J Series

ELECTRIC FORKLIFT TRUCK CPD50/55/60/70/80/85J

CPD50J-LZ4
CPD55/60/70/80/85J-Z4
CPD50/55/60/70/80/85J-I

Service Manual

HANGCHA GROUP CO., LTD.

05/2020
 Foreword
Thanks for purchasing Hangcha J series four-wheel Electric Counterbalanced Forklift Truck
J 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 J 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.
Only trained and authorized operator shall be permitted to operate the truck
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 05/2020 HANGCHA GROUP CO., LTD
 Content
1 Drive system .......................................................................................................................... 1
1.1 Drive axle ................................................................................................................................. 2
1.1.1 Basic structure and working principle of drive axle ................................................................. 2
1.1.2 The structure and work principle of drive axle equipped with wet brake（Option） .............. 6
1.1.3 Adding oil to the drive axle ...................................................................................................... 8
1.1.4 Hoist and deposit ..................................................................................................................... 8
1.1.5 Periodical technical maintenance............................................................................................ 9
1.1.6 Adjustment of main reduction gear and hub reduction mechanism....................................... 11
1.1.7 Driven spiral bevel gear engagement contact condition and adjustment ............................. 12
1.1.8 Fault diagnosis and corrections ............................................................................................ 13
1.1.9 Removal and installation ....................................................................................................... 14
1.2 Drive shaft assembly ............................................................................................................. 21
2 Steering axle ........................................................................................................................ 23
2.1 Main data ............................................................................................................................... 23
2.2 Trouble diagnoses and corrections ....................................................................................... 24
2.3 Removal ................................................................................................................................. 25
3 Brake system ....................................................................................................................... 27
3.1 Service brake system ............................................................................................................ 28
3.1.1 Brake pedal mechanism ........................................................................................................ 28
3.1.2 Hydraulic boosted brake........................................................................................................ 29
3.1.3 Brake master cylinder assembly ........................................................................................... 33
3.1.4 Service brake......................................................................................................................... 34
3.1.5 Exhaust air in the brake piping .............................................................................................. 36
3.1.6 Trouble diagnoses and corrections ....................................................................................... 37
3.2 Parking brake system ............................................................................................................ 38
4 Hydraulic system ................................................................................................................ 39
4.1 Hydraulic system principle diagram ....................................................................................... 39
4.2 Multiway valve........................................................................................................................ 41
4.3 Gear pump ............................................................................................................................. 44
4.4 Hydraulic steering gear .......................................................................................................... 46
4.5 Spin-on line filter .................................................................................................................... 50
4.6 Steering cylinder .................................................................................................................... 52
5 Lifting system ...................................................................................................................... 53
5.1 Data ........................................................................................................................................ 53
5.2 Mast removal and adjustment ............................................................................................... 54
5.3 Disassembly and installation of lifting cylinder ...................................................................... 59
5.4 Disassembly and installation of tilting cylinder ...................................................................... 61
5.5 Noticing proceeding of debugging ......................................................................................... 63
5.6 Fault ....................................................................................................................................... 64
6 Electrical system ................................................................................................................. 65
6.1 Fuse assembly....................................................................................................................... 67
6.2 Combination switch................................................................................................................ 68
6.3 Motor ...................................................................................................................................... 70
6.3.1 Main Parameter ..................................................................................................................... 70
6.3.2 Motor maintenance ................................................................................................................ 70
6.3.3 Caution of motor disassembling ............................................................................................ 70
6.3.4 Common fault and corrections .............................................................................................. 72
6.4 Controller assembly ............................................................................................................... 78
6.5 OPS system（optional） ....................................................................................................... 93
6.6 Electrical schematic diagram ................................................................................................. 95
1 Drive system
Drive system is mainly composed of drive axle, rim, tire, parking brake, brake disc, drive shaft
assembly, flange assembly and traction motor etc. Refer to fig.1-1.

1.Drive axle 2.Rim

3.Tire 4.Parking brake
5.Brake disc 6. Drive shaft assembly
7.Flange assembly 8. Traction motor
Fig.1-1 Drive system
Note：Detailed motor introduction refers to Electrical System.
After installing the brake pedal adjust the nuts, and make the clearance between brake shoe and
brake disc as 0.2～0.5mm.

1
1.1 Drive axle
1.1.1 Basic structure and working principle of drive axle
Basic drive axle structure refers to fig.1-2: it is mainly composed of axle housing assembly, main
driver, half shaft, hub reduction gear and left/right shoe brake etc.

1.Hub reduction assy 2.Oil seal FB150×120×12 3.Bolt 4.Spring washer

5.Brake hub 6.Left/right brake 7.Half shaft 8.Axle housing assy
9.Main reducer assy 10.Screw M20×1.5 11.Bonded washer 20 12.Bolt
13. Spring washer 12 14.Breather plug
Fig.1-2 Drive axle assembly
Working principle of drive axle is shown as fig. 1-3: driving torque inputs into main reducing gear,
by means of mutual vertically installed main axle drive bevel pinion and driven bevel pinion,
changes power direction, reduces speed, enlarges the transferred torque, and then transmits
power to the wheel by differential and haft shaft. After further slowing down by hub reduction
mechanism, transmit movement and torque to two drive wheels.

Fig.1-3 Working principle of drive axle

2
Main drive structure
Main drive is composed of spiral bevel gear and differential(refer to fig.1-4). Differential is a
differential planet gear transmission gear, that is composed of two tapered straight tooth half shaft
gears, four tapered straight tooth planetary gears, left/right differential carrier and universal joint
etc.

1.Round nut M24×1.5 2.Gasket24 3. Gasket 4.Seal cartridge

5.Connecting flange 6.Spring washer12 7.Bolt M12×55 8.Oil seal 60×90×12
9.O-ring40×2.65 10.Bearing 31308 11.Adjusting shim 12. Adjusting shim
13.Spacer bush 14.Bearing sleeve 7310E 15. Angle gear 16. Bearing 102605
17.Bracket 18.Check ring on shaft 20 19. Bearing 32214 20. Adjusting nut safety piece
21.Locking gasket 22. Bolt M10×20 23. Gasket 16 24.Bolt M16×95
25. Gasket 12 26. Bolt M12×1.25×88 27.Left differential carrier 28. Planetary gear
29. Spherical washer 30.Universal joint 31.Basin gear 32.Right differential carrier
33. Bolt M14×1.5×40 34. Spring washer 14 35. Half axle gear washer 36.Half axle gear
37.Bearing cap 38.Adjusting nut 39.O-ring 125×3.1 40.Bush
Fig.1-4 Main drive

3
Hub reduction gear and axle housing structure
Hub reduction gear is planetary reducing gear, mainly composed of hub, planet carrier, inner gear,
planetary gear and sun gear, inner gear is fixed to shaft through spline, planet carrier fix together
with hub, refer to fig.1-5.

1. Locking gasket 2.BoltM8×25 3. Spring washer 8 4.Hub

5.BoltM10×25 6. Spring washer 10 7.O-ring136×2.65 8. Planetary carrier
9.End cap 10.ScrewM14×1.5 11.Bonded washer14 12.Adjusting pillar
13.Steel ball 14.Planet shaft 15.Roller pin 2.5×20 16.Spacer bush
17.Planet gear catch 18. Spring washer 12 19. .Bolt M12×30 20.Planet gear
21.Inner gear 22.Nut 23. Bearing 7221E 24. Rim thread insert
25.Big rim nut 26.Rim bolt 27.Small rim nut 28.Oil sealFB100×125×12
29.Bearing7220E 30.BoltM16×1.5×50 31. Spring washer 16 32.Set bolt M16×1.5×60
33.Spacer16 34.Sun gear 35.Copper bush 36. Spline housing
37.ScrewM12×40
Fig.1-5 Hub reduction gear

4
Main technical parameter

Overall speed ratio 38.96

Center speed ratio 7.143

Wheel speed ratio 5.455

Load 185 kN

Output torque 35 kNm

Brake torque 20.8 kNm

Brake oil pressure 9.5 MPa

Quality 593 kg

5
1.1.2 The structure and work principle of drive axle equipped with wet brake
（Option）

Basic drive axle structure is shown as the following figure: it is mainly composed of axle housing
assembly, main driver assembly, half shaft, wheel reducer assembly and wet brake etc. Driving
torque is input into the main driver, by means of mutual vertical installation of driving bevel gear
and driven bevel gear, changes the power direction, reduces the speed and increases the
transmitted torque, transmits the power to the wheel through differential and half shaft, and then
transmits the motion and torque to two driving wheels after further deceleration by wheel reducing
mechanism.

1.Wheel reducer 2.Wet brake 3. Axle housing 5.Main reducer

4. Half shaft
assembly assembly assembly assembly
9.Spring
6. Screw plug 7. Bonded washer 8. Screw plug 10. Breather plug
washer
11.Round pin 12. Bolt 13. Spring washer 14.O-ring 15. Screw plug

Main technical performance parameter

Total drive ratio 20.72 Output torque 35000 Nm
Braking torque 17500 Nm Brake oil pressure 8 MPa
3
Axle load 12×10 Kg Overall axle length 1849 mm
Axle weight 593 Kg

Wet brake structure and work principle

Wet brake structure is shown as the following figure: it is mainly composed of cylinder body, piston,
sliding friction plate and static friction plate etc. After a certain pressure of brake oil enters into the
piston oil chamber from the oil inlet (No.15 in the above figure), it forms a certain working pressure
on the ring section of the piston, which promotes the piston to move left. Sliding friction plate is

6
fixed on the gear ring and moves with the hub at equal angular velocity. Static friction plate is fixed
in the inner gear ring, and its angular velocity is zero. Relative movement of sliding and static
friction plates under normal pressure generates friction force between the friction layer, and the
integral of each friction force point in the brake radius is brake torque. Wheel is braked under the
force of brake torque. When fuel cut-off, make piston return by the spring(No.6 in the following
figure), then the brake torque is relieved, and wheel can drive normally.

1.Cylinder body 2.X-ring 3.X-ring 4.Piston 5.Spring guide screw

6.Spring 7.Static friction plate 8. Sliding friction plate 9.O-ring 10. Taper tube hexagon

Wet brake testing

Work pressure of the brake is 8MPa. Before the main machine runs, please adjust the foot brake
to make brake flexible and reliable. When testing, first tighten the bleeder screw, then step on the
brake pedal continuously until you feel hard to step, at this time, keep the brake pressed, release
the bleeder screw to deflate, stop when bubble is given off, and then screw down the bleeder
screw and release the pedal. Repeat the above procedures until no bubbles appear. Both left and
right brakes are operated according to the above requirements.

7
1.1.3 Adding oil to the drive axle
Get the arrows on the left/right wheel end cover of the drive axle straight down, open the oil level
plug at left and right wheel, add gear oil to the left, right and middle position, until overflow from the
oil level hole, refer to the following figure. (Note: generally use GL-5 85W/90 gear oil for
heavy-load truck, standard code GB12895-92, oil capacity is 7L.)

Oil level plug Drain plug Filling plug Air respirator Filling/drain plug Oil level plug

图 1-4
1.1.4 Hoist and deposit
When hoisting the drive axle, hoist through rope according to the arrow listed place, if shovel
needed, shovel according to the arrow listed place. No matter hoist or shovel, collision or
obscission is prohibited.
There should be insulation between axles to avoid bump during drive axle transportation. Flange
plate of final drive should be wrapped with water proof paper to avoid rust, axle vent hole and
brake oil port should be blocked with rubber plug
Drive axle should be placed in the storehouse, but not on the open ground. The longest deposit
time for axle drive should not exceed 1 year, otherwise replace easily damaged parts.

8
1.1.5 Periodical technical maintenance
Grade I technical maintenance (about work 50 hours)
– If it is new truck running-in, replace gear oil. (Note: When replacing oil, first drive truck
warming, release oil, and then wash with carbon oil. After that, add oil to specified position.)
– Check each drive parts move condition, abnormal noise is not allowed.
– Check if wheel, main drive, brake outer fastener loosen and screw down.
– Check brake pad wear condition and exhaust air.
– Check each part oil leak condition and repair in time. All sealing elements are not allowed to
reuse once dismantled.
Serial
Specification Tightening torque Remark
No.
3 M16×1.5×45(55) 205 Nm Brake connecting bolt（Fig.1-2）
12 M12×35(60) 78 Nm Bracket connecting bolt（Fig.1-2）
1 M24×1.5 708 Nm Driving gear nut（Fig.1-4）
7 M12×55 78 Nm Bearing housing bolt（Fig.1-4）
22 M10×20 45 Nm Locking washer bolt（Fig.1-4）
24 M16×95 283 Nm Bearing cap bolt（Fig.1-4）
26 M12×1.25×88 85 Nm Differential carrier bolt（Fig.1-4）
33 M14×1.5×40 134 Nm Basin gear connecting bolt（Fig.1-4）
5 M10×25 45 Nm End cap bolt（Fig.1-5）
19 M12×35 78 Nm Planet carrier bolt（Fig.1-5）
24 M20×1.5 418 Nm Rim thread insert（Fig.1-5）
25 M20×1.5 490 Nm Big rim nut（Fig.1-5）
30 M16×1.5×50 205 Nm Brake hub connecting bolt（Fig.1-5）
Grade II technical maintenance (working time about 1200hours)
– According to the requirement of "Adjustment way to main reducing gear and hub reduction",
check and adjust bearing and basin gear clearance.
– Replace gear oil according to season or major repair requirement. When replacing oil, first
drive truck warming, release oil, and then wash with carbon oil. After that, add oil to specified
position.
– Check and clean greasy dirt, soil and dust, especially breather plug on the axle housing
should keep smooth.
– Check brake pad wear condition.
– Check and fasten external fastener. If any loosen, apply LOCTITE 242 anti-loose glue and
screw down.
Grade III technical maintenance (working time about 2400hours)
– Disassemble hub reduction gear, main drive and brake to check, repair and change damaged
parts. When assembling, clean the parts originally applied to sealant with solvent, and apply
SD-314 silica gel after drying. All fastener bolts should clean up and apply LOCTITE 242 after

9
 drying, then screw down, and the tightening torque should meet requirement of table 4.
– Adjust main drive and hub reduction gear.
Easily damaged parts details
Serial
Designation Specification Quantity Remark
No.

2 Oil seal FB150×120×12 1 For drum brake (Fig.1-2)

Oil seal For final drive input flanged
8 60×90×12 1
shaft (Fig.1-4)

10
1.1.6 Adjustment of main reduction gear and hub reduction mechanism
– Axial clearance of driving spiral bevel gear bearing(No.10 in Fig.3) is 0.06～0.10mm, the gear
rotates flexibly, no axial float when pushing with hand, adjust the axial clearance of bearing
with shims(No.12 in Fig.3).
Locating distance of spiral bevel gear must be adjusted to correct position to guarantee
correct meshing mark and clearance. Adjust by nut (No.38 in Fig.3) and shim(No.11 in Fig.3).
The axial clearance of bearing is 0.05~0.10mm, backlash of driving and driven spiral bevel
gear is 0.20~0.35mm, check the meshing mark with staining method, and the correct meshing
mark of driven spiral bevel gear refers to fig.5. Contact pattern along tooth depth and tooth
length is not less than 50%, and the incorrect mark adjustment refers to Table 6.

Big end

Forward compression surface

Reverse compression surface

Contact surface close to the central

slightly towards the small end

Fig.1-5 Correct meshing mark of driven spiral bevel gear

– Minimum meshing clearance between half shaft gear and planet gear of the differential is
0.1mm, adjust with half shaft gear shim(No.35 in Fig.3), after assembling, gently rotate with
hand but no jamming.
– As to the check and replace of hub reduction gear, check contact spot with staining method,
along the tooth depth larger than 45%, along the tooth length larger than 50%. After installing
the hub, rotate with hand, get the bearing in correct position, screw down the round nut
gradually until the hub can rotate hardly, then return the round nut 1/10 cycles, now the hub
can rotate flexibly, no axial float and swing. At last, install the locking gasket(No.1 in Fig.4),
and control the axial clearance within 0.1mm.
– When replacing the needle roller in the hub planet gear, select all needle rollers in group, thus
make the diameter is not larger than 0.005mm, needle roller column 0.003mm and axial
clearance between needle roller, gear hole and bearing pin is 0.02~0.03mm in the same
group.

11
1.1.7 Driven spiral bevel gear engagement contact condition and adjustment

Driven gear contact area Adjustment way Adjustment direction

First reduce the thickness of

bearing bush adjusting shim, get
driving gear close driven gear, if
the backlash is too small, move
driven gear outward.

First increase the thickness of

bearing bush adjusting shim, move
the driving gear out from driven
gear, if the backlash is too big,
move driven gear inward.

First reduce the thickness of

bearing bush adjusting shim, get
driving gear close driven gear, if
the backlash is too small, move
driven gear outward.

First increase the thickness of

bearing bush adjusting shim, move
the driving gear out from driven
gear, if the backlash is too big,
move driven gear inward.

12
1.1.8 Fault diagnosis and corrections
Condition Possible reason Corrections

Open to check or repair

Parts wear
parts
Bad gear engagement Re-adjustment

Mounting parts loose Tighten

Abnormal noise
Hub bearing damage or wear Replace

Incorrect hub bearing adjustment Adjust

Axle shaft spline wear Replace

Insufficient lubrication Add lubricating grease

Oil seal burned or aged. Replace oil seal

Bolt loose Tighten bolt

Oil leak
Poor lubrication Improve lubrication
Add oil to specified
Over high oil level
position
Bad lubrication Improve lubrication
Too high axle housing
Adjust according to
temperature Incorrect gear and bearing installation
drawing.
Adjust brake pad
Brake pad stuck to brake hub.
Brake locking clearance
Check brake return oil
Problem in brake return oil line.
line.

13
1.1.9 Removal and installation
Drive axle assembly removal and
installation
Removal
– Raise front end of forklift truck and
support frame with wooden blocks
– Dismantle the mast.
– Dismantle front tires.
– Hoist drive axle with lifting gear and rope.
– Place a pan under axle case, drain oil
from axle case.
– Disconnect brake nuts from left and right
cylinders.

Caution
Plug brake tube openings to prevent oil
from flowing out.

– Dismantle supporting cover and frame

connected bolt.

– Remove drive shaft

Warning： – Dismantle drive axle.

Be careful to avoid brake oil pipe and other To install drive axle assembly, reverse the
spare parts damage. order of removal.

14
Hub reduction gear removal and
installation
Removal
– Dismantle pinion from drive axle hub until
discharge gear oil completely.
– Pull out half shaft.
– Dismantle brake.
– Dismantle locking ring and locking nut.
– Dismantle wheel gear from hub.
– Connect hub and brake to dismantle.
– Dismantle brake disc.
15
– Rap along the bearing by stick matted
with soft cloth and dismantle inner
bearing.
Installation
To install, reverse order of removal.
– Place hub outer bearing into hub stably.
– Check if the deflation mouth of the oil seal
faces outward and assemble.
– Bearing adjustment
Adjust bearing according to planet carrier, half
shaft and gear ring.
- Apply lubricating grease to the taped
roller bearing.
- Screw down hub bearing lock nut until
hub can not be turned by one hand.
- Rotate lock nut 60° to opposite direction
according to above position.
- Turn hub 2-3 rings to opposite direction
to match bearing bracket.
- Fasten lock nut again until hub can not
be turned by one hand. Then turn nut
60° to opposite direction.
Main reduction gear removal and
installation
Dismantle drive axle and main reduction gear
from the truck.
– Support the rear wheel with wood.
– Support the front forklift, put a wood under
each supporting sleeve.

Warning To install, reverse order of removal.

Be careful and put a wood under Removal
counterbalance weight. Before dismantle, please fully check the
– Make sure the bearing cover safely put on backlash of drive and driven spiral bevel gear,
the block. check engage area among drive gear, driven
– Dismantle mast and relevant parts. gear and half axle gear, then diagnose the
– Drain oil in the drive axle housing. correct fault.
– Dismantle half axle(the same as drive Dismantle differential carrier
axle dismantle). – Mark on left & right differential carrier and
– Jack up the main drive housing. right & left bearing bracket.
– Dismantle drive axle from the main – Dismantle thrust washer on the right & left
reduction gear. bearing bracket.
– Dismantle brake oil pipe.
– Safely dismantle supporting cover
connected bolt.
– Dismantle drive axle and main reduction
gear carefully.

– Release bearing bracket mounting bolt

slightly, and dismantle adjusting nut.

– Dismantle main reducing gear mounting

bolt, and separate main reducing gear.

– Dismantle bearing bracket mounting bolt

and right＆left bearing bracket.
– Hoist differential assembly with calabash
or other way, be careful not to damage

16
 outside bearing area.

– Dismantle the mounting bolt of spiral

– Dismantle bearing from left & right
bevel gear. Pre-apply LOCTITE 262 glue
differential carrier with bearing puller.
to bolt.
Disassembly of driving spiral bevel gear
– Remove check ring and guide bearing
from driving spiral bevel gear with shaft
bearing replacer.

– Dismantle differential carrier connecting

bolt, disassemble differential carrier.
Pre-apply LOCTITE 262 glue to bolt.

– Dismantle bearing bracket and cover

connecting bolt.
– Dismantle flange locking round nut,
washer, flange, cover, oil seal and spacer
bush.
– Press the driving spiral bevel gear and
pull out bearing bracket.
– Dismantle planetary gear, thrust washer,
planet gear shaft, half axle gear and thrust
washer of half shaft gear.

17
 Make sure the above tips and do the opposite
orders to dismantle and make proper
adjustment.
Assemble driving spiral bevel gear
– Press the out bearing to bearing bracket.

– Dismantle adjusting washer and washer

from drive spiral bevel gear. Pull out
conical roller bearing with bearing puller.
– Press in guide bearing to the top of drive
spiral bevel gear and install snap ring
– Press in the conical roller bearing.

– Dismantle conical roller bearing from

bearing bracket.

– Pre-adjust rive spiral bevel gear assembly

- Install any adjusting washer and washer
to driving spiral bevel gear

Installation
Tips：
– Use clean gear oil when re-assembling.
– When assembling differential conical
roller bearing and adjusting nut, left & right
Caution
spare parts should not be mistaken.
To avoid over pre-tight, first choose
– Do not forget to assemble oil seal and
thicker adjusting shim, and then reduce
gasket.
thickness until gain proper pretension
– Confirm that the driving and driven spiral
force.
bevel gear are in pairs.
- Install driving spiral bevel gear into

18
 bearing bracket. – Mark on the differential carrier
- Install spacer bush, oil seal, bearing successively.
bracket adjusting washer, cover (hand – Assemble differential carrier. Pre-apply
brake support) and flange on the top of LOCTITE sealant to connecting bolt and
driving spiral bevel gear shaft. tighten to specified torque100Nm.
- Choose adjusting washer until locking – Assemble spiral bevel gear. Pre-apply
nut reaches defined tightening torque LOCTITE sealant to connecting bolt and
343-441Nm, starting torque of driving tighten to specified torque120Nm.
spiral bevel gear is 2.0-3.9Nm.
- After pre-tight, exit flange and cover
(brake support).
– Place oil seal applied with lubricating
grease into cover (brake support).
– Install spacer bush and flange.
Install differential carrier
– Impress the inner differential bearing
Assemble reducer housing
surface facing the left differential carrier.
– Install drive spiral bevel gear assembly
– Install half shaft gear and paired planetary
into reducer housing. Add any adjusting
gear, gear shaft and paired adjusting
washer, tighten connecting bolt to fixed
washer on differential carrier.
torque 45Nm.
– Measure the backlash between half shaft
- Drive spiral bevel gear needs to place
gear and planetary gear pair.（backlash：
into reducer housing smoothly, if
0.19～0.25mm. If the backlash is not in
damage the snap ring, please change
this scope, please change planetary gear it.
and half shaft gear.） - When assembling washer, it needs
combined type with mono-sheet type.
Caution
Planetary gear shaft should not move
when measuring.
– Install half shaft gear and thrust washer.

– Put a roll bearing outer ring on the

differential assembly, and then put into the
– Impress inner differential bearing surface differential housing.
facing the right differential carrier.

19
– Do measuring mark when observing
removal, pre-tighten bearing bracket bolt,
and adjust with side lock nut.
– Pre-tighten lock nut and push the bearing
to the end.
– Measure teeth backlash of drive and
driven spiral bevel gear, adjust the teeth
backlash to 0.2-0.35mm by lock nut.

– Adjusting the teeth backlash to

0.2-0.35mm by the above way, lock the
nut completely and make the bearing pre
tightening force as 29-49 Nm.
– Screw down bearing bracket mounting
bolt with tightening torque 170 Nm.
– Mount locking plate and screw down
adjusting bolt 10-15 Nm.

20
1.2 Drive shaft assembly
Drive shaft is composed of flange yoke, universal joint, bearing and center prong etc.. Universal
joint is installed in the earhole of center fork, needle bearing bush in four bearing brackets,
universal joint is installed with oil cup, and this cup can be used to infuse lubricating oil and
lubricate all bearing through oil gallery.
When universal joint has overlarge clearance among needle bearing, flange yoke should be
dismantled, change bearing or universal joint accordingly, bearing must be changed in group. Two
lubricating nozzles of universal joint should be in the same side.
Drive shaft needle bearing should apply MoS2# lubricating oil and is forbidden to apply thick
oil(such as butter, cause butter may cause the needle roller cannot run on the universal joint and
quicken abrasion). Work with thick dust should add lubricating oil frequently.

Fig.2-1 Drive shaft

Damage and repair of universal joint
– When there is nick, dent on universal joint journal and journal wear is larger than 0.04mm,
repair it by chromium plating or iron-plating. It can also grind four journals to the same size,
and then equip with oversize rolling needle, if journal carbon after shrink is insufficient, do
carburizing and heat treatment. Error between journal circularity and cylindricity after grinding
should not be larger than 0.01mm; verticality error of two axes should not be larger than
0.1mm.
– When assembling, tolerance clearance between journal and bearing is 0.02～0.09mm, and
the largest clearance should not be larger than 0.13mm.
– Replace rolling needle of universal joint bearing if there is wear, fracture or groove.
Check and repair of flange yoke and center prong
– Replace if there is fracture on flange yoke and center prong.

21
– It adopts bead weld method to repair and bore a hole to fit dimension when needle bearing
hole wears.
– Fasten the thread of bearing cover, snap ring groove matches with pin ring, and no looseness
is allowed.

22
2 Steering axle
2.1 Main data
Axle type Center bearing, rotary type Axial clearance（F/R） ≤0.70mm

Steering Inner max. 75° End axle adjusting 0.6,1.0,2.0 mm

steering angle shim thickness
angle Outer max. Part No.
53° 50W-410011
steering angle
Kingpin Hub bearing

Axial clearance of kingpin ≤0.20mm Tighten the knuckle nut until

the hub cannot be turned by
Adjusting shim of kingpin Pre-tension hand, and then release 1/6
ring. Or the initial turning
Thickness（mm） Part No. force for hub connecting bolt
is les than25.5N
0.8,1.0,1.2,1.4 50W-410008 Axial ≤0.08mm
clearance

1.Wheel nut 2. Wheel nut 3.Steering wheel 4.Gasket 5. Nut

6.Steel bushing 7. Gasket 8.End cap 9.Paper washer 10. Nut
11.Thrust washer 12.Bearing 13.Hub 14. Bearing 15.Oil seal
16. Left knuckle 17.Set screw 18. Nut 19.Bearing 20.Check ring
21. Adjusting shim 22.Bolt 23. Gasket 24.Oil cup 25.Cover plate
26.King pin 27. Bearing 28. Bolt 29. Gasket 30.Steering axle body
31.Bush 32.Adjusting shim 33. Bolt 34.Steering cylinder 35.Oil cup
36.Right knuckle 37.Pin 38.Bearing pin 39.Pull rod device 40.Bushing
Fig.2-1 Steering axle structure

23
2.2 Trouble diagnoses and corrections

Condition Probable cause Corrective action

Loose wheel nut Tighten

Wheel bearing out of adjustment. Adjust

Unstable driving
Improperly adjusted shims Adjust

Faulty steering system Refer to Hydraulic System

Insufficient lubrication. Apply calcium grease

Loose bolts and nut Tighten

Noises Improperly adjusting shim for axle end Adjust
shaft.
Damaged joint bearing at two ends of rod Replace

24
2.3 Removal dropping.

Hub – Take off knuckle (including thrust bearing,

– Jack up and support forklift truck body
with wooden blocks;
– Remove tire;
– Remove hubcap;
– Dismantle knuckle locknut, thrust washer
and adjusting nut;
– Pull off hub assembly;
– Remove bearing inner race.
CAUTION
 Not to drop bearing inner race.
 Be careful not to damage oil seal.
Kingpin and steering knuckle
– Dismantle nut in the joint of knuckle and
pull rod device, disassemble pull rod
device;
– Loose lock bolts;
dust cover, shim).
Inspection：
– Replace knuckle if cracked;
– Replace bearing if its rollers or roller
surfaces are rusted or nicked;
– Replace needle bearing if it damaged;
– Replace thrust bearing and dust cap if
they damaged.
Installation：
To install, reverse the order of removal. Careful
observes the following.
– Always insert kingpin from lower side;
– Install thrust bearing, set the straining ring
below the support and loosen-ring. Adjust
axial play to specification with shims. Axial
play is less than 0.2mm;

CAUTION
Thrust ball bearing is installed on the
upper knuckle, and the adjusting shim is
installed on the down knuckle.
– Apply all grease between dust proof
inside, loosen-ring, and straining ring;
– Do not apply grease to the of needle
– Dismantle oil cup from steering king pin； bearing outer ring and knuckle faying
– Remove kingpin; surface;
– Apple grease to roller of roller bearing and
ball of thrust bearing;
– Apply sufficient grease into the oil cup.
Hub bearing installation and adjustment
– Apply rust preventive oil on bearing
contact area and threaded knuckle nut;
– Slowly rotate hub with one hand. Tighten
locknut with the other hand until it is hard
CAUTION to rotate steering hub, and then rotate the
 Hold kingpin to prevent it from
nut 1/6～1/4 circles in reverse direction;

25
– Rotate hub 2～3 cycles, and rotate the
bearing roller in place;
– Repeat action 2, put into thrust washer
and lock with knuckle nut.
– Rotate the hub for 2 cycles, measure the
rotation initial force and axial clearance, it
should meet the following requirement, or
adjust if necessary. Axial clearance is less
than 0.08mm, rotation initial force is less
than 25.5N(at the hub bolt)

Steering axle body

Removal
– Jack up the forklift truck and support with
wooden blocks;
– Remove tire;
– Remove the slotted nut on the pull rod
device;
– Jack up the steering axle body;
– Dismantle steering pipeline and bearing
seat;
– Remove steering axle body.

CAUTION
 Supporting stably to avoid accident.
Installation
To install, reverse the order of removal. But
note the following: adjust steering axle shims,
make the axial clearance within the specified
value and axial clearance is less than 0.7mm.

26
3 Brake system
Brake system is composed of service brake and parking brake.
Service brake realizes truck braking through hydraulic boosting. This mechanism is mainly
composed of brake pedal mechanism, hydraulic boosted braking assembly, brake master cylinder
assembly, brake line, and service brake etc.. Hydraulic boosting brake assembly is composed by
the joint of hydraulic boosted brake and brake master cylinder, makes foot stepping easier and
comfort, thus reduce operater’s fatigue. Even in the event that the hydraulic boosting is invalid, it
can use hydraulic braking to brake.
Parking brake mechanism is mainly composed of parking brake pull rod, parking brake cable,
parking brake and brake disc etc.
Brake pedal

Free travel 10～20 mm

Height that the pedal is away from front base
150±5mm
plate
Stepping height ＞60mm

Rated flow 25L/min

Hydraulic booster

Rated pressure 16MPa

Assist rate 4

Spare travel 0.6～1.2mm

Sequence valve adjusted pressure 4±0.55MPa

Brake master cylinder

Type Quick charge type

Full travel of brake piston 28±1mm

Capacity of oil reservoir 150mL

Highest work oil pressure 10MPa

Brake fluid HZY3 or DOT3 or DOT4 or equivalent oil

Hydraulic boost, oil pressure, internal
Type
expanding front-wheel mechanical brake
Service
brake

Clearance between friction plate and drum

0.25～0.5 mm
brake
Wear limit of friction plate(to the rivet head) Larger than 0.5 mm

Type Mechanical, work on parking brake

brake
Hand

Less than 80 mm
Travel （With 147N tension force, at hand brake
handle）

27
3.1 Service brake system
3.1.1 Brake pedal mechanism
Brake pedal adjustment：
– Adjust brake pedal stop bolt, make the pedal pad point P 150±5mm from the front base plate
and screw down the nut;
– Adjust hydraulic booster manipulator push rod length, and make the spare travel of the point P
to point Q is 1～3mm, and lock the nut;
– When step the brake pedal 10～20mm gradually, the brake light switch is completely
connected, and release the foot to this state, brake light switch should disconnect.

Fig.3-1 Brake pedal adjustment

28
3.1.2 Hydraulic boosted brake
Hydraulic boosted brake and steering system share the same hydraulic oil, they can work
separately, or joint to use when necessary, but do not intervene mutually.

Oil port connection：Port P connect the oil-out of steering gear pump

Port T connect oil return pipe of hydraulic oil tank
Port PS connect P port of hydraulic steering gear
Fig.3-2 Hydraulic boosted brake shape and working principle

Fig.3-3 Parts drawing of hydraulic boosted brake

29
Dismantle
– Dismantle rod connector and input rod.
– Remove the brake booster nuts from
pedal bracket.
– Dismantle the pipeline from brake master
cylinder to brake booster.
– Take down brake booster and brake
– Remove snap ring and pull out slide bar,
master cylinder.
spring and baffle plate from piston.
– Separate brake booster and brake master
cylinder.
To install, reverse the removal procedures.

Caution
After dismantling pipeline, avoid dust
and impurity getting into inner cavity.
Hydraulic boosted brake disassembly
– Remove plug, reducing valve and spring,
– Remove dust cap and input rod.
do not disassemble reducing valve
– Remove guiding rod and output rod.
assembly.

– Remove O-ring, piston spring and washer. To reinstall spare parts, reverse the
– Dismantle piston guiding. disassembly procedure.
Inspect
– Check sealing gasket and replace if
damaged.
– Replace damaged O-ring.
– Check if there is scratch or wear on
cylinder body, piston, slide bar, working
beam, output rod, guiding rod, reducing
– Remove piston and working beam.
valve assembly and piston guiding sliding
surface, replace if necessary.
Attention to reinstall hydraulic boosted
brake：
– Use light oil(not gasoline) to clean parts.

30
– Avoid impurity get into parts inner cavity.
– Apply hydraulic oil to the moving part
surface before assembling.
– Pay attention to the direction when
assembling reducing valve assembly and
slide bar.
– Do not install the slide bar reversely.
– Install the snap ring in place.
– Insert piston and working beam into
cylinder body and make sure piston
groove direction. The below figure shows
the mounting position of brake master
cylinder and tightening position of piston
guide. Piston guide tightening torque is
26～36N·m.

– Install guide rod to downward the air vent.

– Install dust cover to downward the air
vent.
– After installing cylinder body, piston,
output rod or guide rod, adjust the
projected length of output rod with shim.
Projected length is（9.9～10）mm.

31
Hydraulic booster trouble diagnoses and corrections

Condition Probable cause Corrective action

Oil leakage Repair or add oil

Oil pump or priority valve Repair or add oil

failure
Insufficient Impurity in the slide bar Clean or replace
brake force valve
Impurity in the reducing Clean or replace
valve
Oil seal wear or leakage Replace

Hard brake Slide bar valve failure Replace

Brake locking Impurity in the slide valve Clean or replace

(Oil pressure is not zero when
releasing the pedal) Output rod absorbs impurity Clean or replace

32
3.1.3 Brake master cylinder assembly

1. Internal circlip
2. Auxiliary leather collar
3. Piston
4.Piston gasket
5. Leather collar
6. Spring seat
7. Spring
8. Cylinder body
9. Oil cup assembly
10. Bleeder screw shield
11. Bleeder screw
12.Dust plug
Fig.3-4 Parts drawing of brake
master cylinder
Removal
1）Separate brake master cylinder and brake booster.
2）Take down snap ring, remove piston, insulation pad, spring seat and return spring.

Caution
 Throw away the removed leather collar, and replace with new one.
 Remove the parts in clean ground and place them in sequence neatly.
Check
Clean all parts in the brake fluid and check their condition.
Serial No. Check condition Corrective action

Obvious scratch or wear on moving surface of

1 Replace
cylinder and piston
Clearance between cylinder and piston should
2 Replace
not exceed 0.15mm.
Weak and damaged No,1 and No.2 auxiliary
3 Replace
leather collar
4 Weak and damaged spring Replace

5 Distortion and damage of oil reservoir Replace

Caution
 Do not use other cleaning agent to clean parts.

33
 3.1.4 Service brake
Adopted shoe brake is mainly composed of brake pad, brake shoe, brake cylinder and brake pad
adjusting mechanism.
When brake connects with drive axle, according to marks (left, right) on brake, bleeder screw is on
the slight upper, oil line should be cleaned before connecting.
When brake shoe does not work and lies in original position, there should be proper clearance
between friction plate and drum brake, and adjust the brake clearance to 0.25～0.5mm. Adjust
clearance in time after friction plate wears. If friction plate wears severely, (distance between rivet
head and friction plate is less than 0.5mm) replace it in pairs.

1.Bolt M8×45 2. Spring washer 8 3.Case 4.Rubber plug

5.Compressed spring rod 6. Bolt M6×10 7. Spring washer 6 8. Brake bottom plate
9. Pin 10. Pin 11. Brake shoe with friction plate assy 12. Pin
13. Compressed spring seat 14. Spring F 15. Spring B 16. Spring C
17.Pawl 18. Left/right adjuster assy. 19.Sring riveting device 20.Cotter
21Gasket 22Rocker arm 23.Left/right pull rod 24. Spring E
25.Brake cylinder assy 26. Pin 27. Pin
Fig.3-5 Service brake

34
Replace brake shoe
– Place the forklift truck on level concrete.
– Start engine and raise forks about 100mm.
– Place chocks behind rear wheels to prevent movement of forklift truck.
– Loosen wheel nuts two or three turns each.
– Tilt mast fully backward, and place a wooden block under each side of outer mast.

WARNING
 Do not allow wooden blocks to touch
front tires.
– Tilt mast forward until front tires are raised from ground.

CAUTION
 Do not unscrew the wheel nut before
the front wheel rise from the ground.
– Support forklift truck by putting additional wooden blocks under each side of front-end frame.
– Stop engine.
– Remove wheel tire nuts and tire. Remove half-shaft, lock nut, and washer.
– Remove wheel hub and brake drum.
– Replace brake shoes with new ones.
– Reinstall hub, brake drum, locknut and lock sheet. Adjust bearing clearance.
– Adjust shoe to drum clearance: rotate wheel counterclockwise and at the time press down
brake pedal several times
– Take out every padding block：take out according to reverse procedures when inserting.
– Make sure no person or obstacle is around forklift, then operate forklift in reverse at 2 km/h to
3 km/h, set foot on brake pedal 2～3 times.

35
3.1.5 Exhaust air in the brake piping
Park the truck on flat and solid road surface, shut down and pull up the hand brake. One person
continually step the brake pedal and generate enough pressure; another person stay under the
truck, releases bleeder screw, exhausts air, and then screws down the bleeder screw. After repeat
this action several times until fully exhausts the air. After that, add enough brake fluid in time.

36
3.1.6 Trouble diagnoses and corrections

Condition Probable cause Corrective action

Oil leakage in brake lines Correct and replenish
Air in brake lines Bleed air
Water or oil on linings Clean or replace
Insufficient brake Uneven wear or contact of brake linings Grind or replace
force Improper functioning of master cylinder or
Correct or replace
wheel cylinder
Clogged oil lines Clean
Improper functioning of hydraulic boosted
Correct or replace
brake or steering gear pump
Uneven tire pressure Adjust
Brake out of adjustment Adjust
Water or oil on brake linings Clean or replace
Foreign particles in brake drum Clean
Deteriorated lining surface Grind or replace
Improper contact of linings Grind or correct
Unequal braking Worn lining Replace
(forklift truck veers Worn, warped, rusted or damaged brake
to one side) Correct or replace
drums
Improper operation of wheel cylinder Correct or replace
Improper sliding shoes Adjust
Loose back plate blots Tighten or replace
Warped back plates Replace
Improperly adjusted wheel bearing Adjust or replace
Clogged oil lines Clean
No free play of brake pedal Adjust
Improper shoe sliding Adjust
Improper operation of wheel cylinder Adjust or replace
Faulty piston cup Replace
Brake dragging Weak or broken return springs Replace
Clogged master cylinder returns port Clean
Clogged oil lines Clean
Wheel bearing out of adjusting Adjust or replace
Malfunction of hydraulic boosted brake Adjust or replace
Lining surface harden or foreign particles
Repair or replace
on it
Warped back plates or loosed blots Repair or replace
Brake noise Brake shoes warped or improper install Repair or replace
Worn linings Replace
Loose wheel bearing Repair

37
3.2 Parking brake system
Parking brake system adopts hand flexible shaft mechanism, and works on the brake at the output
shaft of drive axle. Only after the forklift is parked, then apply the parking brake system. If the
service brake system malfunctions, it can also use parking brake to stop the truck.
63°

P
1
R1
98

A
C

1. Parking brake handle

2. Parking brake cable
3
3.Parking brake
Fig.3-6 Parking brake system
drawing
Parking brake adjustment
Adjust when the free stroke of hand brake handle is over large. Firstly release the parking brake
lever to limiting position, adjust handle head screw with screw driver, screw down in clockwise,
and unscrew in counterclockwise.
Pulling force of the parking brake handle is adjusted through the screw on the handle head. Rotate
the screw in clockwise, the pulling force is increased. Rotate the screw in counterclockwise, the
pulling force is decreased. Pulling force is within 100～300N.
Adjusting main point:：（1）Mount brake dragline, fasten nut B；（2）Adjust nut A, until the handle
force(point P) is no larger than 15 kg when locking the handle；（3）Apply sufficient lithium base
grease to guide rail C.

38
4 Hydraulic system
4.1 Hydraulic system principle diagram

CPD50/55/60/70/80J/-JZ4/J-I Hydraulic system principle diagram

39
CPD85 J/-JZ4/J-I Hydraulic system principle diagram

40
4.2 Multiway valve

Main parameter

Nominal pressure 20 MPa

Nominal diameter 20 mm

Rated flow 180 L/min

Allowable back pressure 1.5 MPa

Setting pressure of main relief valve 19.8±0.5 MPa

Setting pressure of overload valve 15±0.25 MPa

Forward brake Control pressure ≤2 MPa

valve
Inner discharge ≤40 mL/min

Control force ≤300 N

Working temperature -20℃～100℃

41
Trouble diagnoses and corrections

Trouble Probable cause Corrective action

Loose of pressure-adjust screw. Readjusted and re-tighten.

Distorted or damaged pressure-adjust

Pressure of relief spring. Replace.
valve is not
steady or too low. Worn or blocked relief valve core. Replace or clean.

Pump abated. Examine and repair pump.

Replace valve core and tilt lock

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

Mast is unstable
when tilting Malfunctioning tilt relief valve. Replace tilt relief valve assembly.
forward.
Valve body and spool valve lever is Replace spool valve with
worn and their clearance is too great. specified clearance.
The carriage is
downward when Spool valve lever is not in centre. Keep being in the centre.
the control lever
is in the neutral Cylinder seal abated. Examine and repair cylinder.
position.
Overload valve is worn or blocked by
Replace or clean taper valve.
dirt.

Damaged or distorted reposition-spring. Replace spring.

Dirt exists between valve body and

Spool valve is Clean.
valve lever.
unable to return
neutral position. Blocked control device. Adjusted.

Not coaxial parts at reposition Reinstall, be coaxial

Damaged O-ring. Replace.

Faulty seal of joint. Check and retighten.

Leakage
Clean seal plate and retighten
Loose seal plate.
blots.
Loosed lock-nut of relief valve and
Tighten.
connect-nut between plate and plate.
Control valve
can’t move Control valve adjusting handle Adjust
forward or interference
backward

42
Main relief valve pressure adjustment
Main relief valve pressure has also been adjusted in the factory, so please don’t adjust it at will.
Take forklift with 1600kg rated load as example, explain the adjusting ways:
– Place 125% rated load on the forks stably, that is 2000 kg.
– Step accelerating pedal to the end, operate lift lever, if the forks can lift to 0～300mm, the
main relief valve pressure is right, otherwise do the step3.
– If the forks do not lift, please increase the main relief valve pressure, open the front baseboard,
release the main relief valve locking nut and screw the adjusting bolt in clockwise; if the lifting
height of forks is over 300mm, you should screw the adjusting bolt in counterclockwise, thus
reduce safety valve pressure.
– Step the accelerating pedal to the end, make the forks lifting within 0-300mm. Otherwise do
step 3 to meet the requirement.

WARNING
 Goods must be placed stably.
 Once the pressure is adjusted, please do not adjust casually.

43
4.3 Gear pump
The truck equips with two gear pumps, working gear pump is the external gear pump which can
self-compensate the axial clearance and keep balance of radial hydraulic. It adoptes a
three-opening structure of character "8" location check. DU bushing is appllied in both front and
back covers within the casting aluminum alloy, central part is equipped with special casting iron
pieces. Therefore, it is impact resistance and in spread use of oil temperature, rotational speed
condition even in the case of high temperature and low speed, it can still keep high performance.
Steering gear pump adopts double pump structure, asymmetric tooth gear, integrate pump body,
DU bushing and powder metallurgy plate. It has small pressure fluctuation and low noise.
Working gear pump
Item Working gear pump Steering gear pump
（Low noise）

Model SGP1A36A4H1-R482D TMG1A34A1H1-R517D DSG05C14.5F9H9-R277C

Nominal
36 34 14.5
displacement（mL/r）
Rated pressure
20.6 18.1 20.6
（MPa）

Max. pressure（MPa） 24.5 20.6 22.6

Rated speed（r/min） 2500 2500 2000

Min. speed（r/min） 400 500 500

Max. speed（r/min） 3000 2600 3000

Volume efficiency Efficiency in the speed range≥80%；Efficiency in the rated speed≥93%

Working oil
-10℃～90℃
temperature
Installation Instructions
– Before installation, make sure the rotation direction of gear pump can meet the system
requirement
– The coaxially between the gear pump axle and the motor axle must be less than 0.05mm,
– Connect the inlet and outlet connector, do not misconnect.
– Install the flanges and connectors. No bump ,scratch or burr, in case of oil or gas leakage and
noise-producing
– Avoid that there is no axial force or radial force on the gear pump axle. Install it smoothly
during the installation, no mounting or dismounting by force.
Operation and Maintenance
– Always follow the Instruction, never overload.
– Hydraulic oil requirement: summer, L-HM32 or similar viscosity hydraulic oil; winter, L-HV32
low temperature hydraulic oil;

44
– Starting for the first time, run without load to bleed the air in hydraulic system, until there is no
bubble.
– Keep the oil clean. Clean the oil tank and oil lines fully before refilling.
– Inspect the oil cleanliness and strainers periodically, replace as necessary.

Trouble diagnoses and corrections

Trouble Probable cause Corrective action

Low oil level in tank Add oil to specified level.

No oil from oil
pump Clean oil line and tank. If oil is dirty,
Suction pipe or strainer plugged
replace.
Bearing worn, retainer or O-ring
Replace malfunctioning parts.
damaged
Readjust to specified pressure using
Maladjusted relief valve.
pressure gauge.

Low discharge Retighten suction side pipe.

pressure on oil
pump Add oil in oil tank.
Air in oil pump.
Check pump oil seal.

Do not operate pump until bubbles in

Cavitation due to crushed suction
hose or plugged strainer.
Air being sucked from loose
suction side joint.
Oil pump noise
Cavitation due to too high oil
viscosity.
Bubbles in hydraulic oil
Faulty oil seal on pump, faulty
Oil leakage
O-ring or worn sliding surfaces
from oil pump
on pump.
tank disappear.
Adjust or replace hoses and clean
strainer.
Retighten each joint
Replace new oil with proper viscosity for
temperature at which pump is to be
operated.
To operate when oil temperature is
normal
Check for the cause of bubbles and then
take action
Replace faulty parts.

45
4.4 Hydraulic steering gear
The steering gear belongs to open center non-reaction cycloid rotary valve hydraulic steering gear,
and the integration of overflow valve, bi-directional buffer valve, bi-directional oil valve and inlet
check valve makes compact structure and easier use. This steering gear is mainly composed of
servo rotary valve and a pair of cycloid cam meshing. Among them, valve element, valve bush and
valve body constitutes rotary follow-up valve: control the direction of oil flow, valve element is
directly connected to steering wheel. Rotor and stator constitute a pair of meshing gear, that is a
pair of cycloid cam meshing; it work as motor when power steering, guarantee the oil flow to the
steering cylinder is in direct proportion to the steering wheel inclination; it works as manual pump
when manual steering; universal driving shaft and pull pin that connect rotor and valve bush: it
guarantees the valve bush synchronizes with rotor when power steering, and works to transfer
torque when manual steering. Spring shim: it guarantees that follow-up valve does not return
automatically. Check valve between oil inlet and return port: when manual steering, oil in one
chamber of the steering cylinder flows to the oil inlet through return port, and then press into the
other chamber of the cylinder through a pair of cycloid cam meshing. Also guarantee oil does not
flow to Port T through Port P when power steering.
This steering gear owns characteristics as easy operation, reliable work, few fault, compact
structure, easy installation and manual steering in downtime. Meanwhile, it controls the working
pressure of steering system, offers cylinder pressure buffer and oil refilling protection, and prevent
the oil backflow.

Port P connects brake booster

Port Ps
T A
Port T connects multi-way
valve Port T2
P B
Port A connects right chamber
of steering cylinder
Port B connects left chamber
of steering cylinder
Main parameter

Displacement 200mL/r

Rated flow 20L/min

Max. inlet pressure 16MPa

Overflow valve pressure settings 13MPa

Buffer valve settings 19MPa

Continuous backpressure ≤ 2.5MPa

46
Port thread M20×1.5 O-ring

Sealing way Taper angle sealing

Weight 6.79kg

47
Installation notices
– When installing steering gear, make sure the coaxiality of steering gear and steering column,
and there should be 1mm clearance in the axial direction.
– Depth of the steering column tightened bolt screwing in the steer gear connecting threaded
hole is less than or equal 15mm.
– After installing the steering gear, check the steering wheel return, make return flexible.
– Connecting line: Port P, Port T connects oil return tank, Port A, B connect the left and right oil
chamber of the steering cylinder separately.
– Diameter of steering wheel should not surpass 500mm.
– Allowable normal working oil pressure for the steering gear is 20℃～80℃, allowable limitation
working oil pressure is -30℃～100℃. Note: under abnormal working oil temperature, steering
performance will reduce.
– Take a trial operation after steering system is assembled: before operation, clean oil tank, and
add hydraulic oil to the highest oil level. Release the steering cylinder screwed joint, rotate the
pump in low speed and then deflate, until the oil flows are without foam. Dismantle the joint of
the steering cylinder piston road and steering wheel, rotate the steering wheel, get the piton
reach the leftmost or rightmost position(do not stay at the two limiting position), and then add
oil to the oil tank to specified oil level. Tighten all the thread joints(do not tighten with pressure),
connect piston rod, check if the steering system works normally under each work condition.
– Make sure the fluid clean. Avoid the dirt block the spare parts of the steering gear and cause
the malfunction of steering. Therefore, it’s important to check the condition of the filter element
and the fluid. Replace it as necessary.(Put a drop of hydraulic oil on the blotter, if there is
black center in the oil stains, replace oil immediately)
– If it is difficult to steer or the steering gear failed to turn, check for the cause carefully. In order
to protect the spare parts, do not turn the steering wheel blindly. Neither casually dismantles
the steering gear. It’s prohibited to turn steering wheel by two operators simultaneously.

48
Trouble diagnoses and corrections
Condition
Oil leak at junction surface of the
end cap, stator, separation disc
and valve body of the steering gear
Oil leak at the steering gear journal
Steering wheel is light when turning
slowly, heavy when quickly
Foam in the oil and irregular noise.
Cylinder moves unstably when
turning the steering wheel.
Continuous heavy turning
Steering wheel is heavy when
turning quickly or slowly, and no
pressure for turning
Turn lightly without load or with
light load, and turn heavily with
increased load.
Steering wheel cannot return
automatically
Steering wheel self rotates or
swing automatically
It is unable to turn to the limiting
position
After turn to the limiting position,
steering wheel can rotate easily.
When turn without power, steering
wheel rotates but the cylinder does
not move
When truck runs deviation or
rotates the steering wheel, cylinder
moves slowly
Pressure of the steering system
cannot adjust
Probable cause
Bolts at the junction surface of the
end cap stator and valve body
loosen or the combined sealing
gasket or the O-ring on the junction
surface is damaged.
Seal ring at the steering gear
journal wears too much or is
damaged.
Insufficient oil supply from pump to
the steering gear
Air in the steering system
Oil in the oil tank is below the
specified level.
Oil viscosity is too large.
Check valve in the P,T oil circuit is
invalid
Overflow valve pressure is lower
than the steering required pressure
valve.
Overflow valve is stuck or the
spring is invalid or the seal ring is
damaged.
Spring piece breaks off or
permanent deformation
Install the rotor and universal
driving shaft wrongly
Low pressure of safety valve in the
steering system
Low pressure of bi-directional
cushion valve
Radial clearance or axial clearance
of stator and rotor is too big
Oil viscosity is low.
Bi-directional cushion valve is
invalid(steel ball is stuck or the
spring is invalid or the seal ring is
damaged)
Spring breakage
Sealing of safety valve port is bad,
thus the valve is often open.
Valve element is stuck due to burr
or oil dirt
Valve element works bad
Spring bends or is weak
Oil is dirty, damping hole of the
valve element is blocked.
49
Corrective action
Tighten the bolts to specified valve
alternately and evenly; replace seal
ring.
Replace seal ring.
Check if pump works normally and
pipeline is smooth.
Exhaust air in the system. Check if
the oil suction pipe leaks or the oil
return pipe is below the level.
Add oil to specified level.
Use specified oil.
If steel ball is missing, install steel
ball; if steel ball is stuck, clean it;
the two conditions need check the
recovery of the sealing tape.
Adjust overflow valve pressure to
specified value(not over 16MPa)
Clean overflow valve(check the
recovery of the sealing tape) or
replace spring or seal ring.
Replace spring piece(no
substitution)
Stop the truck.
Align the gear with point of
compact on the universal driving
shaft at the tooth space(thinnest
place seen from the end face) of
the spline in the rotor
Improve safety valve pressure
properly(adjust with pressure
gauge)
Improve cushion valve pressure
properly
Replace stator, rotor meshing pair
Replace oil
Clean bi-directional cushion valve,
replace spring or seal ring
Replace spring
Match with valve element and
valve seat or replace spare part.
Dismantle, check and repair
Check if valve element is stuck by
oil dirt
Replace spring
Replace with clean and unclog the
damping hole
4.5 Spin-on line filter
Spin-on line filter is installed in the hydraulic oil return line, filter the oil return in the hydraulic oil,
filter metal powder from component wear and rubber impurity from the sealing element, thus keep
the return oil clean.

T
P1

P2
Multi-way valve

Spin-on
line
filter

P1 P2

Spin-on line filter working principle

Hydraulic oil tank

P1 P2

Spin-on element

Technical parameter

Filter model SPB-10×10

Filter head model SPH-10

Filter element model SPBX-10×10

Max. working pressure 0.70MPa

By-pass valve opening pressure 0.25MPa

Burst pressure 2.0MPa

Max. return oil flow 320L/min

Filter fineness 10um

Pipe thread R11/4

Weight 3.0kg

50
Filter installation
– Install with hand, first apply oil to the sealing gasket, rotate it on the tread of filter head and
screw down.
– Check if oil leakage.
Note：Hydraulic filter head must have by-pass valve.
Filter element replacement
There is filter indicator on the filter head to check the element
condition, when the pointer is in the red region, it means the filter
element blocks severely, by-pass valve on the filter head is open,
then the filter does not work, twist off the filter cylinder and
replace new element.

51
4.6 Steering cylinder
Steering cylinder is double-acting through type, both ends of the piston rod is connected to the
right/left knuckle of steering axle through connecting rod, and the pressure oil from the steering
gear makes the piston rod move to left and right through steering cylinder, thus realize the left and
right steering. Refer to fig.6-3.

1.LBH dust ring 2.O-ring 3.Guard circle 4.ISI seal ring 5.Guide sleeve
6.O-ring 7.O-ring 8.Composite bush 9.Cylinder body 10.Bushing
11.Glyd ring 12.Support ring 13.Piston rod 14.Piston 15.Steel ball
Fig.2-4 Steering cylinder

52
5 Lifting system
5.1 Data
Check and adjust
Assembly clearance Repair clearance（mm）(no
Place
（mm） parts changed)
Mast to roller mm 0.1～0.8 0.2～1.0

Shims mm 0.5 / 1.0 / 2.0

Mast to back up metal mm 0.1～0.8 0.2～1.0

Shims mm 0.5 / 1.0 / 2.0

Inner mast to carriage side
mm 0.1～0.6 0.2～1.0
roller
Shims mm 0.5 / 1.0 / 1.5

Lifting chain deflection mm 25～30

53
5.2 Mast removal and
adjustment

Warning
Be careful when removing and installing
the forks, carriage and mast, as they are
heavy.
Remove forks and mast assembly
1） Remove adjusting cylinder（8t-10t）and 5） Support mast assembly with steel wire.
connecting hose.
2） Remove fork shaft baffle, pull out fork
shaft and remove fork.

Warning
 Keep hands and feet away from
forks. Remove and install forks
carefully. Keep feet and hands clear.
 Do not remove forks from the top of
the fork. Severe injury can result if
6） Pull out set bolts and axle pin from the
the fork is dropped.
front end of tilting cylinder.

1） Attach wire ropes to fork carriage 7） Remove bearing cap bolts under the outer
assembly and lift it with a lifting device. mast.
2） Remove chain attaching nuts, and detach
chains from the lower end of fork carriage.

8） Remove mast assembly.

9） To install mast assembly, reverse order of
3） Remove fork carriage assembly from
removal.
inner mast.
4） Detach lifting high and low pressure Disassembly
hoses. Warning
Be careful when disassembling the
masts as they are heavy.
Remove lifting cylinder

54
– Place mast on ground. Remove bolts from
lifting cylinder piston, U-bolt and tighten
screw from outer mast.
– Slide inner mast, and then remove lifting
cylinders.
Remove roller
– Extend the inner mast downward. Take out
main roller and side trundle.
– Unclench rollers carefully (knock evenly and
symmetrically) if no bearing puller, or rollers
would be smashed.
Remove inner mast
Attach wire rope to middle of inner mast and slide
it out with a lifting device.
Install roller
Slide inner mast into outer mast and securely
attach lift rollers.
Lift roller-to-mast clearance adjustment
1） Adjust clearance “A” to 0.15～1.2mm
with shims.
2）It is suitable that clearance of roller and
outer mast is about 0.8mm ～ 1mm.
Clearance can’t be adjusted. Replace it if
roller wears too much.
3）Apply lubrication (butter) to interface of inner
mast and outer mast, interface of roller and
channel steel guide. To prevent sand from
entering, it is decided whether to apply
lubrication or not in the area where sand
blown by wind heavily.
Clearance of guide plate and mast channel
steel
Adjust clearance “B” to 0.2～1.0 with shims
between guide plate and inner mast pole,
which may not use. Thickness of shim is
0.2mm.

Inspection
– Check lift rollers, roller shafts, and
associated parts for wear or damage.
– Replace damaged parts as required.
Assembly and adjustment

Warning
Be careful when assembling the masts Apply a coat of grease to guide plate. Install
as they are heavy. mast and lifting cylinder on forklift truck.

55
Connect circle tube and high-pressure tube.
Install left/right cylinder and initially
adjust the cylinder position
– Install left and right lifting cylinder on mast,
bolt must be installed into orientation hole of
outer mast lower cross beam.
– Install upper side of piston rod into cylinder
seat on inner mast. Inner mast lay evenly in
To adjust tension of lifting chain, lower lifting
the direction of left, right, upper and lower. If
cylinder until forks are on the ground, and
it is not even, please adjust by putting
adjust chain adjusting nut (three every side) so
washer between hole of cylinder support
that dimension C will be as listed below when
and upper end of piston rod.
the middle portion of chain is pressed by a
– Surround the cylinder on the fixed plate of
finger.
outer mast with U-bolt, and then screw
down the nuts. The other side. Screw Length of “C” : 25～30mm.

down the screw on the other side and put

locknut.

Lifting chain adjustment

Installs fork carriage on inner mast, and install
lifting chain, then install two nuts on end of every
side. With mast set straight up, lower carriage
completely. Adjust clearance of carriage to
127mm above ground (for 5-7t). If necessary,
adjust with chain adjusting nut.
Clearance of fork carriage assembly
and rollers adjustment
Clearance adjustment among rollers on 5t~6t
forklift fork carriage assembly
There equips with 4 main rollers and 4 side
rollers on the fork carriage, and the side rollers
are installed on both sides of inner and outer of
the right column steel flange. Outer side roller
has welded before delivery and is unable to
adjust. Only adjust the clearance between side
roller and shape steel through adjusting the
shims of inner side roller:
a. Fork carriage lifts or lowers along the inner
mast, clearance between side rollers and

56
 shape steel flange is 0.2~1.0mm.
b. When lifting or lowering, the inner side
rollers roll along the inside of the flange, no
clamping on both sides.
c. If the outer side roller wears too much,
replace it, cause it cannot be adjusted by
shims.

Adjusting shim
0.5mm 1mm
a. Number of shims must be the same on
the right and left sides when using shims.
Clearance adjustment among rollers on 7t forklift
b. After clearance adjustment, push fork
fork carriage assembly
carriage assembly to see if it operates
There equips with 6 main rollers and 5 side
properly.
rollers on the fork carriage, among them, 4
side rollers can adjust the clearance between
side rollers and mast column by adjusting Clearance adjustment among rollers on 8t-10t

shims. One outer side roller has welded before
delivery and is unable to adjust.
1） Measure inside width “A” between inner
mast two U-bar guide rails. Make
measurements at the top, bottom and
center (cross beam) sections, meanwhile
measure inside width “ Aˊ” between
inner flange of inner mast two U-bar.
2） Measure upside outer side roller on fork
carriage B, left and right distance Bˊof
bottom side roller.
3） Calculate A-B, A ˊ -B ˊ . Each result
shows clearances between each roller and
inner mast U-bar.
Adjust shims of each roller evenly on the left
and right and make clearances between
smallest part of inner mast U-bar and carriage
side roller.
A-B = 0.2 ～1mm
Aˊ-Bˊ= 0.2 ～1mm
forklift fork carriage assembly
There equips with 4 main rollers and 4 side
rollers on the fork carriage for 8T forklift, adjust
side rollers by adjusting shims, to control the
clearance between side rollers and mast
column.
There equips with 6 main rollers and 6 side
rollers on the fork carriage for 10T forklift,
among them, 4 side rollers can adjust the
clearance between side rollers and mast
column by adjusting shims. Two outer side
rollers have welded before delivery and is
unable to adjust.
1） Measure inside width “A” between inner
mast two U-bar guide rails. Make
measurements at the top, bottom and
center (cross beam) sections, meanwhile
measure inside width “Aˊ” between
inner flange of inner mast two U-bar.
2） Measure upside outer side roller on fork
carriage B, left and right distance Bˊof

57
 bottom side roller.
3） Calculate A-B, Aˊ-Bˊ. Each result shows
clearances between each roller and inner
mast U-bar.
Adjust shims of each roller evenly on the left
and right and make clearances between
smallest part of inner mast U-bar and carriage
side roller：
A-B = 0.2 ～1 mm
Aˊ-Bˊ= 0.2 ～1 mm
Adjusting shims
0.5mm 1mm
a. Number of shims must be the same on the
right and left sides when using shims.
b. After clearance adjustment, push fork
carriage assembly to see if it operates
properly.

58
5.3 Disassembly and installation of
lifting cylinder

Warning
Keep body away from equipment.
– Park the forklift to appointed place, lower
the lifting cylinder to the lowest
position(drop the piston to cylinder bottom),
return all oil to the oil tank.
– Disconnect the oil return pipe of lifting
cylinder and disassemble inlet pressure
hose of the bottom regulator valve and the
pressure hose connected to the cylinders.
– Remove the U bolts on the dead plate of
outer mast and set screw on the opposite
side.
– Unscrew the cylinder support bolts on the
piston rod and the mast.
– Dismount the chain on the mast, Caution
Never reuse removed dust gasket ring,
meanwhile dismantle bolts on the cylinder
O-ring, Y-ring, must replace.
body.
– Lift the inner mast with steel wire and take 3） Draw out piston rod, remove seal ring

away the left and right lifting cylinders. from end of piston.
Install and replace faulty parts
1） Cleanup parts with clean oil before
installation
2） Then cleanup guiding bush and piston
with hydraulic pressure oil the same as oil
box trademark.
3） Dust or dunghill doesn’t drop into lifting
cylinder.
4） The order of installation is reverse the
Disassembly
order of disassembly.
Remove tighten skew and nylon stopper, then
5） Install seal ring on piston.
remove cylinder head.
6） Install piston rod assembly (including
1） Remove dust ring.
piston rod, piston, support ring and seal
2） Remove seal ring with screwdriver.
ring) into clean cylinder body.

59
 Caution
The end of cylinder body must slick and
clean, installation must set center, avoid
scratching Y-ring.

7） Install replaced dust ring and Y-ring in

guiding bush and cylinder head.

Caution
Apply hydraulic pressure grease which
trademark is the same with tank on guide
sleeve installed gasket ring.

8） Rip cylinder head into piston rod, screw

down cylinder body.

60
5.4 Disassembly and – Dismantle cylinder head 14 and guide
sleeve 12.
installation of tilting cylinder
– Pull out piston rod assembly 25(refer to

Warning the following fig.)

– Dismantle all exposed dust ring, o-ring
 Attach wire rope to outer mast, avoid
and seal ring.
mast fall down after removing tilting
cylinder.
 Keep body away from equipment, no
standing under the fork arm carrier.
Dismantle
– Lay down fork carriage completely.
– Remove oil pipe from the inlet of tilting
cylinder.
– Remove bolt on the left and right bracket
from outer mast, moreover pull bearing – Remove dust gasket ring in the cylinder
pin out. head. Means is the same as removal of
– Remove bolt from the bracket of chassis, dust gasket ring in the cylinder head of
and pull axle pin out, then move tilting lifting cylinder (see disassembly and
cylinder. installation of lifting cylinder).
– The order of installation is reverse the – Remove O-ring from the outer ring of the
order of disassembly. guide sleeve.

Disassembly
9） Remove O-ring and seal ring from the
– Clamp the tilting cylinder with pliers, then
inner hole of guide sleeve (see
pull piston rod come-and-go as opening of
disassembly and installation of lifting
inlet and outlet on the tilting cylinder, so
cylinder fig.).
remaining oil is discharged from tilting
cylinder. Caution
Never use the dismantled dust ring and
– Screw earring 21 out.
seal ring
– Dismantle cylinder head bolts and Nylon
Installation after replacing seal ring
plug.
The order of installation is reverse to the order

61
of disassembly, but should notice follow
proceedings:
– Lubricate parts with clean hydraulic
pressure oil.
– Avoid dust and oil dirty dropping into tilting
cylinder.
– Avoid scratching the end of cylinder body,
and inlet and outlet for oil.
– Push piston rod to cylinder body when
setting center, especially avoid scratching
seal ring.
– Apply the same brand hydraulic oil as
work oil to lubricate among seals.
– Don’t scratch O-ring outside in the guiding
bush when installing.
– Remember to install nylon stopper and
tighten screw after screw cylinder head.

62
5.5 Noticing proceeding of
debugging
Adjust forward and backward of the mast
Park forklift truck on the level ground, operate
control lever to realize that mast inclined
forward or backward extremely. As assembly
debugging data required, adjust combined
screw thread length of the tilting cylinder
piston rod and till meet data of backward. Then
lock earring ring.
Readjust installation position of left and
right lifting cylinder
– Adjust washer in the piston rod and inner
mast bracket if one lifting cylinder is not
synchronization with the others when
rising or falling, and if one lifting cylinder is
different height from the others.
– Loose two nuts on the U-bolts. Lift or
lower the mast for several times until
relative position of U-bolt and cylinder is
suitable. Then screw down nuts and
tightening screw on the U-bolt. Thus lifting
cylinder can be used longer and wear of
piston rod can be reduced
Please refer to our company regulated bolt
tightening torque if you want know tightening
force of bolt or screw.（refer to Operation and
Maintenance Manual）.

63
 5.6 Fault
Condition Probable cause Corrective action

Fork carriage or Tilt cylinder and seal ring abraded excessively Replace piston ring or tilting cylinder.
mast tilts
automatically The hydraulic control valve spring is inoperative. Replace it.

The fork carriage

Caused by piston jamming or piston rod bent. Replace the faulty parts.
moves up and
down sluggishly. Too much dirt is accumulated in the cylinder. Clean

Adjust clearance with thrust metal and

Carriage assembly out of adjustment.
carriage side roller.

Insufficient clearance between rollers and mast channel. Adjust roller clearance
Fork carriage is
lifted or lowered Foreign materials clamped against moving part. Remove foreign materials.
unsmooth
Apply grease on contact surfaces of sliding
Insufficient lubrication.
parts.（butter）

Inner mast deflection or fork carriage bent Repair or replace.

Forks are lifted

Lift chains out of adjustable. Adjust lift chains.
unevenly
Grease stiffened or dirt accumulated on lift roller Clean and lubricate lift rollers.
Lift roller does
not rotate
Improperly adjusted lift roller. Adjust.

Insufficient lubrication. Lubricate.

Improperly adjusted lift roller, after extending mast,

Adjust roller, side roller adjusting shim
Excessive mast descend to bump with mast channel
noise Adjust shim and cushion, get the inner mast
Cushion under outer mast does not work on container first touch cushion when inner mast drops,
forklift and then the piston rod in the cylinder can
touch the bottom of cylinder.
Excessive wear occurs between the oil pump body and
Replace the worn parts or the oil pump.
gears, causing too much clearance.
The lifting cylinder piston seal ring has worn, resulting in
Replace Y-ring.
excessive inner leaks.
Springs of the multiple control valves and its relief valve
Replace new spring.
are inoperative.
Excessive wear occurs of the hydraulic control valve,
Insufficient lift Replace.
resulting in excessive oil leaks.
power or no lift
Oil leaks occur between the hydraulic control valve Dismantle for regrinding the joint surfaces
movement. sections. and reassemble the valve.
Tighten the joint nuts and inspect the seal
Leakage occurs in the hydraulic pipe.
for damage.
Change the wrong hydraulic oil or stop
The hydraulic oil temperature is too high. Oil viscosity is
operation for reducing the oil, find out the
too low and the rate is insufficient.
reasons for high oil temperature

The load carried is beyond the designed capacity. Lift according to requirement.

64
6 Electrical system
Electrical system of this truck is double wire circuit, all circuits are not grounded. Working voltage
for control circuit and main circuit is 96V, for signal and illumination circuit is 24V.
For ease of check and repair, main components like controller mainly assembled under the left
side plate of the truck.

Cables are covered with color-coded vinyl for easy identification. In the wiring diagram, colors are
indicated by one or two alphabetical letters.
Cable color
Cable colors are indicated by one or two alphabetical letters.
B：Black， R：Brown，G：Green，
U：Blue， O：Orange，R：Red，
W：White，Y：Yellow，S：Grey，P：Purple
Main wires are normally used monochrome. Others are used double color:
B/W： Black white
G/Y： Green yellow

Warning
 Before checking any parts of electrical system, remove rings and jewelry to prevent
short circuit, and turn off ignition switch and then disconnect battery ground cable.
 Before doing any electrical maintenance, make sure battery cable has been
disconnected.

Inspect
Inspect all electrical circuit, referring to wiring diagrams. Circuits should be tested for continuity or
short circuit with a conventional test lamp or circuit tester. Before inspecting circuit, ensure that：
– Each electrical component part or cable is securely fastened to its connector or terminal.

65
– Each connection is firmly in place and free from rust and dirt.
– No cable covering shows any evidence of cracks, deterioration or other damage.
– Each terminal is a safe distance away from any adjacent mental parts.
– Each cable is fastened to its proper connector or terminal.
– Wiring is kept away from any adjacent parts with sharp edges.
– Wiring is kept away from any rotating or moving parts.
– Cables between fixed portions and moving parts are long enough to withstand shocks and
vibrations.
– The wiring keeps a safety distance with the high temperature thing such as the vent-pipe.

66
6.1 Fuse assembly

Procedures：
– Park the forklift.
– Open the right door and remove the
battery plug.
– Open fuse box cover.
– Check if the fuse value set correctly
or damaged according to the
following parameter list, replace
damaged fuse in time.
Recover the fuse box cover.
6
5
4
3
2
1

Fuse parameter list

No. Description Control circuit Manufacturer/Model/Specification

Alarm lamp，Rear lamp，

1 FU4 Littelfuse / ATO 257 / 32V / 20A
Steering lamp，Brake light

2 FU5 Headlight，Meter，Sensor Littelfuse / ATO 257 / 32V / 10A

Reserved 24V connector，

3 FU6 Littelfuse / ATO 257 / 32V / 10A
Cooling fan

4 FU1 Controller total feed Littelfuse / ATO 257 / 32V / 10A

5 FU2 Empty, reserved Littelfuse / ATO 257 / 32V / 10A

6 FU3 Empty, reserved Littelfuse / ATO 257 / 32V / 10A

Caution
 Remove battery plug before checking the forklift electrical system.
 Take off the metal accessories from the hand before checking the forklift electrical
system.
 Replace fuse with the same specification.

67
6.2 Combination switch

Forward/reverse selector switch

Check
Disconnect switch connector clip, and check if each point is connected.
Use multimeter (with ohm) to inspect whether each position is connected.
Light combination switch

68
Light switch check
Disconnect switch connector, and check
whether each connection point is on.
Use multimeter (with ohm) to inspect
whether it is on when lighting switch is on
these positions: head lamp, width lamp,
OFF.

Position Contact
Head lamp 4-6
Width lamp 4-5
OFF OFF

69
6.3 Motor
6.3.1 Main Parameter

Rated Rated Rated Rated Max.

Insulation Frequency
Work type Type power voltage current speed Duty Phase temp.
class Hz
kW V A r/min ℃

Traction motor HPQ35HC-96 35 65 225 3800 H S2-60min 128 3 40

Working motor HPB40HC-96 40 65 420 2300 H S2-5min 81 3 40

Steering motor HPZ3HC-96 3 60 85 1600 H S2-60min 57 3 40

CAUTION
 AC motor does not have commutator and brush. No maintenance. But it needs
regular inspection and dusty clearing.

6.3.2 Motor maintenance

– Motor must be maintained well so as to guarantee safety work and extend service life.
– Motor installation and each fastener should be reliable.
– Power cable should be correctly and firmly connected, no protrusion, no oil stain on the
insulation part, and keep dry.
– Idle motion should be quick.
– If there is any abnormal phenomenon, stop immediately, such as overheating or abnormal
noise. Operate until malfunction is corrected.
– Do not disassemble the motor arbitrarily, follow the rules of CAUTION OF MOTOR
DISASSEMBLING;
– Clean the surface of motor regularly, replace the grease of the motor bearing
annually(working temperature of grease is -40℃~+200℃)
– Washing the motor case with high pressure liquid is strictly prohibited, in case of case
deformation.
– To protect the shaft extension, do not remove the motor by putting ropes on motor shift, during
the disassembling and assembling process
6.3.3 Caution of motor disassembling
– Be careful of the outer coder, no strike and protect the connectors of both signal wire. Do not
knock against coder gear when disassembling and inspecting the coder. Clear the gear
before assembling
– Clear rust and other stain fully before assembling.
– No any part damages during the assembling

70
– Wire connection should be correct and secure. No cutting-edge protrusion, no stain on
insulation, and keep dry
– The motor rotor can rotate easily by hands.

71
6.3.4 Common fault and corrections

Trouble Probable cause Corrective action

Inspect the voltage of battery, switch, wire line, contact
Power failure terminal, motor connect terminal. Find out the causes and
correct
Check for the reason of fuse burnout and correct. Reinstall
Fuse burnout
a new fuse according to the motor capacity
Check for the connection of control circuit according to
Faulty connection of control circuit
electric schematic. find out the causes and correct
Inspect the coil by using multimeter, tramegger or indicator
Stator or rotor coil open circuit lights. If there is an open circuit, find out the open place
and reconnect.
Check for equilibrium of motor there phases, Check for
Motor fail Short circuit or earth connection of
earth connection of coil, find out the disorder place and
to start stator coil phases
correct
Recalculate the load, select the proper motor or lighten the
Overloaded or mechanical part gets
load, check if mechanical transmission mechanism gets
stuck
stuck and correct
Improper thermorelay or thermorelay
Select proper thermorelay and readjust according to motor
is adjusted small, or overflow relay is
rated electric current
adjusted small
Faulty connection of motor, causing
Reconnect the motor according to the motor nameplate
the motor fail to start on heavy load
Recheck the head or tail port of stator coil, connect
Faulty connection of stator coil
correctly
Inspect the power line, motor connect terminal, fuse,
Starts on single phase switch, contact terminal, Find out the disconnection and
correct
The sectional area of fuse is too
Fuse was Rematch and replace a new fuse.
small
burned
A coil phase is shorten to the ground Disassemble and repair the motor coil
out, when
motor Overloaded or mechanical part gets Adjust the load to the rate value, and eliminate the
starts stuck mechanical failure
shorten circuit of connecting wires
Repair after finding out the shorten place
between battery and motor
The starting resistance of motor with Eliminate the shorted circuit or increase the starting
coils rotor is too small or shorted. resistance
Check for the voltage of power, ask power supply
Lower voltage of power
department for helps
Inspect the voltage of power, contactor, switch, one phase
Phase lack of power
disconnection ,find out the causes and correct
The head or tail port of motor is Power DC to the stator coil inspects the polarity of the coil.
misconnected or inner connection of Check the correct connection of the head or tail port of
Motor fails coil connects contrary coil, and reconnect.
to start Misconnect △to Y connection Change Y to △connection
and gives
Find out the open circuit place and repair, Check the
out
contact condition of brush of coil rotor and collecting ring.
buzzing Coil of stator or rotor is shorted
Check open circuit of the staring resistance or big
noise after
resistance
power on
Overloaded or mechanical part got Release the load, eliminate the mechanical failure or
stuck replace the motor
Tight installation or hard grease Reinstall, and replace the grease
When polarity changing and
Select proper coil type and pitch. Lathe the rotor diameter
rewinding, the match of wedge and
improperly, Recalculate the parameters of coil
groove select improperly
Charged Misconnection of power wire and
Eliminate the fault connection, motor shell should connect
motor ground wire. Badly earth connection
to the protective ground wire securely
shell of the motor

72
 Trouble Probable cause Corrective action

Wet coil and insulation aging Dry the coil and replace the insulation aged coil
Lead wire and terminal box interfere
Pack up or replace the extension line
with the ground
Top end of the coil is connected to Find out the grounded place, pack up, insulate and paint,
the ground and add insulator into the end cover
When the Cage rotor broken bar or break
Check broken bar or break welding place, and repair
motor runs welding
with or One phase brush of cage rotor is Adjust the stress of brush, increase the contact surface of
without poor contacted brush and collecting ring
load, the Collecting ring short circuiting device
current of cage rotor type motor contact Inspect and maintain or replace short circuiting device
keep poorly
unsteadily One phase open circuit of coiled
Find out the open place and correct
rotor

73
 Trouble Probable cause Corrective action
Check the voltage with a voltmeter or multimeter and reset
Too low voltage
the voltage.
Misconnect △ to Y to the motor. Correct the connection by changing Y to △.

Hard to Misconnection of coil ends Find the correct ends and connect in a right way.
start the Due to cage rotor broken bar or
motor. Find out the broken bar or break welding and repair.
break welding
Speed is Overload or the mechanical Decrease the load or replace the motor. Improve the
lower than transmission is not flexible. transmission mechanism.
the rated Poor contact of the starting rheostat Inspect and repair the contact resistance of starting
when of the cage rotor motor. rheostat.
added Improve the contact area of brush and collector ring.
with rated Coils of stator and rotor misconnect.
Adjust the brush pressure.
load. Poor contact of the brush and
Correct the connection way.
collector ring.
One phase open circuit of coiled
Find the open circuit and eliminate the fault.
rotor.
Too many turns when rewinding. Rewind by the correct coil turns.
Basic strength is not enough or foot
Strengthen or add spring cushion. Fasten the bolts.
screws loosen.
Drive pulley, relaying wheel or gear
install improperly which cause the Reinstall, correct or replace the fit key.
wearing of fit key.
Bearing wears and the clearance is
Check the bearing clearance and replace the bearing.
too big.
There is Uneven air gap Adjust the air gap
violent Clean up the fastening bolts of the rotor and find out the
vibration The rotor is unbalanced.
dynamic balance.
when the
motor is Iron core deforms or loosens. Revise the iron core and remount.
running. Spindle bends Straighten the spindle
Fan blade deforms or unbalanced. Revise the fan blade. Find out the dynamic balance.
Cage rotor broken or welding break Rewelding or replace the cage bar.
Rotor coil short circuit Find the shorted position and eliminate.
Stator coil short circuit, open circuit
Find out the cause and eliminate the fault.
or misconnect to the ground.
Too high or too low voltage. Check the voltage. Contact with power supply department.
Check the vibration cause and find the iron core and
Iron cores of stator or rotor lessens
process.
Too big clearance of the bearing Check or replace the bearing.
Lack of lubricating grease on the
Clean the bearing and add more lubricating grease.
bearing.
Stator and rotor interferes each
Install in a correct way. Adjust the air gap.
There is other.
noise Fan interferes with the fan guard and
Repair the fan guard and clear the air channel.
when the the air channel blocked.
motor is Rotor interferes with insulation paper
Trim the insulation paper or repair.
running or the slot wedge.
The resistance is unbalanced for
Find out the short circuit position and repair accordingly or
each phase coil. There is partial
replace the coil.
short circuit.
Misconnect of the stator coil. Find the correct ends and connect in a right way.
Slot wedge mismatches when
Inspect the slot wedge match of stator and rotor.
changing the polarity and rewinding.
Turns quantity of each phase are Rewind and correct the quantity of turns.

74
 different when rewinding.
Check the power, fuses, and contactor and eliminate the
Run the motor by single phase
faults.
Sweat coil insulation Process with heating and drying.
Coil is pasted with dust and Clean up the dust and clingage and process with drying
Low clingage. and dipping.
insulation Clean up and process with drying and painting. Or replace
coil insulation aged
resistance the insulation.
Wiring board of the motor damaged.
Remake the lead wire insulation. Repair or replace the
Lead wire insulation aged and
wiring board.
broken.

75
 Trouble Probable cause Corrective action
Excessive or insufficient lubricating Clean up and add lubricating grease to 1/2~2/3 volume of
grease the bearing housing.
Inspect the oil and check for impurities. Replace but
Bad quality oil with impurities
qualified lubricating grease.
The bearing is over worn and with Replace the bearing. Clean and replace the oil for bearing
impurities. with impurities.
The seals are over tight. Repair or replace the seals.
Inspect dimensional tolerance of the shaft. Adhere it with
Too tight or too loosen match
resin when it’s too loose. Process with lathe when it’s too
between bearing and the shaft
tight.
The motor
Decent rated connection between
bearing
the motor and transmission Correct the central line of the transmission mechanism.
overheats
mechanism. The driving belt is too Adjust the tension of the driving belt.
tight.
Inner cap of the bearing is decent Repair the inner cap of the bearing. Adjust the suitable
rated. It interferes with the shaft. clearance with bearing.
Bi-ends cover of motor and bearing During the installation, flatly mount the end covers and the
hood is not correctly installed. bearing hood and screw up the bolts.
Too tight or too loosen match
Mount bush when it’s too loose. Process with lathe when
between the bearing and the ends
it’s too tight.
covers.
Main shaft bends. Straightening the shaft.
Check the voltage. Contact with power supply
Too high or too low voltage.
department.
Check for load condition and decrease the load or
Run the motor when overloads
increase the motor capacity.
Check the power, fuses, and contactor and eliminate the
Run the motor by single phase
faults.
Operates correctly. Decrease the times of running or
Frequent starts and brakes and
corotation and inversion of the motor. Or replace by a
corotation and inversion
proper motor.
Fan damaged and ventilation Repair or replace the fan. Clean up the dirt in the air
blocked channel.
Ambient temperature is too high Take cooling measures
The motor Short circuit occurs between turns of
overheats coil and between phases. Coil Find out the cause and repair.
or occurs connected to the ground.
smoking Misconnect △ to Y of the motor. Or Misconnect Y to △.
Faulty connection of the coil
Correct the connection.
Iron core damaged during an
overhaul which increases the iron Check the iron core and repair. Eliminate the faults.
loss.
Iron core of the stator interferes with
Install in a correct way and adjust the clearance.
the core of rotor.
Broken arm of cage rotor or rotor
Find out the broken bar or the loose place. Reweld or
coil loosens when connected to the
fastens the screws.
ground.
Check the cooling water unit and see if the ambient
The inlet air temperature is too high
temperature is normal.
Insufficient dipping of the coil after
Process with second dipping or vacuum dipping.
rewinding.
The current Misconnect the ends of the coil Correct the ends of the coil and connect correctly.
is Check the voltage. Find out the cause and take corrective
unbalanced Unbalanced voltage
action.
or varies There is short circuit between the
violently Check for the polarity of the coil and find out the shorted
turns of coil. One coil assembly is
when the reason and reconnect. Eliminate the faults.
misconnected.

76
motor is
When rewinding, the turns of coil
without Wind the coil again.
are different.
load.
Check the voltage. Contact with power supply
Too high voltage
department.
Current Misconnect △ to Y of the motor. Change the coil to Y connection
increases
when the Air gap is uneven or it increases. Adjust the air gap.
three
Incorrect installation of the motor. Check for the installation condition and remount.
phase
motor is Overheat of the iron core and cause Check the iron core or redesign to compensate with the
unloaded damage during the overhaul. coil.
Turns of coil are not enough when
Add the turns of coil.
rewinding.

77
6.4 Controller assembly

1. Heat dissipation
4
3
2.150A fuse
3
2 3.500Afuse
8
4.200A contactor
5.80A contactor
7
6.Steering motor controller
4 7.Working motor controller
5 8.Traction motor controller
1 6 Fig.6-X Controller assembly
Controller
International advanced closed-loop system and the advanced vector control technology are
integrated in the controller which is produced by American CURTIS company. It is designed with
big screen which can display general information clearly, such as power volume, speed, total
running time, etc. Faults display by codes, which can improve the efficiency of maintenance. Four
kinds of operation modes can be set on the dashboard, which can be used for different working
conditions.
Safety and protection features
– Polarity protection of the battery;
– Connection errors;
– All inputs are protected against connections errors;
– Current overload protection;
it have detecting element，limit peak current;
– Thermal protection;
① If the controller temperature exceeds 85°C, thermal protection will work; the maximum current
reduces in proportion to the thermal increase. Once the temperature exceeds 95°C, it will shut
down automatically and give a warning.
② If the motor temperature exceeds 145°C, thermal protection will work; the maximum current
reduces in proportion to the thermal increase. Once the temperature exceeds 160°C, it will shut
down automatically and give a warning.
– Battery overdischarge protection;
When the capacity of flattery is low, the maximum speed and current reduce greatly.
– External guard protection;
Electric control is hermetical which can protect against dust and liquid into the body.

78
– Starting order protection;
Starting should follow right operating orders. If the operating orders are incorrect, truck cannot
start. Drive demand should be sent after turning the key on, thus the truck starts.
– When electrical elements are damaged, the control can protect itself to avoid more damage.
Operation features
– Close-loop control system make the vehicle speed follow accelerator, which make control
easily whether low speed or high speed.
– Two archives speed and acceleration design can apply to many applications.
– Regeneration technology make direction change more smoothly.
– Three regenerative braking mode
① Regenerative brake from accelerator pedal release partly.
② Regenerative brake from direction reverse.
③ Regenerative brake from traveling downhill.
Except increasing driving security，it can recycle parts of electric energy, and prolong work hours
of every shift.
– Speed control during traveling downhill: motor speed lies on accelerator. If motor speed
exceeds the setting value of accelerator，the controller will brake automatically, which gives
an optimal protection of ramp
Note：
– Before maintaining the controller, cut off the power. Connect a 10-100 ohm resistance to the
positive and negative poles of controller to release residual voltage in the capacitor, or else
there might be an electric shock.
– Magnetic field and radiation of surroundings will effect on the inverter, controller may be
damaged due to the long time effect. So keep away from magnetic field and radiation.

79
 Controller fault code
Each controller contains 2 LED lights which can display different message though different colors
of lights combination. see as below;：

Display Message
Controller is disconnected, dead battery, or other
Both LED light off
line fault.
Yellow LED flashing Controller works properly

Yellow and red LEDs both are on Controller is updating software

Red LED and yellow LED flash together Controller has fault

Fault Handheld programmer

Probable Cause
code displayed code
1. Short circuit of link ends U, V or W of the motor.
1,2 Controller Overcurrent 2. Mismatch of the motor parameter
3. Malfunction of the controller
1. Truck frame short circuit by motor U, V, and W
1,3 Current Sensor Fault through stator.
2. Malfunction of the controller
1. External loading of the capacitor bank(B+ terminal)
prevent capacitor charging.
1,4 Precharge Failed
2.Refer to 1311 battery testing menu: capacitor
voltage
1. Controller is operating in an extreme environment,
Controller Severe below -40℃.
1,5
Undertemp 2. Refer to 1311 controller monitoring menu:
temperature
1. Controller is operating in an extreme environment,
over +95℃.
2. Over load on vehicle.
1,6 Controller Severe Overtemp
3. Improper mounting of controller.
4.Refer to 1311 controller monitoring menu:
temperature
1. Battery Menu parameters are misadjusted.
2. Over load on vehicle.
3. Battery resistance is too high.
1,7 Severe Undervoltage 4. Battery disconnects when driving.
5.Refer to 1311 battery monitoring menu: capacitor
voltage
6. B+ fuse burn-out or main contactor is open.
1. Battery Menu parameters are misadjusted.
2. Over high resistance of the battery generated
regeneration current.
1,8 Severe Overvoltage
3. Battery disconnects when regenerative braking.
4. Refer to 1311 battery monitoring menu: capacitor
voltage

80
Fault Handheld programmer
Probable Cause
code displayed code
1. Controller does not work, if below -25℃.
Controller Undertemp 2. Controller works under severe environment.
2,1
Cutback 3. Refer to 1311 controller monitoring menu:
temperature
1. Controller does not work, if above 85℃.
2. Controller is operating in an extreme environment
3. Over load on vehicle.
2,2 Controller Overtemp Cutback
4. Improper mounting of controller.
5. Refer to 1311 controller monitoring menu:
temperature
1. In normal condition, error displays the battery need
charging. Controller function will be restricted under
this voltage.
2. Battery Menu parameters are misadjusted.
3. Check if there is any other power consumption.
2,3 Undervoltage Cutback
4. Battery resistance is too high.
5. Battery disconnects when driving.
6. Refer to 1311 battery monitoring menu: capacitor
voltage
7. B+ fuse burn-out or main contactor is open.
1. Normal operation. Error displays the regenerative
braking current improves the battery voltage during
regenerative braking. Controller function will be
restricted under this voltage.
2. Battery Menu parameters are misadjusted.
2,4 Overvoltage Cutback
3. Over high internal resistant when the battery gains
rated regenerative current.
4. Battery disconnect when regenerative braking.
5. Refer to 1311 battery monitoring menu: capacitor
voltage
1. Too low resistivity for external loading of +5 V
supply terminal (pin 26)
2,5 +5V Supply Failure 2. Refer to 1311 input monitoring menu：5V and Ext
supply current.

1. Too low resistivity for external loading of digital

output drive end 6 (pin 19)
2,6 Digital Out 6 Overcurrent

1. Too low resistivity for external loading of digital

output drive end 7 (pin 20)
2,7 Digital Out 7 Overcurrent

1. Motor temperature is larger or equals the

programming setting thermal cut-off temperature,
motor temperature is larger than145℃.
2,8 Motor Temp Hot Cutback 2. Incorrect controller temperature control data
adjustment.
3. Refer to 1311 motor testing menu： temperature
and motor input：Analog2

81
 Fault Handheld programmer
Probable Cause
code displayed code
4. If there is no thermistor, temperature
compensation and temperature cut-off are set as
OFF.

1. Incorrect motor thermistor connecting.

2. If there is no thermistor, temperature
compensation and temperature cut-off are set as
2,9 Motor Temp Sensor Fault OFF.
3. Refer to 1311 motor monitoring menu ：
temperature and motor input：Analog2
1. Open or short on driver load.
2. Dirty connector pins.
3,1 Coil 1 Driver Open/Short 3. Wire harness damage or wiring error.

1. Open or short on driver load.

2. Dirty connector pins.
3,1 Main Open/Short 3. Wire harness damage or wiring error.

1. Open or short on driver load.

2. Dirty connector pins.
3,2 Coil2 Driver Open/Short 3. Wire harness damage or wiring error.

1. Open or short on driver load.

2. Dirty connector pins.
3,2 EM Brake Open/Short 3. Wire harness damage or wiring error.

1. Open or short on driver load.

2. Dirty connector pins.
3,3 Coil3 Driver Open/Short 3. Wire harness damage or wiring error.

1. Open or short on driver load.

2. Dirty connector pins.
3,4 Coil4 Driver Open/Short 3. Wire harness damage or wiring error.

1. Open or short on driver load.

2. Dirty connector pins.
3,5 PD Open/Short 3. Wire harness damage or wiring error.

1. Motor encoder failure.

2. Wire harness damage or wiring error.
3,6 Encoder Fault 3. Refer to 1311 motor monitoring menu：motor RPM

82
Fault Handheld programmer
Probable Cause
code displayed code
1. Motor U, V, W is open.
2. Cable damage or wiring error.
3,7 Motor Open

1. Main contactor pin end welded.

2. Motor phase U is disconnected or open.
3,8 Main Contactor Welded 3. An alternant voltage way(eg. external precharge
resistor) supplies capacitor bank(B+ terminal)
current.
1. Main contactor cannot close.
2. Main contactor pin end is oxidized.
Main Contactor Did Not
3,9 3. External loading of the capacitor bank(B+ terminal)
Close
prevent capacitor charge.
4. B+fuse burn-out.

1. Over high throttle wiper voltage.

4,1 Throttle Wiper High 2. Refer to 1311 input monitoring menu：throttle
potential

1. Too low throttle wiper voltage.

4,2 Throttle Wiper Low 2. Refer to 1311 input monitoring. menu：throttle
potential

1. Over high brake wiper voltage.

4,3 Brake Wiper High 2. Refer to 1311 input monitoring menu ： Brake
potential

1. Too low brake wiper voltage.

4,4 Brake Wiper Low
2. Refer to 1311 input testing menu：Brake potential

1. Too low low-side connected potentiometer

4,5 Pot Low Overcurrent resistivity
2. Refer to 1311 motor monitoring menu：low-side

1. EEPROM fails to read-in.

The possible failure may caused by EEPROM
4,6 EEPROM Failure
read-in through VCL, CAN bus, adjust 1311 data or
load new software to controller.

1. Improper sequence of switch, interlock, direction

and accelerator inputs.
4,7 HPD/Sequencing Fault 2. Switch, interlock, direction or accelerator inputs
cable, coil and change-over switch fault.
3. Refer to 1311 input monitoring menu

83
 Fault Handheld programmer
Probable Cause
code displayed code

1. Emergency reverse operation stops, but the

4,7 Emer Rev HPD throttle, forward, reverse input, interlock switch do
not return to neutral position.

1. Safety fault caused by some 1311 parameter

change can be eliminated by re-open the switch.
4,9 Parameter Change Fault For example, if user changes throttle type, it will
cause this fault, re-open the switch can you operate
the truck.
1. VCL code runtime error。
2. Refer to 1311 controller monitoring menu：VCL
6,8 VCL Runtime Error error module and VCL error. This error can be
compared to error defined in runtime VCL module ID
and OS system information file.
1. Current generates from 5V and 12 V input of
external loading is too large or too small.
External Supply Out of 2. External max. input and min. input of the error
6,9
Range check menu parameter do not adjust correctly.
3. Refer to 1311 input monitoring menu: external
input current.

7,1 OS General 1. Inner controller fault.

1. Time of CAN PDO messages received exceeded

7,2 PDO Timeout
the PDO limited time.

1. Stalled motor.
2. Motor encoder failure.
7,3 Stall Detect 3. Wire harness damage or wiring error.
4. Malfunction of power supply for motor encoder.
5. Refer to 1311 motor monitoring menu：motor RPM.

8,7 Motor Characterization Fault 1. Description of motor characterization is wrong.

1. Description of encoder characterization is wrong.

Encoder Characterization 2. Impulse frequency of motor encoder is not a
8,8
Fault
standard value.（32, 48, 64, 80ppr）

8,9 Motor Type Fault 1. Motor type parameter is out of range.

84
Fault Handheld programmer
Probable Cause
code displayed code

1. Vehicle is still moving after the EM Brake has been

9,2 EM Brake Failed to Set applied.
2. EM brake cannot hold the rotating motor.

1. Whatever encoder error(code 36) or stall detection

fault(code 73), limit operation control mode will be
Limited Operating Strategy activated.
9,3
（LOS） 2. Motor encoder error.
3. Wire harness damage or wiring error.
4. Truck stalls.

1. Emergency reverse is in activate state but stop

9,4 Emer Rev Timeout working, cause it is in timeout.
2. Emergency reverse signal bonding.

85
ZAPI controller
Italian ZAPI controller is reliable and high efficient, with great speed control. On the instrument is
state of charge, speed, total run time. If malfunctioned, cause of failure can be quickly and
efficiently determined by fault code or fault module part number. Operator can choose four
operation mode for different working conditions by using the instrument buttons.
Walking controller delivers excellent speed control and reliable regenerative braking performance.
– The motor velocity is controlled by the accelerator. Regenerative braking system will be
activated if speed increases above the default;
– Braking system (electric braking on the slope) will be activated if parked on a slope for a
preset time;
– Regenerative braking system for speed reducing on a slope;
– Regenerative braking system for accelerator pedal release (slowing down);
– Regenerative braking ratio can be adjusted to proportionally by analog input;
– High sensitivity at low speed;
– Longer driving torque (with current control) when started or overloaded.
– Electric braking system will be activated by the inverter;
The oil pump controller is designed for electric forklifts to improve better controller control. It
consists of “lift”, “forward/backward”, “power-assisted steering”, “side shifting(forward)” control
levers. It guarantees the speed while it has the characteristics as stably, safety, precision, bottom
noise, no arc spark, no large current impact to the battery when started.

Cautions：
1. No reverse of the battery polarity of the controller assembly.
2. Battery nominal voltage shall be no more than controller assembly nominal voltage.
3. No inversely connected U, V, W phase wires.
4. No connection between the charging circuit and the controller when charging.
5. Take safety measures during assembly, test run and maintenance, especially when galloping,
high current arc and battery liquid splashing.

86
ZAPI Fault code
Microcontroller Vehicle
Restart the
fault list Error Description Function status after
program
code test
Main contactor is not
FLASH checksum closed, Key switch
MDI mode allarm Program detects the fault electromagnetic brake Start restart the
71 starts, traction/lifting system
stop
Main contactor
Analog disconnects,
Analog channel, no reading Traction/lifting
MDI mode allarm electromagnetic brake Start, run
update request
96 starts, traction/lifting
stop
Main contactor is not
Difference between the key
closed,
switch voltage and battery Traction/lifting
Wrong set battery electromagnetic brake Start
nominal voltage is 20% larger request
starts, traction/lifting
than the standard voltage.
stop
Main contactor is not
Cpacitor charge closed,
Power capacitor voltage does not Traction/lifting
MDI mode allarm electromagnetic brake Start
increase request
60 starts, traction/lifting
stop
Main contactor is not
Coil shorted hw ko The main contactor or solenoid closed,
Traction/lifting
MDI mode allarm valve/short auxiliary coil is electromagnetic brake Start
request
76 damaged starts, traction/lifting
stop
Main contactor
disconnects(command
Driver shorted Main contactor drive circuit
has sent), start Start, stand Traction/lifting
MDI mode allarm shorted, unable to open the
electromagnetic by, run request
74 contactor
brake, traction/lifting
stop
Main contactor
disconnects(command
Solenoid valve/auxiliary drive
has sent), start Start, stand Traction/lifting
Aux driver shorted circuit shorted, unable to open
electromagnetic by, run request
the contactor.
brake, traction/lifting
stop
Safety in Main contactor Key switch
Safety input disconnect（do not Start, stand
MDI mode allarm disconnects, restart the
connect-BATT） by, run
86 electromagnetic brake system

87
 Microcontroller Vehicle
Restart the
fault list Error Description Function status after
program
code test
starts, traction/lifting
stop
Main contactor
disconnects,
Safety output drive circuit is Traction/lifting
Safety out electromagnetic brake Start
damaged （short or open）. request
starts, traction/lifting
stop
Main contactor
disconnects, Key switch
Watchdog#1 Incorrect status of watchdog Start, stand
electromagnetic brake restart the
MDI mode allarm 8 circuit signal #1 by, run
starts, traction/lifting system
stop
Main contactor is not
closed, Key switch
Watchdog #2 Incorrect status of watchdog Start, stand
electromagnetic brake restart the
MDI mode allarm 8 circuit signal #2 by, run
starts, traction/lifting system
stop
Main contactor is not
Keyoff shorted closed, Key switch
Cut off the circuit low logic signal
MDI mode allarm electromagnetic brake Start restart the
at startup
76 starts, traction/lifting system
stop
Main contactor is not
closed,
Logic failure#1 Detect too low or too high voltage Start, stand Traction/lifting
electromagnetic brake
MDI code alarm 54 signal by, run request
starts, traction/lifting
stop
Main contactor is not Traction/lifting
Logic failure #3 closed, request
High current protection circuit is
MDI mode allarm electromagnetic brake Start
damaged
17 starts, traction/lifting
stop
Main contactor is not Traction/lifting
Power mos shorted closed, request
MDI mode allarm MOS tube shorted electromagnetic brake Start
89 starts, traction/lifting
stop
Main contactor is not
closed, Start, stand Traction/lifting
VMN high Overhigh motor output voltage
electromagnetic brake by request
starts, traction/lifting

88
 Microcontroller Vehicle
Restart the
fault list Error Description Function status after
program
code test
stop

Main contactor
VMN low disconnects,
Traction/lifting
MDI mode allarm Too low motor output voltage electromagnetic brake Start, run
request
72 starts, traction/lifting
stop
Main contactor is not
In the standby condition (no
Stby I high closed,
motor supply current), current Traction/lifting
MDI mode allarm electromagnetic brake Start
feedback value exceeds the request
53 starts, traction/lifting
allowable range
stop
Main contactor is not
closed,
Wrong 0 voltage Feedback value of motor phase Traction/lifting
electromagnetic brake Start
MDI code allarm 53 voltage is out of range request
starts, traction/lifting
stop
Main contactor is not
Contactor closed closed,
Traction/lifting
MDI mode allarm LC contactor blocked electromagnetic brake Start
request
75 starts, traction/lifting
stop
Main contactor is not
Watchdog circuit emitted fault closed, Key switch
Hardware fault 20 signal cannot close MOS driver electromagnetic brake Start restart the
circuit. starts, traction/lifting system
stop
Main contactor is not
The main contactor or solenoid closed, Key switch
Hardware fault 21 valve/short auxiliary coil is electromagnetic brake Start restart the
damaged starts, traction/lifting system
stop
Main contactor is not
Watchdog circuit emitted fault closed, Key switch
Hardware fault A1 signal cannot close main electromagnetic brake Start restart the
contactor driver circuit. starts, traction/lifting system
stop
Main contactor After the
Coil shorted MC
disconnects, main Traction/lifting
MDI mode allarm Main contactor coil shorted
electromagnetic brake contactor is request
76
starts, traction/lifting closed, start,

89
 Microcontroller Vehicle
Restart the
fault list Error Description Function status after
program
code test
stop stand by, run

Main contactor After the

Coil shorted EF Solenoid valve/ auxiliary coil disconnects, main
Traction/lifting
MDI mode allarm shorted electromagnetic brake contactor is
request
68 starts, traction/lifting closed, start,
stop stand by, run
Main contactor After the
Contactor open disconnects, main
Main contactor coil is activated Traction/lifting
MDI mode allarm electromagnetic brake contactor is
but not closed request
77 starts, traction/lifting closed, start,
stop stand by, run
Main contactor
disconnects(command
Logic failure#2
Feedback circuit of motor phase has sent), start Traction/lifting
MDI mode allarm Stand by, run
voltage is damaged(fail to close) electromagnetic request
55
brake, traction/lifting
stop
Main contactor
disconnects(command
Contactor driver
Main contactor drive circuit is has sent), start Traction/lifting
MDI mode allarm Stand by, run
damaged(fail to close) electromagnetic request
75
brake, traction/lifting
stop
Main contactor
Solenoid valve/ auxiliary drive disconnects,
Traction/lifting
Aux Driver Open circuit is damaged( fail to start the electromagnetic brake Stand by, run
request
solenoid valve) starts, traction/lifting
stop
Main contactor
disconnects,
Encoder Error Traction/lifting
Encode reading error electromagnetic brake Run
MDI code allarm 82 request
starts, traction/lifting
stop
Main contactor
Program detected that the
Wrong Ram disconnects, Key switch
registration information of
Memory electromagnetic brake Continue restart the
memory can be erased and find
MDI code allarm 71 starts, traction/lifting system
the error value
stop
Vacc not OK Accelerator / lifting potentiometer Traction/pump motor Start, stand Traction/lifting
MDI code allarm 78 value is greater than the stop by, run request

90
 Microcontroller Vehicle
Restart the
fault list Error Description Function status after
program
code test
minimum record value, while the
direction / enable switch is off
Incorrect start Traction/pump motor Start, stand Traction/lifting
Incorrect start sequence
MDI code allarm 79 stop by, run request
Accelerator input signal is beyond
the scope of the minimum
Vacc out of range acceleration signal value - the Traction/pump motor Start, stand Traction/lifting
MDI code alarm 85 maximum acceleration signal stop by, run request
value, the range is set by the
parameter PROGRAMM VACC
Linear decrease of the
The controller temperature
current value of
Temperature reaches 85 ℃ at maximum
traction controller from Continue
MDI code allarm 62 current, and forms speed
maximum(85℃) to 0A
reducing condition
（105 ℃）
Motor temperature sensor is
Maximum current
Motor temperature disconnected (if it is a digital
halved and speed Continue
MDI code alarm 65 sensor) or exceed 150 ℃
reduced
threshold (if analog sensors)
In the case where the request No function, only
without the hand brake, the brake display fault signal Traction/lifting
Brake run out Continue
potentiometer input signal is the through handheld request
maximum value. programmer
Traction request signal and the
Traction/lifting
Handbrake hand brake input signal are Traction motor stop Stand by, run
request
effective at the same time
The maximum current gain
Current Gain parameters is factory defaults, Controller worked but
Start, stand
MDI code allarm indicating the maximum current lower than maximum
by
92 adjustment program is not current
implemented
Sens mot temp KO Output signal of motor Maximum current
MDI code allarm temperature sensor is out of halved and speed Continue
65 range reduced
Thermic sens Ko Output signal of controller Maximum current
MDI code allarm temperature sensor is out of halved and speed Continue
61 range reduced
Slip profile
Wrong Slip profile parameter Traction/pump motor Traction/lifting
MDI code alarm Continue
setting stop request
99

91
Microcontroller Vehicle
Restart the
fault list Error Description Function status after
program
code test
EEPROM KO Controller used
MDI code allarm Eeprom error parameter is the Continue
71 default one
Forward+Backward Walking command is effective in Start, stand Traction/lifting
Traction stop
MDI code alarm 80 forward and backward directions by, run request

92
6.5 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.

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

93
 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.

94
6.6 Electrical schematic diagram

Key switch

Flasher
Battery Parking
brake
Light Brake switch
Reversing High
switch light
light Reset speed
switch switch
Low
Steering speed SA2 SS2 Ti lt
SS3 Sid e shift
lamp Directional
switch switch Brake SS4 th e fou rth val ve
SS5 Lifting
Forward switch
Reverse

Low
Reset speed 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
Front Temperature
Temperature
windscreen High sensor Temperature sensor
wiper speed sensor

turn to
L.H. R.H. L.H. R.H. L.H. R.H. L.H. L.H. R.H. R.H. L.H. R.H. L.H. R.H.
Front steering lamp

Rear steering lamp

Rear steering lamp

Front steering lamp

Reversing buzzer
Front headlight

Reversing light

Brake light

Cooling fan

Warning light

Cab light
Cooling fan

Rear lamp

Front windscreen wiper

Front headlight

Horn button
Fan

Front wiper washing machine

Horn
Rear indicator

red
red dim-dip High beam white
white white
Yellow

Pump motor Flasher

Traction motor Relay

Battery connector Horn

Wire color Black White Red Green Yellow Brown Blue Grey Violet Orange Pink

Code Fuse Brake light switch

Fuse Red stop button

Fuse Seat switch

Fuse Key switch

Parking brake switch Directional switch

The fourth valve Turn signal swich

Lateral displacement control Light switch

Tilt control Main contactor

Rise control Horn filter

CPD50/55/60/70/80/85J Electrical schematic diagram（standard）

95
 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16

电位
器，

pump motor relay

traction motor horn
Battery connector braking light switch

fuse red stop button

、 fuse seat switch
fuse key switch
fuse Directional switch
braking switch Steering light switch

fourth light switch

sideshift control Main contactor
tilt control Horn filter
Lifting control rear light
front light
Horn button front lamp
Alarm lamp battery
Reversing buzzer
flasher

CPD50/55/60/70/80/85J Electrical schematic diagram（OPS options ）

96
 AC 4
TRACTION
96V/550A

Smart DISPLAY 24V

AC 4
PUMP
96V/550A

SEAT 3A6

CAN L 3A20
CAN H 3A21
CAN T 3A12
KEY 3A1

ACE 2 CPOT 3A3

STEER
96V/215A -BATT 3A9

SAFETY IN 3A11

PLC/PEB 3A17
NLC 3A16

CPD50J-LZ4 CPD55/60/70/80/85J-Z4 Electrical schematic diagram

97
 CPD55/60/70/80/85J-I Electrical schematic diagram

98
 Maintenance record

Date Repair or maintenance items serviceman

HANGCHA GROUP CO. , LTD.

■ Address For: OVERSEAS USERS

■ Address: 666 Xiangfu Road, Lin'an Economic Development Zone,
Zhejiang, China ■ ZIP:311305
■ Fax: 0086-571-88926789 0086-571-88132890
■ Web: http://www.hcforklift.com ■ E-mail: sales@hcforklift.com