Ice 301 B

Service Manual
ICE301B
Electric Forklift Truck
Release Date Version No. Changes (Serial number)
2020-09-12 SM-3132 09.20 EP V1
Service Manual * If there are any changes, revised version will be published once every 12 months;
if there is no change, please follow the most recent version.
* Please refer to the corresponding version of the service manual against the purchase time
ICE301B of your vehicle.
* If you need the latest versions of the manual, please contact our service department or
Electric Forklift Truck dealer to obtain.
This manual applies to:
Model Specifications
ICE301B 3,000 Capacity, Full Height Series, Four-wheel

TABLE OF CONTENTS
FOREWORD TABLE OF CONTENTS

　
This Service Manual can help readers learn more about the truck system components,
maintenance and troubleshooting, and other related information. The operation and
SECTION PAGE
maintenance personnel must read this Manual carefully before using the product. And when 1. INFORMATION & SPECIFICATIONS..................................1
vehicle is in use, be sure to follow the complete operation and maintenance information in
this Manual for vehicle maintenance. 1.1 After-sales Service Platform..............................................3
1.2 Introduction..........................................................................4
Before using, please check if the pages of the Manual are clear and complete, so as not 1.3 Common Tools....................................................................5
to affect your normal use because of incomplete information. If the contents of the Manual
1.4 General Tightening Torques..............................................6
have been illegible or damaged, which may affect reading, please contact our company or
dealer for replacement.
2. MAINTENANCE.....................................................................9
With the constant update and improvement of our products, the equipment you are using
2.1 Overview............................................................................ 11
may be slightly different from what has been described in this Manual, therefore, we must
reserve the right to modify the appearance, configuration and technical specifications. If you 2.2 Maintenance......................................................................12
have any questions, please contact our sales department or dealer. 2.2.1 Cleaning..........................................................................12
2.2.2 Inspection........................................................................12
2.2.3 Lubrication......................................................................17
3. TROUBLESHOOTING.........................................................19
Safety signs and instructions:
3.1 Preparation Before Troubleshooting...............................21
3.1.1 Check the Voltage of Battery..........................................21
Please strictly adhere to these safety instructions to avoid personal injury.
3.2 Troubleshooting Solutions of Common Faults ��22
Please pay attention to the important safety instructions.
4. DRIVING SYSTEM...............................................................33
i Instructions. 4.1 Drive Wheel.......................................................................35
4.1.1 Removal and Installation.................................................35
4.2 Drive Motor........................................................................36
Copyright 4.2.3 Checking and Testing......................................................37
4.3 Drive Axle...........................................................................38
Copyright of Service Manual belongs to EP Equipment Co., Ltd. 4.3.1 Removal and Installation.................................................38
4.3.2 Component.....................................................................39
4.3.3 Gear Oil...........................................................................40
EP Equipment Co., Ltd. 4.4 Differential..........................................................................41
EP Industrial Park, Xiaquan Village, 4.4.2 Component.....................................................................41
Dipu Town, Anji County, Zhejiang Province, P.R.China
4.5 Gearbox.............................................................................42
www.ep-ep.com 4.5.1 Removal and Installation.................................................42
4.5.2 Component.....................................................................42
4.6 Accelerator Pedal..............................................................43
4.6.2 Interface Description.......................................................43
REV. SM-3132 09.20 4.6.3 Checking and Testing......................................................44
REV. 09/2020
1-3
TABLE OF CONTENTS TABLE OF CONTENTS
TABLE OF CONTENTS TABLE OF CONTENTS
SECTION PAGE SECTION PAGE

5. STEERING SYSTEM...........................................................45 8.1.1 Removal and Installation.................................................72
5.1 Rear Steering Wheel........................................................47 8.1.2 Lifting Chains..................................................................73
5.1.1 Removal and Installation.................................................47 8.1.2.1 Chain Adjustment.........................................................73
8.1.2.2 Chain Replacement.....................................................74
5.2 Steering Bridge.................................................................48
8.1.3 Mast Tubing....................................................................75
8.1.4 Lift Cylinder.....................................................................76
5.2.2 Component.....................................................................49
8.1.4.1 Cylinder Removal (with mast on the vehicle) ��76
5.3 Steering Cylinder..............................................................50
8.1.4.2 Cylinder Maintenance..................................................77
8.1.4.3 Cylinder Installation......................................................77
5.3.2 Steering Cylinder Maintenance.......................................50
8.1.5 Built-in Side Shifter.........................................................78
8.1.5.1 Side Shifter Removal...................................................78
6. BRAKE SYSTEM.................................................................51 8.1.5.2 Side Shifter Installation................................................78
6.1 Parking Brake....................................................................53 8.1.6 External Side Shifter.......................................................79
6.1.1 Removal and Installation.................................................53 8.1.6.1 Side Shifter Removal...................................................79
6.1.2 Adjustment......................................................................53 8.1.6.2 Side Shifter Installation................................................79
6.2 Service Brake....................................................................54 8.2 Two-stage Full Free Mast................................................80
6.2.1 Removal and Installation.................................................54 8.2.1 Removal and Installation.................................................80
6.2.2 Air Discharge / Adding Brake Fluid.................................54 8.2.2 Lifting Chains..................................................................81
8.2.2.1 Chain Adjustment.........................................................81
7. HYDRAULIC SYSTEM........................................................55 8.2.2.2 Chain Replacement.....................................................82
7.1 Overview............................................................................57 8.2.3 Mast Tubing....................................................................83
7.1.1 Hydraulic Schematic Diagram ........................................58 8.2.4 Lift Cylinder.....................................................................85
7.2 Pump Motor & Gear Pump..............................................59 8.2.4.1 Cylinder Removal ........................................................85
7.3 Multi-way Reversing Manual Valve ................................60 8.2.4.2 Cylinder Maintenance..................................................87
7.3.1 Removal and Installation.................................................60 8.2.4.3 Cylinder Installation......................................................89
7.3.2 Interface Description.......................................................61 8.2.5 Built-in Side Shifter........................................................89
7.4 Redirector..........................................................................62 8.2.6 External Side Shifter.....................................................89
7.4.1 Removal and Installation.................................................62 8.3 Three-stage Full Free Mast.............................................90
7.4.2 Interface Description.......................................................62 8.3.1 Removal and Installation.................................................90
7.5 Tilt Cylinder........................................................................63 8.3.2 Lifting Chains..................................................................91
7.5.1 Cylinder Removal Precautions........................................63 8.3.2.1 Chain Adjustment.........................................................91
7.5.2 Cylinder Installation Precautions.....................................64 8.3.2.2 Chain Replacement.....................................................92
7.5.3 Removal and Installation.................................................65 8.3.3 Mast Tubing....................................................................94
7.5.4 Cylinder Maintenance.....................................................66 8.3.4 Lift Cylinder.....................................................................96
7.6 Refueling Cap ...................................................................67 8.3.4.1 Cylinder Removal ........................................................96
7.6.1 Removal and Installation.................................................67 8.3.4.2 Cylinder Maintenance..................................................97
7.6.2 Hydraulic Oil....................................................................67 8.3.4.3 Cylinder Installation......................................................98
7.7 Hydraulic Symbol..............................................................68 8.3.5 Built-in Side Shifter........................................................98
8.3.6 External Side Shifter.....................................................98
8. MAST.....................................................................................70
8.1 Wide-View Two-stage Mast.............................................72
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2-3 3-3
SAFETY WARNING
For your own safety and that of others, please observe the following safety instructions:
1. INFORMATION & SPECIFICATIONS 1
Thorough and normative maintenance is one of the most important prerequisites to ensure
stable and reliable operation of truck. Neglecting regular maintenance could easily lead
to the truck malfunction and failure, and potential threats to staff and operational safety.
Therefore, there must be adequate maintenance equipment, professional maintenance
personnel and a comprehensive maintenance plan in place.
Please perform the maintenance and inspections according to the following provisions:
1. To strictly enforce the truck maintenance, lubrication and inspection plans.
2. Truck maintenance, lubrication and inspection personnel must be approved by accredited
certification or evaluation agency.
3. The following operations shall be performed before you leave the truck:
- No parking on slopes.
- Fully lower the forks.
- Cut off the power supply.
- Turn the switch lock to “STOP” and remove the key.
4. Prior to truck maintenance:
- Raise the drive wheel off the ground, or cut off the power supply connection.
- Use wooden wedges or other effective fixtures.
- When performing maintenance underneath the vehicle, make sure that the lifting device
or jack leg is secure.
- Park your vehicle in a safe and secure area.
5. Never use an open flame to check level of electrolyte, other oils or fluids for leaks.
6. Keep the parking lot clean, well-ventilated and dry.
7. Regular checks and maintenance should be conducted to braking, steering, control, warning
and safety devices to keep them in good condition.
8. All nameplates and safety signs on the truck should be cleaned regularly to make them
clearly visible.
9. Regular checks and maintenance should be conducted to all the devices of lifting system to
ensure them to be safe for use.
10. The hydraulic system should be checked regularly based on usage. Hydraulic cylinders,
hydraulic valves and other hydraulic components should be ensured to be without leakage.
11. Regular checks and maintenance should be conducted to batteries, motors, controllers,
limit switches, protective devices, wires and connectors, and so on. Please pay particular
attention to the electrical insulation.
12. Park the truck in a clean environment to minimize the risk of fire.
13. Without the permission of the manufacturer, users are not allowed to change or increase
the capacity of the truck. After having been changed under permission, the nameplates and
safety signs on the truck should also be changed accordingly.
14. The field modification and installation of electrial accessories shall be carried out by trained
personal only.
1
INFORMATION & SPECIFICATIONS
NOTE: 1.1 After-sales Service Platform

Claims/Replacement Parts Service Platform: After-sales Maintenance Service Platform:
1
i NOTE
In order to provide you with a fast and efficient
after-sales service, when you claim / order spare
parts or after-sales service upon maintenance,
please provide accurate truck model, vehicle
body serial number and part number.
REV. 09/2020
2 3
INFORMATION & SPECIFICATIONS INFORMATION & SPECIFICATIONS
1.2 Introduction This series are electric forklift trucks. Its impor-
tant structure is as shown in Fig3132-00003SM.
1 WARNING
- Please refer to the nameplate for rated load
1
capacity of the vehicle.
- The vehicle can only be used on the level gro-
und indoors, never use it on mezzanine or
balcony area.
WARNING
Truck can only be operated by single operator;
other personnel is forbidden from riding.
1.3 Common Tools
No. Name Remark

1 Hex Head Socket Wrench 8#~27# One Set
2 Phillips Screwdriver 2# One Piece
3 Slotted Screwdriver 2# One Piece
4 Sockets and Knobs One Set
5 Circlip Pliers One for holes and one for shaft
6 Hammer One Piece
7 Spreader, Crane One Pair
8 Cylinder Wrenches For removal and installation of cylinders
9 Diagonal Pliers One Piece
10 Cylinder Pliers One Piece
11 Grease Gun One Piece
No. Name No. Name 12 Tiger Tooth Wrench 22#/27# One of Each
1 Counter-weight 9 Load backrest
2 Warning Light 10 Forks
3 Overhead Guard 11 Steer wheels
4 Steering wheel 12 Battery Hood
5 Rearview mirror 13 Chassis
6 Mast 14 Driver Seat
7 Headlight 15 Drive wheels
8 Headlight 16 Rear Combination Lights
REV. 09/2020 REV. 09/2020
4 5
INFORMATION & SPECIFICATIONS INFORMATION & SPECIFICATIONS
1.4 General Tightening Torques

Table 1.4.2 Metric Screws/Bolts Tightening Torque Table (n•m)
Screws or bolts used on the truck are of 8.8
1 grade or higher performance level.
When you are conducting truck maintenance, Nominal Diameter 5.8
Performance Level
8.8 10.9 12.9
1
you can refer to Table 1.4.1 and Table 1.4.2 to (mm) Proof Stress (MPa)
select the suitable screws or bolts for replace-
ment. 380 600 830 970
M6 7~8 10~12 14~17 17~20
Table 1.4.1 Screws/Bolts Performance Levels M8 16~18 25~30 34~41 41~48
M8×1 17~20 27~32 37~43 43~52
Performance Level Material Specification (mm)
M10 31~36 49~59 68~81 81~96
5.8 5.8 grade Low carbon steel M6 ~ M48 M10×1 35~41 55~66 76~90 90~106
M12 55~64 86~103 119~141 141~167
Quenched and tempered medium M12×1.5 57~67 90~108 124~147 147~174
8.8 8.8 grade M6 ~ M48
carbon steel
M14 87~103 137~164 189~224 224~265
10.9 10.9 grade M6 ~ M48
carbon alloy steel
M16 136~160 214~256 295~350 350~414
12.9 12.9 grade M6 ~ M48
carbon alloy steel
M18 186~219 294~353 406~481 481~570
M18×1.5 210~247 331~397 457~541 541~641
CAUTION M20 264~312 417~500 576~683 683~808
- The performance levels of screws or bolts are M20×1.5 294~345 463~555 640~758 758~897
marked on the heads of the screws or bolts. M22 360~431 568~680 786~941 918~1099
- If you find the screws or bolts used on certain
M22×1.5 395~473 624~747 803~1034 1009~1208
position are not marked with performance
level, please select spare parts with perform- M24 457~547 722~864 998~1195 1167~1397
ance level of at least 8.8 grade or higher level M24×2 497~595 785~940 1086~1300 1269~1520
for replacement.
M27 669~801 1056~1264 1461~1749 1707~2044
M27×2 723~865 1141~1366 1578~1890 1845~2208
M30 908~1087 1437~1717 1984~2375 2318~2775
M30×2 1005~1203 1587~1900 2196~2629 2566~3072
M36 1587~1900 2506~3000 3466~4150 4051~4850
M36×3 1680~2011 2653~3176 3670~4394 4289~5135
M42 2538~3039 4088~4798 5544~6637 6479~7757
M42×3 2731~3269 4312~5162 5965~7141 6921~8345
M48 3813~4564 6020~7207 8327~9969 9732~11651
M48×3 4152~4970 6556~7848 9069~10857 10598~12688
REV. 09/2020 REV. 09/2020
6 7
INFORMATION & SPECIFICATIONS
2. MAINTENANCE
1
2
REV. 09/2020
8 9
MAINTENANCE
NOTE: 2.1 Overview

i NOTE
Only by performing regular vehicle maintenance - Under harsh working conditions: such as, the
and repair, can ensure the continuous and external temperature is too high or too low,
reliable use of the truck. dusty, or implementing multiple shifts per day,
Only specially trained and qualified personnel the maintenance and care interval should be
are capable of maintenance and repair shortened.
operations of the equipment. If you want to
perform the maintenance and repair on your
- Prior to lubrications, replacement of filters or
operating the hydraulic system, please clean
2
own, it is recommended that on-site training the external parts carefully and use a clean
should be conducted to your maintenance container.
personnel by the service representative of the
- Only compliant lubricants can be used See
vendor.
Table 2.2 Lubricants.
Working conditions:
- Truck must be parked on the level ground
reserved for maintenance (such area needs
to be clean and with less dust), block the
wheels with wooden wedges, disconnect
the key switch and disconnect the battery
connections.
- When lifting the truck, the lifting tools can
only be installed on the fixed positions as
specified.
- When jacking up the truck, appropriate tools,
such as wedge blocks, wooden blocks, and
so on, must be used to secure the truck to pr-
event the occurrence of accidental rolling or
tipping over.
WARNING
When lifting load components or during the
operations under the cabin, sufficiently strong
chains or safety device must be used to secure
the vehicle.
CAUTION
Without the supplier's consent, it is strictly
forbidden to make modifications to truck, espe-
cially to the safety devices. It is strictly forbidden
to change the various working speeds of the
truck.
REV. 09/2020
10 11
MAINTENANCE MAINTENANCE
2.2 Maintenance Regular inspection and maintenance under

Table 2.1 Inspection & Maintenance List
harsh conditions of use:
2.2.1 Cleaning Under harsh working conditions, especially: Interval in days/months/years 7d 60 d 90 d 6m 1y
- Dusty environment
- Do not use flammable liquids to clean the Interval in hours 50 250 500 1000 2000
- Corrosive environment
truck. - Cold storage environment Functions and Control
- Before starting to clean, all necessary
2 security measures must be taken to prevent
sparking (short circuit) during operation. If the
The maintenance intervals should be shortened
by half.
Check the functions of the operation switches and
display
A 2
truck is powered by battery, battery plug must Check alarm system functions A
be pulled out.
Check parking brake functions A
- When cleaning electrical and electronic com-
ponents, you should use low-intensity suction Check the emergency switch functions A
gas or compressed dry air. Meanwhile, clean Check the steering wheel functions A
the dust on the surface of components with
non-conductive and antistatic brush. Check the cables for damage and if the terminals are
A
secure
- Do not use vapor steam to clean the equipm-
ent. Check the seat switch functions A
Check and tighten the controllers and contactors A
Check accelerator pedal functions A
2.2.2 Inspection Check fault information records and operating hours A
Regular inspection and maintenance under Power Supply & Drive System
normal conditions of use:
Check the battery cables for damage and replace if
A
necessary
Operating
Requirements Check the battery charge connector A
Hours (h)
50 At least once per 7 days Check if the cable connections between battery mon-
omers are secure, apply some grease to electrodes if A
250 At least once per 60 days
necessary
500 At least once per 90 days
Check battery temperature A
1000 At least once every 6 months
Check battery locking mechanism A
2000 At least once per year
Check and tighten motor mounting bolts A
Check the connections of motor connectors A
CAUTION
When the truck is at running-in phase (after A = Check / Adjust
approximately 100 hours of operation), the Please refer to Inspection & Maintenance List
equipment user must check the fastening of for regular inspection and maintenance of the
wheel nuts and bolts and re-tighten them if vehicles.
necessary. L = Lubrication
Under harsh conditions, the lubrication intervals
should be shortened by half.
REV. 09/2020 REV. 09/2020
12 13
Table 2.1 Inspection & Maintenance List (Continued) Table 2.1 Inspection & Maintenance List (Continued)
Interval in days/months/years 7d 60 d 90 d 6m 1y Interval in days/months/years 7d 60 d 90 d 6m 1y
Interval in hours 50 250 500 1000 2000 Interval in hours 50 250 500 1000 2000
Power Supply & Drive System Braking System
2 Check the position of various bearings for noise

Check gear oil level
A
A
Check the braking functions
Check the brake fluid level
A
A
2
Clean or replace the gear oil Replace once every 1000 hours Check the pump and piping connections for leaks A
Check the gearbox for abnormal noise or leaks A Check the release of brake pedal is normal A
Check the drive wheel and steering wheel for worn or Check the braking distance of brake A
A
damage
Mast System
Check and lubricate the wheel bearings A/L
Check the mast for damages A
Check the travel speed A
Clean and lubricate the rolling surface of lift mast
Hydraulic System A/L
column with grease
Check the functions of hydraulic system A Check and lubricate mast rollers A/L
Check if the hoses, pipes and interfaces are fastened Check the fixation of lift mast A
A
or sealed securely, and check if there is damage
Check the tubing on mast for connections and leaks A
Check the connections of pump motor connectors A
Check the side shifter functions A
Check and tighten pump motor mounting bolts A
Check and lubricate the chains A/L
Check the gear pump fixation and check for leaks A
Check the lifting chains and chain guides for wear,
A
Check the cylinders for leaks A adjust and grease
Check the cylinders for damages and check the fixation A Check the fork carriages for wear and damage A
Check the oil tank for leaks A Visual inspection of rollers, sliders and stoppers A
Check the hydraulic oil level A Check the lifting and lowering speed A
Clean or replace the hydraulic oil Replace once every 2000 hours Other
Check and clean oil tank air filter A Check if the signs are clear and complete A
Replace the oil tank air filter and filter A Check the chassis for cracks or damages A
Check the relief pressure A Check the connections of bolts and nuts A
A = Check / Adjust
A = Check / Adjust
Please refer to Inspection & Maintenance List
for regular inspection and maintenance of the Please refer to Inspection & Maintenance List
vehicles. for regular inspection and maintenance of the
vehicles.
L = Lubrication
L = Lubrication
should be shortened by half. Under harsh conditions, the lubrication intervals
REV. 09/2020 REV. 09/2020
14 15
2.2.3 Lubrication Please see Table 2.2 for the lubricants used in
Table 2.1 Inspection & Maintenance List (Continued) this truck.
Interval in days/months/years 7d 60 d 90 d 6m 1y Lubricant
CAUTION
Interval in hours 50 250 500 1000 2000 - Improper operations may constitute hazards
to the operator's health and life, as well as to The use and disposal of lubricants must be
Other the surrounding environment. carried out in strict accordance with the manufa-
2 Check tire pressure

Check the fixation of battery and battery tray
A
A
- When storing or adding lubricant, use clean
containers. It is strictly forbidden to mix
cturer's regulations.
2
different types and specifications of lubricants
Check the seat fixation and adjustment functions A with each other (except for those can be
mixed under clear statement).
Check the seat belt and functions A
2000-hour
Check the overhead guard and cabin A 1000-hour
Checking covering parts for damages A
Check if the optional features are functioning properly A
Bearing Steering Axle

A = Check / Adjust
Please refer to Inspection & Maintenance List
for regular inspection and maintenance of the Oil Tank
vehicles.
L = Lubrication
Gear Box
Bearing
Drive axle
Mast Pin Shafts
Mast Pin Shafts

Mast Brake Fluid
Adding Grease Gear Oil Checks Brake Fluid Checks
Changing Changing Gear Oil

Hydraulic Oil
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MAINTENANCE
Table 2.2 Lubricants
Code Type Specification Amount Position 3. TROUBLESHOOTING

Hydraulic
A Anti-wear hydraulic oil L-HM46 See Table 2.3
System
2 B Multi-purpose grease Polylub GA352P Appropriate amount

Sliding surface
(See Table 2.4)
C Heavy duty gear oil 85W-90GL-5 4.5L (Align with oiling port) Drive Axle
After the gas within the
D Brake fluid ZSM207DOT3
system is completely
discharged, add to 2/3 of
Brakes 3
the oil cup
Table 2.3 Application Amount of Table 2.3 Application Amount of

Hydraulic Oil 1-2 Hydraulic Oil 2-2
Lifting height Amount Lifting height Amount
Mast Series Mast Series
(mm) (L) (mm) (L)
2000 30 4300 38
2500 34 4500 40
Full Free 2700 34 4800 42

3-stage Mast
2-stage Mast 3000 36 5000 44
3300 36 5500 46
3500 38 6000 45
2000 30
2500 34
2700 34
3000 36
Wide-view 3300 36
2-stage Mast 3500 38
3600 38
4000 42
4300 42
4500 44
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18 19
TROUBLESHOOTING
NOTE: 3.1 Preparation Before Troubleshooting

- Park the truck on level ground and block the
wheels with wooden wedges; CAUTION
- Fully lower the forks and press the emergen- If the battery voltage is still abnormal after being
cy stop switch. charged: open the battery compartment, check
- Turn off the key switch; the voltage of each battery and its connection
- Open the cover and check the controller. circuit respectively:
1) Check if the voltage of single battery is

CAUTION normal;
- Even if key switch is turned off, the controllers

are still energized.
2) Check if the cables for connections between
3
each battery are normal, check for open circ-
- Before checking or repairing the controllers, uit and if the connection between connectors
ma ke su re th e b a tte ry p l u g h a s b e e n is secure.
unplugged and the electrical circuit is
disconnected. - Battery leakage check: disconnect the battery
connection, black probe (-) connected to
(-) terminal of battery plug; red probe (+)
3.1.1 Check the Voltage of Battery connected to the chassis. Read the voltage
reading on the meter.
- Unplug the battery plug;
No voltage (0V): normal;
- Measure the battery voltage with a multim-
With voltage: battery leakage (remove battery
eter: black probe (-) connected to (-) terminal compartment, check each battery and cables)
of battery plug; red probe (+) connected to
the (+) terminal of battery plug. Read the
voltage reading on the meter.
- Identify if the battery voltage is normal
according to the measured voltage.
As shown in the following table:
Battery Voltage Judgment
65V~87.6V Normal
80V
<65V or >87.6V Battery Fault
i NOTE
Enter TESTER Menu to check the battery
voltage.
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TROUBLESHOOTING TROUBLESHOOTING
3.2 Troubleshooting Solutions of Common Faults

Table 3.1 Troubleshooting of Common Faults
Table 3.1 lists the common faults that may occur and handling
methods. Mainly consists of the following items: Fault Fault Symptom Probable Causes Troubleshooting
Table 3.1 Troubleshooting of Common Faults 4. Abnormal tyre 1. Replace the drive wheel;
wear, cracking or • Improper use 2. Replace the rear steering
Fault Fault Symptom Probable Causes Troubleshooting degumming wheel.
1. Check the voltage of storage 5. Drive wheel slipping

• Power supply failure • Wear 1. Replace the drive wheel
battery or jumping
• Fuse failure
Power supply 1. Whole vehicle power • 2. Check the fuses
3 failure outrage
•
Emergency stop switch or circuit
failure
Key switch or circuit failure
3. Check key switch and its
circuit
4. Check emergency stop switch
Travel Fault
6. Vehicle sways while
• Wheel lock nut loosening 1. Tighten the nuts
3
running
and its circuit
Controller failure error, carry out • Insufficient brake fluid; 1. Add brake fluid;
troubleshooting according to the 7. Brake performance
• Brake master pump blocked; 2. Replace the master pump;
• Parking brake switch and seat fault code information on the weakened or failure
• Brake pipeline leaks. 3. Replace the brake pipeline.
switch or its circuit connection instrument.
failure 1. Check if parking brake • Cable U, V, or W is broken;
1. Replace the Cable U,V, or W;
1. Forward and reverse • Gearbox failure switch and seat switch or the • Loosening connections to cable
2. Tighten the nut;
moving failures of • Travel switch or its circuit connection of its circuit is U, V or W ;
1. Motor does not 3. Check the stator coil;
the vehicle, but other connection failure normal; • Stator coil open circuit;
rotate 4. Replace the motor bearing;
functions are normal • Drive motor or its circuit 2. Check the gearbox; • Motor bearing damage;
5. Check the speed encoder, if
connection failure 3. Check the travel switch and • Speed encoder or its circuit
neccessary replace it.
• Controller failure its connection circuit; failure.
4. Check the drive motor and its 2. Motor is rotating
1. Remove the cables and re-in-
connection circuit; in slow speed and • Cable connection error
stall;
5. Replace the controller. reverse
Controller failure error, carry out • Uneven clearance between stator
Travel Fault troubleshooting according to the and rotor;
Failures due to external factors: 3. Motor with abnormal 1. Replace the drive motor or
fault code information on the • Bearing failures;
• Motor bearing blocked noise or vibration pump motor;
instrument . • Loosening fixing screws on motor
2. The vehicle can • Gearbox bearing blocked Motor Fault
1. Remove the motor, check if housing.
travel at low speed, the motor rotation is normal;
Failures due to internal factors:
but cannot travel at • Drive motor speed encoder 2. Check the speed encoder
4. Motor smoking or • Stator winding short circuit, motor 1. Replace the drive motor or
high speed and its connection circuit;
failure burning smell burnt pump motor;
3. Remove the gearbox, check
• Controller failure
if the gear rotation is smooth
and if there is blocking; • Stator winding short circuit;
4. Replace the controller • Motor U, V and W terminals with
surface ;
5. Motor temperature
• Bearing failure, resulting in 6. Refer to the rated capacity
too high, controller
3. Drive axle Bearings • Bearing fatigue damage or severe heating; marked on the nameplate;
1. Replace the bearings failure
noise or jammed foreign • Motor cooling duct blockage with
foreign body;
• Overload.
* Carry out trouble shooting in accordance with the order listed in the table, it can help you quickly * Carry out trouble shooting in accordance with the order listed in the table, it can help you quickly
identify problems and resolve accordingly. identify problems and resolve accordingly.
REV. 09/2020 REV. 09/2020
22 23

Fault Fault Symptom Probable Causes Troubleshooting
• Insufficient voltage of battery; 1. Check the voltage of battery;

• Overload; 2. Refer to the rated capacity 1. Pump motor does not work: 1. Pump motor does not work:
6. On load, motor
• U, V, W terminals with abnormal marked on the nameplate; • Parking brake switch and seat i. Check if parking brake switch
Motor Fault speed is turning
voltage input; 3. Check the battery output; switch or its circuit connection and seat switch or the con-
slow
• Speed encoder or its circuit 4. Replace the speed encoder failure nection of its circuit is normal;
failure. or wiring harness; • Pump motor or its circuit ii. Check the pump motor and its
connection failure connection circuit;
3 1. Gearbox Abnormal
Noise
• Supporting bearing wear;
• Gear wear, the gap is too big;
• Foreign objects in gear oil.
1. Replace the bearing;
2. Replace the gear;
3. Replace the gear oil.
• Control switch or its circuit
connection failure
• Controller failure
iii. Check the control button and
its connection circuit;
iv. Replace the controller.
3
2. Gearbox Oil Leaks • Oil seal wear or aged 1. Replace the oil seal 2. Pump motor works:
Gearbox Fault i. Refer to the rated capacity
marked on the nameplate;
1. The vehicle cannot
2. Pump motor works: ii. Lower the mast to the bot-
• Gear fastening screws or nuts lift
1. Tigten the screws or nuts; • Overload tom, check if the amount of
loosening; • Insufficient hydraulic oil oil in theoil tank can meet the
3. Gearbox Stuck 2. Replace the support bearing;
• Support bearing damage • Hydraulic pipeline leakage requirements;
• Foreign objects in gear oil. • Pump motor reverse rotation iii. Check the pipe and hydraulic
• Cylinder failure (blocked) components for oil leaks;
• Supporting bearing wear; 1. Replace the bearing; • Solenoid valve blocked and iv. Check the pump motor wiring;
1. Drive Axle Abnormal Hydraulic cannot reset v. Check the cylinder for dam-
• Gear wear, the gap is too big; 2. Replace the gear;
Noise Failure • Valve body failure: age or deformation, remove
• Foreign objects in gear oil. 3. Replace the gear oil.
• excessive wear of gear pump, the cylinder to check for wear
serious internal leaks, insufficient or aged seals inside;
Drive Axle pressure of relief valve or vi. Wash or replace the solenoid
2. Drive Axle Oil Leaks • Oil seal wear or aged 1. Replace the oil seal
Fault blocked, check valve blocked spool
vii. Wash or replace the valve
• Drive Axle fastening screws or body
1. Tigten the screws or nuts;
nuts loosening;
3. Drive Axle Stuck 2. Replace the support bearing;
• Support bearing damage
• Foreign objects in gear oil.
• No free play of brake pedal.
• Improper shoe sliding. 1. Adjust. 1. Check the lowering button and
• Improper operation of wheel 2. Adjust. its connection circuit;
cylinder. 3. Adjust or replace. • Solenoid valve (or manual valve)
2. Check the solenoid valve and
• Faulty piston cup. 4. Replace. or its circuit connection failure
Brake Fault 1. Brake dragging its connection circuit;
• Weak or broken return springs. 5. Replace. • Lowering switch or its circuit
2. The vehicle cannot 3. Check the cylinder for defor-
• Clogged master pump return 6. Clean. connection failure
mation, remove the cylinder to
port. 7. Clean. be lowered • Valve failure;
check if the internal assembly
• Clogged oil lines. 8. Adjust or replace. • Cylinder deformation or blocked
is normal
• Wheel bearing out of adjusting. • Explosion-proof valve blocked
4. Clean or replace the valve;
5. Replace the explosion-proof
valve.
* Carry out trouble shooting in accordance with the order listed in the table, it can help you quickly
identify problems and resolve accordingly. * Carry out trouble shooting in accordance with the order listed in the table, it can help you quickly
identify problems and resolve accordingly.
REV. 09/2020 REV. 09/2020
24 25
Table 3.1 Troubleshooting of Common Faults (continued)

• Overload 1. Refer to the rated capacity
1. Check the hydraulic oil level. • Hydraulic pipeline leakage marked on the nameplate;
• Insufficient oil;
2. Replace the hydraulic oil. • Valve failure: 2. Check the pipe and hydraulic
• High viscosity of oil; 1. Slow Lifting of
3. Check the oil suction pipe. • Gear pump wear, internal components for oil leaks;
1. Noisy pump • Oil suction pipe air leak; Vehicle
4. Clean the oil inlet piping, re- leakage occurs 3. Wash or replace the valve
• Filters clogged by impurities;
place the filter, if necessary. • Insufficient relief valve pressure body
• Hydraulic oil with foam;
5. See Fault 2. or blocked
3 1. Check the amount of oil;

2. Check if the viscosity of hy-
draulic oil is normal;
2. Slow Lowering of
Vehicle
• Solenoid valve blocking
• Valve body failure: throttle valve
1. Wash or replace the solenoid
pool
2. Wash or replace the valve
3
failure or blocked
2. Hydraulic oil with • Pump cavitation; 3. Check the oil inlet piping for body
foam • There is water in the oil. air leaks;
4. Discharge and clean, and 1. Adjust the chain tension;
replace with new hydraulic • Chain loosening; 2. Check if the steel channel
oil. • Poor lubrication between steel grease is normal, clean and
3. Unstable Lifting / channel and rollers; relubricate steel channel and
Lowering of Vehicle • Improper adjustment of rollers, or rollers;
1. Discharge and clean, and blocked. 3. Adjust the side roller spacing
3. Pump or oil • Oil is too thin; add new hydraulic oil; through roller screw; or
temperature is too • Pump cavitation; 2. Check the oil inlet piping for replace the roller.
high • Valve body internal relief. air leaks;
3. Replace the valve body. Lifting System
Hydraulic
Failure • Tilt cylinder and ring abraded
Failure 1. Replace piston ring tilt
4. Fork arm carrier or excessively
cylinder.
mast tilt by itself. • The hydraulic control valve spring
2. Replace it.
• Insufficient oil; 1. Check the hydraulic oil level; is inoperative.
4. Low System
• Relief valve failur 2. See Fault 6;
Pressure
• Pump wear, internal leakag 3. Replace the gear pump.
• Caused by piston jamming or
5. The fork arms carrier
bent piston rod. 1. Replace the faulty parts.
moves up and down
• Too much dirt is accumulated in 2. Strip it down and clean.
sluggishly.
the cylinder.
1. Check and clean the solenoid
valve spool.
5. On load, declined • Solenoid valve failure;
2. Check the multi-way manual
• Carriage bracket assembly out of
valve and it installation.
adjustment. 1. Adjust clearance with thrust
• Insufficient clearance between metal and carriage side roller.
inner and outer masts or rollers 2. Adjust clearance with rollers.
• Pressure adjustment screw too 1. Adjust to proper pressure 6. Forks are lifted or
and mast. 3. Remove foreign materials.
loose; through hydraulic pressure lowered unsmooth.
• Biting foreign materials between 4. Apply grease on contact sur-
6. Relief valve pressure • Relief valve spring breakage or gauge. moving parts. faces of sliding parts.
unstable or too low deformation; 2. Replace the relief valve. • Insufficient lubrication. 5. Repair or replace.
• Relief valve spool wear or 3. Clean or replace the relief • Bent carriage bracket assembly.
blocked. valve.
* Under the circumstances of normal lifting and lowering, if failure occurs to any of other
* Carry out trouble shooting in accordance with the order listed in the table, it can help you quickly hydraulic actions (forward/backward shifting, forward/backward tilting and left/right shifting),
identify problems and resolve accordingly. perform troubleshooting to the corresponding control switch and its control circuit.
REV. 09/2020 REV. 09/2020
26 27

• Grease stiffened or dirt • Insufficient hydraulic oil; 1. Replace the hydraulic oil;
1. Lift roller does not accumulated on lift roller and 1. Clean and lubricate lift rollers. 1. Gear pump does not • Pump body defects; 2. Replace the gear pump;
rotate mast sliding surfaces. 2. Adjust. absorb oil or of small • Poor sealing with leakage; 3. Replace the sealing;
• Improperly adjusted lift roller. flow • Oil filter clogging; 4. Clean or replace the oil filter;
• Oil temperature is too high. 5. Cool down the hydraulic oil.
1. Lubricate.
• Insufficient lubrication.
2. Adjust. 1. Replace the gear pump;
• Improperly adjusted lift roller,
3. By adjusting shims and
3 2. Excessive mast
noise
side roller and back-up metal.
• Rubber pad on lower of outer
mast is useless for container fork
rubber pad, piston rod is in
touch with bottom of cylinder 2. Insufficient gear
pump output
• Pump body defects;
• Pump body with cracks or leaks;
• Impurities in the pump, oil filter
2. Replace the gear pump;
3. Replace the hydraulic oil and
clean the gear pump;
3
body after inner mast is in clogging; 4. Replace the hydraulic oil with
lift truck. pressure
touch with rubber pad. • Low viscosity of hydraulic oil; higher viscosity;
• Excessive wear occurs between • Oil temperature is too high. 5. Cool down the hydraulic oil
the oil pump body and gears,
1. Replace the worn parts or the
Lifting System causing too much clearance.
oil pump.
Failure • The lifting jack piston Yx-ring has • Pump body defects;
2. Replace Yx-ring. 1. Replace the gear pump;
worn, resulting in excessive inner Gear Pump • Gear pump inlet tubing diameteris
3. Replace. 2. Replace the inlet tubing;
leaks. Fault too small;
4. Replace. 3. Too much vibration 3. Clean the oil filter, adjust the
• Springs of the multiple control • Oil filter clogging, or motorspeed
5. Dismantle for regrinding the and noise motorspeed to a lower value;
valve and its relief valve are is too high;
joint surfaces and reassemble 4. Remove and reinstall the
inoperative oil leaks. • Motor and oil pump shaft
3. Insufficient lift power the valve. motor.
• Excessive wear occurs of the misalignment.
or no lift movement. 6. Tighten the joint nuts and
hydraulic control valve, resulting
inspect the seal for damage.
in excessive oil leaks.
7. Change the wrong hydraulic 1. Replace the gear pump;
• Oil leaks occur between the • Pump body defects;
oil or stop operation for 2. Remove and reinstall the seal
hydraulic control valve sections. 4. Oil leaks • Seal skeleton spring off;
reducing the oil temperature. skeleton;
• Leakage occur in the hydraulic • Shaft sealing surface scratche
Find out the reasons for high 3. Replace the shaft sealing.
pipe.
oil temperature and eliminate
• The hydraulic oil temperature is
the trouble.
too high. Oil viscosity is too low 1. Replace the gear pump;
and the rate is insufficient. • Pump body defects;
5. Pump is not 2. Remove and reinstall the gear
• Poor alignment of pump
• Valve failure; functioning properly pump;
1. Replace the manual valve; andmotor coupling;
• Valve seat blocked by large or blocked 3. Remove and clean the gear
2. Remove and clean the valve • Impurities in the pump.
impurities; pump.
seat;
1. The vehicle • External leakage:
3. Replace the sealing;
cannot perform the i. sealing damaged; 1. Replace the redirector;
4. Replace the screwed joint;
hydraulic control ii. poor threaded connection; • Redirector defects; 2. Remove and reinstall the
5. Replace the manual valve; 1. Oil leaks
instructions iii. valve body defects; • Poor sealing with leakage; redirector, if neccessary
6. Replace the hydraulic oil with
• High viscosity of hydraulic oil; replace the redirector.
lower viscosity;
• High frequency of use, service
Manual Valve 7. Replace the manual valve; Redirector
life has expired already.
Fault Fault 1. Replace the redirector;
• Redirector defects;
• Overflow valve in the connection 2. Redirector is not 2. Add the hydraulic oil;
1. Restart the truck; • Insufficient oil;
block started; functioning properly 3. Discharge the air in the oil;
2. Replace the valve seat; • There is air in the oil;
• Valve seat leakage; or noise 4. Replace the hydraulic oil with
3. Clean the valve rod, if necc- • High viscosity of oil.
• Valve rod cannot push/pull to lower viscosity;
2. Slow pace of essary replace the valve;
bottom; the channel cannot be
actuator 4. Replace the hydraulic oil with
fully opened;
lower viscosity; * Carry out trouble shooting in accordance with the order listed in the table, it can help you quickly
• High viscosity of hydraulic oil;
• High frequency of use, service
5. Replace the manual valve; identify problems and resolve accordingly.
life has expired already.
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28 29

Controller failure error, carry out

1. Check the light and its cir-
troubleshooting according to the a. Light failure or circuit not
cuit connection;
fault code information on the conducted
2. Check Lighting combination
instrument . b. Lighting combination switch or
• Steering potentiometer or its switch and its connection
1. Check the steering potentiom- its circuit connection failure
circuit connection failure 1. Lights do not light circuit;
eter or its connection circuit;
• Redirector or the tubings c. Fuse failure 3. Check fuse and its connec-
2. Check if the mechanical
1. The vehicle cannot connection failure tion circuit;
connection between steering d. DC-DC converter failure
3 be steered (the
• Steering bridge or the tubings
connection failure
vehicle can travel) • Pump motor failure
wheel and redirector is solid;
3. Check the redirector or the
4. Check DC-DC converter
and its connection circuit. 3
tubings connection; Other Failures
• Gear pump failure
4. Check the steering bridge or 1. Check the horn button and
• Pump controller failure
the tubings connection. its connection circuit;
5. Check the pump motor or its a. Horn switch or its circuit 2. Check the horn and its con-
connection circuit; connection failure nection circuit;
6. Check the pump; 2. Horn does not 3. Check fuse and its connec-
b. Horn failure
7. Replace the controller. sound tion circuit;
c. Fuse failure 4. Check DC-DC converter
d. DC-DC converter failure and its connection circuit.
2. Steering Bridge
• Supporting bearing wear 1. Replace the bearing
Abnormal Noise
• Oil seal wear or aged * Carry out trouble shooting in accordance with the order listed in the table, it can help you quickly
3. Steering Bridge Oil 1. Replace the Oil seal identify problems and resolve accordingly.
• Not flat of shim in limiting position
Steering Fault Leaks 2. Grinding shim or replace it
bolt
4. Steering Bridge
• Support bearing damage. 1. Replace the bearing
Stuck
• Not enough oil supported by

pump
• Air enters in the line of steering
gear
• Not enough oil in tank 1. Adjust control valve
• Too low pressure setting of the 2. Bleed the air
relief valve in the dividing valve 3. Fill oil
or blocking in valve 4. Adjust pressure or clear dirt
5. High effort for
• Too high viscosity oil 5. Replace wrong oil
steering of failure
• The steering fails to return to its 6. Replace wrong spring
to rotate steering
natural position due to breakage 7. Replace it
wheel
of locking spring or insufficient 8. Replace coupling
spring pressure 9. Replace spring
• Break or deform of swivel pin 10. Replace seal or cylinder
• Break or deform of coupling 11. Repair it
• Wrong in spring or safety valve
• Too much internal leakage in the
steering cylinder
• Deform of steering axle
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30 31
TROUBLESHOOTING
4. DRIVING SYSTEM
3
4
REV. 09/2020
32 33
DRIVING SYSTEM
NOTE: 4.1 Drive Wheel - Unscrew the six nuts (2) and remove the
drive wheel assembly (3).
4.1.1 Removal and Installation
Removal Installation
-- Turn off the truck power and remove the key; - Install according to the reverse order of rem-
-- Place the jack (1) under the chassis near the oval.
drive wheels, make the drive wheels off the
ground;
CAUTION
- Screw the eight nuts as shown in Fig3131-
20004SM.
- Tighten the nuts by order and mark with the
torque: 220 Nm.
4
WARNING
Make sure the lifting equipment is solid and CAUTION
secure, and the load capacity should be greater After installation, check whether the tire inflation
than the total weight of the vehicle.Lifting height reaches the specified value. After running for a
of not more than 100mm, to prevent the hazards short distance, check whether the bolts of each
to the maintenance personnel working under part are loose.
the vehicle for wheel removal and installation.
CAUTION
Tyre wear can affect the stability of the truck,
replace the drive wheel with heavy wear.
Quality of tyres directly affects the stability and
driving performance of the device. If you need
to replace the factory-fitted tyres, please use
original spare parts provided by the equipment
manufacturer to reach the original design
performance of the truck.
REV. 09/2020
34 35
DRIVING SYSTEM DRIVING SYSTEM
4.2 Drive Motor 4.2.3 Checking and Testing

This truck obtains drive force through AC motor. U, V, W Terminals
- Identify if the motor windings are normal
through measuring the resistance of U-V, V-W,
and U-W respectively, if there is short circuit
or breakage;
as shown in the following table:
CAUTION
Due to the small size of windings, when measu-
ring with a multimeter, put it on a low resistance
range.
Installation Resistance
4 - Install according to the reverse order of rem-
oval.
Measurement
With readings,
Judgment
Normal *
4
4.2.1 Removal and Installation but very low
Drive Motor CAUTION Winding internal short circuit
0Ω
(replace the motor)
Removal - Motor gear should fully engage with the gear
within the gearbox, rotate the gearbox without Winding internal open circuit
Drive motor is mounted on the gearbox. blocking, and then fix it with five screws.
∞Ω (replace the motor)
-- Power off the truck and remove the key; * The difference between the resistance values
-- Remove the cushion and open the floorboard; measured at U-V, V-W and U-W shall not be
-- Remove U, V and W cables on the drive greater than 2%.
motor;
-- Disconnect the connection between the drive - Identify if there is leakage current through
motor and main wiring cables; measuring the resistance between U, V, W
and motor housing respectively.
CAUTION Resistance
Judgment
Before going on with the next step, please fix Measurement
the drive motor properly first. Be sure to avoid Leakage current
0Ω
the falling of motor during removal, resulting in (replace the motor)
personal injury. ∞Ω Normal *
* For normal motor, U, V and W terminals are
-- Unscrew the five bolts (1), remove the drive
insulated from motor housing.
motor (2) from the gearbox (3);
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36 37
4.3 Drive Axle Installation
4.3.1 Removal and Installation -- Install according to the reverse order of rem-
oval.
Removal -- Loosen the oil drain plug and drain all gear
-- Power off the truck and remove the key; oil;
-- Unscrew the twelve bolts (7) and remove the CAUTION
-- Remove the drive wheel; (see Section 4.1.1)
seal (8), then dismantle the drive axle (9). After installing the new drive axle, please add
-- Remove the mast; (see Section 8.1.1)
gear oil (see Section 2.2.3 for specification and
-- Remove the cushion and floorboard, then
filling amount).
remove U, V and W cables on the drive
motor;
-- Disconnect the connection between the drive 4.3.2 Component
motor and main wiring cables;
-- Remove the tubings on the brake;
4 -- Remove the cotter pin (1) and unscrew the
nut (2), then kncok out the pin shaft (3);
4
-- Unscrew the four bolts (5) and remove
the bearing cap (4), then remove the drive
assembly (6) from the chassis;
No. Name No. Name No. Name No. Name

1 Seal Ring 7 Brake Hub 13 Axle Shaft 19 Nut
2 Axle Housing 8 Oil Seal 14 Nut 20 Bearing
3 Seal 9 Bolt 15 Thrust Ring 21 Lip Seal
4 Nut 10 Plug 16 O-ring 22 Brake Assembly R
5 Bolt 11 Gasket 17 Lip Seal 23 Parrallel Pin
6 Hub 12 Bolt 18 Bearing 24 Plug
REV. 09/2020 REV. 09/2020
38 39
4.3.3 Gear Oil 4.4 Differential

Check gear oil level CAUTION 4.4.1 Removal and Installation
- Loosen the oiling port plug (1, Fig3132- Gear oil may damage truck parts and con- Removal (Fig3132-20009SM)
20011SM) and observe the oil level; taminate the environment. When replace the
gear oil, place a clean container under the drive -- Remove the drive assembly from the chassis
- If oil level is aligning with lower level of oiling and dismantle the drive axle;(see Section
axle for discharge of gear oil.
port, it indicates that the oil level is normal; 4.2.1)
- If the oil level is below the lower level of oiling -- Unscrew the four bolts (1) and remove the
port, it is necessary to add gear oil. bearing cap (2);
-- Dismantle the differential (3) and two bearings
2
(4).
Installation
oval.
4
4.4.2 Component
1
Fig3132-20011SM
Add / Replace Gear Oil
-- Loosen the oil drain plug (3), drain the gear
oil within the gearbox;
-- Remount the oil drain plug (3), Loosen the oil
fill plug (2) at the bottom of the drive axle and
add the gear oil of same specification through
oiling port;
-- Remount the oil fill plug (2).
3
No. Name No. Name

1 Bearing 6 Bevel Side Gear
2 Bolt 7 Universal Joint
3 Gear Ring 8 Planetary Gear
4 Differential Housing-R 9 Washer
Fig3132-20012SM 5 Washer 10 Differential Housing-L
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40 41
4.5 Gearbox 4.6 Accelerator Pedal

4.5.1 Removal and Installation 4.6.1 Removal and Installation 3
Removal (Fig3132-20004SM) -- Power off the truck and remove the key;
-- Remove the drive assembly from the chassis -- Remove the cushion;
and dismantle the drive axle;(see Section -- Disconnect the connection between the
4.2.1) accelerator pedal wiring (1) and main wiring
-- Dismantle the differential; (see Section 4.4.1) harness ;
-- Unscrew the five bolts (1), remove the drive -- Unscrew the two bolts (2) with wrench and
motor (2) from the gearbox (3). remove the accelerator pedal (3) from the
chassis;
-- Install according to the reverse order of rem-
Installation oval.

oval.
1 2
Fig3132-50004SM 4
4.6.2 Interface Description
4.5.2 Component
Interface Description
Pin Description Color Remark

A Pedal power supply Red 10-15Vdc
B Output signal White 0.2±0.1V~9±0.3V
C Pedal signal grounding Black -
No. Name No. Name No. Name No. Name D Pedal Switch - Positive Electrode Green Switch output (10-60V)
1 Bearing Cap 5 Washer 9 Gear Shaft 13 Shaft E Pedal switch output Grey Switch output
2 O-ring 6 Housing 10 Gear Shaft 14 O-ring - - - -
3 Bearing Cap 7 Pin 11 Dual Gear 15 Housing Cover
4 O-ring 8 Bearing 12 Seal Cap 16 Bracket
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42 43
DRIVING SYSTEM
4.6.3 Checking and Testing - Press the accelerator pedal. Measure the vol-
Checking
tage between the interfaces with a multimeter.
5. STEERING SYSTEM
- Check if the accelerator pedal is reset pro-
perly, also check for damage;
Press the accelerator pedal
Connection
- Check if the accelerator pedal and its wiring Voltage Measurement
interface
harness are in good condition, and if the
connectors are connected securely. A-C 12 V
Changing within the range of 0V
Testing A-B
to 9V with the level of pressing
- Press the accelerator pedal, if the accelerator A-E 12 V
information on the display does not change, it
indicates there is failure with the accelerator B-C 0V
4 pedal or its circuit;

Turn off the vehicle to check the accelerator
pedal and its wiring harness. (See Fig3131-
50017SM)
- Provide a voltage of 12V between accelerator
pedal harness connectors (A) and (C), check
5
the voltage at each port of the wiring harness
with a multimeter;
- Place the accelerator pedal at original
position Measure the voltage between the
interfaces with a multimeter.
Accelerator pedal at original position

Connection
Voltage Measurement
interface
A-C 12 V
A-B 0V
A-E 12 V
B-C 0V
REV. 09/2020
44 45
STEERING SYSTEM
NOTE: 5.1 Rear Steering Wheel -- Unscrew the eight nuts (1,Fig3530-10002SM)
and remove the steering wheel assembly (2)
5.1.1 Removal and Installation from the steering bridge (3).
Removal
-- Turn off the truck power and remove the key;
-- Place the jack (1) under the chassis near
steering wheels, make the wheel off the
ground;
5
Installation and Commissioning
- Install according to the reverse order of rem-
ova.
CAUTION
WARNING - Screw the eight nuts as shown in Fig3132-
Make sure the lifting equipment is solid and 70002SM.
secure, and the load capacity should be greater - Tighten the nuts by order and mark with the
than the total weight of the vehicle.Lifting height torque: 220 Nm.
of not more than 100mm, to prevent the hazards
to the maintenance personnel working under
the vehicle for wheel removal and installation.
WARNING
When replacing wheels, be sure that the truck
won't tilt.
REV. 09/2020
46 47
STEERING SYSTEM STEERING SYSTEM
-- Turn the wheel to see if it is rotating smoothly, -- Unscrew the four bolts (2) and remove the fix 5.2.2 Component
and if there is blocking or not; plate (3), then dismantle the steering bridge
-- Run the truck to see if the steering wheel is (5) from the chassis;
functioning properly. If there is blocking or -- Remove the two damping pads (4) from the
noise, please check if the wheel bearings are steering bridge (5).
functioning properly.
CAUTION Please add grease (see

Section 2.2.3 for specifica-
Quality of tyres directly affects the stability and tion ).
driving performance of the device.
If you need to replace the factory-fitted tyres, Be sure to bend a cotter pin.
please use original spare parts provided by the
equipment manufacturer to reach the original
design performance of the truck.
5 5
5.2 Steering Bridge
5.2.1 Removal and Installation Installation
Removal - Install according to the reverse order of rem-
-- Turn off the truck power and remove the key; oval.
-- Dismantle the rear steering wheels; (see
Section 5.1.1) CAUTION
-- Remove the two tubings (1) from the steering
bridge; When removing the tubing and steering bridge,
the system will lose some hydraulic oil, please
refer to Section 2.2.3 for supplementary adding
of hydraulic oil.
CAUTION
Hydraulic oil may damage truck parts and cont-
aminate the environment. When removing joints
or tubings, place a clean container under it for
discharge of hydraulic oil.
No. Name No. Name No. Name No. Name
CAUTION 1 Hub Cover 7 Steering Knuckle 13 Bearing 19 Oil Cup
2 Cotter Pin 8 Gasket 14 Bolt 20 Connect Rod
Before going on with the next step, please
fix the steering bridge properly first. Be sure 3 Nut 9 Bearing 15 O-ring 21 Steering Cylinder
to avoid the falling of steering bridge during 4 Bearing 10 Sleeve 16 Bearing 22 Axle Body
removal, resulting in personal injury. 5 Hub 11 Pin 17 Scraper Seal 23 Space Plate
6 Seal 12 Check Ring 18 Master Pin 24 Bolt
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48 49
STEERING SYSTEM
5.3 Steering Cylinder -- Secure the cylinder to hose clamp and gently
clamp the cylinder middle;
5.3.1 Removal and Installation -- Unscrew the cylinder cap (1,Fig3132-
6. BRAKE SYSTEM
70005SM) from side with cylinder wrench;
Removal
-- Remove the circlip (2), snap ring (3), dust ring
(4), rubber ring (5&8), O-ring (6 & 7) and seal
-- Dismantle the steering bridge; (see Section (9) from the cylinder cap;
5.2.1)
-- Pull out the piston rod (10) from cylinder block
-- Unscrew the four bolts (24,Fig3132-70004SM) (16);
and remove the space plate (23) from the
-- Separate the piston (11) from the piston rod;
connect rod (20);
-- Remove the support ring (12), O-ring (13),
-- Knock out the pin (11), then remove the two
seal (15) and balls (14) from the piston;
check rings (12) and bearing (13);
-- Unscrew the four bolts (14) and dismantle the - Clean with hydraulic oil of the same specifi-
steering cylinder (21) from the steering bridge cations;
(22). - Replace the problem parts and assembly in
reverse steps.
Installation

oval.
CAUTION
When removing the steering cylinder, the
6
system will lose some hydraulic oil, please refer
to Section 2.2.3 for supplementary adding of
hydraulic oil.
5.3.2 Steering Cylinder Maintenance
CAUTION
- Use suitable hose clamps to avoid cylinder
deformation caused by severely tight hose
clamp.
- Carry out the maintenance work in a clean
environment to prevent impurities from enter-
ing into cylinder, causing cylinder damage; CAUTION
- During the installation, hydraulic oil of
the same specifications must be used for - If the piston rode or cylinder tube is damaged,
cleaning or lubrication. please replace the entire cylinder.
- If the seals are aged or damaged, please
replace the complete set of seals.
- When replacing or repairing the cylinder,
please refill the lubricant through the grease
nipples at both ends of the cylinder.
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50 51
BRAKE SYSTEM
NOTE: 6.1 Parking Brake 6.1.2 Adjustment
6.1.1 Removal and Installation CAUTION

-- Turn off the truck power and remove the key; Prior to parking brake adjustment, please use
-- Use triangle wooden wedges to fix the wheels; triangle wooden wedges to fix the wheels.
-- Disconnect the connection between the brake
switch (1,Fig3132-10001SM) on the parking
brake (4) and the main wiring harness;
-- Remove left / right brake cable on the parking
brake;
-- Loosen the two nuts (2) and bolts (3), remove
the parking brake (4).
-- Install according to the reverse order of rem-
oval.
-- Press and hold the button (1), push the

parking brake lever (2) from A position (brak-
ing) to B position (released);
-- Through adjusting bolt (3) to adjust the opera- 6
ting torque for pulling the brake lever (2) from
B position to A position.
-- Operating torque: 147~196 Nm
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52 53
BRAKE SYSTEM
6.2 Service Brake

6.2.1 Removal and Installation Installation 7. HYDRAULIC SYSTEM
Removal
oval.
- Add brake fluid into the oil cup until it fills 2/3
-- Remove the cushion and open the floorboard; of the cup. Please apply as specified (see
-- Loosen the nut (1) and remove the two tubings Section 2.2.3 for specifications).
on the brake master pump (5);
-- Remove the cotter pin (2) on the pin shaft (3),
then knock out the pin shaft (3) from side; CAUTION
-- Unscrew the two bolts (4), then remove the
After replacing the brake master cylinder or
brake master pump (5) from the chassis.
tubings, the air within the entire brake pipeline
1 must be discharged.
6.2.2 Air Discharge / Adding Brake Fluid

5 - Fill the oil cup with brake fluid;
- Press the brake pedal repeatedly until the
4
stepping pressure becomes heavy;
6 3
- Open the vent on brake cylinder of drum
brake, press the brake pedal pressure to the
2 bottom, discharge the residual air from the
vent through high level of brake fluid;
- When there is flow of fluid running out of
the vent, it indicates that the air discharge is 7
completed, release the brake pedal and close
the vent.
Fig3132-10002SM
CAUTION
CAUTION
During the entire process of operation, there
When removing the tubing and brake pump, the must always be brake fluid in the oil cup.
system will lose some brake fluid, please refer
to Section 2.2.3 for supplementary adding of
brake fluid.
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54 55
HYDRAULIC SYSTEM
NOTE: The system pressure of the entire hydraulic Hydraulic Oil

system pressure is provided by hydraulic power
unit system, which is used for lifting/tilting/ Hydraulic oil for truck:
sideshifting. While the hydraulic power unit is Specifications: Anti-wear Hydraulic Oil L-HM46.
equipped with a relief valve to ensure that the
entire system pressure is always within the
safety limits that can lift the maximum load
Hydraulic Seals
capacity.
Multi-way Manual valve is used for the control of The seals installed within the cylinder are made
lifting-lowering, tilting and sideshifting. Throttle of rigid polyurethane. The deformation during
valve is used for the control of lowering speed. assembly due to compression will not cause a
Inlet is equipped with a filter to prevent the permanent deformation.
impurities in the hydraulic oil from entering into When assembling, pay attention to prevent the
the pump. seals from being broken, rolled and undercut.
Oil pipeline explosion-proof valve is installed at
the hydraulic cylinder to prevent the explorsion
of the system pipeline. Assembly Instructions
Hydraulic Schematic Diagram is as shown in The tools used to install the seals must be made
Fig3530-40001SM; of soft metal or suitable plastic, without burrs
See Section 7.6 for hydraulic symbol descripti- and sharp edges on surfaces. It is prohibited
ons. to use the tools that can easily damage the
surface of seals, such as, screwdriver or other
similar tools with hard front edges.
7.1 Overview Where the hydraulic seals to be installed should
be free of burrs, sharp edges and cracks. If the
- Lower the mast to the bottom, remove the air installation of seals needs to cross sharp edges,
filter on cylinder, observe the oil level with the grooves or cuts, protective devices must be
oil dipstick. When adding hydraulic oil, please
use hydraulic oil of the same specifications.
used for protection. Before installing, lubrication
should be performed to the seals and the 7
- When the mast occasionally jitters, that may mounting positions first.
be leaks in the cylinder, or there could be
leaks on the valve body. Dismantle and clean CAUTION
(to clean with hydraulic oil of the same spe-
The lubricant used during assembly must be of
cifications) the valve on the valve body, disch-
the same specifications with the hydraulic oil
arge the foreign bodies within the valve body
used in the vehicle.
through repeatedly lifting and lowering of the
mast.
- If hydraulic oil is becoming less, please tho-
roughly check the hydraulic system for leaks.
- Disassembly of cylinder needs to be perfor-
med in a clean environment. Before removing
the cylinder, the stains on the cylinder must
be removed first. Carefully remove the piston
rod to prevent the cylinder wall from being
scratched by its end surface or damaged
part. Every time when replacing the cylinder,
also replace the cylinder seals.
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HYDRAULIC SYSTEM HYDRAULIC SYSTEM
7.1.1 Hydraulic Schematic Diagram 7.2 Pump Motor & Gear Pump
This truck obtains hydraulic power through the CAUTION
AC pump motor.
When removing the tubing and pipe, the system
will lose some hydraulic oil, please refer to
Section 2.2.3 for supplementary adding of
hydraulic oil.
-- Unscrew the two bolts (6) and remove the

gear pump (6) from the pump motor (8).
Removal
-- Remove the AMP connector on the pump
motor and remove the cables U, V and W
from the pump motor; Installation
-- Loosen the tubing connector (1) with a
wrench, and then remove the tubing from the
oval.
gear pump;
-- Loosen the clips on the clamp (5), remove the
7 pipe (3) from the gear pump;
-- Unscrew the four bolts (4) and remove the
7
pump motor & gear pump assembly from the
chassis;
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7.3 Multi-way Reversing Manual Valve 7.3.2 Interface Description

The valve rod is driven by lever to switch the ON
and OFF of tubing within the valve body, thus to
control the Lifting - Lowering, Forward Shifting -
Retract, Tilting Forward - Tilting Backward and
Left Shifting - Right Shifting of the vehicle.
Installation
Removal (Fig3132-40005SM) oval.

-- Remove the cushion and open the floorboard; CAUTION
-- Remove the tubings on the multi-way valve (1) As some hydraulic oil will be lost when remov-
and disconnect the connection between the ing the manual multi-way valve, please add
control switch (2) and main wiring harness; appropriate amount of hydraulic oil after the Connection Interface
Symbol Interface Function
7 CAUTION
replacement is completed (see Section 2.2.3 for
specifications and adding amount).
A1 Lifting, lifting / lowering solenoid valve controls
Terminals
Lift Cylinder
Size
M20×1.5
7
A2 Backward tilting, backward tilting solenoid valve controls Tilt Cylinder M20×1.5
Hydraulic oil may damage truck parts and con-
taminate the environment. When removing B2 Forward tilting, forward tilting solenoid valve controls Tilt Cylinder M20×1.5
joints or tubings, place a clean container under A3 Right shifting, right shifting solenoid valve controls Side-Shift Cylinder M20×1.5
it for discharge of hydraulic oil.
B3 Left shifting, left shifting solenoid valve controls Side-Shift Cylinder M20×1.5
-- Remove the cotter pin (3) on pin shaft (4), A4 Reach, reach solenoid valve controls Reach Cylinder M20×1.5
remove the connecting rod (5) from the multi- B4 Retracting, retracting solenoid valve controls Reach Cylinder M20×1.5
way valve;
P Oil Inlet Gear Pump M22×1.5
-- Unscrew the three bolts (6), then remove the
multi-way valve (5) from the mounting plate T Drainback Tank ø25
(7);
-- Remove the rubber cover (8) and unscrew
the bolt (9), then remove the bracket (10)
from the multi-way valve.
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7.4 Redirector 7.5 Tilt Cylinder - Upon removal, the damage to cylinder
1 4 3 threads, oil port threads, cylinder cap threads,
7.5.1 Cylinder Removal Precautions piston rod surface and inner cylinder wall
should be prevented.
2 - Before removing the cylinder, be sure to reli-
eve the hydraulic circuit first, which is to lower In order to prevent piston rod from bending or
the lifting mast to the bottom. Otherwise, deformation, support it wooden block when
when removing the tubing connected with the placing.
cylinder, the pressured hydraulic oil within When removing seals, the use of sharp
the circuit may be sprayed out at high speed tools should be avoided, so as not to stab
along with the tubing, and there is risk of the seals. For the seals that are difficult to
causing personal injury. remove, soak them with boiled water, remove
Turn off the power source, so that the entire them when getting softened.
hydraulic system will stop functioning, then - Before removing, try to create conditions
the connecting tubing can be loosened; in
Fig3132-40007SM to prevent the cylinder parts from being
order to avoid the residual pressure within the
contaminated by the surrounding dust and
circuit, the tubing joint should be loosened
impurities. For example, try to disassemble
-- Unscrew the four bolts (3), dismantle the slowly, loosen the joint by half and shake the
the equipment in a clean environment; after
redirecor (4). tubing to see if there is overflow of pressured
the disassembly, all parts should be covered
-- Install according to the reverse order of rem- oil, and then go on with the removal;
7.4.1 Removal and Installation with plastic, do not cover with cotton cloth or
oval. - Cylinder is the powered actuator in hydraulic other cloth used during operation;
-- Turn off the truck power and remove the key; system. Therefore, before removing the - For the cylinder which is found with internal
-- Remove the cushion and open the floorboard; cylinder from the equipment, the connection or external leakage during use, if the piston
CAUTION
part must be supported with appropriate rod or cylinder tube is not scratched, such
-- Loosen the joint (1) and remove the tubings
As some hydraulic oil will be lost when re- supporting to avoid personal injury or damage case may be due to wear or aged seals.
(2) on the redirector (4);
moving the redirector, please add appropriate to the equipment;
amount of hydraulic oil after the replacement is - Cylinder is the powered actuator in hydraulic
CAUTION completed (see Section 2.2.3 for specifications CAUTION
system. Therefore, before removing the
7 Hydraulic oil may damage truck parts and con-
taminate the environment. When removing
and adding amount). cylinder from the equipment, the connection
part must be supported with appropriate
When the seals need to be replaced, replace
with the complete set of seals in the cylinder 7
joints or tubings, place a clean container under supporting to avoid personal injury or damage repair kit.
it for discharge of hydraulic oil. to the equipment;
- Pay special attention to the cylinder tube,
- Upon disassembly of the cylinder, you should piston rod and other moving parts for bumps
know the main structure of the cylinder to and scratches. If only minor damage, sand
7.4.2 Interface Description avoid sightless removal. Due to the different the edge point around the damaged part with
size, structure, purpose of use of the fine stone and then polish the part smooth
Connection Interface cylinders, the sequences and methods used with metallographic sandpaper.
Symbol Interface Function
Terminals Size for removal are also different;
T Drainback Tank M18×1.5 - When removing each part, do not hammer
P Oil Inlet Gear Pump M20×1.5 forcefully, it such case cannot be avoided,
please lay a copper rod to avoid damage
L Left turning, steering wheel controls Steering Bridge M18×1.5 to the parts; special tools must be used for
R Right turning, steering wheel controls Steering Bridge M18×1.5 the parts having such requirements, do not
hammer forcefully or pry. Fine pitch threaded
EF Port, to the Port P of multi-way valve Multi-way Malve M20×1.5
cylinder cap, after being shaken loose,
loosen it with cylinder wrench with even force,
copper rod can be used to hammer the part
that cannot easily deform, do avoid violent
shocks.
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62 63

CAUTION
Cylinder Cap Tilt cylinder is installed on the chassis and outer
- O-ring is quite flexible and easy to install,
mast.
but it must not be pulled up to the extent of
permanent deformation, nor scroll it while -- Fix the mast, block the truck wheels with
installing; wooden wedge, press the emergency stop
switch and turn off the key switch;
Cylinder Wrenches - Y-ring or X-ring needs to be identified if it is
for shaft or hole to avoid misplacement; -- Unscrew the two nuts (1) and remove the two
tubings (2) from the tilt cylinder (3);
- The removed O-rings and dust rings should
be replaced with new ones. -- Unscrew the anchor bolt (6) from the outer
Piston Rod mast with socket wrench and pull out the pin
- Cylinder parts must not be arbitrarily repla- shaft (7);
ced, the original products provided by the -- Unscrew the anchor bolt (4) from the chassis
manufacturer should be used; with socket wrench and pull out the pin shaft
- After maintenance and assembly of the cylin- (5);
Cylinder Tube der is completed, pressure leak testing must -- Remove the tilt cylinder (3);
be carried out before it can be put operation -- Replace with new cylinder and install in rever-
once again. se order;
Before the testing, discharge the air within -- Add hydraulic oil of the same specifications
the cylinder, run the cylinder in a small range into the tank, see Section 2.2.3;
of movement for several times, and pay
* See Section 8.1.4 / Section 8.2.4 or Section attention if it is moving without blocking and if 3 7 6
8.3.4 for the removal and installation of lift there is uneven resistance during the moving.
cylinder and side shift cylinder. Upon the pressure testing, raise the pressure
slowly and observe carefully for leaks.
* See Section 5.3.1 for the removal and instal-
lation of steering cylinder.
7 7.5.2 Cylinder Installation Precautions 2

7
- All parts should be cleaned up before asse-
mbly, then to be assembled after being
dried;(during assembly, apply appropriate
amount of hydraulic oil for lubrication)
1 4 5
- The tools used to install the seals must Fig3132-40007SM
be made of soft metal or suitable plastic,
without burrs and sharp edges on surfaces.
It is prohibited to use the tools that can CAUTION
easily damage the surface of seals, such as, Hydraulic oil may damage truck parts and con-
screwdriver or other similar tools with hard taminate the environment. When removing
front edges. joints or tubings, place a clean container under
Where the hydraulic seals to be installed it for discharge of hydraulic oil.
should be free of burrs, sharp edges and
cracks. If the installation of seals needs to - Pull out emergency switch and turn on the
cross sharp edges, grooves or cuts, protective key switch;
devices must be used for protection. Before
- Repeat tilt cylinder to discharge the air within
installing, lubrication should be performed to
the tubings and cylinder;
the seals and the mounting positions first with
hydraulic oil. - Check the hydraulic oil level and make sure
that the liquid is at standard level.
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7.5.4 Cylinder Maintenance 7.6 Refueling Cap -- Remount the oil drain plug (6), Loosen the oil
fill cap (5) and add the hydraulic oil of same
CAUTION specification through oiling port;
- Use suitable hose clamps to avoid cylinder -- Turn off the truck power and remove the key; -- Remount the oil fill cap (5).
deformation caused by severely tight hose -- Loosen the nuts (1) and remove the tubings
clamp. (2) from the refueling cap (4);
- Carry out the maintenance work in a clean -- Unscrew the eight bolts (3) and remove the CAUTION
environment to prevent impurities from enter- refueling cap (4) from the chassis;
ing into cylinder, causing cylinder damage; Hydraulic oil may damage truck parts and con-
-- Install according to the reverse order of rem- taminate the environment. When replace the
- During the installation, hydraulic oil of oval. hydraulic oil, place a clean container under the
the same specifications must be used for 1 2 drainage outlet for discharge of hydraulic oil.
cleaning or lubrication.
-- Secure the cylinder to hose clamp and gently

clamp the cylinder bottom;
-- Unscrew the nut (4, Fig3530-40004SM) and
bolt (3), then remove the ear (2) from the
piston rod (18);
-- Unscrew the cylinder cap (13) with cylinder
wrench;
-- Remove the dust ring (6), check ring (7),
retainer ring (8), seal (9), and check ring (10)
from the cylinder cap (13); 4 5 3
-- Remove the bearing (14), O-ring (11) and Fig3132-70007SM
retainer ring (12) from the cylinder cap (13);
CAUTION
-- Pull out the piston rod (18) from cylinder block
7 (15);
-- Remove the seal (16) and support ring (17)
- If the piston rode or cylinder tube is damaged,
please replace the entire cylinder.
7.6.2 Hydraulic Oil
7
Add / Replace hydraulic oil
from the piston rod; - If the seals are aged or damaged, please
replace the complete set of seals. -- Loosen the oil drain plug (6), drain the
- Clean with hydraulic oil of the same specifi- hydraulic oil within the oil tank;
cations; - When replacing or repairing the cylinder,
please refill the lubricant through the grease
- Replace the problem parts and assembly in
nipples at both ends of the cylinder.
reverse steps.
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7.7 Hydraulic Symbol

Symbol Description Symbol Description
Symbol Description Symbol Description
Tank Manual valve

Brake valve
Pipe end below liquid Three-way six-pass
Proportional valve
level
Tank Speed requlating valve Explosion-proof valve

Pipe end above liquid
Check valve
level
Solenoid valve
Redirector
Cylinder Two-way two-pass
Filter
Single-acting direction
Service line
Cylinder
(Supply line or return
Double-acting
line)
direction
Control line
(Drain line) Relief valve
7 7
Solenoid valve
Connecting pipe
Two-way two-pass
Port
Solenoid valve
(Test port)
Three-way four-pass
Motor Balancing valve
Hydraulic pump Check valve
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8. MAST
70 71
MAST MAST
8.1.2 Lifting Chains

8.1 Wide-View Two-stage Mast
-- Remove the shafts (2) between the outer
mast and tilt cylinders (A and B); 8.1.2.1 Chain Adjustment
-- Unscrew the bolts (3) and remove the fixed - Lower the mast to the bottom;
Removal (Fig3132-60001SM) plate (4) between the outer mast and chassis
- Press the emergency stop switch and discon-
(C and D);
-- Switch off the power supply, block the truck nect the key switch;
-- Remove the mast from the truck.
wheels with wooden wedges,
-- Disconnect the connections between lifting - CAUTION
lowering tubing, left shifting tubing and right Installation Switch off the power supply before any adjust-
shifting tubing and mast tubing; ments or operations!
-- Wrap the sling (1) around the upper beam of
oval. - Loosen the lower jam nuts (2) on chain bolt (1,
inner and outer masts, slightly lift the mast
with crane; Fig3131-60003SM);
- Through screwing upward the jam nut (8) in
WARNING the upper, the chain will slowly tension;
Make sure the lifting equipment is solid and - When the chain is adjusted to be tensioned
secure, and the load capacity should be greater with no obvious loosening, fasten the lower
than the total weight of the vehicle. jam nut;
CAUTION
When the adjustment is completed, there sh-
ould be an adjustable distance of at least three
pitches over the chain bolts.
- Pull out emergency stop switch and turn on
the key switch;
- Through repeatedly lifting/lowering the mast
to test if the chain is tensioned. If the chain is
still loose, repeat the steps above.
8 8
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MAST MAST
8.1.2.2 Chain Replacement 8.1.3 Mast Tubing

- Block the truck wheels with wooden wedges,
raise the fork carriage with lifting tools to Code Description
make the chains loose for the following rem-
oval; A1 Lifting / Lowering Mast Tubing
A3 Right Shift Mast Tubing
CAUTION
B1 Left Shift Mast Tubing
Please place supporting under the fork carriage
to prevent it from falling, resulting in personal
injury.
- Remove the cotter pin (7, Fig3131-60003SM),

then unscrew the jam nuts (2 & 8) and from
the chain joint (1) and chain joint (6);
- Remove the cotter pin (3), pull out the pin
shaft (4), separate the chains (5) from the
chain joint (1) on outer mast;
- Remove the chain assembly from the chain
sprocket;
- Replace with new chains and hang the new
chain assembly onto the chain sprocket;
- Put the chain connector (6) through the fork
carriage chain-hanging plate, screw the jam
nut (2);
- Put the chain connector (1) through the outer
mast chain-hanging plate, screw the jam nut
(2);
- Adjust the chains according to Section
8.1.2.1.
8 8
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MAST MAST
8.1.4 Lift Cylinder supporting; 8.1.4.2 Cylinder Maintenance

- Remove the tubing (5, Fig3131-60005SM)
8.1.4.1 Cylinder Removal (with mast on to make it separate from the three-pass CAUTION
the vehicle) component (2); - Use suitable hose clamps to avoid cylinder
Left Cylinder Removal deformation caused by severely tight hose
- Lower the mast to the bottom, press the em- CAUTION clamp.
ergency stop switch and disconnect the key Hydraulic oil may damage truck parts and cont- - Carry out the maintenance work in a clean
switch; aminate the environment. When removing joints environment to prevent impurities from
- Block the truck wheels with wooden wedges, or tubings, place a clean container under it for entering into cylinder, causing cylinder
raise the inner mast (2, Fig3530-60002SM) discharge of hydraulic oil. damage.
for 500mm with lifting tools, insert wooden - Remove the regulator (6) from the three-pass - During the installation, hydraulic oil of
block between inner mast and the ground for component (2); the same specifications must be used for
supporting; - Unscrew the bolt (3, Fig3530-60002SM) and cleaning or lubrication.
- Disconnect the connection between the tubing remove the cylinder clamp (4);
(5) and straight coupling (3); - Secure the cylinder to hose clamp and gently
- Unscrew the mounting bolt (7) from the bott-
clamp the cylinder bottom;
om of the cylinder;
- Unscrew the cylinder cap (3) with cylinder
- Unscrew the bolt (6), lift the cylinder (5) up wrench;
CAUTION and remove it from the truck;
- Remove the dust ring (1), seal (2), O-ring (4)
- Remove the three-pass component (2,
Hydraulic oil may damage truck parts and and bushing (5) from the cylinder cap (3);
Fig3131-60005SM) from the right cylinder.
contaminate the environment. When removing - Pull out the piston rod (6) from the cylinder
joints or tubings, place a clean container under tube (15);
it for discharge of hydraulic oil.
- Remove the support ring (8) and the piston (9)
from the piston rod;
- Unscrew the bolt (3, Fig3530-60002SM) and
- Remove the O-ring (7), bushing (10),
remove the cylinder clamp (4);
rataining ring (11) and seal (12) from the
piston;
CAUTION
- Remove the O-ring (14) and bushing (13)
Before going on with the next step, please fix from the piston;
the cylinder properly first. Be sure to avoid the
- Clean with hydraulic oil of the same specific-
8 falling of cylinder during removal, resulting in
personal injury.
ations;
8
- Unscrew the mounting bolt (7) from the bott- reverse steps.
om of the cylinder; 8.1.4.3 Cylinder Installation
- Unscrew the bolt (6), lift the cylinder (5) up - Install the cylinder according to the reverse
and remove it from the truck. order of removal according to 8.1.4.1;
CAUTION
- Add hydraulic oil of the same specifications
If the piston rode or cylinder tube is damaged,
Right Cylinder Removal into the tank, see Section 2.2.3;
- Lower the mast to the bottom, press the em- - Pull out emergency stop switch and turn on
If the seals are aged or damaged, please
ergency stop switch and disconnect the key the key switch;
switch; - Repeat Lift - Lower cylinder to discharge the
- Block the truck wheels with wooden wedges, air within the tubings and cylinder;
raise the inner mast (2, Fig3530-60002SM) for - Check the hydraulic oil level and make sure
500 mm with lifting tools, insert wooden block that the liquid is at standard level.
between inner mast and the ground for
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MAST MAST
8.1.5 Built-in Side Shifter

8.1.6 External Side Shifter
8.1.5.1 Side Shifter Removal
8.1.6.1 Side Shifter Removal
- Lower the mast to the bottom, press the eme-
rgency stop switch and disconnect the key - Lower the mast to the bottom, press the eme-
switch; rgency stop switch and disconnect the key
switch;
- Block the truck wheel with wooden wedge;
- Block the truck wheel with wooden wedge;
- Unscrew the four bolts (1, Fig3530-60003SM),
- Unscrew the four bolts (3, Fig3530-60004SM),
remove the retaining shelf (2) from the built-in
side shifter (3); remove the retaining shelf (1) from the exter-
nal side shifter (2);
CAUTION
CAUTION
Hydraulic oil may damage truck parts and cont-
aminate the environment. When removing joints Hydraulic oil may damage truck parts and cont-
or tubings, place a clean container under it for aminate the environment. When removing joints
discharge of hydraulic oil. or tubings, place a clean container under it for
discharge of hydraulic oil.
- Remove the right shifting tubing (8, Fig3131-
60005SM) and left shifting tubing (7) from the - Remove the right shifting tubing (8, Fig3131-
built-in side shifter; 60005SM) and left shifting tubing (7) from the
built-in side shifter;
CAUTION
CAUTION
Before going on with the next step, please
fix the side shifter properly first. Be sure to Before going on with the next step, please
avoid the falling of side shifter during removal, fix the side shifter properly first. Be sure to
resulting in personal injury. avoid the falling of side shifter during removal,
resulting in personal injury.
- Remove the chain assembly and remove the
- Remove the external side shifter (2, Fig3530-
side shifter from inner mast.
60004SM) from fork carriage (4).
8 8.1.5.2 Side Shifter Installation 8.1.6.2 Side Shifter Installation 8

- Install the side shifter according to the rever- - Install the side shifter according to the rever-
se order of removal according to 8.1.5.1; se order of removal according to 8.1.6.1;
- Add hydraulic oil of the same specifications - Add hydraulic oil of the same specifications
into the tank, see Section 2.2.3; into the tank, see Section 2.2.3;
- Pull out emergency stop switch and turn on - Pull out emergency stop switch and turn on
the key switch; the key switch;
- Repeat left shifting - right shifting operations - Repeat left shifting - right shifting operations
to discharge the air within the tubing and side to discharge the air within the tubing and side
shift cylinder; shift cylinder;
- Check the hydraulic oil level and make sure - Check the hydraulic oil level and make sure
that the liquid is at standard level. that the liquid is at standard level.
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MAST MAST
8.2 Two-stage Full Free Mast - Unscrew the bolts (3) and remove the fixed
8.2.2 Lifting Chains
plate (4) between the outer mast and chassis
8.2.1 Removal and Installation (C and D); 8.2.2.1 Chain Adjustment
Removal (Fig3132-60002SM) - Remove the mast from the truck.
- Lower the mast to the bottom;
Installation - Press the emergency stop switch and discon-
- Disconnect the connections between lifting -
lowering tubing, left shifting tubing and right - Install according to the reverse order of rem- nect the key switch;
shifting tubing and mast tubing; oval.
- Wrap the sling (1) around the upper beam of CAUTION
inner and outer masts, slightly lift the mast WARNING Switch off the power supply before any adjust-
with crane; Make sure the lifting equipment is solid and ments or operations!
- Remove the shafts (2) between the outer secure, and the load capacity should be greater
- Loosen the upper lock nut (3,Fig3131-60011SM)
mast and tilt cylinders (A and B); than the total weight of the vehicle.
and the lower lock nut (1) on chain bolt;
- Through screwing upward the adjusting nut
(2) in the middle, the chain will slowly tension;
- When the chain is adjusted to be tensioned
with no obvious loosening, fasten the upper
and lower lock nuts;
CAUTION

the key switch;
8 8
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MAST MAST
8.2.2.2 Chain Replacement 8.2.3 Mast Tubing

- Block the truck wheels with wooden wedges,
raise the fork carriage with lifting tools to Code Description
make the chains loose for the following rem-
oval; A1 Lifting / Lowering Mast Tubing
CAUTION
Please place supporting under the fork carriage
injury.
- Unscrew the lock nut (1, Fig3131-60011SM)

and adjusting nut (2) from the chain joint (4);
- Remove the cotter pins (6), pull out the pin
chain joint (4) on free middle cylinder;
chain joint (10) on fork carriage;
- Remove the chain assembly from the chain
sprocket;
- Replace with new chains and hang the new
chain assembly onto the chain sprocket;
- Put the chain connector (10) through chain
hole of fork frame, insert the pin shaft (9) and
pins (8);
- Put the chain connector (4) through the free
middle cylinder chain-hanging plate, screw
the adjusting nut (2) and lock nut (1), insert
the pin shaft (7) and pins (6);
8 - Adjust the chains according to Section
8.2.2.1.
8
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8.2.4 Lift Cylinder

Code Description CAUTION
8.2.4.1 Cylinder Removal Before going on with the next step, please fix
A3 Right Shift Mast Tubing
Left Cylinder Removal (with mast down) the cylinder properly first. Be sure to avoid the
B1 Left Shift Mast Tubing falling of cylinder during removal, resulting in
- Remove the mast from the chassis according personal injury.
to Section 8.2.1;
- Unscrew the mounting bolt (8) from the bott-
- Lay down the mast with lifting tools (with
om of the cylinder;
outer mast underneath the inner mast), place
sleepers at both ends for supporting; - Unscrew the bolt (3), lift the cylinder (5) up
and remove it from the truck;
- Remove the tubing (1, Fig3131-60012SM)
to make it separate from the three-pass
component (2);
- Remove the regulator (4) from the three-pass Full Free Middle Cylinder
component (2); (with mast on the vehicle)
- Unscrew the bolt (6, Fig3530-60006SM) and - Lower the mast to the bottom, press the
remove the cylinder clamp (7); emergency stop switch and disconnect the
key switch;
CAUTION - Remove retaining shelf (see Section 8.1.5.1);
Before going on with the next step, please fix - Block the truck wheels with wooden wedges,
the cylinder properly first. Be sure to avoid the raise the fork carriage for 500mm with lifting
falling of cylinder during removal, resulting in tools, insert wooden block between it and the
personal injury. ground for supporting;
- Unscrew the mounting bolt (8) from the bott- CAUTION

om of the cylinder;
Hydraulic oil may damage truck parts and
- Unscrew the bolt (3), lift the cylinder (4) up
and remove it from the truck; contaminate the environment. When removing
joints or tubings, place a clean container under
- Remove the three-pass component (2, it for discharge of hydraulic oil.
Fig3131-60012SM) from the right cylinder.
8 - Loosen the joints (6, Fig3131-60012SM) to
separate the middle cylinder and tubing (5);
8
Right Cylinder Removal(with mast down) - Disconnect the connections between the
- Remove the mast from the chassis according tubings (2, Fig3131-60013SM) around the
to Section 8.2.1; middle cylinder and rigid pipe assembly (3);
- Lay down the mast with lifting tools (with - Remove the fork carriage chains according to
outer mast underneath the inner mast), place Section 8.2.2.2;
sleepers at both ends for supporting; - Unscrew bolt (18, Fig3530-60006SM) and
- Remove the tubing (1, Fig3131-60012SM) to remove the middle cylinder roller guard (16);
make it separate from the direct coupling (3); - Unscrew the nut (19), remove the middle
- Remove the tubing (5) to make it separate cylinder tube shaft (12) and middle cylinder
from the right cylinder; tube roller (11);
- Unscrew the bolt (6, Fig3530-60006SM) and - Unscrew the bolt (9) and remove the middle
remove the cylinder clamp (7); cylinder fixing plate (10) and sprocket seat
(13) from the cylinder (14);
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CAUTION CAUTION
Before going on with the next step, please fix - Use suitable hose clamps to avoid cylinder
the cylinder properly first. Be sure to avoid the deformation caused by severely tight hose
falling of cylinder during removal, resulting in clamp.
personal injury. - Carry out the maintenance work in a clean
- Unscrew the bolt (15), separate the cylinder environment to prevent impurities from
(14) from the inner mast (2); entering into cylinder, causing cylinder
damage.
- Remove the cylinder (14) from the truck.
the same specifications must be used for
cleaning or lubrication.
8.2.4.2 Cylinder Maintenance
- Secure the cylinder to hose clamp and gently
Left Lifting Side Cylinder clamp the cylinder bottom;
- Unscrew the cylinder cap (4, Fig3131-
60015SM) with cylinder wrench;
- Remove the dust ring (1), cover plate (2),
seal (3), cover plate (7) and O-rings (8) from
the cylinder cap;
- Remove the bearing (5) and guide bush (6)
from the cylinder tube (17);
- Pull out the piston rod (9) from the cylinder
tube (17) and remove the bushing (11);
- Remove the support ring (12) from the piston
and unscrew the fixing screw on the piston,
then separate the piston rod from the piston
(13);
rod, then remove the retaining ring (14),
8 spring (16) and buffer plunger (15) from the
piston;
8
- Clean with hydraulic oil of the same specifica-
tions;
reverse steps.
CAUTION
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Full Free Middle Cylinder - Secure the cylinder to hose clamp and gently
Right Lifting Side Cylinder clamp the cylinder bottom;
CAUTION - Unscrew the cylinder cap (4, Fig3131-
CAUTION 60017SM) with cylinder wrench;
- Use suitable hose clamps to avoid cylinder
- Use suitable hose clamps to avoid cylinder deformation caused by severely tight hose - Remove the dust ring (1), cover plate (2),
deformation caused by severely tight hose clamp. seal (3), O-ring (5), bearing (6) and O-ring (7)
clamp. - Carry out the maintenance work in a clean from the cylinder cap;
- Carry out the maintenance work in a clean environment to prevent impurities from - Pull out the piston rod (8) from the cylinder
environment to prevent impurities from entering into cylinder, causing cylinder tube (16);
entering into cylinder, causing cylinder damage. - Remove the support ring (10) and seal (9),
damage. - During the installation, hydraulic oil of retaining ring (12) and seal (13) from the
- During the installation, hydraulic oil of the same specifications must be used for piston;
the same specifications must be used for cleaning or lubrication. - Remove the shaft ring (15) and the cushion
cleaning or lubrication. assembly (14) from the piston rod;
- Clean with hydraulic oil of the same specifica-
- Secure the cylinder to hose clamp and gently tions;
clamp the cylinder bottom; - Replace the problem parts and assembly in
- Remove the connector (18,Fig3131-60016SM) reverse steps.
and O-ring (19) from the piston rod (9);
- Unscrew the cylinder cap (4) with cylinder CAUTION
wrench; If the piston rode or cylinder tube is damaged,
- Remove the dust ring (1), cover plate (2), please replace the entire cylinder.
seal (3), cover plate (7) and O-rings (8) from If the seals are aged or damaged, please
the cylinder cap; replace the complete set of seals.
- Remove the bearing (5) and guide bush (6)
from the cylinder tube (17); 8.2.4.3 Cylinder Installation
- Pull out the piston rod (9) from the cylinder - Install the cylinder according to the reverse
tube (17) and remove the bushing (11); order of removal according to 8.2.4.1;
- Remove the support ring (12) from the piston - Add hydraulic oil of the same specifications
8 and unscrew the fixing screw on the piston,

then separate the piston rod from the piston
(13);
into the tank, see Section 2.2.3;
8
the key switch;
- Repeat Lift - Lower cylinder to discharge the
rod, then remove the retaining ring (14),
spring (16) and buffer plunger (15) from the air within the tubings and cylinder;
piston; CAUTION - Check the hydraulic oil level and make sure
- Clean with hydraulic oil of the same specifica- If the piston rode or cylinder tube is damaged,
tions; please replace the entire cylinder.
- Replace the problem parts and assembly in If the seals are aged or damaged, please 8.2.5 Built-in Side Shifter
reverse steps. replace the complete set of seals. Reference Section 8.1.5.

Reference Section 8.1.6.
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MAST MAST
8.3 Three-stage Full Free Mast - Unscrew the bolts (3) and remove the fixed 8.3.2 Lifting Chains
plate (4) between the outer mast and chassis
8.3.1 Removal and Installation (C and D); 8.3.2.1 Chain Adjustment
- Remove the mast from the truck. - Lower the mast to the bottom;
Removal (Fig3132-60003SM)
Installation - Press the emergency stop switch and discon-
- Disconnect the connections between lifting - nect the key switch;
lowering tubing, left shifting tubing and right - Install according to the reverse order of rem-
shifting tubing and mast tubing; oval. CAUTION
- Wrap the sling (1) around the upper beam of
inner and outer masts, slightly lift the mast WARNING Switch off the power supply before any adjust-
with crane; ments or operations!
Make sure the lifting equipment is solid and
- Remove the shafts (2) between the outer secure, and the load capacity should be greater - Loosen the upper lock nut (1,Fig3131-60011SM)
mast and tilt cylinders (A and B); than the total weight of the vehicle. and the lower lock nut (3) on chain bolt;
- Through screwing upward the adjusting nut
(2) in the middle, the chain will slowly tension;
- When the chain is adjusted to be tensioned
with no obvious loosening, fasten the upper
and lower lock nuts;
CAUTION
the key switch;
8 8
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MAST MAST
8.3.2.2 Chain Replacement Fork Carriage Chains

Mast Chains - Block the truck wheels with wooden wedges,
raise the fork carriage for 500mm, insert
- Block the truck wheels with wooden wedges, wooden block between inner mast and the
raise the inner mast (2, Fig3131-60019SM) ground for supporting;
for 500mm, insert wooden block between
inner mast and the ground for supporting; CAUTION
CAUTION Please place supporting under the inner mast
Please place supporting under the inner mast injury.
injury. - Unscrew the lock nut (1, Fig3131-60011SM)
and adjusting nut (2) from the chain joint (4),
- Unscrew the lock nut (1, Fig3131-60011SM) then remove the chain joint (4) from middle
and adjusting nut (2) from the chain joint (4), cylinder;
then remove the chain joint (4) from outer - Remove the cotter pins (6), pull out the pin
mast; shaft (7), separate the chains (5) from the
- Remove the cotter pins (6), pull out the pin chain joint (4);
chain joint (4); shaft (9), separate the chains (5) from the
- Remove the cotter pins (8), pull out the pin chain joint (10) on fork carriage;
shaft (9), separate the chains (5) from the - Remove the chain assembly from the chain
chain joint (10) on inner mast; sprocket (17, Fig3131-60019SM);
- Remove the chain assembly from the chain - Replace with new chains and hang the new
sprocket; chain assembly onto the chain sprocket;
- Replace with new chains and hang the new - Put the chain connector (10) through chain
chain assembly onto the chain sprocket; hole of fork carriage, insert the pin shaft (9)
- Put the chain connector (10) through chain and pins (8);
hole of inner mast, insert the pin shaft (9) and - Put the chain connector (4) through the
pins (8); middle cylinder chain-hanging plate, screw
8 - Put the chain connector (4) through the outer

mast chain-hanging plate, screw the adjusting
nut (2) and lock nut (1), insert the pin shaft (7)
the adjusting nut (2) and lock nut (1), insert
the pin shaft (7) and pins (6); 8
and pins (6); 8.3.2.1.
8.3.2.1.
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8.3.3 Mast Tubing

Code Description
Code Description A3 Right Shift Mast Tubing

B1 Left Shift Mast Tubing
A1 Lifting / Lowering Mast Tubing
8 8
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MAST MAST
8.3.4 Lift Cylinder - Unscrew bolt (18, Fig3131-60019SM) and

CAUTION remove the middle cylinder roller guard (16);
8.3.4.1 Cylinder Removal Hydraulic oil may damage truck parts and - Unscrew the nut (19), remove the middle
Left Cylinder Removal (with mast down) contaminate the environment. When removing cylinder tube shaft (12) and middle cylinder
joints or tubings, place a clean container under tube roller (11);
- Remove the mast from the chassis according it for discharge of hydraulic oil. - Unscrew the bolt (9) and remove the middle
to Section 8.3.1;
- Unscrew the bolt (6, Fig3131-60019SM) and cylinder fixing plate (10) and sprocket seat
- Lay down the mast with lifting tools (with (13) from the cylinder (14);
remove the cylinder clamp (7);
outer mast underneath the inner mast), place
sleepers at both ends for supporting; CAUTION
CAUTION
- Disconnect the connections between the tub-
Before going on with the next step, please fix Before going on with the next step, please fix
ing (1, Fig3131-60020SM) and three-pass
the cylinder properly first. Be sure to avoid the the cylinder properly first. Be sure to avoid the
assembly (2);
falling of cylinder during removal, resulting in falling of cylinder during removal, resulting in
- Remove the tubing (4) from the three-pass personal injury.
personal injury.
component (2);
- Unscrew the bolt (15) and separate the
- Unscrew the mounting bolt (8) from the
CAUTION cylinder (14) from the inner mast (2);
bottom of the cylinder;
Hydraulic oil may damage truck parts and - Remove the cylinder (14) from the truck.
- Unscrew bolt (3) and remove the cylinder (5)
contaminate the environment. When removing from the mast.
joints or tubings, place a clean container under
it for discharge of hydraulic oil. 8.3.4.2 Cylinder Maintenance
- Unscrew the bolt (6, Fig3131-60019SM) and Full Free Middle Cylinder
Lifting Side Cylinder
remove the cylinder clamp (7); (with mast on the vehicle)
- Lower the mast to the bottom, press the CAUTION
CAUTION
emergency stop switch and disconnect the - Use suitable hose clamps to avoid cylinder
Before going on with the next step, please fix key switch; deformation caused by severely tight hose
the cylinder properly first. Be sure to avoid the - Remove retaining shelf (see Section 8.1.5.1); clamp.
falling of cylinder during removal, resulting in
- Block the truck wheels with wooden wedges, - Carry out the maintenance work in a clean
personal injury.
raise the fork carriage for 500mm with lifting environment to prevent impurities from
- Unscrew the mounting bolt (8) from the tools, insert wooden block between it and the entering into cylinder, causing cylinder
8 bottom of the cylinder;
- Unscrew bolt (3) and remove the cylinder (4)
ground for supporting; damage.
8
from the mast. CAUTION the same specifications must be used for
- Remove the three-pass component (2, Hydraulic oil may damage truck parts and cleaning or lubrication.
Fig3131-60020SM) from the left cylinder. contaminate the environment. When removing - Remove the O-ring (9), bushing (11), rataining
joints or tubings, place a clean container under - Secure the cylinder to hose clamp and gently ring (12) and seal (13) from the piston;
it for discharge of hydraulic oil. clamp the cylinder bottom;
- Remove the round wire (15) and the bushing
Right Cylinder Removal(with mast down) - Unscrew the cylinder cap (3,Fig3131- (14) from the piston;
- Loosen the joints (6, Fig3131-60020SM) to 60022SM) with cylinder wrench;
- Remove the mast from the chassis according separate the middle cylinder and rigid pipe - Clean with hydraulic oil of the same specific-
to Section 8.3.1; assembly (5); - Remove the dust ring (1), seal (2), O-ring (4) ations;
and bushing (5) from the cylinder cap;
- Lay down the mast with lifting tools (with - Disconnect the connections between the - Replace the problem parts and assembly in
outer mast underneath the inner mast), place tubings (2, Fig3131-60021SM) around the - Pull out the piston rod (6) from the cylinder reverse steps.
sleepers at both ends for supporting; middle cylinder and rigid pipe assembly (3); tube (16), then remove the shaft sleeve (8)
- Remove the fork carriage chains according to from the piston rod;
- Remove the tubing (1, Fig3131-60020SM) to
make it separate from the direct coupling (3); Section 8.3.2.2; - Remove the piston (10) from the piston rod;
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MAST
CAUTION
Full Free Middle Cylinder

Reference Section 8.2.4.2.
8.3.4.3 Cylinder Installation

- Install the cylinder according to the reverse
order of removal according to 8.3.4.1;
- Add hydraulic oil of the same specifications
into the tank, see Section 2.2.3;
the key switch;
- Repeat Lift - Lower cylinder to discharge the
air within the tubings and cylinder;
- Check the hydraulic oil level and make sure
8.3.5 Built-in Side Shifter

Reference Section 8.1.5.

8 Reference Section 8.1.6.
REV. 09/2020
98

Ice 301 B

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Service Manual

This manual applies to:

ICE301B 3,000 Capacity, Full Height Series, Four-wheel

FOREWORD TABLE OF CONTENTS

TABLE OF CONTENTS TABLE OF CONTENTS

SECTION PAGE SECTION PAGE

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NOTE: 1.1 After-sales Service Platform

1.3 Common Tools

No. Name Remark

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1.4 General Tightening Torques

REV. 09/2020 REV. 09/2020

NOTE: 2.1 Overview

2.2 Maintenance Regular inspection and maintenance under

REV. 09/2020 REV. 09/2020

2 Check the position of various bearings for noise

REV. 09/2020 REV. 09/2020

2 Check tire pressure

Bearing Steering Axle

Mast Pin Shafts

Adding Grease Gear Oil Checks Brake Fluid Checks

Changing Changing Gear Oil

REV. 09/2020 REV. 09/2020

Table 2.2 Lubricants

Code Type Specification Amount Position 3. TROUBLESHOOTING

2 B Multi-purpose grease Polylub GA352P Appropriate amount

Table 2.3 Application Amount of Table 2.3 Application Amount of

Full Free 2700 34 4800 42

NOTE: 3.1 Preparation Before Troubleshooting

1) Check if the voltage of single battery is

- Even if key switch is turned off, the controllers

Battery Voltage Judgment

3.2 Troubleshooting Solutions of Common Faults

1. Check the voltage of storage 5. Drive wheel slipping

REV. 09/2020 REV. 09/2020

Table 3.1 Troubleshooting of Common Faults

• Insufficient voltage of battery; 1. Check the voltage of battery;

REV. 09/2020 REV. 09/2020

Table 3.1 Troubleshooting of Common Faults (continued)

3 1. Check the amount of oil;

REV. 09/2020 REV. 09/2020

Table 3.1 Troubleshooting of Common Faults (continued)

REV. 09/2020 REV. 09/2020

Table 3.1 Troubleshooting of Common Faults (continued)

Controller failure error, carry out

• Not enough oil supported by

REV. 09/2020 REV. 09/2020

4.2 Drive Motor 4.2.3 Checking and Testing

REV. 09/2020 REV. 09/2020

4.3 Drive Axle Installation

No. Name No. Name No. Name No. Name

REV. 09/2020 REV. 09/2020

4.3.3 Gear Oil 4.4 Differential

No. Name No. Name

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4.5 Gearbox 4.6 Accelerator Pedal

4 - Install according to the reverse order of rem-

Pin Description Color Remark

REV. 09/2020 REV. 09/2020

4 pedal or its circuit;

Accelerator pedal at original position

CAUTION Please add grease (see