The truck will tip much faster than you
can jump. Spread your feet and grip the steering wheel with both hands to keep yourself within
the confines of the forklift.

Fasten Seatblet

IN CASE OF TIP-OVER
Follow these
WARNING instructions： Lean Away Hold on Tight Brace Feet Do Not Jump!

52
 CAUTION the max load and load center

The horizontal distance between the centre of gravity of the

load on the forks and the backrest or the front face of the
forks (whichever is shorter) is called the load centre
distance. Maximum load is the maximum load that a forklift
truck can carry at a standard load centre distance. The
relationship between maximum load and load centre
distance is stipulated in the forklift truck's load capacity
graph. If the load centre distance moves towards the front of
the forks, the overall centre of gravity shifts forward.
Therefore, the load capacity decreases.

53
 Gravity and
CAUTION stability

Forklift stability depends on the common centre of gravity

of the forklift. When the forklift is unloaded, the centre of
gravity (CoG) remains unchanged. When the forklift is
loaded, the centre of gravity is formed by the combined
centre of gravity of the forklift and load.
The load's centre of gravity depends on whether the mast is
tilted forward or backward, raised or lowered, which means
that the combined centre of gravity also changes
accordingly.
The forklift's combined centre of gravity is determined by the
following factors:
– Load size, weight and shape;
– Lifting height;
– Mast tilt angle;
– Tire inflation pressure;
– Acceleration, deceleration and turning radius;
– Driving surface conditions and inclination;
– Attachment type

the stability zone of the center of

CAUTION gravity

In order to stabilize the forklift, the combined centre of

gravity must be located inside a triangle formed by the front
wheels and the midpoint of the rear axle.
If the combined CoG is located on the front axle, the two
front tires will form a fulcrum point on which the forklift will tip
forward. If the combined CoG moves out of the stability
triangle, the forklift will tip in the direction that the combined
CoG has moved.

54
 the load
CAUTION capability chart

This graph shows the relationship between the position of

the load centre distance and the maximum load. Prior to
loading, check whether the load and the load centre distance
are within the limits of the load capacity graph. If a load has
a complex shape, the heaviest part of the load should be
centred over the forks and close to the load bracket.

speed and
CAUTION acceleration

A stationary object will remain stationary unless an external force acts on it. Similarly, in the
absence of an external force, a moving object will continue moving at the same speed. This is
inertia.
Due to inertia, a rearward force is exerted when the forklift starts moving, and a forward force
is exerted when the forklift stops moving.
Sudden braking is dangerous because it generates a large forward force that will cause the
forklift to tip over, or the load to slide off.
When the forklift turns a corner, a centrifugal force is exerted outward from the centre of the
turn. This force pushes the forklift outward and makes it tip sideways.
The truck has narrow lateral stability, so cornering must performed slowly to prevent the forklift
from tipping sideways. If the forklift is handling an elevated load, the overall centre of gravity is
higher and therefore the forklift is more prone to forward or lateral tipover.

55
8. During running-in
New forklifts should initially be run under low-load conditions. In particular the following
requirements should be met within the first 100 hours of operation:
– Battery over discharge must be prevented during initial use.
– In general, the battery should be recharged promptly when the charge level has decreased to
20% of its capacity.
– Required preventive maintenance must be carried out thoroughly.
– Avoid sudden braking, acceleration or cornering.
– Carry out oil changes or lubrication ahead of schedule in accordance with regulations.
– Limit the load weight to 70%～80% of the rated load.

56
9. Routine Maintenance
Careful, all-round maintenance will keep the
forklift truck in good working condition. It
guarantees the safety of the forklift and your 1
3 8
personal safety at work.
5 6
WARNING
 In addition to testing lights and 7 4
checking operating performance, 2

before checking the electrical

system, turn off the key switch and
disconnect the battery plug.
 Never use a forklift that has any kind Rear wheel（steering wheel）
of fault.
 Even a small fault can cause a
serious accident.
1. Check for leakage of hydraulic oil, 1
electrolyte and brake fluid 3 6
Check for oil spills or leakage around the
hydraulic fittings, battery, and brake systems
5 4
by hand feeling or carrying out a visual
2
inspection. Never use an open flame.
2. Check wheel fixation
– Park the truck.
– Screw down wheel retaining nut with
Change of tires
spanner crosswise.
Bolt tightening torque：

Rear wheel hub Warning

Front wheel hub nut
nut • When using an air compressor, first
Single wheel Dual wheel adjust the air pressure of the compressor.
Failure to do so will cause a serious
588～736
363～490 Nm 441～588 Nm
Nm accident, since the compressor delivers the
Front wheel（Driving wheel） maximum pressure.
• To ensure safety, put the tire in a
defend casing while inflating.

57
 ○
13 Adjust tire pressure to specified value.

Front wheel

①Park forklift truck on level concrete;

② Start engine and raise mast about
100mm height.
③ Place chocks behind rear wheels to
prevent movement of forklift;
④ Loosen wheel nuts 1-2 turns each by
turning them counter-clockwise;
⑤ Tilt mast fully backward, and place a
wooden block under each side of outer
mast;
⑥ Tilt mast forward until front wheels are
raised from surface;
Caution

Do not loose nuts before the front wheels

leave the ground.
⑦ Support truck by putting wooden blocks
under both sides of the front truck frame.
Stop the engine.
⑧ Take out the wheel nuts and replace the
front wheel.
Caution

a. When removing tire from wheel rim, do

not remove rim set bolts and nuts before
releasing air; Rear wheel
b. Make sure that wooden blocks used to ① Park forklift trucks on level concrete.
support lift truck are solid, one-piece units. ② Pull the parking brake lever and place
c. Never get under forklift while it is
chocks before front wheels to prevent
supported only by wooden blocks. movement of forklift.
⑨ Retighten the wheel nut temporarily. ③Put the lifting jack under the
⑩ Start the engine, and take out the counterweight.
wooden block. Caution ： Make sure the jack capacity is
○11 Tilt backward the mast and lower down greater than 2/3 of service weight of forklift.
the mast slowly, then take out the wooden ④ Loosen wheel nuts 1-2 turns by turning
block under the outer mast and rear wheel. them counter-clockwise.
○12 Retighten the wheel nut with correct
torque.

58
 Warning

Do not remove wheel nuts until rear tires

are raised from ground.

⑤ Raise the forklift with jack until rear

wheels off the ground. Support forklift truck
by putting additional wooden blocks under
both sides of the front truck frame as shown
below.
⑥ Take out the wheel nut of rear wheel,
and then replace the wheel.

Warning

a. When removing tire from wheel rim,

do not remove rim set bots and nuts before
releasing air;
b. Make sure that wooden blocks
used to support lift truck are solid,
one-piece units;
c. Never get under forklift while it is
supported only by wooden blocks.
⑦ Retighten nuts as shown in figure below.
3. Brake pedal check
⑧ Remove the wooden block under
chassis body. Let down the forklift slowly. – Depress the brake pedal and check that it
Then take away the chocks and jack from moves freely without jamming.
the rear part of the front wheel. – The correct braking distance without a
⑨ Retighten the wheel nut with the correct
load is 2.5 metres.
torque. Please refer to Tightening Torque
Table. – Adjust pedal height: regulate the limit bolt
⑩Adjust tire pressure to specified value. so that the midpoint of the upper face of
the pedal pad is 115-125mm from the
front baseplate.
– Adjust the length of the pushrod of the
brake master cylinder so that the pedal
free play is 1–3mm.
– The brake light switch should turn on fully
when the brake pedal is gradually
depressed 10–20mm.
4. Hand brake lever check
The operating force is regulated by means of
an adjusting screw on the rod tip. Twist
clockwise to increase the operating force; twist
anti-clockwise to reduce it.
Make sure that when pulled tight and released,

59
the hand brake lever returns to its original the marks. Add if necessary and then close the
position effectively. cover.

CAUTION
 Depressing the brake pedal helps to
tighten or loosen the hand brake
lever.
"65"
5. Accelerator pedal check 65
"60"

As the accelerator pedal is depressed through "50"

its full stroke, there should be a clear change 50

"30"
in the rate of acceleration, and the pedal
30

should return freely to its original position

when released.
Working device movement make the pipeline
6. Brake fluid check
full of oil, working device reset, and the oil
Check whether the brake fluid level is between
level in the hydraulic oil tank reached the
the scale marks. Top up if necessary. Also
picture scale.
check for air trapped in the brake line.
“30” means liquid level for mast with 3M lifting
height or below
“50” means liquid level for mast with 5M lifting
height or below
“60” means liquid level for mast with 6M lifting
height or below
“65” means liquid level for mast with 6.5M
lifting height or below.
Note: when installing with attachment, add
proper hydraulic oil according to the
CAUTION
 Use pure-grade brake fluid. Do not attachment.
9. Seat adjustment
mix different grades of brake fluid.
Move the seat adjustment lever to the right
 Do not spill brake fluid on painted
surfaces, otherwise it will damage until the seat is comfortably positioned relative

the paint. to the hand and foot controls, then lock in

place. Adjust the weight setting.
 When adding brake fluid, avoid
10. Battery check
getting dust and water in the
Check that the lock pin is securely inserted
reservoir.
and the battery is firmly fixed.
7. Check hydraulic oil
Check the specific gravity of the electrolyte.
Open the front cover, unscrew the hydraulic oil
See Battery section.
filler cap on the rear right side, pull out the
Check where the wiring of both terminals is
dipstick and check whether the oil is between

60
loose or damaged. Adjust or replace the wiring lubrication intervals accordingly. During busy
if necessary. months, increase the number of lubricated
parts.
Depending on the operation of the forklift, coat
the lift guide wheel and the contact surfaces
on the inner and outer sides of the mast with a
layer of grease.
15. Chain tension check
– Raise the forks to a height of 10–15cm
with the mast vertical.
Plug the battery plug and open the cover – Press the middle section of the chain with
Turn on the key switch your thumb to check whether the tension
11. Instrument display check (power, between the left and right chains is
faults) identical.
See Instrument section. – Tension adjustment: loose the lock nut
12. Lift lever, tilt lever, and attachment and turn the adjuster nut to adjust the
lever chains so that they both have the same
Check the lift lever, tilt lever and attachment tension, then tighten the lock nut.
lever for looseness. Make sure that they return
freely to the original position when released.
13. Mast
Check the mast and forks to ensure that：
– Forks are not cracked or bent, and that
they are firmly and correctly installed in
the fork carriage;
– Check the oil cylinder and pipeline for
leakage;
– Check that the rollers turn condition;
– Check the mast for cracks and
deformation;
– Operate the lifting, tilting and attachment
levers, check if the mast operates
16. Steering system check
normally and no noise.
Turn the steering wheel to the left and right to
14. Mast lubrication
check the functionality of the steering system.
Apply grease to the inside and outside of the
17. Turn signal lights, horn, other lights
mast track regularly according to the periodic
check
maintenance and lubrication table.
Push and pull the turn signal switch to check
In heavy or severe operating conditions, adjust
whether the turn signal lights are functioning

61
properly.
Press the horn button to check the sound of
the horn.
Check all other lights and the reversing
buzzer.
18. Battery maintenance
Refer to Battery section.
19. Others
Check for abnormal noise.

62
10. Starting and Operation Driving
Slowly depress the accelerator pedal until the
WARNING forklift starts to travel forward or backward.
 Never start the truck before any
Decelerating
damage or failure to the truck has
Slowly release the accelerator pedal, the
been settled.
forklift will slow down.

Starting
CAUTION
– Open the cover, connect the battery plug, Always decelerate in the following
and then close the cover. situations:
 When turning;
 When approaching cargo or pallets;
 When approaching stacked cargo
areas;
 When entering narrow aisles;
 When ground or road is in poor
condition.
– Put the direction lever in the neutral
position. WARNING
– Turn on key switch.  Never depress the accelerator pedal
– Grip the steering wheel knob with your left and the brake pedal at the same
hand and turn on the key switch with your time.
right hand.
– Tilt mast backwards Steering
– Operate the lifting lever to raise the forks A forklift is not like an ordinary vehicle in that it
10 to 20cm off the ground. Operate the tilt has rear-wheel steering, which means that the
lever to tilt the mast all the way back. rear counterweight swings outward when
– Operate the direction lever cornering.
– To drive forward: push the direction lever Decelerate, then rotate the steering wheel in
forward; the direction that you want to turn. The
– To reverse: pull the direction lever back. steering wheel needs to be turned slightly
– Release hand brake lever: earlier than it would in a vehicle with
– Depress the brake pedal, push the hand front-wheel steering.
brake lever all the way forward.
– Grip the steering wheel knob with your left
hand and rest your right hand on the
steering wheel.

63
 – Lifting the load：
CAUTION
 Drive slowly and operate the - First raise the forks 5–10cm off the

steering wheel carefully. Ensure that ground and make sure that the load is

there is sufficient room for the rear secure.

end to swing out when making the - Tilt the mast all the way back, raise the

turn. load 5–10 cm off the ground, then move

off.
Parking
– When a bulky load restricts vision, the
– Decelerate, then depress the brake pedal
forklift should be driven in reverse, except
until the vehicle stops.
when driving up a gradient.
– Get the shift lever in neutral.
– Apply the hand brake.
– Lower the forks to the floor and tilt the
mast all the way forward.
– Turn the key switch to the OFF position,
disconnect the battery plug, remove the
key and keep it in a secure place.

CAUTION
 Dismount carefully — do not jump
off.
 The vehicle must not be parked
along driving routes.

Stacking
– Slow down when approaching the deposit
location.
– Stop the vehicle in front of the deposit
location.
– Check the condition of the deposit
location.
Loading – Tilt the mast forward so the forks are

– Adjust the spacing between the forks to parallel to the floor and raise them until

ensure a well-balanced load they are slightly above the drop-off

– Position the forklift square to the load. position.

– Pallets should be placed symmetrically – Inch forward until the load is over the

with respect to the forks. drop-off position, then stop.

– Insert the forks into the pallet as far as – After making sure that the load is squarely

possible over the drop-off position, slowly lower the

64
 forks and then check that the load is
CAUTION
safely deposited.
 When it is difficult to insert the forks
– To perform necessary lifting and tilting
fully into the pallet, drive forward so
operations, reverse the forklift to remove
that the forks are inserted to 3/4 of
the forks from the loads.
their length. Raise the forks by
– Make sure that the fork tips are clear of
5–10cm, back up 10–20cm, then
the load, then lower the forks to 15–20 cm
lower the pallet or rack. Drive
off the ground.
forward again until the forks are fully
– Tilt the mast all the way back
inserted.

CAUTION – Raise the forks 5–10cm off the stack.

Slow down to the below condition: – Look around the vehicle to make sure
 When turn; there are no obstacles in your path, then
 Approach loads or tray; back up slowly.
 Approach stock area; – Lower the forks 15–20cm off the ground,
 Enter narrow aisle; tilt the mast all the way back, then carry
 Bad ground or road condition. the load to its destination.

Post-operation checks
WARNING After use, clean the forklift and carry out
 Do not tilt the mast when the load is
the following checks：
raised above 2 m.
– Check for damage and oil leaks.
 Do not dismount or leave a vehicle
– Add lubricant if required.
unattended with a load elevated.
– Check tires for damage and foreign
bodies embedded in the treads.
Unstacking
– Check for loose wheel nuts.
– Slow down when approaching the pick-up
– Check the electrolyte level.
location.
– If the forks have not been elevated to their
– Stop when the forklift is 30cm away from
maximum height during the day, after
the load.
finishing work, raise them to their
– Check the condition of the load.
maximum height 2 to 3 times.
– Tilt the mast forward until the forks are
parallel to the floor, then raise the forks to CAUTION
the level of the pallet or rack.  If you discover any defects or faults,

– Make sure that the forks are aligned with have them repaired immediately.

the pallet, move forward slowly and insert  Do not use the forklift until it has

the forks all the way into the pallet, then been fully repaired.

stop.

65
11. Storage the battery electrolyte on a monthly basis.
– Apply one equalizing charging every
Daily storage
month.
– Park the forklift in a designated area and
chock the wheels. WARNING
– Put the shift lever in neutral.  The wooden blocks must be single
pieces that are sturdy enough to
– Engage the hand brake.
support the weight of the forklift.
– Turn off the key switch. Operate the
 Do not use wooden blocks that are
multi-way valve lever several times to
more than 300mm (11.81 inches) in
release the residual pressure in the
height.
cylinders and lines.
 Raise the forklift just enough to
– Disconnect the power plug
allow it to be placed onto the
– Remove the key and keep it in secure
wooden support blocks.
place.
 Place wooden blocks of identical
– Refrigerator type forklift is not allowed to
size under left and right sides of the
park in the refrigerator when off power.
frame.
Long-term storage
 After supporting the forklift with the
Pay attention to the following points, in
wooden blocks, rock the forklift back
addition to those for daily storage, when
and forth from all four sides to make
storing the forklift truck for extended periods：
sure that it is safely secured.
– Disconnect the battery plug to prevent
Forklift operation after long-term
discharge and store the vehicle in a dark
storage
place.
– Remove anti-corrosion agent from
– Apply anti-corrosion agent to shafts, rods
exposed parts.
and other exposed parts.
– Drain out the gear oil in the drive axle and
– Cover the breather and other openings
reduction gearbox, then fill with fresh oil.
where moisture may enter.
– Charge the battery, install it on the forklift
– Fully cover the vehicle with a sheet or
and connect to the battery cables.
similar.
– Carry out a careful inspection before
– Lubricate with oil or grease where
using the forklift, checking motor start-up,
necessary.
forward and reverse drive, steering and
– Support the underside of the body and
the lifting, lowering and forward/backward
counterweight with wooden blocks to
tilt functions.
reduce the weight on the rear wheel.
– Start the forklift at least once a week.
Raise the forks to their maximum height
several times.
– Measure the specific gravity and level of

66
12. Battery water and dirt can cause automatic discharge.

Battery maintenance
It is important that the battery be properly
charged in time, which will affect vehicle
performance and battery life.
Over-discharge and over-charge will reduce
（ 7） Tighten the vent cap and clear the
battery life.
small holes to prevent dust from entering the
If there is abnormal situation such as odor, too
electrolyte.
fast electrolyte drop, high electrolyte
（8）Measures in winter: Maintain a good
temperature, please contact the agent or
charging environment. Do not park the truck
Hangcha after-sales service.
out in the cold or in the freezer for long time
1.1 Maintenance precautions especially after the battery is used, it is
（ 1 ） Maintenance personnel must forbidden to put it in a low temperature
undergo rigorous training. environment below 0 °C.
（2）Never connect the battery's positive
Warning
and negative terminals to each other, as this
1. It is forbidden to place metal components
may cause a spark, fire or explosion.
and any other objects on it, and it is
Fireworks, mobile phones and electronic
forbidden to connect the two poles of the
products are strictly prohibited.
battery to avoid short circuit, spark, or even
explosion.
2. The electrolyte contains sulfuric acid,
which is highly corrosive. If it comes into
contact with the body, it may cause burns.
Wear goggles, rubber shoes and rubber

（ 3） Maintain and replace batteries and gloves when handling. Contact with
clothing: take off immediately. Contact with
charge in designated well-ventilated areas,
skin or eyes: flush with running water for 15
and place fire and power warning signs in
to 20 minutes. Accidental ingestion: drink
conspicuous places. plenty of water and see a doctor
（4）Check the electrolyte level daily. Do immediately.
not use the truck when the electrolyte volume 3. Explosive gases are generated inside
is low. Fill the distilled water (after charging) the battery, smoking, flames and sparks
and always keep the electrolyte level at the are prohibited. Mobile phones and other
specified height. electronic products are prohibited.
（5）The specific gravity of electrolyte was Otherwise, the battery will explode.
measured weekly. 4. Use a damp cloth when cleaning (no dry
（ 6 ） Make sure the battery surface is cloth or fabric) to prevent static electricity.
clean and dry. The connection terminals
should be kept clean and dry. Surface area

67
1.2 Daily, weekly, monthly, long-term Time Content
storage maintenance
Time Content The battery should be stored in a

Long-term
storage
dry, ventilated place. Before storing
1. After the battery is discharged, it
the battery, fully charge it, and then
needs to be charged in time.
charge it once every 30 days.
2. Check the electrolyte level. When
the electrolyte level is low, add Specific gravity detection and
distilled water to the specified liquid conversion
level (after charging). If it is too high,
The specific gravity of the electrolyte is tested
it should be sucked out
at least once a week.
Daily

3. Check if the vent cap is damaged.

2.1 Specific gravity detection
4. Keep the battery surface clean
（ 1 ） Use a thermometer to measure the
and tidy.
temperature of the electrolyte.
5. Check whether the appearance is
（ 2 ） Vertically insert the flexible tube of a
deformed, whether the surface is pipette-type density meter into the
oxidized, stripped, whether the electrolyte and squeeze the bulb.
installation position is offset, Electrolyte will enter the glass tube and
whether the box is damaged or not. the float will rise up.

1. The specific gravity of the （3）Take the density reading.

electrolyte is tested and recorded. Caution

2. Check if the small hole of the vent Hold the density meter vertically so that the
cover is blocked and dredged to float does not touch the sides of the glass
prevent dust from falling into the tube.
Weekly

battery.
3. Check if the battery stud bolt
connection is loose (use torque
wrench, torque is 25Nm).
4. Check if there is any fluid in the
box and handle it.
1. Check whether the battery stud
bolt is oxidized, whether the battery
Monthly

socket is damaged or deformed, or

there is foreign matter.
2. Equalizing charge is performed
once a month.

68
Use a hydrometer to measure the specific
Warning
gravity of electrolyte.
1. Using a battery when the electrolyte level
is low may lead to overheating and shorten
the life span of the battery.
2. When the amount of electrolyte is not
correct, it will cause the battery to overheat
and even burn the battery and electrical
system components.
3.1 Check electrolyte level
Battery without hydrometer
Electrolyte is 15 ～ 20mm higher than
2.2 Specific gravity conversion splashguard level.
Convert electrolyte density at the standard Battery with hydrometer
temperature of 30oC based on the following Measure electrolyte level by reading the vent
formula: cap hydrometer.
D30＝Dt＋0.0007（t-30）
Wherein：D30——electrolyte density at 30℃
Dt——measured electrolyte density at
t℃.
t——electrolyte temperature during density
measurement.
The specific gravity of the electrolyte
mentioned in the manual refers to the specific
gravity at 30 °C.
Specific gravity of the electrolyte varies with
temperature.
Electrolyte after full charge: specific gravity
1.28 g/cm3
Electrolyte after 80% discharge: specific
gravity 1.14g/cm3

Check the electrolyte level and

add distilled water 3.2 Topping up distilled water

Do not use the truck when the electrolyte is After the charging is completed, distilled water
low. should be added, and the liquid level is
Check the electrolyte level once a day. When 15-20mm higher than protective screening
the electrolyte level is low, add distilled water (that is, in the middle position of the screen).
to the specified surface height (should be But don't overdo it.
replenished after charging).

69
 （5）After topping up, tightly fasten the vent or
battery caps.
（ 6 ） Use a damp cloth to wipe clean the
surface of each battery cell.
（7）Use a squeeze ball pipette to draw off any
excess water.

Procedures： Warning
（1）Wear protective eyewear, rubber boots 1. When adding distilled water, do not
and rubber gloves. exceed the specified maximum level.
（2）Fill a squeeze bulb pipette with a certain Adding too much water may cause
amount of distilled water. electrolyte leakage and damage the forklift
（3）Open all the vent or filler caps on the when charging or discharging the battery.
battery unit. 2. Do not use a dry cloth or fabric to wipe
（4）Inject distilled water into battery cells the surface of the battery to prevent static
using squeeze bulb pipette. electricity from causing an explosion.
Battery with hydrometer
Stop adding water when the red hydrometer Battery charging
float rises and a white line appears.
Warning

1. The forklift should be charged as

soon as possible after use. It must be
charged in time before the battery is 20%
left. Excessive discharge will shorten
battery life.
2. Charge in a designated
well-ventilated place, away from
inflammable and explosive materials, and
place a fire and electric warning sign in
conspicuous places.
3. Open the forklift hood and battery
vent cover while charging to completely
release hydrogen. When charging the
battery, it is forbidden to use an open
flame, mobile phone or other electronic
products to prevent explosion. Do not
charge when thunder.
4. During the charging process, it is
Battery without hydrometer forbidden to suddenly turn off the power
Stop adding water when electrolyte is switch or unplug the battery, otherwise it
15-20mm higher than splashguard level.

70
 will cause sparks and damage the plug and
electrical components. Usually it is
continuously and automatically filled.
5. After the charging is completed,
distilled water should be added, and the
liquid level is 15-20mm higher than
protective screening (that is, in the middle
position of the screen). But don't overdo it. （1）When the forklift meter shows 20% of the
4.1 Charger requirement and selection remaining power, it should be charged in
4.1.1 Charger time.
（1）When the charger is in use, its casing （2）Turn off the forklift key switch and press
needs to be reliably grounded. the red emergency stop button.
（2）Disconnect power when replacing fuse. （3）Open the forklift cover and unplug the
（3）Only qualified professionals are permitted forklift cable from the battery socket.
to disassemble the charger casing for （4）Open the battery venting cover to release
testing or maintenance. the explosive gas, and measure the
（4）Do not rebuild or disassemble charger. temperature of the electrolyte. If it
（5）Take measures to prevent damage exceeds 45 °C, it needs to be naturally
caused by charger overheating in high cooled to below 45 °C, and then charged.
temperature season. If necessary, The electrolyte temperature during
suspend work temporarily. charging should not exceed 55 °C.
（6）Never continuously charge multiple （5）Check if the charger plug and the battery
batteries, which will overheat the charger socket are damaged. After checking the
and may even damage it. After charging, error, plug the battery into the charger
let the charger rest for an hour before plug. It is strictly forbidden to misconnect
re-using it. positive and negative poles.
4.1.2 Charger selection （ 6 ） Plug in the charger and press the
Choose charger according to battery voltage charger's charging switch to charge.
and capacity (see parameter list). Generally, （ 7 ） After the charging is completed, the
the charger current is selected according to charging device is automatically
the middle value of the battery capacity (1/10 powered off. Now disconnect the power
to 1/7), that is, the current = (1/10 to 1/7) of the charger and then unplug the
battery capacity. For example, the battery charger.
capacity is 630Ah, the charger current = (1/10 （8）Check the electrolyte level as required in
~ 1 / 7) 630 = 63A ~ 90A, the choice of the manual. If it is not enough, add
70A-80A charger is most suitable. distilled water (filled with Hangcha pure
Please use the Hangcha pure charger. distilled water).
4.2 Daily charging procedures （9）For those equipped with automatic water
filling system, distilled water should be
added according to the relevant parts of
Operation and Maintenance Manual

71
 (Automatic Water Filling System of
Battery (optional)).
（10）Close the vent cover, clean the battery
surface, and close the battery cover.
Plug the forklift cable plug into the
battery socket and the charging is
completed.
4.3 Equalizing charge

4.3.1 Reason of equalizing charge

With time, the voltage, density and capacity of
a battery tend to become unbalanced. The
voltage and specific gravity of some cells
increase more slowly compared with other
cells when charging, and decrease at a faster
rate when discharging.
Equalizing charge should be applied when any
of the following situations occur：
（1）The discharge voltage frequently falls
below the cut-off voltage;
（2）The discharge current is frequently too
high;
（3）The battery is not charged in a timely
manner after discharge is complete;
（4）The battery frequently gets insufficient
charge, or hasn't been used for a long time;
4.3.2 Equalizing charge method
Please follow the instructions of the charger.
Set to equalizing charge mode and charge.
Equalizing charge is performed once a
month.

72
 Battery specification
Battery of this truck is formed by front and rear batteries in series.

CPD60-XC4 CPD70-XC4 CPD80-XC4 CPD90-XC4 CPD100-XC4 CPD80-XLC4

Item Model
CPD60-XC5 CPD70-XC5 CPD80-XC5 CPD90-XC5 CPD100-XC5 CPD80-XLC5

Length [L] mm 1420 1420 1420 1420 1420 1420

Battery box

Width [W] mm 610 610 610 825 825 825

Height [H] mm 570 570 570 570 570 570

Height [H1] mm 624 624 624 624 624 624

Voltage V 96 96 96 96 96 96

Capacity A.h 720 810 945 1104 1260 945

Allowable lightest kg 1149 1251 1408 1717 1940 1476
(Front Battery)
Allowable lightest kg 1161 1264 1420 1723 1946 1482
(Rear Battery)
Front of the
machine

73
Battery charging
– Park the truck at the appointed charging
area.
– Open the cover

– Take out the battery charging plug from the

truck outlet

– Open each battery filling cap.

74
– Connect the battery charging plug to the
charger plug

WARNING
 Charging cable polarity must keep the
same with the charger output terminal
polarity.
 When the charging cable is connected
to the battery plug, notice that the
polarity keep the same. Otherwise it
may damage battery.

– Start the charger to charge.

After the battery is fully charged, take out
battery charging plug, close each battery filling
cap, and close the cover.

CAUTION
 Charge in appointed and well ventilated place.
 Place No Flame signs when charging.
 Before charging, first check if wire or outlet damaged. Check if battery connector
loosens and tighten.
 Electrolyte temperature during charging should not exceed 50℃, or try to cool, if the
temperature does not drop, suspend charging, after the temperature drops, continue
to charge.

75
Battery replacement

CAUTION
 Before replacing a battery, make sure that the voltage, capacity, weight and
dimensions of the new battery match the forklift specifications.
 Do not use replacement batteries with a different voltage, weight or dimensions
without the manufacturer's permission.

– Park the truck at the appointed area.

– Open the front/rear cover.

– Screw off the handle of left/right battery cover

panels, and take out the left/right battery cover
panels

76
– Dismantle the battery plug and place the
battery cable in the battery box.

– Take down the front/rear battery box locating

pins.

– Choose proper lifting appliance to hook up the

four lifting holes of the battery box.

77
– Lift out the battery.

WARNING
 Lift the battery by attaching hooks to all 4 lifting holes. Do not lift with only 2 of the
holes as this may subject the casing to uneven stress, causing the cells to rupture.
 Do not touch the steering wheel or other equipment when lifting the battery to avoid
damage.
 When lifting up the battery box in lateral, keep stable and lift up slowly, avoid
bumping against the forklift to cause damage.
 Do not discharge the battery liquid waste at will, but dispose it according to local
environment protection law.

78
13. Lithium battery
Lithium battery parameter （CATL）

Item 6t~8t

Length（L） mm 1420
Width（W） mm 610
Height（H） mm 580
Heaviest weight kg 609
Lightest weight kg 580
Rated capacity Ah 542
Rated voltage V 96

Item 9t~10t L8t

Length（L） mm 1500 1500

Width（W） mm 610 610
Height（H） mm 666 666
Lightest weight kg 638 638
Rated capacity Ah 606 606
Rated voltage V 96 96

79
Safety instructions protected to prevent the installation personnel
from contacting during the installation process.
1.1.1 It is strictly forbidden to touch the positive
When installing the system, mechanical
and negative poles of the battery box with both
hoisting should be adopted. When moving to
hands at any time.
the battery system warehouse, the speed
should be slow and the position should be
correct to prevent the extrusion deformation of
the battery box. When the system is connected,
the phenomena of negative and positive pole
1.1.2 Maintenance personnel are required to
reverse connection and short circuit are
hold the qualified electrician certificate and
avoided. In rainy and snowy weather, pay
ENEROC maintenance authorization issued
attention to the protection of connectors to
by the Safety Supervision Bureau in order to
prevent rainwater from entering.
carry out maintenance operations
1.2.2 Inspection after installation: After
1.1.3When operating and maintaining the
installation of the system, check the
battery system, please wear insulting gloves
positioning pin/fixing bolt of the battery system
and take off metal orraments.
to confirm that it meets the installation
requirements. Check the connection of the low
voltage connector is correct/reliable. Check
the high voltage positive and negative cable
connection is correct/reliable. Turn the key

1.1.4 When cleaning forklifts, high-voltage switch to ON gear and the relay should be able

components should be avoided to adverse to suck in normally without battery alarm. If

consequences after contact with water. battery failure alarm occurs, the power supply
should be cut off immediately and the
after-sales service department of our company
should be notified to solve the problem.

Basic terms for lithium ion

battery
Installation instructions 1.3.1. Battery system
1.2.1 Installation requirements : Installation Electric energy storage system, usually
personnel should be on duty with a certificate, including one or more battery modules, battery
wear labor insurance supplies, and pay management system, thermal management,
attention to safety protection. Low voltage high and low voltage lines, connectors and
must be cut off before system installation. The structural components.
high-voltage output interface should be 1.3.2 SOC

80
Refers to the percentage of battery remaining Discharge Temperature : -28 ℃ ~55 ℃ ，
electricity. Storage Environment Temperature: -28 ℃
1.3.3 Nominal voltage
~55℃.
An appropriate approximate value used to
1.4.2 Pre-departure inspection：After the key
represent the voltage of a battery.
switch is closed, confirm that the instrument
1.3.4 Rated capacity
panel has no battery system alarm information.
The capacity value specified by the
Check the remaining power before leaving the
manufacturer when the battery is fully charged
car. It is recommended to charge up to
under specified conditions.
50%~100% before leaving the car. It can not
1.3.5Overdischarge
overdischarge the power battery system.
When the battery voltage is lower than the
Overdischarge will cause irreversible
discharge cut-off voltage, the state can usually
permanent damage to lithium-ion power
be seen as that the battery enters the
battery.
overdischarge state, generally referring to the
1.4.3 Charging instructions: Forklift truck in
state when the battery voltage reaches 0 V or
operation after stopping or battery system
even the voltage is negative.
SOC less than 20%, please charge in time.
1.3.6 Overcharging
Use the special charging equipment
When the battery voltage is higher than the
authorized by the manufacturer to charge. If
maximum charging voltage, the state of the
there is a fault alarm during charging, the
battery can usually be regarded as the state of
power battery system and charger will stop
overcharging.
charging, and the charger will show the fault.
1.3.7 Explosion:
Charging environment should be dry and
The battery shell is broken and solid material
ventilated without flammable and explosive
rushes out of the battery and makes sound.
materials. Cars should be fully charged once a
1.3.8 Fire
week.
Open fire appears in the battery case.
1.4.4 Long-term parking storage: Before
1.3.9 Leakage
parking, it is necessary to confirm the battery
The internal components of the battery
power of the vehicle: 50%-70%. Maintenance
(electrolyte or other substances) leak from the
is carried out every three months.The
battery.
electricity is filled by full charging, and then
1.3.10 CAN
discharged to 50%~70% before parking. The
Communication: Control Area Network,
vehicle has been parked for more than three
Controller Area Network.
months. Please make sure that the dashboard
Instructions for Use alarms before reusing. If so, please contact
1.4.1 Temperature Characteristics of the vehicle manufacturer for maintenance.
Batteries：Working Environment Temperature : Forklift parking environment should be kept
-25 ℃ ~55 ℃ ， Permissible Charging as dry and ventilated as possible, away from
Temperature:0 ℃ ~55 ℃ ， Permissible heat sources.

81
Maintenance the process of charging and using, the
abnormalities that may occur in the power
1.5.1 Outside appearance of inspection box:
battery system are as follows: Battery systems
Check whether there are any debris, obvious
or local temperatures rise sharply. There is
deformation, rust and other abnormal
abnormal odor in any part of the battery
conditions in the battery system outer box.
system. Smoke and fire occur at any part of
1.5.2 National Standard Charging Port: When
the battery system.
the power is off, check whether there are any
1.6.2Emergency plan
abnormal conditions such as debris and rust in
6.2.1Personnel leave the vehicle quickly and
the intPlug-in rface.
dial the alarm phone according to the situation
1.5.3 Plug-in: When the power is off, check
on the spot.
whether the connector is loose or damaged.
6.2.2To ensure personal safety, the following
1.5.4 Parameter Detection: Check the battery
operations are carried out conditionally:
voltage and temperature on the display before
a. Use carbon dioxide or dry powder fire
charging and discharging to ensure that all
extinguishers if the battery harness smokes
values are in the normal range.
and ignites.
Emergency plan
b.If the battery is on fire, use a
1.6.1Scenarios,extreme anomalies
high-pressure water gun to extinguish the fire
Users should establish a good sense of
at a long distance.
security in the use process, strictly prohibit
c. If smoke is inhaled carelessly, please
illegal operation, avoid battery system abuse
transfer it to the doctor as soon as possible.
(overcharge, overdischarge, short circuit,
6.2.3 Contact forklift brand dealers to obtain
extrusion, puncture, environmental
professional treatment advice.
overheating, high current discharge, etc.). In

82
 SLC-96250 Operation instructions for intelligent charger (CATL
battery charger)
Start-up interface

Start-up interface

Click on the icon： , Enter the help description interface.

Click on the icon： or , on-off alarm sound, to turn on the alarm sound state, to

83
turn off the alarm sound state.
The control operation requires password permission. The default password is: 123456.
Click on the boot icon: toggle charging control to turn on or off.
Click on the purple part of the charging status information bar, enter into the single charging
module information display bar.

Click on the icon： , return to main interface.

Click on the reservation icon to set the time for booking mode. The default password is
123456.

Click on the icon ： , enter the password input interface, enter the correct
password into the factory parameter setting interface
Appointment setting instructions:

84
 Password input interface:

Enter the correct password in the password entry box. The default password is 888888.

Click on the icon： , return to help description interface.

Click on the icon：, enter the password modify interface.

Click on the icon： , if the password is entered correctly, enter the parameter setting
interface, otherwise the password input error is prompted. Please enter it again.
Password modification interface

85
 Enter in sequence according to the prompt: Enter the user's old password, enter the new
password for the first time and enter the new password for the second time.

Click on the icon： , if the user's old password is entered correctly, the first time the
new password is entered and the second time the new password is entered, the modification is
successful. Otherwise, the prompt modification fails. Please re-enter.

Click on the icon： , Return to the password entry interface.

Parameter setting interface

Click on the icon： , return to the help description interface.

Parameter setting information: rated voltage, rated current and shunt range are related to
machine hardware, and must not be arbitrarily modified after the factory.
Consult the manufacturer if the above parameters need to be modified. The charging machine

86
number is easy for the user to distinguish, and the user can set it at will.
Debug interface for the factory to adjust the test, users can not operate at will.

Click on the icon： , switch module information backward.

Click on the icon：, return to the main interface.

Click on the icon： , switch module information forward.

Display single power module output voltage, output current, various operating conditions.
BMS information display interface:

Click the icon: to switch the module information forward.

Click the icon: ，to return to the main interface.。

Click the icon:： ，to switch back the module information.。

Following the national standard GBT20234-2015, the information transmitted by various
BMSs is parsed and displayed.

87
Charging process explanation

The charging step：

1. Choose "turn on" charging control mode. The "CAN" and "485" indicator lights are bright
green.
2. DC charging gun and battery connection is normal.
3. "Residual capacity" is less than "allowed to charge the SOC limit" to start charging.
4. "Battery" indicator light is bright green (charging machine detected the battery voltage, this
light), "BMS" indicator light green.
5. The "working" light is bright green. When the "output voltage" is similar to the "battery
voltage", the charging motor outputs the relay to absorb and the charging machine officially begins
to charge the battery. At this point, "output current" and "output voltage" will be output according to
"current demand" and "voltage demand".
6. BMS charging complete, send charging termination command, charging motor end
charging.
7. During the charging process, charging motor failure ("overheated "and" abnormal "lights of
charging motor information are all charging motor failures), BMS charging or" charging allowed "in
a prohibited state, and artificial charging control in a" stop "state, all will terminate the charging.
The user's AC wiring part is located at the rear lower cabinet door. See the picture above for
details.
AC input MCB power switch. PE is the earth, N is the neutral line, A is the A-phase power
supply, B is the B-phase power supply, and C is the C-phase power supply.
Warning: PE protection earth must be connected, otherwise it may threaten life safety. The N
line cannot be connected wrongly, otherwise it may burn the charging and connect the internal
devices.

88
Cautions
a. Before the charger is turned on, it should be checked whether the battery box wiring is
correct, whether there will be a short circuit or a positive and negative electrode connection. To
avoid overloading the charging machine and burning components or lines.
b. It can be put into use only after the charger has no abnormal, overheating and other
warning information.
c. For the safety of charging machines and equipment, it is forbidden to directly disconnect
the battery switch under the condition of output current, except in case of emergency.
Operating instructions

Power check
Make sure that AC input zero wire and DC output positive and negative electrode wiring are
correct, and that there is no short circuit in input and output; The input voltage and frequency are
normal; At any time in the state of electricity.Offline online charging lines can not be connected at
the same time.
Power on
Check whether the AC fan wind direction is correct after the power is on.The touch screen
can be turned on normally, communication with the charging machine is normal.
Access to the battery
The battery voltage level and current level meet the requirements of the charging machine.
Battery polarity is not reversed. Battery's fine. No abnormalities.
Power off
After the charging current and voltage drop to 0, exit the battery.Turn off the AC input air
switch.

89
Lithium battery charging Note: There is a thin slot above the

Park the forklift safely. socket, which is used to buckle the lock when

Open the charging door cover the charging gun is inserted into the
charging.

Note: The flat side of the plug is

The charging port of the lithium battery is equipped with a locking hook, which is used
visible, and the charging port is covered with a to buckle into the slot when inserted into
cover. Open the cover, the charging port is the battery socket.
visible

Lithium
battery charging port Only press the lock button (6) on the
structure charging gun head to insert or pull out.

90
Daily battery maintenance and care
(1) Check before use
After the vehicle key switch is closed, confirm that the instrument panel has no battery system
alarm information. Please check the remaining power before use. It is recommended to use SOC
between 50% and 100%. If the SOC is lower than 30%, it is not recommended to continue to use
it.
(2) Charging instructions
The battery system SOC is lower than 20%, please charge in time. Please use the special
charging equipment specified by the manufacturer for charging. If a fault alarm occurs during
charging, the battery system and the charger will stop charging, and the charger will display the
fault information. The charging environment should be dry and ventilated, and there are no
flammable and explosive materials around. The battery system should be fully charged once a
week.
(3) Long-term storage
Before long-term storage, confirm that the battery system power is not less than 50%. The
charging maintenance should be carried out every three months: the power is charged to 100%.
Store for more than three months, please confirm whether there is a fault alarm in the power
battery system before using it again. Keep the storage environment as dry and ventilated as
possible, away from heat sources. Tip: When the ambient temperature is low, the charging time of
the battery system will be extended, which is normal. To ensure the best performance of the
battery system, the battery management system automatically adjusts the charging time as the
temperature changes.
(4) Clean
①Clean the cabinet: Check the battery system for abnormalities such as foreign objects, obvious
deformation, and corrosion.
② Charging port cleaning: In the power off state, check the interface for abnormalities such as
damage, foreign objects, rust, etc.
③Plug cleaning: Check if the connector is loose or damaged under power failure.
④ Status detection: Observe the battery system voltage, temperature and other status
information on the display screen of the charger during charging to ensure that all status
information is within the normal range.

Chapter VI Common failures of batteries and their Solutions

The battery voltage is too low after filling
1、 The batteries have not been used for a long time and have not been maintained in accordance
with the regulations. Solution: recharge the battery.
2、 The battery has been subjected to severe collisions characterized by damage to the outer
surface of the cell case or the smell of electrolyte in the battery pack. Solution: this kind of
situation is generally not within the scope of maintenance. If the maintenance needs to be
determined, there is a problem in the output line or in the battery itself. First, disconnect the

91
 battery case to see if the battery P+/C+ and P-/C- lines or solder joints are damaged. If there is
any damage, they need to be replaced. Then the battery is odored by the method of incitement.
If there is an exciting electrolyte odor, the battery has been leaked. It needs to test the battery
of each battery. If a series of voltages is too large and very low, it is necessary to contact the
manufacturer to change the battery.
3、 Shortage of capacity. Solution: charge and discharge cycle for the battery, usually 3-5 cycles.
When the battery is fully charged (the charger shows full charge), the voltage
is zero or on the low side.
1、 Battery disconnection. Solution: take apart the battery, check whether the circuit is broken,
check whether the solder joint has fallen off, repair the damaged place according to the
situation.
2、 The protective plate is not working. Solution: first of all, make sure whether the shield plate is
in good contact with the shield board, and observe whether the solder joint falls off. If the
above conditions are the same, test the voltage between B + B- and P + P-, if the difference
between the two voltages is large, the protection board is broken and needs to be tested in
detail. The test does not pass and needs to be replaced.
Battery voltage instability
1、Virtual welding .Solution: use the internal resistance tester to test the internal resistance of the
battery. If the internal resistance exceeds the specified value, there may be false welding
inside the battery, which needs to be disassembled and rewelded.
2、Abnormal protective plate. Solution: replace the protective plate

3、Poor contact between terminals or connectors. Solution: replace terminals or connectors

Normal charging, abnormal discharge or normal discharge, abnormal
charging.
1、 The protective plate is broken.Solution: the protection plate needs to be replaced.
Chapter VIII Emergency Preparedness
Extreme anomalies that may occur during battery operation：In the process of use,
users should establish a good sense of safety prevention, prohibit illegal operation strictly, avoid
battery system abuse (overcharge, over-discharge, short-circuit, extrusion, puncture,
environmental overheating, high-current discharge, etc.).Possible anomalies in the battery system
during charging and use are as follows:
a. The battery system or the local temperature rises sharply.
b. The battery system has abnormal odor at any part of the system.
c. The battery system will smoke and fire at any part of the system.
Emergency measures in case of smoke and fire in battery system during
operation In the event of smoke or open fire occurring in the battery system during the use of the
battery, it is dealt with promptly in the following order:
a. Stop the car and turn off the electricity.
b. Personnel evacuate the vehicle quickly, call the police according to the situation of the scene.
c. In order to ensure their own safety, depending on the specific circumstances of the site, the
following operations may be carried out:

92
Using carbon dioxide fire extinguishers or dry powder fire extinguishers to extinguish smoke or fire
site under the condition of ensuring the safety of personnel.
d. Notify our company personnel as soon as possible to deal with.

93
14. Maintenance Summary
– The forklift must be regularly checked and maintained to keep it in good working order.
– Inspection and maintenance is often easily overlooked. Early detection enables problems to
be addressed in a timely manner.
– Use original Hangcha Group spare parts.
– Do not use different types of oil when changing or topping up oil.
– Waste oil and battery fluid must not be poured away indiscriminately, but recycled or disposed
of in accordance with local environmental laws and regulations.
– Establish and follow a comprehensive maintenance and service schedule.
– Maintain current and complete records of all maintenance and servicing activities.
– Untrained personnel must not attempt to carry out forklift repairs.

CAUTION
 No Open flames！
 Turn off the key switch and disconnect the battery plug before carrying out any
servicing or maintenance. (except when carrying out certain obstacle checks).
 Clean electrical parts with compressed air. Do not clean with water.
 Do not put your hands, feet or any part of your body between the mast and
dashboard.

Weight of counterweight：
Counterweight weight Counterweight weight
Type Type
（kg） （kg）
CPD60-XC4(-I)(-IX) CPD100-XC4(-I)
CPD60-XC5(-I) 1910 CPD100-XC5(-I) 2560
CPD60-XD3(-I) CPD100-XD3(-I)
CPD70-XC4
CPD70-XC5 2400 CPD100-XC4-IX 3070
CPD70-XD3
CPD70-XC4-I CPD90-XC4
CPD70-XC5-I 2560 CPD90-XC5 2580
CPD70-XD3-I CPD90-XD3
CPD90-XC4-I(-IX)
CPD70-XC4-IX 3070 CPD90-XC5-I 3070
CPD90-XD3-I
CPD80-XC4 CPD80-XLC4
CPD80-XC5 2560 CPD80-XLC5 2580
CPD80-XD3 CPD80-XLD3
CPD80-XC4-I(-IX) CPD80-XLC4-I(-IX)
CPD80-XC5-I 3070 CPD80-XLC5-I 3070
CPD80-XD3-I CPD80-XLD3-I

94
Periodic maintenance schedule
〇 —check, correct, adjust ×—replace
D—Daily; W—Weekly; M—Monthly; T—Trimonthly; S—Semiannually; Y—Yearly
Battery

Service D W M T S Y
Item Tool
required (8 h) (40 h) (166 h) (500 h) (1000h) (2000h)

Visual
Electrolyte level 〇 〇 〇 〇 〇
inspection

Electrolyte
specific gravity
Hydrometer 〇 〇 〇 〇 〇

Battery power 〇 〇 〇 〇 〇 〇
Check for loose
connection 〇 〇 〇 〇 〇 〇
terminals
Check for loose
Battery

connection 〇 〇 〇 〇 〇 〇
cables

Clean the battery

surface 〇 〇 〇 〇 〇 〇

Check for tools

left on battery 〇 〇 〇 〇 〇 〇
Check vent caps
are tight, vents 〇 〇 〇 〇 〇
unobstructed

Keep away from

flames 〇 〇 〇 〇 〇 〇

Controller

D W M T S Y
Item Service required Tool
(8 h) (40 h) (166 h) (500 h) (1000h) (2000h)

Check condition of
contacts 〇 〇 〇
Check mechanical
movement of 〇 〇 〇
contactors
Check pedal
microswitches are
〇 〇 〇
Controller

functioning
properly
Check condition of
connections
between motor, 〇 〇 〇
battery and power
unit
Check controller
faults to determine 2 years
whether system is for first
functioning time
properly

95
Motor

D W M T S Y
Item Service required Tool
(8 h) (40 h) (166 h) (500 h) (1000h) (2000h)
Clear foreign
bodies on motor 〇 〇 〇 〇
housing
Clean or replace
bearings 〇 〇
Check wear
condition of
carbon brushes, 〇 〇 〇 〇
commutators,
Motor

check spring force

Wiring correct and
secure 〇 〇 〇 〇
Brush away
carbon powder
from grooves
between
commutator 〇 〇 〇
segments and on
commutator
surface

Transmission system

D W M T S Y
Item Service required Tool
(8 h) (40 h) (166 h) (500 h) (1000h) (2000h)

for abnormal
noise
〇 〇 〇 〇 〇 〇

Check for
leakage
〇 〇 〇 〇 〇 〇
Driving axle(front axle

Change oil × ×

Check for hub

bearing
looseness and
〇 〇 〇 〇 〇
noise
Wipe and add
）

lubricating oil
× × ×

Check for
leakage
〇 〇 〇 〇 〇 〇

Check axle
deformation, 〇 〇 〇 〇
crack or damage

96
Wheels (Front, Rear Wheels)

Service D W M T S Y
Item Tool
required (8 h) (40 h) (166 h) (500 h) (1000h) (2000h)

Inflation pressure Barometer 〇 〇 〇 〇 〇 〇

Wear, cracks or
damage 〇 〇 〇 〇 〇 〇

Check for nails,

stones or other
Tires

foreign objects in 〇 〇 〇 〇
the tread
Check for
damaged rims 〇 〇 〇 〇 〇 〇

Split type rim bolt Test

looseness hammer
〇 〇 〇 〇 〇 〇

Steering System

D W M T S Y
Item Service required Tool
(8 h) (40 h) (166 h) (500 h) (1000h) (2000h)

Check play 〇 〇 〇 〇 〇 〇
Steering wheel

Check axial looseness 〇 〇 〇 〇 〇 〇

Check radial
looseness 〇 〇 〇 〇 〇 〇

Check operation 〇 〇 〇 〇 〇 〇
Steerin
g gear

Check for loose

mounting bolts
〇 〇 〇 〇

Check king pin for

looseness or 〇 〇 〇 〇
Rear wheel knuckle

damage
Check for
deflection,
deformation ,cracks
〇 〇 〇 〇
or damage
Check for Test
installation hammer
〇 〇 〇 〇

Check for operation 〇 〇 〇 〇 〇 〇

Steering cylinder

Check for leakage 〇 〇 〇 〇 〇 〇

Check for looseness

when mounting and 〇 〇 〇 〇
hinging.

97
Braking system

D W M T S Y
Item Service required Tool
(8 h) (40 h) (166 h) (500 h) (1000h) (2000h)

Free play Ruler 〇 〇 〇 〇 〇 〇

Brake pedal

Pedal stroke 〇 〇 〇 〇 〇 〇

Operation 〇 〇 〇 〇 〇 〇

Check for air in

brake lines
〇 〇 〇 〇 〇 〇

Check braking is
Parking brake

safe and reliable, 〇 〇 〇 〇 〇 〇

operation

stroke is sufficient

Operating
performance
〇 〇 〇 〇 〇 〇

Operating
〇 〇 〇 〇
Rods, cables, etc.

performance

Loose connections 〇 〇 〇 〇

Gear box
connector wear
〇 〇 〇

Damage, leakage,
rupture
〇 〇 〇 〇
Pipelines

Connection,
clamping parts, 〇 〇 〇 〇
looseness

Leakage 〇 〇 〇 〇 〇 〇

Check oil level,

change oil
〇 〇 〇 × ×
Master brake cylinder

Master cylinder,
wheel cylinder 〇 〇 〇
action
Master cylinder,
wheel cylinder
leakage and
〇 〇 〇
damage
Inspect master
and wheel cylinder
piston cups and
check-valves for
× ×
wear and damage,
replace

98
Hydraulic system

Service D W M T S Y
Item Tool
required (8 h) (40 h) (166 h) (500 h) (1000h) (2000h)

Check oil level,

Hydraulic oil reservoir

change oil
〇 〇 〇 〇 × ×

Clean oil filter 〇 〇

Clear foreign
bodies
〇 〇

Loose
Control valve

connections
〇 〇 〇 〇 〇 〇
linkage

Operation 〇 〇 〇 〇 〇 〇

Leakage 〇 〇 〇 〇 〇 〇
Multi-way valve

Operation of
safety valve and
self-locking tilt
〇 〇 〇 〇
valve
Oil
Measure safety
pressure 〇 〇
valve pressure
gauge
Leaks, looseness,
Line connectors

rupture,
deformation,
〇 〇 〇 〇
damage
×
Replace pipes 1-2
years
Hydraulic pump

Check pump for

leaks and noise
〇 〇 〇 〇 〇 〇

Check wear of
pump drive gear
〇 〇 〇 〇

99
Lifting system

D W M T S Y
Item Service required Tool
(8 h) (40 h) (166 h) (500 h) (1000h) (2000h)
Check chain tension,
check for
deformation, damage 〇 〇 〇 〇 〇 〇
and corrosion
Chain sprocket

Lubricate chain 〇 〇 〇 〇
Riveting pins and
looseness
〇 〇 〇 〇
Sprocket deformation
and damage
〇 〇 〇 〇
Looseness of
sprocket bearings
〇 〇 〇 〇
Check chain tension,
Attachm

check for
ents

deformation, damage 〇 〇 〇 〇
and corrosion
Piston rod and piston
rod threading, loose Testing
connections, hammer
〇 〇 〇 〇 〇 〇
Lift and tilt cylinders

deformation, damage
Operation 〇 〇 〇 〇 〇 〇
Leakage 〇 〇 〇 〇 〇 〇
Wear and damage of
pins and cylinder
steel-backed
〇 〇 〇 〇
bearings
Fork damage,
deformation, wear 〇 〇 〇 〇
Damage and wear of
Forks

fork stoppers
〇 〇 〇
Cracking and wear of
welded part of fork 〇 〇 〇 〇
heel coupling
Cracking and
damage of welding
on inner mast, outer 〇 〇 〇 〇
mast and crossbars
Wear, cracking and
damage of welding
on tilt cylinder
〇 〇 〇 〇
brackets and mast
Wear, cracking or
damage of welding
〇 〇 〇 〇
Mast and fork carriage

on inner and outer

masts
Wear, cracking and
damage of welding 〇 〇 〇 〇
on fork carriage
Loose roller bearings 〇 〇 〇 〇
Wear and damage of
mast support bearing 〇 〇
bushes
Looseness of mast Testing
〇
support cover bolts hammer (first time 〇 〇
only)
Looseness of lift
cylinder piston rod Testing
〇
head bolts and plate hammer (first time 〇 〇
bolts only)

100
 D W M T S Y
Item Service required Tool
(8 h) (40 h) (166 h) (500 h) (1000h) (2000h)
Cracking and
damage of welding
on inner mast, outer
〇 〇 〇 〇
mast and crossbars
Other

Service D W M T S Y
Item Tool
required (8 h) (40 h) (166 h) (500 h) (1000h) (2000h)

Check
Testing
Overhead mounting is 〇 〇 〇 〇 〇 〇
hammer
secure
guard and Check for
load backrest deformation,
cracking, 〇 〇 〇 〇 〇 〇
damage
Turn signal
Operation
lights and mounting 〇 〇 〇 〇 〇 〇

Horn Operation
and mounting 〇 〇 〇 〇 〇 〇

Lights and
Operation
bulbs and mounting 〇 〇 〇 〇 〇 〇

Reversing
Operation
buzzer and mounting 〇 〇 〇 〇 〇 〇

Instrument Operation 〇 〇 〇 〇 〇 〇
Harness
damage, 〇 〇 〇 〇 〇
Electrical looseness
cables Circuit
connection 〇 〇 〇 〇
looseness

101
Forklift used oil and lubrication
D A

B
E

Oil filler for hydraulic oil Drain plug for hydraulic oil tank
Oil filler plug for main axle housing of Oil control plug for main axle
drive axle housing of drive axle
Oil filler/drain plug for hub reduction Drain plug for main axle
of drive axle housing of drive axle
Oil control plug for hub
Lubricating surface
reduction of drive axle
Lubricating nozzle E Ventilation device

Braking oiler

Fuel
Code Description Specification charge Remark

Common environment：L-HM32 （L）

Hydraulic oil
A Hydraulic oil 30～60L
Cold environment：L-HV32 tank
Gear oil for heavy
B GL-5 85W/90 4.5 Drive axle
load truck
Choice HZY3 brake fluid（Add before
C Brake fluid 1.5 Braking oiler
delivery） or DOT3 brake fluid
General purpose lithium Lubricating
D Lubricating grease
lubricating grease for automobile part
Battery
Industrial vaseline 2#
terminal

102
Replace hydraulic oil
Hydraulic oil should be changed every half year：
– Park the truck on level ground;
– Turn the steering wheel right to the end, make the oil drain plug have enough space;
– Tilt the mast backward to the end and drop the forks on the ground;
– Apply the hand brake;
– Open the cover, screw off the oil filler cap of the fuel tank, and take out the dipstick;
– Put one container under the truck frame, remove oil plug, and drain oil;
– Take away the container, dispose waste oil according to local environmental law, and do not
dump at will;
– Screw back the drain plug, add new hydraulic oil and check for leakage;
– Start forklift, raise forks for 3-5 times, and tilt the mast forward or backward for 3-5 times;
– Add oil to specified scale.

103
Periodic replacement of safety-critical parts
– Some parts are difficult to inspect during periodic maintenance. Therefore, in order to further
improve safety, users should carry out periodic replacement of the parts listed in the following
table.
– If any of these parts are found to be damaged or faulty before they are due for replacement,
they should be replaced immediately.

Name of safety-critical part Useful life (years)

Brake hose or rigid pipe 1～2

Lifting system hydraulic hoses 1～2

Lifting chain 2～4

Hydraulic system high-pressure hoses 2

Brake fluid cup 2～4

Brake master cylinder cover and dust cover 1

Hydraulic system inner seals and rubber

2
parts

Rubber pad for steering axle 4

104
Bolt tightening torque table
Unit：N·m
Grade
Bolt diameter
4.6 5.6 6.6 8.8

6 4～5 5～7 6～8 9～12

8 10～12 12～15 14～18 22～29

10 20～25 25～31 29～39 44～58

12 35～44 44～54 49～64 76～107

14 54～69 69～88 83～98 121～162

16 88～108 108～137 127～157 189～252

18 118～147 147～186 176～216 260～347

20 167～206 206～265 245～314 369～492

22 225～284 284～343 343～431 502～669

24 294～370 370～441 441～539 638～850

27 441～519 539～686 637～784 933～1244

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

105
15. The use, install and safety rules of attachment
HANGCHA will choose attachment that in accordance with International standard ISO2328 Forklift
pothook fork and installation size of carriage, such as sideshifters, fork positioner, rotator,
push/pull and clamp ect.

sideshifter fork positioner rotator push/pull coil boom

bar arm clamp paper roll clamp block clamps load Stabilizer turnaload

Attachment install
– Untempered technology license of our company, any refit at safety and capability to
attachment is strict prohibited.
– Actual rating load capacity should be the least of rating load capacity, the load capacity of
attachment, combined load capacity of truck. Generally speaking, the combined load capacity
of truck is the least. Attachment load capacity just a count value of attachment pressure.
– Installation goes to in reason, credibility, safety to avoid the attachment glide around carriage
in using.
– After hang attachment, embed the rise catch block to the gap of top beam, let the offset of
centre line of attachment and carriage is less than 50mm.Otherwise, it will affect the
landscape orientation stability of forklift.
– To these attachment with rotating function, such as paper roll clamp, bale clamp,
muti-purpose clamp, drum clamp, it needs to weld chock block in the joint of carriage beam
and attachment to prevent move from side to side in the operation.
– Install the attachment of below catch orientation, it need to adjust the clearance between
below catch and beam of carriage.

Attachment use
– Know well the content of nameplate on attachment, read the instruction manual before usage.
(Especially the manual from attachment company) Before operate the attachment, the people
should be trained and obtain the qualification.
– It should be understand the basic capability and operate methods of attachment. Especially
the admit load, lift height, size of cargo and adapt range of attachment.
– Operate the multi-functional attachment, such as with side-shifter, clamp or rotator, it is not
allowed that two action at one time. Operate one functional then do another one.

106
– Prohibit the cargo at a high position when truck moves with attachment. If the size of cargo is
too big, prohibit the truck move on. Transport the cargo, make sure that the distance of bottom
of cargo and ground is less than 300mm and mast incline back.
– The weight of cargo couldn’t exceed the limited value of combination carrying capacity of
forklift and attachment. It is not allowed that partial load at high position. It is a short time work
for attachment with side-shifter. Partial load is around 100mm (Above 5 ton (including 5 ton),
the side-shifter movable within 300mm.
– In the range of the projection forth 2m of the lower of attachment and cargo, prohibit standing
to avoid the suddenness except the driver position under overhead.
– It is not allowed that an emergency brake in moving. Run slowly with load.
– Prohibit outside force when attachment working;
– It couldn’t be use at malfeasance situation and overstep normal work range.
– When the attachment has trouble, prohibit using without check.

107
Attachment check and maintenance
– Check the clearance of carriage beam and below catch of attachment if meet the attachment
manual.
– Check the rise catch is right on the flute of fork carriage.
– Use the auto general lithium-grease per 500 hours to bearing surface.
– If the tighten firmware become flexible.
– Check the tie-in of hydraulic pressure loop, if tube attaint. Prohibit use after repair.
– Check the drive of attachment or if the rotating elements fray or block, change in time.
– Check if each element and attachment working pressure is normal as well as attachment
works normally under load. If not, check the hydraulic pressure loop, find out the broken part,
change sealing element or whole loop element.

108
16. Battery automatic filling water system(Option)
Makeup of the automatic filling watering system：
– Automatic Watering Plug
– End Plug
– Floater
– T-piece & L-piece
– Flow Indicator（with filter）
– 6mm, 8mm ,10mm watering pipe
– Male & Female couplings (Kv10 and
KV6, etc.)
– Water Tank

Application specification and installation

During the period of development and long-term practical usage, the leak tightness of FRÖTEK
automatic watering system has received complete recognition. But when you use it, you need to
keep the automatic watering system clean and there can’t be any filth on the surface.
How to properly install the automatic watering system：Our automatic watering system is easy to
operate, no need to finish watering the electrolyte in the storage battery by hand, time saving and
labor saving, besides, it can extend the service life.
How to correctly install the water tank, choose proper floaters, how to confirm the specification &
quantity of the installed accessories according to different types of battery, including correct
application rules for automatic watering plug, watering pipe, T/L-pieces and male/female couplings
as well as the cleaning of the flow indicator. We will give you a brief introduction for the above
items as follows:

109
 Watering
T-piece Flow 6mm 10mm
Battery head End Male/female Water tank
spec. （6-10-6） indicator Watering Watering
plug K10 Spec.
T-piece （filter） pipe pipe

24V 12 pcs 1 pc 1 pc 3m 5m 2 pcs 1 pc 30L 1 pc

48V 24 pcs 1 pc 1 pc 5m 5m 2 pcs 1 pc 30L 1 pc

80V 40 pcs 1 pc 1 pc 10m 5m 2 pcs 1 pc 60L 1 pc

Automatic Watering System of Forklift Storage Battery-48V battery cells

Floater
How to choose proper floaters correctly：
– According to different storage battery, we have five kinds of floaters for you to choose. In
order to achieve our expected standard and completely reflect the effectiveness of the
automatic watering system, the most important thing is to choose proper floaters. At present
our company can offer a rule for the client to make judgment and choose the type of floater.
(see diagram)
– The diagram the installation way of the floaters:

110
T=T1-(5～17mm)

T Length 47 50.5 58 61 72

Float 13 16.5 24 27 38

Watering pipe
Our company offers watering pipes of different types and the clients can choose what they need
according to the specification of the battery. The watering pipe must be perfectly sealed with
T-piece and L-piece.
Notes during the filling process：
– In order to ensure a safe watering process, we hereby recommend you to use flow indicator
(with filter), the flow indicator with filter can not only timely indicate whether it finishes watering,
but also avoid unclean impurities entering the battery to result interruption.
– The watering pressure should be within the range of 0.02-0.06, no less than 20mMPa water
tank is 2-5M higher than the battery surface.
– You’d better conduct watering within the specified periods, because frequent filling will lead to
overflowing for too much water, which will do great damage to the storage battery.
Note：Filling after finishing charging is the best ideal state, besides, do not filling before charging.
Maintenance（Cleaning）
When you use it, you must pay much attention to keep the automatic watering system clean. No
filth remaining on the surface. The users should regularly clean the watering plug for the plug is a
kind of plastic good. Clean the surface directly with tap water and no need to use other detergent.

111
 open close
Structure Diagram of the Watering Plug
Characteristics of the automatic filling watering system:
– No need to water by hand, labor saving.
– No malfunction factor leading to damage the battery.
– Easy operation, safe.
– Ensure a precise electrolyte level in every battery cell.
– Prevent leakage when watering.
– Effectively avoid the acid liquid to erode the storage battery and the electrolytic bath.
– Extend the service life of the battery.
– Environment protection.
– Save energy.
Function Introduction：
Function of the automatic watering system: the floater of the automatic watering plug can reach
correct water level, when the level rises in the cell, the pressure closes the valves and prevents
further water entering the cell.
When the system finishes watering, the flow indicator will stop running and you can see the
water-level indicator clearly through the top of the watering system.
Besides, the material of FRÖTEK floater can avoid damage and ineffectiveness.
As for the structure of automatic watering system, there is a terraced step, when the electrolyte
gas rises to the watering plug, the terraced part can prevent the leakage of the electrolyte gas as
well as quickly cool the electrolyte gas to make them go back to the storage electrolyte gas as well
as quickly cool the electrolyte gas to make them go back to the storage.

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 Related safety standards (for trucks exporting to Europe)
The TRUCKS covered are conform to the following European Directives and standards:

2006/42/EC Machinery Directive

2014/30/EU EMC Directive

EN ISO 12100:2010 Safety of machinery — General principles for design — Risk

assessment and risk reduction
EN ISO 3691-1:2015+A1:2020 Industrial trucks — Safety requirements and verification — Part 1:
Self-propelled industrial trucks, other than driverless trucks, variable
reach trucks and burden-carrier trucks
EN 1175:2020 Safety of industrial trucks – Electrical/electronic requirements
EN 16307-1:2020 Industrial trucks — Safety requirements and verification — Part 1:
Supplementary requirements for self-propelled industrial trucks,
other than driverless trucks, variable-reach trucks and
burden-carrier trucks
EN 12053:2001+A1:2008 Safety of industrial trucks — Test methods for measuring noise
emissions
EN 13059:2002+A1:2008 Safety of industrial trucks — Test methods for measuring vibration
EN 12895:2015+A1:2019 Industrial trucks — Electromagnetic compatibility
EN 60204-1:2018 Safety of machinery - Electrical equipment of machines - Part 1:
General requirements

● The noise tests are according to EN 12053:2001+A1:2008.

● The vibration tests are according to EN 13059:2002+A1:2008.
● The static test coefficient used for lifting accessory is 1.33.
● Test results of noise and vibration:
Noise pressure level in the Whole-body vibration
Model
operator’s position dB(A) m/s2
CPD60-XC4 / CPD60-XC4-I
CPD60-XC5 / CPD60-XC5-I 75 0.9
CPD60-XD3 / CPD60-XD3-I
CPD70-XC4 / CPD70-XC4-I
CPD70-XC5 / CPD70-XC5-I 75 0.9
CPD70-XD3 / CPD70-XD3-I
CPD80-XC4 / CPD80-XC4-I
CPD80-XC5 / CPD80-XC5-I 75 1.0
CPD80-XD3 / CPD80-XD3-I
CPD80-XLC4 / CPD80-XLC4-I
CPD80-XLC5 / CPD80-XLC5-I 75 1.0
CPD80-XLD3 / CPD80-XLD3-I
CPD90-XC4 / CPD90-XC4-I
CPD90-XC5 / CPD90-XC5-I 76 1.1
CPD90-XD3 / CPD90-XD3-I
CPD100-XC4 / CPD100-XC4-I
CPD100-XC5 / CPD100-XC5-I 76 1.1
CPD100-XD3 / CPD100-XD3-I

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 杭叉集团股份有限公司
HANGCHA GROUP CO., LTD.

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