S327!6!2022 Operation & Maintenance Manual (English)

OPERATION &
SERVICE MANUAL
G2 series lithium battery powered
counterbalanced forklift truck
1.5-3.8t
FOREWORD
G2 series 1.5-3.8t lithium battery counterbalanced forklift truck is HELI newly
designed trucks to satisfy market needs based on advanced lithium battery manage
system and characteristics of high battery energy density. The truck has characters of
environment friendliness, maintenance free, long service life, high efficient, energy
saving, safety and it is suitable for low temperature. These trucks are all suited for
handling and stacking packed goods in stations, ports, goods yards and warehouses and
used widely in food processing, light and textile, mining industries and other factories,
with some of attachments fitted, the trucks can be applied more and more.
This product is not suitable for working in dusty, charged dust, high temperature,
high corrosion environment! For working in a small amount of dust (non-conductive)
environment, it is necessary to regularly clean and maintain all parts!
Due to the new PI concept and ergonomic design, this product has advanced
components such as low-noise and high-efficiency integral drive bridge, large angle
steering bridge, wide field lifting system, integral stamping type overhead guard with
ceiling, tailless structure body, etc., and is equipped with high-quality electric motor,
battery, MOSFET electric control and colorful large screen liquid crystal combination
instrument, hydraulic operation valve, full LED lamp and other advanced parts. Therefore,
it has the advantages of superior performance, convenient operation, wide field of vision,
flexible steering, reliable braking, good dynamic performance, low noise, no pollution
and beautiful appearance.
This manual states the trucks’ specifications, operation, maintenance, service, main
assemblies’ constructions and working principles so as to help operators to use the trucks
correctly and attain the highest functions. It is necessary to read over the manual before
they operate the trucks or service personnel operate these trucks.
The rules and notices in the manual should be abided seriously by all of relative
personnel to enable these trucks in optimized working state for long period and bring the
highest efficiency.
This manual content might not correspond with the actual condition because of the
improving of our products. Our products are subject to improvements and changes
without notice.
CONTENTS
Ι. Safety Rules for Operation and Daily Maintenance of Forklift Truck ............................ 1
1.Delivery of Forklift Truck ........................................................................................ 1
2.Storage of Forklift Truck.......................................................................................... 1
3.Precautions Before Operation .................................................................................. 1
4.Operation of Forklift Truck ...................................................................................... 2
5.Daily Maintenance of Forklift Trucks...................................................................... 3
6.Vehicle Identification Number position ................................................................... 5
7.Capacity chart .......................................................................................................... 6
Ⅱ. Main Specifications of Forklift Truck ............................................................................ 9
Ⅲ. Construction, Principle, Adjustment and Maintenance of Forklift Trucks ................. 17
1. Transmission System ............................................................................................ 17
2. Brake System ........................................................................................................ 21
3. Steering System..................................................................................................... 36
4. Electric System ..................................................................................................... 43
5 Hydraulic System ................................................................................................. 123
6. Lifting System ..................................................................................................... 135
Appendix: Electrical schematic diagram of the lithium battery ..................................... 155

Ι. Safety Rules for Operation and Daily Maintenance of Forklift
Truck
It is important that driver and manager for forklift trucks remember the principle
of the “first safety” and ensure the safety operation as the description in
《OPERATION AND SERVICE MANUAL》&《OPERATION MANUAL》.
1.Delivery of Forklift Truck
It must be pay attention to the following items when you deliver forklift trucks
with container or trucks.
(1) Apply the parking brake.
(2) Fix the mast and the balance weight with steel wire. Wedge up all wheels.
(3) Sling points should be always at the positions specified in sling index plate when
hoisting up the forklift truck.
(4) Charge the battery to make the electricity quantity to stay between 40% and 60%
and press the emergency button.
2.Storage of Forklift Truck
(1) Lower the mast to the lowest position.
(2) Turn off the key switch and apply the parking brake.
(3) Wedged up the wheels.
(4) Apply antirust to the surface of the parts not painted. Apply lubrication oil to the
lift chain.
(5) Charge the battery to make the electricity quantity to be more than 40% and press
the emergency button.
3.Precautions Before Operation
(1) Don’t check fuel leakage and lever or instruments at the place where there is open
flame. Never fill the fuel tank with the truck running.
(2) Check the tire inflation pressure(not apply for trucks with solid tyre).
(3)Check the devices of lighting, sound and alarm: check the lights, buzzer and horn
1
(button on the handle included).
(4) The forward-reverse lever should be in neutral.
(5) Check all the levers and pedals.
(6) Complete the provisions before starting.
(7) Release the parking lever.
(8) Make trying operation of the mast for lifting, lowing and Fwd/Bwd tilting and the
truck for steering and braking.
4.Operation of Forklift Truck
(1) Only trained and authorized operator shall be permitted to operate the truck.
(2) Wear all the safety guards, such as shoes, helmet, clothing and gloves while
operating the truck.
(3) Check all the control and warning devices before starting the truck. If any
damages or defects are found, operate it after repairing.
(4) At the rated loading center, either overload or overload operation is strictly
prohibited. The center of cargo should be in line with the frame center, not out of the
line. The fork should insert completely under the cargo and make the cargo placed on
it evenly. Do not raise an object with one fork end.
(5) The starting, turning, driving, braking and stopping operation of the truck should
be done smoothly. When steering on the humid or low friction road, the truck should
be decelerated.
(6) Travel with loads as low as possible and tilted backward.
(7) Be careful when traveling on a slope. When climbing grades with a slope of more
than 10%, the truck should forward travel, and when descending so grades, backward
travel. Never turning on a slope. Avoid loading and unloading operation when
descending.
(8) Pay attention to pedestrian, obstacle and bumpy road when driving. Pay attention
to the clearance over forklift truck.
2
(9) Never allow any persons to stand on the forks or the truck to carry persons.
(10) Never permit anyone to stand or walk under upraised forks.
(11) Don’t operate truck and attachment of it at any position out of the drive seat.
(12) On the high lift forklift truck, when the lift high more than 3m, it is noted that the
goods on it should not fall down or the protection measures must be taken if
necessary.
(13) Tilt the mast of the high lift forklift truck as backward as possible while the truck
working. Use minimum forward tilt angle and Min. reverse tilt when loading and
unloading.
(14) Be careful and slowly driving over a dockboard or bridge-plate.
(15) Shut down the truck and don’t stay on the truck when checking fuel level.
(16) The unloaded forklift truck with attachments should be operated as a loaded
truck.
(17) Don’t handle unfixed stacked goods. Be careful to bulky goods to be handled.
(18) If leaving the truck, lower the forks on the ground and let the shift lever to
neutral, shut down the engine or cut down electric supply. If parking on a slope is
unavoidable, apply the parking brake and block the wheels.
(19) Don’t adjust the control valve and relief valve at will to prevent the damage of
hydraulic system and its components because of excessive pressure passing them.
(20) Inflate a tyre according to its stated air pressure. Never over inflate a tyre.
(21) The Max. noise emission is less than 80dB (A) measured according to JB/T3300.
(22) Be familiar with and pay attention to the functions of the decals on the forklift
trucks.
5.Daily Maintenance of Forklift Trucks
(1) Inspection before startup
a) Hydraulic oil volume: oil level should stay in the middle of oil meter scale;
b) Check piping, joints, pumps and valves for leaks or damages;
3
c) Check service brake:
The free travel of brake pedal should be within the range of 20-30mm;
The clearance between the front floor and the pedal should be bigger than 20mm;
d) Check parking brake. The unladen truck can park on the grade ramp with
required gradeability (unloaded), when the parking lever is pulled to the bottom;
e) Check instruments, lighting, switches and wiring to see if they work normally
or not.
(2) Oil used for forklift trucks

Oil adding
Brand, code and applying temperature
volume（L）
HELI special Antifreeze hydraulic oil
Sticky grade
Hydraulic hydraulic oil 40# YYY-LPL-HS32 2-2.5t：44
oil Applying 3-3.5t：50
Normal ambient Cold storage
temperature
Brake fluid 4604 compound brake fluid GB12891 HZY4 /
Lubricating 3# lithium base grease（-20℃~+120℃）
/
grease or 2# L-XDCBB2low temperature grease（-40℃~+120℃）
Gear oil of Sticky grade 85W/90 CLY-LP75W-90
heavy-laden 2-2.5t：6
truck Applying
Normal ambient Cold storage 3-3.5t：7
GL-5 temperature
Note: The fueling volume is the amount for the truck with the standard mast.
4
(3) The table of lubrication system
6.Vehicle Identification Number position
The unique Vehicle Identification Number (the same number as the product
number) is marked on the body of the forklift truck when leaving the factory, and it is
permanently marked on the frame with steel marks, which can trace the production,
sales, maintenance and other information of the truck. The Vehicle Identification
Number is located in the upper part of the right side panel of the truck body, and its
position is shown in the figure below.
Vehicle Identification Number position
5
7.Capacity chart
It is forbidden to overload the forklift truck, otherwise overload may lead to
structural damage, truck tipping over and other serious accidents. If the truck is
equipped with attachments, such as side shifters and scraper pan, the actual carrying
capacity is lower than the corresponding rated load. The actual bearing capacity and
rated capacity are shown as follows.
（1）The actual capacity of forklift truck(The following figure is an example)
（2）The rated capacity chart of forklift trucks
1.5t (2-stage mast) 1.5t (3-stage mast)
6
Light type 2t (2-stage mast) Light type 2t (3-stage mast)
2t (2-stage mast) 2t (3-stage mast)
3t (2-stage mast) 3t (3-stage mast)
7
8
Ⅱ. Main Specifications of Forklift Truck
External view of forklift trucks
9
Main Specifications
Characteristics
1.01 Manufacturer
1.02 Model CPD15 CPD18 CPD15 CPD18 CPD15 CPD18 CPD20
GB2Li-M GB2Li-M
GB2Li-H GB2Li-H GB3Li-S GB3Li-S GE3Li-S
1.03 Configuration No. GB3Li-M GB3Li-M
GB6Li-H GB6Li-H GB6Li-S GB6Li-S GE6Li-S
GY7Li-M GY7Li-M
1.04 Rated capacity Q kg 1500 1800 1500 1800 1500 1800 2000
1.05 Load center distance c mm 500
1.06 Power tyre Lithium battery
1.07 Driving type Sit-on type
1.08 Wheel base y mm 1410
Tyre
2.01 Tyre type Pneumatic tyre Pneumatic tyre Pneumatic tyre Solid tyre Pneumatic tyre Pneumatic tyre Pneumatic tyre
2.02 Wheel No. (front/rear） 2/2
2.03 Front track b10 mm 930
2.04 Rear track b11 mm 920
2.05 Tyre，front 6.5-10-12PR
2.06 Tyre，rear 16×6-8-10PR
Dimensions
3.01 Front overhang x mm 409 409 409 409 409 409 414
3.02 Mast tilt, Fwd/Bwd α/β ° 6/10
3.03 Height, mast lowered h1 mm 1995 1995 1995 1995 1995 1995 1995
3.04 Height, Free lifting h2 mm 155 155 155 155 155 155 155
3.05 Max. lifting height h3 mm 3000
3.06 Max. height h4 mm 4014
3.07 Overhead guard height h6 mm 2140
Fork dimensions s×e
3.08 mm 35×100×920 35×100×920 35×100×920 35×100×920 35×100×920 35×100×920 40×100×920
thickness×width×length ×l
3.09 Fork carrier，DIN 2A
3.10 Truck length（without fork） l2 mm 2140 2140 2140 2140 2140 2140 2145
3.11 Truck width b1 mm 1120
3.12 Turning radius Wa mm 1860
3.13 Mast underground clearance m1 mm 110
3.14 Underground clearance at wheelbase center (loaded) m2 mm 120
Right-angle stacking aisle width (pallet 1000×
3.15 Ast mm 3469 3469 3469 3469 3469 3469 3469
1000mm, clearance 200mm)
10
Right-angle stacking aisle width(pallet 1200×
3.16 Ast mm 3669 3669 3669 3669 3669 3669 3669
3.17 Fork adjusting range( external) (Max. Min.) b5 mm 960/200
Performance
4.01 Driving speed，laden/unladen km/h 19/20 17/18 14/15
4.02 Lifting speed，laden/unladen mm/s 540/600 500/600 480/600 440/600 370/490 340/500 310/500
4.03 Lowering speed，laden/unladen mm/s 470/500
4.04 Max. gradeability，laden/unladen % 26/20 22/20 22/20 20/20 17/20 15/20 15/20
4.05 Max. drawbar（laden） N 14000 12800 11000
4.06 Acceleration time（10m）laden/unladen s 5.0/4.5 5.0/4.5 5.0/4.5 5.0/4.5 5.5/5.0 5.5/5.0 5.5/5.0
Weight
5.01 weight（with/without battery） kg 2950/2720 3180/2950 2950/2720 3180/2950 2950/2720 3180/2950 3280/3050
5.02 Axle load：unladen，front/rear kg 1340/1610 1330/1850 1340/1610 1330/1850 1340/1610 1330/1850 1360/1920
5.03 Axle load：laden，front/rear kg 3810/640 4290/690 3810/640 4290/690 3810/640 4290/690 4650/630
Battery
6.01 Battery voltage/capacity（discharge capacity in 5h） V/Ah 80/202 80/202 80/202 80/202 80/150 80/150 80/150
6.02 Battery weight kg 230 230 230 230 230 230 230
Motor and controller
7.01 Drive motor power （S2-60min） kW 10 9.5 8
7.02 Lift motor power（S3-15%） kW 18.1 16.5 10.6
7.03 Control way of drive motor MOS /AC
7.04 Control way of lift motor MOS /AC
Others
8.01 Service brake/parking brake Hydraulic/Mechanical
8.02 Working pressure of hydraulic system Mpa 21.5
ZAPI/INMOTION/HELI
8.03 Controller mode ZAPI /HELI technology INMOTION/HELI technology
technology
11
Characteristics
1.01 Manufacturer
1.02 Model CPD20 CPD25 CPD20 CPD25 CPD20 CPD25
GB2Li-M GB2Li-M
GB2Li-H GB2Li-H GB3Li-S GB3Li-S
1.03 Configuration No. GB3Li-M GB3Li-M
GB6Li-H GB6Li-H GB6Li-S GB6Li-S
GY7Li-M GY7Li-M
1.04 Rated capacity Q kg 2000 2500 2000 2500 2000 2500
1.08 Wheel base y mm 1650
Tyre
2.01 Tyre type Pneumatic tyre Pneumatic tyre Pneumatic tyre Pneumatic tyre Pneumatic tyre Pneumatic tyre
2.05 tyre，front 7.00-12-14PR
2.06 tyre，rear 18×7-8-14PR
Dimensions
3.01 Front overhang x mm 460 460 460 460 460 460
3.03 Height, mast lowered h1 mm 2000 2000 2000 2000 2000 2000
3.04 Free lift h2 mm 150 150 150 150 150 150
3.08 Fork dimensions thickness×width×length s×e×l mm 40×122×920 40×122×1070 40×122×920 40×122×1070 40×122×920 40×122×1070
3.10 Truck length（without fork） l2 mm 2432 2432 2432 2432 2432 2432
3.12 Turning radius Wa mm 2070
12
3.14 Underground clearance at wheelbase center (loaded) m2 mm 130
Right-angle stacking aisle width (pallet 1000×
3.15 Ast mm 3730 3730 3730 3730 3730 3730
Right-angle stacking aisle width(pallet 1200×
3.16 Ast mm 3930 3930 3930 3930 3930 3930
Performance
4.01 Driving speed，laden/unladen km/h 19/20 18/19 14/15
4.02 Lifting speed，laden/unladen mm/s 490/600 470/600 460/560 440/560 380/490 350/490
4.04 Max. gradeability，laden/unladen % 25/28 24/28 22/28 20/28 18/25 16/25
4.05 Max. drawbar（laden） N 22500 19000 16500
4.06 Acceleration time（10m）laden/unladen s 5.5/4.8 5.8/5.1 5.8/5.1 6.0/5.3 5.0/5.3 6.4/5.6
Weight
5.01 weight（with/without battery） kg 3570/3350 3960/3740 3570/3350 3960/3740 3570/3350 3960/3740
5.02 Axle load：unladen，front/rear kg 1800/1770 1800/2160 1800/1770 1800/2160 1800/1770 1800/2160
5.03 Axle load：laden，front/rear kg 4960/610 5750/710 4960/610 5750/710 4960/610 5750/710
Battery
6.01 Battery voltage/capacity（discharge capacity in 5h） V/Ah 80/271 80/271 80/271 80/271 80/202 80/202
6.02 Battery weight kg 220 220 220 220 220 220
7.01 Drive motor power （S2-60min） kW 17 16.6 15
7.02 Lift motor power（S3-15%） kW 26 25.5 21
Others
8.01 Service brake/parking brake hydraulic/mechanical
8.02 Working pressure of hydraulic system Mpa 21
ZAPI / ZAPI/INMOTION/HELI INMOTION/HELI
8.03 Controller mode
HELI technology technology technology
13
Characteristics
1.01 Manufacturer
1.02 Model CPD30 CPD35 CPD30 CPD35 CPD30 CPD35 CPD38 CPD38
GB2Li-M GB2Li-M GB2Li-M
GB3Li-S GB3Li-S GB3Li-S
1.03 Configuration No. GB2Li-H GB2Li-H GB3Li-M GB3Li-M GB3Li-M
GB6Li-S GB6Li-S GB6Li-S
GY7Li-M GY7Li-M GY7Li-M
1.04 Rated capacity Q kg 3000 3500 3000 3500 3000 3500 3800 3800
1.08 Wheel base y mm 1750 1780
Tyre
Pneumatic tyre Pneumatic tyre Pneumatic tyre
2.01 Tyre type solid tyre solid tyre solid tyre solid tyre solid tyre
/solid tyre /solid tyre /solid tyre
28× 28× 28×
2.05 tyre，front 28×9-15 28×9-15 28×9-15 28×12.5-15-24PR
9-15-14PR 9-15-14PR 9-15-14PR
2.06 tyre，rear 200/50-10
Dimensions
3.01 Front overhang x mm 479 482 479 482 479 482 482 482
3.03 Height, mast lowered h1 mm 2070 2120 2070 2120 2070 2120 2180
3.04 Free lift h2 mm 155 160 155 160 155 160 160
Fork dimensions s×e× 45×125× 50×125× 45×125× 50×125× 45×125×
3.08 mm 50×125×1070
thickness×width×length l 1070 1070 1070 1070 1070
Truck length
3.10 l2 mm 2569 2574 2569 2574 2569 2574 2622
（without fork）
3.12 Turning radius Wa mm 2215 2250
14
Underground clearance at wheelbase center
3.14 m2 mm 140
(loaded)
Right-angle stacking aisle width (pallet 1000
3.15 Ast mm 3894 3899 3894 3899 3894 3899 3934
×1000mm, clearance 200mm)
Right-angle stacking aisle width(pallet 1200
3.16 Ast mm 4094 4099 4094 4099 4094 4099 4134
×1200mm, clearance 200mm)
Performance
4.01 Driving speed，laden/unladen km/h 19/20 18/19 14/15 17/18 16/17
4.02 Lifting speed，laden/unladen mm/s 480/600 440/540 400/520 380/520 370/470 340/430 390/510 340/450
4.04 Max. gradeability，laden/unladen % 22/28 20/28 20/28 18/28 16/25 14/25 17/25 15/25
4.05 Max. drawbar（laden） N 23580 19500 17500 21500 19500
4.06 Acceleration time（10m）laden/unladen s 5.5/4.8 5.8/5.1 5.8/5.1 6.0/5.3 6.0/5.3 5.4/5.6 5.7/5 6.2/5.5
Weight
5.01 weight（with/without battery） kg 4480/4130 4900/4550 4480/4130 4900/4550 4480/4120 4900/4540 5300/4950
5.02 Axle load：unladen，front/rear kg 1968/2512 2012/2888 1968/2512 2012/2888 1968/2512 2012/2888 2228/3072
5.03 Axle load：full laden，front/rear kg 6644/836 7480/920 6644/836 7480/920 6644/836 7480/920 8128/972
Battery
Battery voltage/capacity（discharge capacity
6.01 V/Ah 80/404 80/404 80/404 80/404 80/272 80/272 80/346 80/272
in 5h）
6.02 Battery weight kg 350 350 350 350 350 350 350 350
7.01 Drive motor power （S2-60min） kW 17 16.6 15 17 16.6
7.02 Lift motor power（S3-15%） kW 26 25.5 21 26 25.5
Others
8.01 Service brake/parking brake Hydraulic/Mechanical
8.02 Working pressure of hydraulic system Mpa 21 22.5
ZAPI/
ZAPI/
ZAPI / INMOTION/ INMOTIO INMOTION/
8.03 Controller mode INMOTION/
HELI technology HELI technology N/ HELI HELI technology
HELI technology
technology
15
Main dismountable parts size and weight
Model
Unit CPD20 CPD25 CPD30 CPD35 CPD38
Item
Max. overall dimensions mm 1125×350×800 1125×350×800 1230×350×800 1230×350×800 1230×350×800

Drive axle
weight kg 260 260 310 310 310

Counter balance
Weight kg 1110 1470 1815 2155 2400

Overhead guard
Weight kg 100 100 100 100 100

Mast（M300，without
fork and tilting cylinder）
Weight kg 665 665 725 745 767
16
Ⅲ. Construction, Principle, Adjustment and Maintenance of Forklift
Trucks
1. Transmission System
1.1 General description
The transmission system of lithium battery forklift truck consists of drive axle (Fig.
1-2) and reducer (Fig. 1-3). The drive axle is used to support and load the mast and frame.
The function of the reducer is to increase the input torque and reduce the speed of the
motor, so as to meet the requirements of different working conditions of the truck. The
driving gear of the reducer is directly connected with the traction motor, which transmits
power to all levels of gears in the reducer, and finally to the axle shaft through the half
shaft gear of the differential, and then to the wheel hub. The driving axle tire is connected
with the wheel hub to realize the power transmission. The walking speed of forklift truck
increases with the increase of motor speed, and the change of driving direction is realized
by changing the rotation direction of motor. In the reducer, in addition to all levels of
reduction gear, there is an important component - differential.
1.2 Differential assembly
The differential assembly is located at the end of the transmission system, which
enables the left and right wheels to travel at different speeds when the truck is turning or
curve driving. The differential assembly is installed on the gearbox housing through two
end bearings. The 1.5-3.8t differential is split type with left and right (as shown in Fig.
1-1), which has two half shaft gears and four planetary gears.
17
Figure 1-1 differential assembly (1.5-3.8t)
1.3 Gearbox & axle assembly
The gearbox & axle assembly mainly consists of the housing, half shaft, wheel hubs,
brake and the wheels. It is installed in the front of the frame.
The housing of the truck is of wholly casted structure. The tyre is fixed to the hub
with bolts and nuts through rim. The hub is supported on axle case through tapered roller
bearing. The power is transmitted to the half-shafts through the differential and drives the
front wheels through the hubs. The half-shafts bear only the torque transmitted to the
hubs. In the inside of the hub are oil seals to prevent water and dust from entering or oil
leakage. (See Figure 1-2)
The tyre, rim and the pressure of the front wheel are followed. (See Table 1-1)
Table 1-1
Truck tons 1.5t 1.8t 2t(E) 2t 2.5t 3t 3.5t 3.8t
Tyre 6.5-10-12PR 7.00-12-14PR 28×9-15-14PR 28×9-15 28×12.5-15-24PR
Rim 5.00F-10 5.00Sx12DT 7.0T-15 9.75-15
Tyre pressure 1000kPa 1000kPa 970kPa Solid tyre Pneumatic tire
18
Figure 1-2 Drive axle assembly (1.5-3.8t)
Figure 1-3 Reducer and differential (1.5-3.8t)
1.4 Assembly of wheel hub
(1) Fill the chamber of wheel hub
with lubricating grease about 100cc, and
then fit the hub on the housing.
(2) Screw down the hub nut to a
torque of 1kg.m, then loosen it for 1/8
turn. Figure 1-4 Fill lubricating grease
19
(3) Measure the torque value that the
wheel hub starts rotating. When the torque
value measured reaches to regulated value,
screw down the hub nut.
Initial torque: 5-15kg.m

Figure 1-5 Measure the torque value
(4) Screw down the locking nut and pull up the locking pin.
(5) Assembly of tyre
Fix the drain tap and the cover on the tyre, and screw down wheel-rim bolts.
NOTE: a) make the exhaust valve rod points outside at the gap of the rim.
b) Make sure the hub nut head point outside.
Figure 1-6 Assembly of tyre
20
2. Brake System
2.1 General description
The brake system is the front two-wheel braking type consisting of brake pedal,
master cylinder and service brakes.
2.1.1 Brake pedal
The brake pedal is mainly made up of brake pedal, master brake cylinder, wheel
cylinder and brake. See figure 2-1.1 for principle of service brake and figure 2-1.2 for
brake pedal structure.
The force acts on the pedal is changed to brake fluid pressure through the push rod
of the master brake cylinder.
Figure 2-1.1 Service braking principle diagram Figure 2-1.2 Brake pedal
2.1.2 Master cylinder
The cylinder contains valve seat, return spring, primary cup, piston and secondary
cup, which are all kept in place with a stop washer and a stop wire. The exterior of the
cylinder is protected from the dust by means of a rubber dust cover. The piston is actuated
21
through the push rod by operation of brake pedal. As the brake pedal is pressed, the push
rod pushes the piston forward. The brake fluid in the cylinder flows back to the reserve
tank through the return port until the primary cup blocks up the return port. After the
primary cup passes through the return port, the brake fluid in the cylinder is pressurized
and opens the check valve, flowing through the brake pipeline to the sub cylinder. Thus,
each sub cylinder piston is forced outwards. This brings the friction pieces on the brake
shoes into contact with the brake drum and slows or stops the truck. Meanwhile, the
cavity caused behind the piston is filled with brake fluid led through the return port and
inlet port. When the brake pedal is released, the piston is forced back by the return spring.
At the same time, the brake fluid in each sub cylinder is pressured by the return spring,
returning into the mast cylinder through the check valve. With the piston in its original
position, the fluid in the master cylinder flows into the reserve tank through the return
port. The brake fluid in the brake pipelines and sub cylinders has a residual pressure
proportioned to the set pressure of the check valve, which makes each sub cylinder piston
cup securely seated to prevent oil leakage and eliminates a possibility of air locking when
the truck is sharply braked.
Figure 2-2 Master cylinder

(1) Connecting rod (2) Push rod (3) Dust cover (4) Snap ring
(5) Secondary cup (6) Piston (7) Primary cup (8) Spring (9) Check valve
2.1.3 Service brake
22
The service brake is of double brake shoe type which is fitted to the each end of the
gearbox & axle assembly.
The service brake is made up of two brake shoe, sub cylinder and adjuster.
The brake shoe, one end of it being connected to the anchor pin and the other to the
adjuster, is stressed on backing plate by the spring and spring pull rod.
In addition, a parking brake and a clearance self-adjusting mechanism are fitted on
the service brake. (See Figure 2-8, 2-9, 2-10)
(1) Braking operation
The primary and secondary shoes are respectively forced by a force equal in value
by master cylinder until the upper end of the secondary shoe is against the anchor pin and
the brake shoe moves towards the rotation direction of the brake drum.
The friction force between the friction piece and brake drum increases when the
anchor pin is laid against. A large braking force is produced because the secondary brake
shoe bears a larger force from the primary shoe than from the sub cylinder. (See Figure
2-3)
The operation of the brake is opposite from forward travelling when travelling
backward. (See Figure 2-4)
Figure 2-3 Braking operation in forward travel Figure 2-4 Braking operation in backward travel
(2) Parking brake
23
The parking brake is built in the service brake which is made up of push rod and pull
rod.
The pull rod is mounted to the primary shoe side by pin. The move of the pull rod is
transmitted to the secondary shoe side through push rod. (See Figure 2-5)
Figure 2-5 Parking brake

(3) Clearance self-adjusting mechanism
A proper clearance between the friction piece and the brake drum is maintained by
the clearance self-adjusting mechanism. (See Figure 2-6)
Figure 2-6 Clearance self-adjuster

The clearance self-adjusting mechanism actuates only when the truck in reverse
travel.
24
▲Operation of the clearance self-adjuster
When brake during travelling backward, the secondary brake shoe contact with main
brake shoe and rotate together. Then the pulling rod turn right with point A as pivot and
thus B point is raised up. See figure 2-6. When brake is released, the pulling rod turn left
under the spring action and thus B point lowers. When the clearance between friction disc
and brake drum increases, b rotating vertical dimension increases. The clearance
decreases with the elongating of adjusting rod when the adjuster is stirred one gear. See
figure 2-7. See the follow table for clearance adjusting range:
1.5-2.0t(E) 2-2.5t 3-3.8t
Clearance 0.35～0.55 0.5～0.55 0.25-0.4
Figure 2-7 Clearance self-adjuster
25
Figure 2-8 Brake assembly
(1) Braking cable ass’y (2) Washer 8 (3) Bolt M8×20 (4) Ratchet pawl
(5) Pin roll (6) Torsional spring (7) Parking push rod (8) Spring
(9) Rear brake shoe with friction plate (10) Spring pull rod
(11) Return spring for brake shoe (12) Guide pad (13) Guide plate
(14) Brake cylinder ass’y (15) Front brake shoe with friction plate
(16) Bassplate ass’y (17) Washer 10 (18) Spring washer (19) Pin roll for pull rod
(20) Snap ring (21) Parking pull rod (22) Spring pull rod (23) Spring seat
(24) Spring (25) Plug (26) Pullback spring (27) Clearance self-adjuster
2.1.4 Operating device of the parking brake
The parking brake lever is of a ratchet type. Different brake force can be achieved on
26
slope and ground.
Brake force adjustment: When you turns the adjuster clockwise, the force increases,
otherwise, when you turns the adjuster counter clockwise, the force decreases. (See
Figure 2-9)
Pull force: 20 to 30kg.
Figure 2-9 parking brake shank

2.2 Assembling and disassembling, adjustment of brake
This paragraph covers the disassembly, reassembly and adjustment of the brake in
the state of the wheels and hubs are disassembled. It also covers the adjustment method
of the brake pedal. (The description here is mainly for 2.5ton truck brake, the other truck
brake is similar to it in general.)
27
2.2.1 Service brake disassembly
(1) Remove the support pin,
adjusting lever, adjusting device and
spring of secondary shoe. (See Figure
2-10)
Figure 2-10
(2) Remove two shoes return
springs. (See Figure 2-11)
Figure 2-11
(3) Remove the hold-down springs.
(See Figure 2-12)
Figure 2-12
(4) Remove the primary and
secondary shoes. At the same time,
remove adjuster and adjusting spring.
(See Figure 2-13)

Figure 2-13
28
(5) Remove the brake line from the
brake cylinder. Remove brake cylinder
mounting bolts and detach the brake
cylinder from the backing plate. (See
Figure 2-14)
Figure 2-14
(6) Remove the E-retainer for
securing the parking brake cable to the
backing plate. Remove the backing plate
mounting bolts and detach the backing
plate from the axle. (See Figure 2-15)
Figure 2-15
(7) Remove the boot and push the
piston assembly out of the operating
cylinder. (See Figure 2-16)
Figure 2-16
2.2.2 Inspection of brake
Inspect all parts to make sure if there’s any worn or damaged part. If unsatisfactory,
repair or replace with new one.
29
(1) Check the operating cylinder
inner surface and the piston periphery
surface for rusting. Then, measure the
clearance between the piston and cylinder.
(See Figure 2-17)

Figure 2-17
Standard: 0.03-0.10mm
Maximum clearance: 0.15mm
(2) Visually check the piston cup for damage or deformation. If unsatisfactory,
replace with new one.
(3) Check the free length of the operating cylinder spring. If unsatisfactory, replace
it.
(4) Check the friction piece for
thickness to see if it is excessive worn. If
necessary, replace it. (See Figure 2-18)

Unit：mm
1.0-2.0t(E) 2.0-2.5t 3.0-3.8t
Standard 4.8 7.2 7.8
Figure 2-18
Limiting 2.5 3 3.3
(5) Check the condition of the brake
drum inner surface. If any damage or
excessive wear is found, repair by
machining or replace it. (See Figure 2-19)

Unit：mm
1.0-2 t (E) 2.0-2.5t 3.0-3.8t
Standard Φ254 Φ310 Φ314 Figure 2-19
Limiting Φ256 Φ312 Φ316
30
2.2.3 Service brake reassembly
(1) Apply brake fluid to the piston and the piston cup, and reinstall the spring, cup,
the piston and the dust cover in this order.
(2) Install the operating cylinder on the backing plate.
(3) Install the backing plate on the front axle.
(4) Apply heat-resisting grease on the points indicated in Figure 2-20, with care not
to contaminate the friction piece with grease.
Figure 2-20
(5) Install the brake cable assembly on the backing plate with an E-retainer.
(6) Install shoes on the backing plate with hold-down springs.
(7) Put the spring on the parking
push rod then install the rod on the shoe.
(See Figure 2-21)
Figure 2-21
(8) Install the shoe guide plate on the
anchor pin, and install the shoe return
spring. Install the main shoe first and then
secondary shoe. (See Figure 2-22)
Figure 2-22
31
(9) Install the adjuster, adjuster spring, push rod and its return spring.
Pay attention to the following points:
a) Adjuster thread direction and its mounting direction.
b) Adjuster spring direction. (Do not allow the adjuster gear teeth to contact with the
spring)
c) Return spring direction of the push
rod: Spring hook at anchor pin side should
be located at the opposite side to push rod.
d) Make sure that the adjusting lever
end is in contact with the adjuster gear
teeth. (See Figure 2-23)

Figure 2-23
(10) Install the brake line on the operating cylinder.
(11) Measure the inner diameter of
drum and the outer diameter of brake shoe.
Adjust the adjuster to obtain the 1mm
difference needed between the drum inner
diameter and the friction piece outer
diameter. (See Figure 2-24) Figure 2-24
2.2.4 Operation test to clearance-self-adjuster
(1) Make the brake shoe diameter approach the specified mounting size, and pull the
adjusting level with your finger along the arrow marks to turn the adjuster gear. When
removing off your finger, the adjusting lever should return to its original position without
rotation of the adjuster gear.
32
Note: Even if the adjuster gear turn back along the adjusting lever motion
when removing your finger, the adjuster will still operate normally after it is built in
the machine.
(2) If the adjuster fail to do the above operation when the adjusting lever is pulled,
proceed with the following inspection:
a) Make sure that the adjusting lever, push rod and the return spring for push rod are
securely installed.
b) Check the push rod return spring and adjuster spring for deterioration, and also
check the adjuster gear for rotating condition and undue wear or damage of the meshing
section. Change if necessary.
Figure 2-25
2.2.5 Brake pedal adjustment
(1) Make the push rod short.
(2) Adjust the stopper bolt and the height of the pedal. (See Figure 2-26)
(3) Press the brake pedal. Pull the push rod out until its front end comes into contact
with the master cylinder piston.
33
(4) Tighten the push rod locking nut.
brake oil tank
brake switch
brake pedal support
lock nut
pedal height
Figure 2-26
▲ Brake switch adjustment
a) After you adjust the height of the brake pedal, loose the lock nut of the brake
switch.
b) Pull the plug out to let the lead separate.
c) Turn the switch to make the clearance about 1mm.
d) Make sure that when you press the brake pedal the brake lamp light at the same
time. ( See Figure 2-27)
Figure 2-27
2.2.6 Service brake troubleshooting (See Table 5)
34
Table 5
Problem Possible cause Remedy
1) Fluid leaks from brake system. Repair
2)Poor adjustment of brake shoe clearance. Adjust the adjuster
3)Brake overheating. Check for dragging
Poor 4)Poor contact between the brake drum and Readjust
braking friction piece.
5)Foreign matter adhered on friction piece. Repair or replace
6)Foreign matter mixed in brake fluid. Check brake fluid
7)Poor adjustment of brake pedal. Adjust
1)Hardened friction piece surface or foreign Repair or replace
matter adhered thereto.
Noisy 2)Deformed backing plate or loose bolts. Repair or replace
brake 3)Deformed shoe or incorrect installation. Repair or replace
4)Worn friction piece. Replace
5)Loose wheel bearing. Repair
1)Oil-contaminated friction piece. Repair or replace
2)Poor adjustment of brake shoe piece. Adjust the adjuster
Uneven
3)Malfunctioning sub cylinder. Repair or replace
braking
4)Shoe return spring deteriorated. Replace
5)Deflected drum. Repair or replace
1)Brake fluid leaks from braking system. Repair
Soft or
2)Poor adjustment of brake shoe clearance. Adjust the adjuster
spongy
3)Air mixed in brake system. Bleed air
brake
4)Poor adjustment of brake pedal. Readjust
35
3. Steering System
3.1 General Description
The function of steering system of forklift is to change the driving direction of the
forklift or keep the forklift in straight line driving. The performance of steering system
directly concerns with the driving safety, operation efficiency of forklifts and labor
intensity of drivers. The steering system is divided into two categories of mechanical
steering system (manual steering system) and power steering according to the power
source of steering. The mechanical steering system is operated to overcome steering
resistance moment fully by relying on the force and skill of driver, while in power
steering system, the energy consumed to overcome the steering resistance moment is
provided by prime mover and the driver can operate the system to control the turning
direction with very small force.
As requested by the working characteristic of the forklifts, the operation site and
driving pass are relatively narrow, changing-over is frequent and the minimum radius
turnings are often needed, therefore, the steering system is required to be reliable and
light in operation. Since the load of steering axle occupies about 60% of the vehicle
weight in case of idling, this series produced by our Co. adopt fully hydraulic power
system to alleviate the labor intensity of the driver.
3.2 Working Principle
When the forklifts turn round, the steering moment applied by driver on the steering
wheel (steering control mechanism) makes steering wheel rotate and shift and is
transmitted to the steering gear through steering shaft. Steering gear sends the pressure oil
of appropriate volume to the steering oil cylinder through pipes and the oil cylinder
pushes steering wheel through trapezoidal steering mechanism, thus direction change is
realized.
36
The difference between fully hydraulic and hydraulic power steering gears is the
first substitutes the mechanical elements such as steering gear and longitudinal tie etc and
has high pressure oil pipe connecting fully hydraulic steering gear with oil cylinder. The
pressure-gradient control valve mounted in the loop of load- sensing and fully hydraulic
steering system can ensure distribution of flow to steering system first and sufficient oil
supply at any working conditions. There is less flow passing through steering gear when
it is at neutral position to save the energy.
3.3 Composition of Steering System
(1) Control mechanism of steering
Figure 3-1 Steering control device

3.4 Steering Axle
The steering axle of trucks (See Figure 3-2) includes axle body, steering cylinder, tie
rods and knuckle. The steering trapezium is made of cranks and blocks. When pressure
oil moves the cylinder piston rod, the tie rod revolves the knuckles, then the truck may be
steered. The steering axle is fixed with bolts through support on the lower end face of
counterbalance weight after bumper block is mounted on the front and end plate so that
the axle can sway around the pin roll on the end plate and obtains certain shock-absorbing
37
effect due to bumper block. Left and right knuckles are positioned at two sides of the
steering axle respectively. The rear wheel hubs are fitted to the knuckle shafts through
tapered roll bearings with oil seals keeping the grease in the chambers of the hubs and the
knuckles.
The steering rim and the pressure of the steering wheel are followed:
Table 3-1
Truck model 1.5t, 1.8t, 2t(E) 2t, 2.5t 3t, 3.5t, 3.8t
Tyre size 16×6-8-10PR 18×7-14PR 200/50-10
Rim size 4.33R-8 4.33R-8 6.50F-10
Tyre pressure 860kPa 970kPa Solid tyre
Figure 3-2 steering axle

1. Axle body 2. Link rod 3. Steering cylinder 4. Steering knuckle
5. Axle sleeve 6. Tapered roller bearing 7. Main pin of steering knuckle
8. Potentiometer 9. Tapper roller bearing 10. Tapper roller bearing
11. lock nut 12. Washer 13. Lock pin 14. Hub cover
15. Steering hub 16. Oil seal 17. Oil seal 18. Link pin
1) Steering cylinder
The steering cylinder is of double-action piston type. Both ends of the piston rod are
connected with steering knuckles through connection rod. Left or right of the truck
turning is achieved with the help of the left or right travel of the piston rod driven by the
pressure oil from the powered steering unit. The seal unit is consist of the supporting ring
and “O” ring seal, U-ring seal is adopted between the cylinder head and the piston rod.
38
The cylinder is fitted to the steering axle through two cylinder seats. (See Figure 3-3)
Figure 3-3 Steering cylinder

1. Piston rod 2. U ring 3. Dust proof ring 4. Cylinder cover
5. Cylinder bore 6. Combined seal ring 7. O ring 8. O ring 9. Blade
2) Hub
The hub is fixed to the steering knuckle shaft with two tapered roller bearing. The
wheels are assembled on the hubs through rims. Oil seal is assembled on the inner side of
the bearing to keep the lubrication oil in the hub and steering knuckle cavity. The nut is
used to adjust the tightness of the nut.
Figure 3-4 hub

3.5 Adjustment and Maintenance
3.5.1 Rear wheel bearig pre-load adjustment
39
(1) As shown in Figure 3-5, fill up the chamber formed by wheel hubs, wheel hub
bearings and wheel hub covers with lubricating grease. Coat the lips of the oil seals with
lubricating grease.
(2) Press the hub bearing into the hub and fit the hub on the knuckle shaft.
(3) Fit a flat washer and tighten a castle nut to a torque of 206-235Nm (21-24kgm)
and loosen it, and then tighten it again to a torque of 9.8Nm (1kgm).
(4) To ensure firm installation of the hub, slightly knock at it with a wooden hammer
and in the meantime, rotate the hub for 3-4turns.
(5) Tighten the castle nut and align one of its notches with a cotter pin hole drilled in
the steering knuckle.
(6) Again slightly knock at the hub with a wooden hammer and in this time, rotate
manually the hub for 3-4turns to ensure its smooth rotation with a specified torque of
2.94-7.8Nm (0.3-0.8kgm).
(7) If the torque value necessary to rotate the hub is more than the specified one
above-mentioned, screw out the castle nut for 1/6 turn and measure the torque value then.
(8) When the torque value measured is up to the specified one, lock the castle nut
with a cotter pin.
Figure 3-5 Fill lubricating grease and pre-load adjustment
40
When changing the tires, the hub bolts should be coated with sealant after a new tire
is mounted to ensure the tightening torque of the hub bolts is 160N.m for 1.5～3.8t
forklifts.
3.5.2 Maintenance and service of steering system
(1) The steering king pin needs to be checked every 40 hours and grease be
replenished to the bent neck type grease fittings of king pin every 300 hours, piston rod
and link rod of steering oil cylinder, rotation connection parts of right and left knuckle
arm need to be checked every 40 hours and lubrication grease replenished every 300
hours.
(2) Change the grease of the bearing of steering hub every 1200 hours.
(3) Pay attention to the working condition of steering system during routine
maintenance. The manual operation force on the steering wheel should be 10-25N during
steering and the difference of right and left acting force is not more than 10N. When the
forklift runs in straight line at maximum speed, obvious S-shaped phenomenon is not
allowed. Make analysis and remedies by contrasting Table 3-2 “Fault Analysis Table for
Steering System”.
(4) Apply special lubricating grease to the conductive plate which the steering wheel
horn switch connecting point acts on every 1200h.
3.6 Main Failure and Troubleshooting of the Steering System
3.6.1 Inspect after reassembling the steering system
(1) Turning the steering wheel right and left, inspect whether the steering is smooth.
(2) Check if the hydraulic pipeline is correctly connected and the right and left
steering are installed correctly.
(3) Lift up the rear wheels and slowly turn the steering hand-wheel right and left
several times to exhaust air from the hydraulic pipeline and the steering cylinder.
41
3.6.2 Steering system troubleshooting
Table 3-2
Problem Analyses of trouble Remedies
Pump damaged or breaking down. Replace
Fail to turn Splite flow valve blocked or damaged Clean or replace
hand-wheel Hose or joint damaged or pipeline
Clean or replace
blocked.
The pressure of the relief valve is too low. Adjust the pressure
Air in steering oil circuit. Exhaust air
Difficult to turn Steering unit fail to recover due to spring
Replace spring piece
hand-wheel piece damaged or elasticity-insufficient.
Inspect the seal of the
Oil leakage in the steering cylinder.
piston
Truck’s snacking Spring damaged or elasticity-insufficient. Replace
or moving with Adjust Splite flow valve
Large steering flow
oscillation flow
Too low oil level in the oil tank. Refill oil
Excessive noise
Suction pipeline or oil filter blocked. Clean or replace
Seals of guide sleeve, pipeline or joint
Oil leakage Replace
damaged.
42
4. Electric System
The electrical system of G2 series 1.5-3.8t counterbalanced lithium battery forklift
truck is available in various brands. At present, there are ZAPI, INMOTION and Heli
technology, which can realize the quiet, efficient, smooth, smooth and safe control of the
whole truck.
The electric system is composed of instrument, control system, traction motor, pump
motor, battery pack, control switch, lighting and wiring harness etc..
Notice: Our Company has the right to improve on the production. Please
contact with our company if there is any difference between the product and the
manual.
The circuit diagram of electric system are shown in the following.
43
0
Fuse Box
F1-10A Emergency stop SW. Key SW.
90 3 4 0
C 12V+
保险丝紧急停车开关钥匙开关
F2-10A
DC-DC
1 2
80V+ Converter
预充电阻转换器
Pre-chare resistance
- 200W -
50W 200Ω
450A 100A
Main Contactor Fuse Box 集成电气盒
Fuse
主接触器保险丝
Key 钥匙信号 Key 钥匙信号

1A3 2A1 2A23
M.C. Coil 主接触器线圈
NLC 1A26 40
起升调速传感器 Servicebrake SW. 行车制动开关
Lifting 1A13 2A17
1A22 Lifting CPOT
sensor 1A6
Forward SW. 前进开关 Seat OPS 蜂鸣器
1A15 NENC_P
B+ 1A7
Backward SW. 后退开关
2A16
+12V Enable SW. 使能开关

1A4 PENC_P 1A34
锂电池组 Acc. pot. 12V Lowering Lock valve
CPOT 1A5 2A20
Lithium Battery
1 BN PNP NO Lift Cutback
放电继电器 U 加速电位器 proximity SW.
Discharge relay
放电接触器
上缓冲
Contactor
Coil V 3 BU 2 BK 接近开关
线圈
NENC_T 1A21 2A5
W
CPOT STEER 1A14
JL-3 SAMRT DISPLAY 80V 仪表

BMS Steer pot. 1 BN PNP NO
电池管理系统 +12V 1A4 PENC_P PENC_T 1A10 +12V 转角电位器 Performance Cutback
Speed Encoder
COMBIACE2 NEWGEN PREMIUM

12V 80V proximity SW.
速度编码器
+ + Phase A A相
DC-DC 1A17 CHA_P PIN 1A24 40 2A9
3 BU 2 BK
Pump Motor
TRACTION&PUMP
Converter Phase B B相
_ _ 1A19 CHB_P PEB 1A27
Negative 负极
泵电机
B- B-
1A15 NENC_P NEB 1A28 K4
DC-DC 2A19 K1
Temp.Sensor
转换器 Overspeed alarm relay 超速报警继电器 12V

Reverse relay
温度传感器
CAN_L CAN_H
倒车继电器
1A33 PTH_P Option
NAUX 1A29 K2 选配项 Channel B 2A10 Steering
12V
Encoder
倾斜开关 Tilt SW. Brake relay 刹车继电器 Channel C 2A14
1A1 方向盘启动转向编码器
侧移开关 Sideshift SW.
Model S 2A12
1A11 SPD 2
Model E
属具开关 Attachment sw. Model P 2A13
1A12 SPD 3 PENC_T 1A10 +12V Mode SW.
Temp.Sensor Speed Encoder

模式开关
Phase A A相 B+
速度编码器
Traction Motor
手制动开关 Handbrake SW. 1A2 CHA_T 1A9 2A2
CHB_T 1A20 Phase B B相
座椅开关 Seat SW. NENC_T 1A21 Negative负极 B-
牵引电机
1A8 2A3
B-
2A4
温度传感器
B-
2A18
PTH_T 1A32
CAN_H
2A22
B- 2A15 CAN_T
CAN L 1A30 2A7 CAN_L
CAN H 1A31
CAN T 1A18
100B/100C/100D
Figure 4-1 The principle diagram of electric system（CPD15/18-GB2Li-H/M）
44
集成电器盒 FUSE BOX
紧急停车开关
Emergency stop SW.

DC-DC
Converter
转换器集成电器盒 Fuse Box
Key 钥匙信号
Brake relay
刹车继电器
Lithium Battery Overspeed alarm relay

放电接触器
Contactor
电池管理 DC-DC
Converter
系统
DC-DC Acc. pot.
转换器 Performance Cutback
Steer pot. proximity SW.
Figure 4-2 The principle diagram of electric system（CPD15/18-GB3Li-M, CPD15/18/20-GB(E)3Li-S）
45
紧急停车开关钥匙开关
集成电器盒 Fuse Box
主接触器
Main Contactor
前进开关电子式
组合开关
Fuse 保险丝（高有效Highly effective）后退开关 Electronic
Combination SW.
（高有效Highly effective）
S模式模式开关
E模式
P模式
FJ-M2 Instrument
座椅开关 Seat SW.
Remote version
速度编码器
手制动开关 Handbrake SW.
远程版仪表
行车制动开关 Servicebrake SW.
使能开关 Enable SW.
温度传感器
sensor
加速器
Temp.
锂电池组
放电继电器
放电接触器
上位机转角电位器
OPS蜂鸣器
电池管理（外部设备内置
系统可选短接) 匹配电阻
倒车继电器
集成电器盒
Fuse Box
超速报警继电器
内置
匹配电阻
程
序
烧
录
接
口内置
匹配电阻
Key 钥匙信号
倾斜开关 Tilt SW.

属具开关 Attachment sw.
起升调速传感器
Lifting sensor
速度编码器

刹车继电器
下降电磁阀
温度传感器
sensor
Temp.
Lift Cutback
proximity SW.
上缓冲
接近开关
P21
PNP
方向盘启动转向编码器
（）
Performance Cutback
proximity SW.
PNP
控制器上拉，一周40 （高有效Highly effective）

个脉冲，方波。
漏极开路
Figure 4-3 The principle diagram of electric system（CPD15/18-GB6Li-H、CPD15/18/20-GB(E)6Li-S）
46
集成电器盒 Fuse Box
主接触器
Main Contactor
前进开关电子式
组合开关
Fuse 保险丝（高有效Highly effective）后退开关 Electronic
Combination SW.
S模式模式开关
E模式
P模式
FJ-M2 Instrument
Remote version
速度编码器
远程版仪表
行车制动开关 Servicebrake SW.
使能开关 Enable SW.

温度传感器
sensor
加速器
Temp.
锂电池组
放电继电器
放电接触器
上位机转角电位器
OPS蜂鸣器
电池管理（外部设备内置
系统可选短接) 匹配电阻
倒车继电器
集成电器盒
Fuse Box
内置
匹配电阻
程
序
烧
录
接
口内置
匹配电阻
Key 钥匙信号

Lifting sensor
速度编码器

刹车继电器
下降电磁阀
温度传感器
sensor
Temp.
Lift Cutback
proximity SW.
上缓冲
接近开关
P21
PNP
方向盘启动转向编码器
（）
Performance Cutback
proximity SW.
PNP
控制器上拉，一周40 （高有效Highly effective）

个脉冲，方波。
漏极开路
Figure 4-4 The principle diagram of electric system（CPD20/25/30/35-GB6Li-H, CPD35/38-GB6Li-S）
47
紧急停车开关
Emergency stop SW.

DC-DC
Converter
Key 钥匙信号
Brake relay
刹车继电器

放电接触器
Contactor
Steer pot.
电池管理 DC-DC
Converter Acc.
系统 pot.
DC-DC
proximity SW.
Figure 4-5 The principle diagram of electric system（CPD20/25/30-GB3Li-M/S, CPD35-GB3Li-M）
48
紧急停车开关
Emergency stop SW.

DC-DC
Converter
Key 钥匙信号
Brake relay
刹车继电器

放电接触器
Contactor
电池管理 DC-DC
Converter
系统
DC-DC Acc. pot.
Steer pot. proximity SW.
Figure 4-6 The principle diagram of electric system（CPD35/38-GB3Li-S，CPD38-GB3Li-M）
49
+ +
DC-DC
Converter
NETWORKING DEVICE
VCC 选项 optional function 转换器
GND - -
WORK SIGNAL CANH CANL
Main contactor
B
主接触器M.C.
Forward SW. 前进开关

B
OPSH 12VDC
OPSH
Enable SW. 使能开关
Reverse relay
倒车继电器
12VDC
加速器 OUT 2
Lithium Battery 下降锁止电磁阀
Anti-lower
electromagnetic valve
ACE3 80V/550A Traction controller
放电继电器
ACE3 80V/450A Pump controller

Contactor
放电接触器
Discharge relay Steer POT 1 BN PNP NO

Lift Cutback
转角电位器 2 BK 3 BU proximity SW.上缓冲接近开关
Coil 线圈
Lifting sensor
1 BN PNP NO
Performance Cutback
起升调速电位器 2 BK 3 BU
proximity SW.
B+
C
JL-3 SAMRT DISPLAY 80V

电池管理 12V
+
80V
DC-DC +
系统 Converter
变速方向盘触发转向
_ DC-DC _
B- 转换器 B-
B-
CANL CANH
Phase A A相
1A20 1A21 Phase B B相
Negative负极
Mode SW.
Overspeed alarm relay

B B
100B/100C/100D
Figure 4-7 The principle diagram of electric system（CPD30/35-GB2Li-H）
50
+ +
DC-DC
Converter
转换器
- -
Main contactor
B
主接触器M.C.
Forward SW. 前进开关

B
OPSH 12VDC
OPSH
Enable SW. 使能开关
Reverse relay
倒车继电器
12VDC
加速器 OUT 2
Lithium Battery 下降锁止电磁阀
Anti-lower
electromagnetic valve
放电继电器

Contactor
放电接触器
Discharge relay Steer POT 1 BN PNP NO

Lift Cutback
转角电位器 2 BK proximity SW.上缓冲接近开关
Coil 线圈 3 BU
Lifting sensor
1 BN PNP NO
Performance Cutback
起升调速电位器 2 BK 3 BU
proximity SW.
B+
C

电池管理 12V
+
80V
DC-DC +
系统 Converter
变速方向盘触发转向
_ DC-DC _
B- 转换器 B-
B-
CANL CANH
Phase A A相
Negative负极
Mode SW.
Overspeed alarm relay

B B
100B/100C/100D
Figure 4-8 The principle diagram of electric system（CPD38-GB2Li-M）
51
0
Fuse Box
90 3 4 0
C 12V+
F2-10A
DC-DC
1 2
80V+ Converter
- 200W -
50W 200Ω
450A 100A
Fuse

1A3 2A1 2A23
NLC 1A26 40
Servicebrake SW. 行车制动开关
Lifting 1A13 2A17
1A22 Lifting CPOT Forward SW. 前进开关
sensor 1A6 Seat OPS 蜂鸣器
1A15 NENC_P
B+ 1A7
2A16

1A4 PENC_P 1A34
锂电池组 Lowering Lock valve
Acc. pot. 12V
CPOT 1A5 2A20
Lithium Battery
Di sc h ar g e r el a y
上缓冲
放电接触器
Co nt a ct o r
Co i l V 3 BU 2 BK 接近开关
线圈
NENC_T 1A21 2A5
TRACTION&PUMP 80V/400+400A
W
CPOT STEER 1A14

PENC_T 1A10 +12V 转角电位器 Performance Cutback

电池管理系统 C +12V 1A4 PENC_P
Speed Encoder

速度编码器
+ + Phase A A相
3 BU 2 BK
Pump Motor
_ _ 1A19 CHB_P PEB 1A27
B- B- Negative 负极
泵电机

DC-DC 2A19 K1
Temp.Sensor

Reverse relay
温度传感器
CAN_L CAN_H
倒车继电器
1A33 PTH_P Option
NAUX 1A29 12V K2 选配项 Channel B 2A10 Steering
Encoder
Model S 2A12
1A11 SPD 2
Model E
Speed Encoder
模式开关
Phase A A相 B+
速度编码器
Traction Motor
手制动开关 Handbrake SW. CHA_T 1A9 2A2
1A2 Phase B B相
CHB_T 1A20
NENC_T 1A21 Negative负极 B-
牵引电机
1A8 2A3
B-
Temp.Sensor
2A4
温度传感器
B-
2A18
PTH_T 1A32
CAN_H
2A22
B- 2A15 CAN_T
CAN_L
CAN L 1A30 2A7
CAN H 1A31
CAN T 1A18
100B/100C/100D
Figure 4-9 The principle diagram of electric system（CPD20/25-GB2Li-H, CPD20/25/30/35-GB2Li- M）
52
0
Fuse Box
90 3 4 0
C 12V+
F2-10A
DC-DC
1 2
80V+ Converter
- 200W -
50W 200Ω
450A 100A
Fuse

1A3 2A1 2A23
NLC 1A26 40
Servicebrake SW. 行车制动开关
Lifting 1A13 2A17
1A22 Lifting CPOT Forward SW. 前进开关
sensor 1A6 Seat OPS 蜂鸣器
1A15 NENC_P
B+ 1A7
2A16

1A4 PENC_P 1A34
锂电池组 Lowering Lock valve
Acc. pot. 12V
CPOT 1A5 2A20
Lithium Battery
Di sc h ar g e r el a y
上缓冲
放电接触器
Co nt a ct o r
Co i l V 3 BU 2 BK 接近开关
线圈
NENC_T 1A21 2A5
W
CPOT STEER 1A14

PENC_T 1A10 +12V 转角电位器 Performance Cutback

电池管理系统 C +12V 1A4 PENC_P
Speed Encoder

速度编码器
+ + Phase A A相
3 BU 2 BK
Pump Motor
_ _ 1A19 CHB_P PEB 1A27
B- B- Negative 负极
泵电机

DC-DC 2A19 K1
Temp.Sensor

Reverse relay
温度传感器
CAN_L CAN_H
倒车继电器
1A33 PTH_P Option
NAUX 1A29 12V K2 选配项 Channel B 2A10 Steering
Encoder
Model S 2A12
1A11 SPD 2
Model E
Speed Encoder
模式开关
Phase A A相 B+
速度编码器
Traction Motor
手制动开关 Handbrake SW. CHA_T 1A9 2A2
1A2 Phase B B相
CHB_T 1A20
NENC_T 1A21 Negative负极 B-
牵引电机
1A8 2A3
B-
Temp.Sensor
2A4
温度传感器
B-
2A18
PTH_T 1A32
CAN_H
2A22
B- 2A15 CAN_T
CAN_L
CAN L 1A30 2A7
CAN H 1A31
CAN T 1A18
100B/100C/100D
Figure 4-10 The principle diagram of electric system（CPD20/25/30-GB6Li- S）
53
Figure 4-11 The principle diagram of electric system（CPD15/18-GY7Li-M）
54
Figure 4-12 The principle diagram of electric system（CPD20/25/30/35/38-GY7Li-M）
55
F4-10A 紧急停车开关 Key SW.
3 RU 4 RW 0 Y
C 12V+
Emergency stop SW. 钥匙开关
Fuse Box F3-10A DC-DC
2 RY
80V+ Converter
转换器
50W 200 1N5408
- 200W -
预充电阻
100A
Pre-chare resistance Fuse Box 集成电气盒
450A 2A23
Main Contactor Fuse

主接触器保险丝 80V+
24V+ C
DC-DC
Converter
Key 钥匙信号转换器
KEY 1A3
NLC 1A26 - 80VDC-24VDC -
+5V come from 10A F5
Joystick +B P.B. 1A13
Servicebrake SW. 行车制动开关 3A1 100A
锂电池组 1A22 Forward SW. 前进开关 10A F6

FORWORD 1A6 KEY 3A28
Lithium Battery LIFTING/LOWERING
BACKWORD 1A7
Backward SW. 后退开关 -BATT 3A22
起升调速传感器 VCM
KEY 2A1
放电继电器 24V STANDARD FC9098 起升阀 2Y1 18.8Ω
Lifting ENABLE 1A34 Enable SW. 使能开关
2 1
放电接触器
Contactor
Discharge relay
1A35 TILT UP/DOWN Acc. pot. NEVP1 3A24 2A17 40
Coil sensor 加速器 PENC_T Seat OPS 蜂鸣器
线圈
CPOT 1A5 LIFTING（24V PROP. VALVE）
仪表 JL-3 DISPLAY 80V

下降阀 2Y2 18.8Ω 12VDC
2 1 2A16
倾斜传感器 NEVP2 3A25 OPSH
BMS LOWER（24V PROP. VALVE） 12VDC
电池管理系统 12V
C
80V Tiltting BUZZER 2A19 K1
+ + sensor PEVP1 3A13
DC-DC 属具出阀 Reverse relay

转角电位器 Steer pot. 2Y3 28.4Ω
A2
Converter
_ _ CPOT STEER 1A14 2 1 倒车继电器
B- B-
NEVP3 3A2
NENC_T 2A23 4
AUX. OUT（24V PROP. VALVE）
DC-DC
转换器 PIN 1A24 属具进阀 2Y4 28.4Ω
CANL CANH
+12V come from NEVP4 2 1
PEB 1A27 DCDC
3A3
1 BN PNP NO
Lift Cutback
12VDC
AUX. IN（24V PROP. VALVE） proximity SW.
NEB 1A28 K4 PEVP2 3A14 上缓冲
OverSpeed Relay 后倾斜阀 2Y5 28.4Ω 2 BK 3 BU 接近开关
12VDC 2 1 Lift Cutback 2A5
NAUX 1A29 K2 NEVP5 3A26
Pedal Brake
TILT UP（24V PROP. VALVE）
Relay 前倾斜阀 1 BN PNP NO
28.4Ω
SEAT 1A8 2 1 Performance Cutback
NEVP6 3A27
手制动开关 Handbrake SW. Performance 2 BK proximity SW.
H.B. 1A2 TILT DOWN（24V PROP. VALVE）
3 BU
Cutback
牵引电机 PEVP3 3A15
Traction
U 左侧移阀 2Y7 28.4Ω STEERING
Motor 2 1
V NEVP7 3A4 ENCODER
SIDE SHIFT L（24V PROP. VALVE）
W 右侧移阀 2Y8 28.4Ω 方向盘启动转向编码器
PENC_P PENC_T 2 1
NEVP8 3A5 MODEL S 2A12
+12V 1A4 PENC_P PENC_T 1A10 +12V SIDE SHIFT R（24V PROP. VALVE）
Speed encoder Temp.sensor
MODEL E
Temp.sensor Speed encoder
速度编码器
速度编码器
Phase A A相 Phase A A相 PEVP4 3A16

1A17 CHA_P CHA_T 1A9 MODEL P 2A13
+5V come from
Traction Motor
Phase B B相 Phase B B相 Mode SW.

CHB_T 1A20 Joystick
牵引电机
Pump Motor
1A19 CHB_P 模式开关

泵电机
SIDE SHIFT B+ 2A2

Negative负极 NENC_T 1A21 Negative负极 3A23
1A15 NENC_P RIGHT/LEFT 左/右侧移传感器 B-
2A3
温度传感器
温度传感器
B-
2A4
PTH_T 1A32 AUX IN/OUT 3A35 B-
1A33 PTH_P 2A18
CAN H 2A22
NENC_P -B NENC_T
-BATT 3A29
属具进/出传感器
CAN L 1A30 CAN T 2A15

CAN L1 3A11 CAN L 2A7
CAN H 1A31
CAN H1 3A12
CAN T 1A18
100B/100C/100D
Figure 4-13 Principle Diagram of thumb switch （CPD15/18-GB2Li-H）(Optional item)
56
F4-10A
3 RU Emergency stop SW. 4 RW Key SW. 0 Y
C 12V+
DC-DC
Fuse Box F3-10A
2 RY Converter
80V+
车联网终端转换器
50W 200 1N5408 80VDC-12VDC
NETWORKING DEVICE - -
预充电阻 100A
Pre-chare resistance WORK SIGNAL
450A GND
VCC
MC Fuse
Main Contactor 保险丝 CANH CANL 80V+
optional function 24V+ C
主接触器 DC-DC
Converter
Key 钥匙信号转换器
KEY 1A3
NLC 1A26 - 80VDC-24VDC -
+5V come from 10A F5
Joystick +B P.B. 1A13
Servicebrake SW. 行车制动开关 3A1 100A
锂电池组 1A22 Forward SW. 前进开关 10A F6

FORWORD 1A6 KEY 3A28
Lithium Battery LIFTING/LOWERING Backward SW. 后退开关
BACKWORD 1A7
-BATT 3A22
VCM
起升调速传感器起升阀 2Y1 18.8Ω KEY 2A1
放电继电器 Enable SW. 使能开关 24V STANDARD FC9098
Lifting ENABLE 1A34 2 1
放电接触器
Contactor
Discharge relay
1A35 TILT UP/DOWN Acc. pot. NEVP1 3A24 2A17 40
仪表
Coil
sensor 加速器 PENC_T LIFTING（24V PROP. VALVE） Seat OPS 蜂鸣器
线圈 CPOT 1A5 12VDC
下降阀 2Y2 18.8Ω 2A16
倾斜传感器
COMBIACE2 NEWGEN PREMIUM NEVP2 3A25
2 1 OPSH
BMS
JL-3 DISPLAY 80V A2

C Tilting
TRACTION&PUMP LOWER（24V PROP. VALVE） 12VDC
电池管理系统 12V 80V BUZZER 2A19 K1
+ + sensor 80V/400+400A PEVP1 3A13
DC-DC
Converter A1 CPOT STEER 转角电位器 Steer pot. 属具出阀
2Y3 28.4Ω
1 Reverse relay
_ _ 1A14 2
B- B-
NEVP3 3A2 倒车继电器
NENC_T AUX. OUT（24V PROP. VALVE）
DC-DC 控制器
+12V come from 属具进阀 2Y4 28.4Ω
转换器 PIN 1A24 DCDC
CANL CANH
NEVP4 2 1
PEB 1A27 3A3
12VDC
AUX. IN（24V PROP. VALVE） proximity SW.
NEB 1A28 K4 PEVP2 3A14 上缓冲
OverSpeed Relay 后倾斜阀 2Y5 28.4Ω 2 BK 3 BU 接近开关
12VDC 2 1 Lift Cutback 2A5
NAUX 1A29 K2 NEVP5 3A26
Pedal Brake
TILT UP（24V PROP. VALVE）
Relay 1 BN PNP NO
前倾斜阀 28.4Ω Performance Cutback
SEAT 1A8 2 1
NEVP6 3A27 proximity SW.
H.B. 1A2 Performance 2 BK 3 BU
TILT DOWN（24V PROP. VALVE） Cutback
PEVP3 3A15
U 左侧移阀
2Y7 28.4Ω STEERING
2 1 ENCODER
V NEVP7 3A4
W 右侧移阀 2Y8 28.4Ω 方向盘启动转向编码器
PENC_P PENC_T 2 1
NEVP8 3A5 MODEL S 2A12
+12V 1A4 PENC_P PENC_T 1A10 +12V SIDE SHIFT R（24V PROP. VALVE）
Speed encoder Temp.sensor
MODEL E
Temp.sensor Speed encoder
Phase A A相
速度编码器
速度编码器
Phase A A相 CHA_T 1A9 PEVP4 3A16 MODEL P 2A13

1A17 CHA_P +5V come from
Traction Motor
Phase B B相 Mode SW.

牵引电机
Phase B B相 CHB_T 1A20 Joystick

Pump Motor
1A19 CHB_P Negative负极模式开关

SIDE SHIFT B+ 2A2
泵电机
Negative负极 NENC_T 1A21 3A23

1A15 NENC_P RIGHT/LEFT B-
2A3
温度传感器
温度传感器
B-
左/右侧移传感器 2A4
PTH_T 1A32 AUX IN/OUT 3A35 B-
1A33 PTH_P 2A18
CAN H 2A22
NENC_P -B NENC_T
-BATT 3A29
CAN L 1A30 CAN T 2A15

CAN L1 3A11 CAN L 2A7
CAN H 1A31
CAN H1 3A12
CAN T 1A18
100B/100C/100D
57
紧急停车开关
Emergency stop SW.

+ +
DC-DC
NETWORKING DEVICE Converter
VCC 选项 optional function
转换器
GND - 200W -
WORK SIGNAL CANH CANL
预充电阻
Main contactor Pre-chare resistance
+ +
Fuse
保险丝 Fuse DC-DC
保险丝 Converter
- -
转换器
4KEY
B
10A F5
Forward SW. 前进开关 4A1
B
KEY 4A28 OPSH 12VDC
Enable SW. 使能开关 VCM 4A22 -BATT
OPSH
使能开关 24V STANDARD FC9098 起升阀 18.8Ω
2Y1
2 1
NEVP1 4A24
+5V come from Joystick LIFTING（24V PROP. VALVE）
倒车继电器
锂电池组下降阀 2Y2 18.8Ω 12VDC

加速器 2 1
NEVP2 4A25
Lithium Battery LOWER（24V PROP. VALVE）
放电继电器起升传感器 PEVP1 4A13


属具出阀 2Y3
Contactor
28.4Ω
放电接触器
Discharge relay Steer POT

转角电位器 2 1 1 BN PNP NO
Coil NEVP3 4A2

线圈
AUX. OUT（24V PROP. VALVE）
倾斜传感器 2 BK 3 BU 起升上缓冲
属具进阀 2Y4 28.4Ω
NEVP4 2 1
B+ Servicebrake SW. 行车制动开关
4A3
AUX. IN（24V PROP. VALVE）
BMS C 4A14
12V 80V PEVP2
电池管理系统后倾斜阀 2Y5
+ + 28.4Ω
DC-DC 2 1
NEVP5 4A26
Converter
_ _ TILT UP（24V PROP. VALVE）方向盘启动转向编码器
B- B- 前倾斜阀 28.4Ω
DC-DC
B- NEVP6 4A27 2 1
转换器 Pedal Brake Coil
TILT DOWN（24V PROP. VALVE）
CANL CANH PEVP3 4A15
左侧移阀
2Y7 28.4Ω
Phase A A相
2 1
4A4
NEVP7
Negative负极
右侧移阀2Y8 28.4Ω Mode SW.
4A5 2 1
NEVP8
SIDE SHIFT R（24V PROP. VALVE）
PEVP4 4A16
+5V come from Joystick
SIDE SHIFT
4A23
RIGHT/LEFT 左/右侧移传感器
AUX IN/OUT 4A35
-BATT 4A29
CAN L1 4A11
CAN H1 4A12
B B
100B/100C/100D
58
Figure 4-16 Diagram of thumb switch harness （CPD15/18-GB2Li-H）(Optional item)
59
60
61
4.2 Instrument
4.2.1 JL-3 instrument (with ZAPI controller)
JL-3 instrument is connected to intelligent instrument panel of truck system through
CAN bus. The intelligent instrument panel provides fault diagnosis and setting of the
whole truck control system: intelligent display itself, traction controller, lifting controller
and valve controller.
JL-3 instrument can read and modify the parameters of all modules of CAN bus
network and display on 4.3 color screen. The display forms an interactive interface with
the operator through the main page and many submenus, and the menu structure of the
intelligent display can be accessed through the six operation buttons on the diaphragm
keyboard.
4.2.1.2 Technical specifications
1. Rated working voltage input range: 20V ~ 100V
2. Rated working current: < 150mA
3. Power output (open drain output): 1.5A continuous current
4. Protection grade: IP65
5. Working temperature range: - 20 + 70 ℃
6. Storage temperature range: - 30 + 85 ℃
7. Relative humidity: < 95%
8. Communication mode: can (125k / 250K)
4.2.1.3 23 core connector of instrument

A1 KEY Positive pole of power supply
A2 CMM Positive pole of digital input equipment’s power supply
A3 -BATT Negative pole of power supply
A4 -BATT Negative pole of power supply
A5 DI0 Digital input，voltage ranging from -BATT/+BATT
A7 CAN_L CAN low voltage signal
A8 AI Analog input，0 ~12.0V
A10 DI3 Pulse signal input，0 ~5.0V
62
A14 DI7 Open drain input
CAN terminal，after connecting with CAN_H(A22)，
A15 CAN_T
120ohm CAN terminal impedance can be introduced.
Power open collector output, driven by -BATT, Max.
A16 OUT0
current 1.5A
Power positive pole input, the input must be connected to
A17 +BATT IN
+BATT
A18 -BATT Negative pole for intelligent display power supply
A19 OUT1
current 1.5A
A20 OUT2
current 1.5A
A21 Null
A22 CAN-H CAN high level signal
A23 Null
4.2.1.4 Stucture
External view
Structure of instrument panel
4.2.1.5 Diagram of instrument functions
63
4.2.1.6 Description of instrument functions
Handheld controller: the instrument detects other ZAPI controllers through CAN bus
and displays its version number. Key 1 and 2 and then key 6 to enter the designated
controller to modify its parameters and display its operation data.
64
Brightness setting: set LCD backlight current and select appropriate photosensitive
effect.
Start up interface: the screen content displayed in the initialization stage of
instrument power on is divided into standard interface and neutral packaging interface
meter setting interface.
Password changing: Set the 6-digit password to enter the parameter setting interface.
Fault inquiry: query the fault occurred on CAN bus in history, record the fault node
number and fault value, and keep the latest 10 groups of contents.
Language switching: Chinese and English display switching.
Data reset:
It is divided into mileage clearing, timing clearing and fault clearing
1) The mileage data recorded by the instrument can be reset to zero through the mileage
reset function
2) Time clearing function reserved
3) All fault information recorded by the instrument can be reset to zero through the fault
clearing function
Speed unit: the speed display unit can be selected as kilometer, hour or mile per hour
Date time: set the date, day and current time
Instrument port: through this interface, you can view all the input and output port values
of the instrument
CAN baud rate: CAN bus communication baud rate of 125k, 250K can be selected.
4.2.2 Jiacheng intelligent instrument ( for inmotion controller)
(1) It is a kind of color screen instrument connected to truck system through CAN bus.
The color screen instrument can display the running state of the truck and has the
diagnostic function.
(2) The instrument can read or modify the settings of all control modules connected to the
CAN bus network. The node definition is shown in the following table:
65
Relative number in CAN bus Module
08 Traction controller
07 Pump controller
05 Steering controller
16 Instrument
(3) Panel layout
Figure 4-19 Jiachen instrument panel layout

(4) Display interface
Figure 4-20 displaying information on the instrument
66
Figure 4-21 fault displaying
(5) Function and Application
1) Hour meter
The number shows the accumulated working time of the current truck. After the key
switch is turned on and the truck starts to work, the work timer starts to count.
2) Direction indication
It indicates whether the current truck is in forward or backward gear.
3) Battery electric quantity
The current battery electric quantity icon is displayed, and the current value is
displayed above the battery icon.
4) Operation mode
It displays the current working mode, including "P", "E" and "S".
5) Steering indicator
It indicates the left and right steering of the truck.
6) Steering angle indication
It represents the direction of the steering wheel.
7) Travel speed
It displays the current truck speed in km / h.
8) Fault code display
It displays the current fault code of the whole truck.
9) LED indicator
67
when the operating mode is under S, the indicator is on;
Whe the direction switch is on neutral, the indicator is on;
when the electric quantity is no more than 20%, the indicator is on;
when the electric quantity is less than 15%, the lifting lock indicator is on;
when the operator leaves the seat, the indictor is on;
when the parkign brake is applied, the indicator is on.
4.2.3 HELI technology instrument ( for HELI technology controller)
(1) Panel layout
Figure 4-22 HELI technology instrument panel

Non-home screen functions
Major Main interface
Button
function shortcut function The menu item is not The menu item is
Modify mode
selected selected
switch selected menu Modify the value of the
Up / Page Up
item upward current digit bit
Down / Page Down
item down current digit bit
Left / Move Page Left
item left current digit bit
Right / Move Page Right
item right current digit bit
Hide alarm Return to the upper-level
Back cancel selected Quit Modify mode
information menu or the main screen
Enter the page turning Enter the sub-menu or
Enter selection
Confirm state or a menu item enter the modify mode Confirm edit value
interface of menu
selection state of the menu
68
It includes:
● ●The meaning of gear display is: D - Drive，R - Reverse，N - Neutral
● The speed mode value can be customized as required. The following types are
available:
● Type 1: S – high，P – middle，E – low
● Type 2: S – low，P – middle，E – high
● Type 3: S – low，E – middle，P – high
● The meanings of the current fault icon are as follows:
● Fault indicator light, power-on self-test or fault light; If the fault light is off,
there is no fault and communication is normal. If the fault indicator flashes, it
indicates there is a fault. For details, check the fault code.
● When the parking switch icon is always lighting, it indicates that the parking
switch is off.
● If the seat belt icon is always lighting, the driver is not wearing a seat belt.
● If the fault icon flashes, a warning is displayed. The alarm code is displayed in
the dialog box on the main window.
● If the forbidden to lift icon is not flashing, the lifting is faulty.
● If the seat switch icon is always lighting, it indicates that the seat switch is not
turned off.
● Notification icon, reserved, customizable according to customer requirements.

● Network signal quality：empty – none，one grid – poor，two grids – middle, three
grids – good, More than four grids – excellent
● Internet cloud connect：the icon appears – already connected to the cloud, the
icon not appears –not connected to the cloud
● Positioning type: empty – No positioning, – base station positioning, –

GPS positioning
● The alarm notification area displays the notification information pushed by HELI
intelligent truck management system, such as notification information of truck lock,
speed limit, arrearage reminder, and instrument self-check fault such as over
temperature. Other notification information can be added according to customer
requirements.
4.3 Controller
4.3.1 General description
69
This series of trucks can be equipped with three controllers, namely ZAPI motor
controller imported from Italy, INMOTION motor controller imported from Sweden and
domestic brand Heli technology motor controller. The control system has advanced high
frequency MOS technology, excellent speed regulation performance, good security,
flexibility and first-class protection. At the same time, it has the advantages of advanced
AC flux vector control technology to ensure efficient operation, programmable
acceleration and deceleration characteristic curve and optimal performance curve.
The controller assembly includes motor controller, contactor, relay group, fuse, OPS
warning buzzer, electronic protector and related wiring harness.
Note: the quality of the motor controller shall be guaranteed by the manufacturer. In
case of any fault, the manufacturer shall be informed in time to provide after-sales
service. Please do not open it for maintenance without authorization. If the user
repairs without authorization, the responsibility for personal and property loss shall
be borne by the user.
70
4.4 Motor
4.4.1 Specifications of motors

Table 4-3 Specifications of motors
Truck model
CPD15～18-GB3Li/GB6Li-S
CPD15～18-GB2Li-H/GB6Li-H CPD15～18-GB2Li/GB3Li-M
Item CPD20-GE3Li/GE6Li-S
KDS Wanxin Liaoyuan KDS Wanxin Beijing ZAPI Wanxin Beijing ZAPI
Traction motor
(10KW) (10KW) （10KW） (9.5KW) (9.5KW) (9.5KW) (8KW) (8KW)
Travelling motor YDQ10-4-6190 JXQ-10-2B XYQ-10-HL YDQ9.5-4-6190 JXQ-9.5A-WX B8562106GK JXQ-8A-WX2 B8562105GK
Rated voltage 53V 54V 52V 53V 54V 50V 54V 50V
Rated current 144A 135A 160A 137A 127A 160A 109A 110A
Rated speed 2400 r/min 2050 r/min 1890 r/min 2300 r/min 2046 r/min 2015 r/min 1595 r/min 1485 r/min
AC lifting motor bra KDS Wanxin Liaoyuan KDS Wanxin Beijing ZAPI Wanxin Beijing ZAPI
nd (18KW) (18KW) （18KW） (18KW) (16.5KW) (16.5KW) (10.6KW) (10.6KW)
AC lifting motor mo
YDB18-4-6190 JXQD-18-2B XYD-18-HL YDB18-4-6190 JXQD-16.5A-WX B8432197GK JXQD-10.6A-WX B8432196GK
del
Rated voltage 53V 54V 53V 53V 54V 50V 54V 50V
Rated current 286A 268A 245A 286A 227A 230A 153A 145A
Rated speed 2500 r/min 2476 r/min 2315 r/min 2500 r/min 2322 r/min 2325 r/min 2007 r/min 1750r/min
71
Truck model
CPD20～35-GB2Li-H/GB6Li-H CPD20～35-GB2Li/GB3Li-M CPD20～35-
CPD38-GB2Li/GB3Li-M CPD38-GB3Li/GB6Li-S GB3Li/GB6Li-S
Item
KDS Wanxin Liaoyuan Wanxin KDS ZAPI Liaoyuan Wanxin ZAPI
Traction motor
(17KW) (17KW) （17KW） (16.6KW) (16.6KW) (16.6KW) (16.6KW) (15KW) (15KW)
Travelling motor YDQ17-4-6190 JXQ-17-HL 10260520 JXQ-16.6-HL YDQ16.6-4-6191 SY05-16.6Q 10234876 JXQ-15-HL SY05-15Q
Rated voltage 53V 53 V 53V 52 V 55V 50V 52 52 V 50V
Rated current 246A 232A 232A 225A 220A 205A 225 206A 195A
1750
r/min
KDS Wanxin Liaoyuan Wanxin KDS ZAPI Liaoyuan Wanxin ZAPI
AC lifting motor brand
(26KW) (26KW) （26KW） (25.5KW) (25.5KW ) (25.5KW ) （25.5KW） (21KW) (21KW)
AC lifting motor mode
YDB26-4-6190 JXQD-26-HL 10260521 JXQD-25.5-HL YDB25.5-4-6190 SY04-25.5B 10234875 JXQD-21-HL SY04-21B
l
Rated voltage 53V 52V 52V 52V 53V 50V 52V 52V 50V
Rated current 358A 350A 350A 352A 358A 320A 352A 282A 290A
2650
r/min
72
Truck model
CPD15~18-GY7Li-M CPD20~25-GY7Li-M CPD30~38-GY7Li-M
Item
Traction motor Wanxin（10KW） Wanxin（12KW） Wanxin（16.6KW）
Travelling motor XSR-160T-10 XSR-160T-12 XSR-160T-16.6
Rated voltage 56V 52V 52V
Rated current 130A 166A 226A
Rated speed 1800r/min 2010r/min 1550r/min

AC lifting motor
Wanxin（14KW） Wanxin（16KW） Wanxin（25.5KW）
brand
AC lifting motor
XSR-132-14 XSR-132-16 XSR-132-25.5
model
Rated voltage 54V 52V 52V
Rated current 203A 239A 363A
Rated speed 2250r/min 2600r/min 2250r/min
73
4.4.2 Check and maintenance of the motor
(1) Daily check
a) Insulated resistance. Limit value (≥1 M)
b) Rotor should running agilely without touch.
c) Check up the motor connection whether exact and firm.
d) Check up between commutating piece of commutator whether clean.
Notice: During maintenance, the oil contamination on the commutator should
be wiped clean by lint free cloth dipped in alcohol and electric brush powder
between commutators should be clean up with hairbrush.
e) The fastener whether become flexible and brush rack whether firm.
f) The space between the brush holder of brush rack and the surface of commutator
whether correct and transmuted. (2~4mm).
g) Whether the brush is integrity and glides agilely, the pressure of the balance
spring in gear.
h) The area of interface between brush and commutator should not less than 80%,
and require polished with 00 type of thin emery cloth before instead.
(2) Daily maintenance
Notice the surface of motor, for example the mud or other adherent matter on the
housing, to avoid affect motor dispel heat. Check every half a year in gear, main work as:
a) Check outside and surface of motor and clean, cleanup dust.
b) Check, clean and replace bearing, carefully notice whether exist abnormity noise.
c) Check and replace the brush, check and maintain the commutator.
It is normal that the surfaces of commutator assume accordant light red after used a
long time.
Carve and polish the brush：
74
a) Polish the brush with 00 type of thin emery cloth, drag the emery cloth right or
left during polishing.
b) After polishing brush with emery cloth and cleanup the commutator, the motor
should running with limit speed to assure safety, until the working surface of brush
polished.
(3) Working environment
a) Not higher than 1200m altitude.
b) Temperature between -25ºC ~ +40ºC.
c) Relative humidity large to 100%, form curding dew at surface of motor.
(4) Faults and troubleshoot
The common faults are followed:

Table 4-4 Faults and troubleshoot of motor
No. Commutator fault Causation
1 All sheet copper is black. Wrong press of brush.
Between commutating piece or armature winding
The commutating piece change black in
2 short, welding bad or the commutating piece and
group with regulation.
armature winding bad or turn off.
The commutating piece change black in The center of commutator moved, and the surface
3
group without regulation. of commutator is not circle or flat.
The motor vibrate, the space between brush
holder and brush is too big, the space between
The brush is frayed, change color and
4 brush holder and the surface of commutator is too
disintegrated.
big. The talc between the commutating piece
extruded, the material or type of brush is wrong.
Motor over loading, the commutator is not clean,
the brush contact is bad, the press is not enough
5 The sparkle of commutator is big. or the brush is locked, brush rack become flexible
or vibrate, wrong the polarity of pole and
sequence.
The sparkle of brush is big, the contact between
6 Brush and brush plait heat. brush and soft wire is bad, the section area of soft
wire is too small.
7 noise during the brush running. The surface of commutator is not enough smooth.
Notice: In case of backfire, one must shut off the power when checking and
maintaining the motor.
4.5 Lithium battery and charger
4.5.1 Battery specification
75
Parameters Specifications Notes
80V/202Ah(Standard) Pengcheng
CPD15～18- 80V/271Ah(Optional) Pengcheng
GB2Li-H/GB6Li-H 80V/202Ah(Optional) Heding
80V/272Ah(Optional) Heding
80V/173Ah（Standard*） Pengcheng
CPD15～18- 80V/202Ah(Standard) Pengcheng
GB2Li 80V/271Ah(Optional) Pengcheng
/GB3Li/GY7Li-M 80V/202Ah(Optional) Heding
80V/150Ah(Standard)
Heding
80V/202Ah(Optional)
Heding
80V/272Ah(Optional)
Heding
CPD15～18- 80V/150Ah(Optional)
Pengcheng
GB3Li-S/GB6Li-S 80V/202Ah(Optional)
Pengcheng
CPD20-GE3Li-S/GE6Li-S 80V/271Ah(Optional) Yijiatong
80V/150Ah(Optional)
Yijiatong
80V/220Ah(Optional)
Yijiatong
80V/270Ah(Optional)
80V/202Ah(Standard) Heding
80V/404Ah(Optional) Heding/Pengcheng
80V/220Ah(Optional) Yijiatong
CPD20～25-
GB3Li/GB6Li-S
Nominal 80V/202Ah(Optional) Pengcheng
voltage/ 80V/271Ah(Optional) Pengcheng
capacity 80V/346Ah(Optional) Pengcheng
80V/456Ah(Optional) Pengcheng
80V/228Ah（Standard*） Pengcheng
CPD20～25- 80V/404Ah(Optional) Pengcheng
GB2Li/GB3Li/GY7Li-M 80V/272Ah(Optional) Heding
CPD20～25- 80V/272Ah(Optional) Heding
GB2Li-H/GB6Li-H 80V/404Ah(Optional) Heding
80V/272Ah(Standard) Heding
80V/404Ah(Optional) Heding/Pengcheng
CPD30～35-
GB3Li/GB6Li-S 80V/604Ah(Optional) Pengcheng
76
CPD30～35- 80V/404Ah(Optional) Heding/Pengcheng
GB2Li/GB3Li/GY7Li-M 80V/346Ah(Standard*/Optional) Pengcheng
CPD30～35-
GB2Li-H/GB6Li-H 80V/456Ah(Optional) Pengcheng
80V/404AH(Optional) Heding/Pengcheng
80V/542AH(Optional) Pengcheng
CPD38-GB2Li/GB3Li 80V/544AH(Optional) Heding
/GY7Li-M 80V/346Ah(Standard) Pengcheng
CPD38-GB3Li/GB6Li-S
80V/272AH(Standard) Heding
80V/404AH(Optional) Heding
80V/544AH(Optional) Heding
80V/300AH(Optional) Yijiatong
80V/350AH(Optional) Yijiatong
Working
Actual working
voltage 80V：60V～91V
voltage
range
Rated
charging 200A Constant charging way
current
Charging Charging as soon as it
0～50℃
temperature is used up under 0℃.
Discharging
-25℃～50℃
temperature
Note: Standard* specification is only for CPD15～38-GY7Li-M type trucks.
4.5.2 Lithium battery usage
The correct use and daily maintenance of lithium battery have a great influence on
the performance and service life of battery, therefore, the users must make maintenance
77
and service referring to the actual condition and according to the maintenance instruction
on lithium battery provided by manufacturer. Please read the manual carefully before
using the electric truck and operate and use according to the procedures and methods
regulated in the manual so as to avoid unnecessary personal injury and property loss.
If there is any question, please contact with HELI technical department or after sale
service department.
1）Lithium battery safety notes
(1) Keep the battery away from dangerous objects or environment such as electric
conduction materials, corrosive chemicals, flammable and combustible objects,
dangerous mechanical equipment and high temperature and so on.
(2) Improper using of the product may lead to smoking such as external short circuit,
overcharging, over high temperature and so on. If smoking occurs, cut off the power at
once and put out the fire with sand or dry power extinguisher. At the same time, evacuate
people and call the police at the same time.
(3) Improper using of the product may lead to battery cell ballooning which may
even cause plastic housing broken or crack. If occurs, stop using the truck at once and
contact with HELI technical department or after sale service department.
(4) It is prohibited to disassemble, press, impale, storing under high temperature or
firing battery case to prevent the battery from high strength shaking, external impact
force and falling down. The operation may lead to person injuries or property loss.
(5) It is prohibited to make battery positive and negative pole short circuit. Do not
make the battery pole connect with metals or other electricity conductive objects except
bolt and conductive band. The operation may lead on injuries or property loss.
(6) It is prohibited to expose or store battery in an environment higher than 55℃. Do
not heat or put battery in fire. The operation may lead on injuries or property loss.
78
(7) It is prohibited to charge the battery without proper charging protection devices
(such as lithium battery protective circuit board, battery management system ) or with
battery manufacturer authorized charging equipment (charger, DC power included). The
operation may lead on injuries or property loss.
(8) Non manufacturer authorized technician are prohibited to disassemble and
assemble battery. The operation may lead on injuries or property loss.
(9) It is prohibited to put battery into water or other conductive liquid. The operation
may lead on injuries or property loss.
(10) Before operate the truck, read the manual carefully and children and other
untrained persons are prohibited to use the truck.
(11) It is prohibited to use the lithium battery with other type or model battery in
series or parallel. The operation may lead on injuries or property loss.
(12) It is prohibited to make the lithium battery protective circuit board or battery
management system power system in series or parallel with other system. The operation
may lead on injuries or property loss. If necessary, contact with HELI technical
department or after sale service department.
2) Lithium battery using notes
(1) Charging temperature range: 0-40℃. Charging under low temperature is bad for
battery. Please charge the battery after using at once in low temperature that is below 0℃.
(2) Discharging temperature range: -25~50℃, discharging capacity under low
temperature (-25~0℃) is poorer than under normal temperature. This is normal. The
battery can be used under 40-50℃, but high environment temperature especially staying
that environment for a long time will speed up the aging of battery internal material and
shorten battery service life. So it is not recommended to use the truck under this
temperature for a long time.
79
(3) Storage and longtime operation below -25 ℃ or above 55 ℃ are prohibited.
(4) When the truck has to be stored for a long time, keep the battery electricity to be
40%~60% and store it in dry and shady environment and charge the battery according to
the manual to prevent over low electricity because of self discharge in long time storing
which may cause irreversible capacity loose.
(5) Lithium battery self discharging is affected by environment temperature and
humidity. High temperature and humid temperature will speed up battery self discharging.
The battery is suggested to be stored under -10℃-45℃ dry environment.
(6) Unauthorized person are not allowed to touch, move, disassemble battery and
corresponding high voltage cable or parts with high voltage marking.
(7) If the truck suffers from violent impact, stop the truck in safe area and check if
the battery is well.
(8) If the battery leaks (liquid or smoke) or is damaged, please go to the safe place
and contact with after sale service person.
(9) If the electrolyte leaks, do not touch it. If it is touched accidently, wash with
plenty of water at once. If it goes into eye, wash with plenty of boric acid solution at once
and receive medical treatment.
(10) When the truck or battery is on fire, go to the safe area at once. Put the fire with
sand or dry powder extinguisher. It is prohibited to put fire with water or improper
extinguisher.
(11) Please charge the battery with lithium battery special charger. It is prohibited to
charge the battery with bad quality charger or other type charger.
(12) Disconnect the connection between the battery and the truck and charging
equipment during transporting. Make sure there is no any charging and discharging.
3) Lithium battery maintenance notes
80
(1) When the battery is lower than 20%. Charge it in time and it is prohibited to over
discharge.
(2) Charge the battery full after using. It is prohibited to over charge.
(3) When the truck has to be stored for a long time, keep the battery electricity to be
40%~60%. Do not be full. Charge the battery before using.
(4) Check the lithium battery charging socket regularly and make sure the frame is
firm, the socket cover plate is well sealed, and the terminal inside of the battery is not
rusty and has no foreign matters such as dust, rain and so on.
(5) Keep the lithium battery dry and clean and it is prohibited to wash battery with
water.
(6) Make sure the battery be fully discharged and charged at least once a month.
4.5.3 Charger type

No. Item Note
D80V-200A-Li lithium battery fast charger

1 80V/48V compatibility
D80V-200A-Li-423 lithium battery fast charger
4.5.4 Charger using notes
(1) Charge the battery in a safe environment where is away from dust, fire source
and corrosion.
(2) There should be equipped with fire extinguishing devices such as sand and dry
powder extinguisher for emergent fire extinguishment.
(3) Make sure there is no foreign matters such as dust and water in charger and
socket. If there is, clean it before charging, or poor connection between charger and
socket may cause over heat even fire.
(4) Do not modify or disassemble charging port and charging equipment or fault or
fire may be caused.
(5) Keep the following precautions during charging in order to avoid serious harm:
81
a) Do not contact charging terminal or terminal inside of the charging spearhead.
b) When there is lighting, do not charge the battery or touch the truck. if it is hit
by the lighting, charging equipment may be damaged and human injury may occur.
(6) When charging is finished, do not disconnect charging equipment with wet hand
or standing in water, or electric shock may occur and human injury may be caused.
(7) When charging is finished, close the battery charging opening cover to prevent
foreign matters falling into the opening during travelling or opening is easy to be
damaged.
(8) Pay attention to the following things to avoid the damage of charging equipment:
a) Do not close the charging opening cabin door without close the charging
opening cover.
b) Do not pull the or twist charging cable.
c) The charging equipment should not bear shock.
d) Do not store or use the charging equipment when the temperature is higher than
50℃.
e) It is prohibited to disconnect the changer when there is current output or
electric arc may be produced which will cause person injury or property loss.
f) Keep the charging equipment away from the heater or other heat sources.
4.6 Emergency button
Emergency button is used to cut load current and overload current and it is acts as
safety button. The emergency button on the truck is used under the following application:
(1) It acts as safety switch. Press the button in emergency to ensure truck safety. it
is prohibited to press the button frequently if it is not emergency or parts service lift will
be badly affected.
(2) Press the emergency button in the following cases to prevent battery feed:
82
a) When the truck will not be used for more than 72h, press the button when the
battery quantity meeting storing requirements (refer to lithium battery operation and
service manual for detail).
b) When transporting press the button when the battery quantity meeting
transporting requirements (refer to lithium battery operation and service manual for
detail).
c) When maintaining the truck, press the button.
Note: if the button is not pressed when not use for a long time, battery feed may
be caused and truck may be badly affected.
4.7 Daily Maintenance
(1) Check the wear condition of the contactor. Change it if necessary. Check the
contactor every three months.
(2) Check the pedals or manual inching switch; measure the voltage drop between
the inching switch ends; there is no resistance when the inching switch is closed; there is
ringing sound when release. Check every three months.
(3) Check the main circuit, connecting cable among battery, converter and motor.
Make sure the well insulation condition of the cables and circuits are tightly connected.
Check it every three months.
(4) Check the mechanical moving of the pedal and knob; check if the spring is out of
shape; check if the spring of the potentiometer can reach to the max. length or set length.
Check it every three months.
(5) Check the mechanical moving of the contactor every three months; if there is any
damage or condition affecting the safety, contact with controller dealer.
Notice: After chopper is installed, raise the wheel of vehicle (off the ground) for
test. In this way, there will be no danger even connection is wrong.
83
After electric lock switch is off, there is a certain voltage left in filter capacitor
within a period of time. Cut off the battery power first if the inverter is repaired at
this time and then connect the resistance of 10～100Ω to the positive and negative
poles of inverter to make the voltage on the capacitor short-circuited.
4.8 Troubleshoot
4.8.1 ZAPI control system
Software Version (traction controller ACE3)
CAN
ALARM NAME
CODE
8 WATCHDOG
17 LOGIC FAILURE #3
18 LOGIC FAILURE #2
19 LOGIC FAILURE #1
30 VMN LOW
31 VMN HIGH
37 CONTACTOR CLOSED
38 CONTACTOR OPEN
53 STBY I HIGH
60 CAPACITOR CHARGE
62 TH. PROTECTION
65 MOTOR TEMPERAT.
66 BATTERY LOW
74 DRIVER SHORTED
84
75 CONTACTOR DRIVER
78 VACC NOT OK
79 INCORRECT START
80 FORW + BACK
82 ENCODER ERROR
86 PEDAL WIRE KO
116 WAIT DISP AUTH
117 NO CAN DISP
118 2F4 TIMEOUT
119 2F3 TIMEOUT
120 2F2 TIMEOUT
121 HARDWARE WRONG
122 LIFT POT OUTRNG
123 LIFT POT NOT OK
124 TILT POT OUTRNG
125 TILT POT NOT OK
126 SHIFT POT OUTRNG
127 SHIFT POT NOT OK
128 REACH POT OUTRNG
129 REACH POT NOT OK
85
130 FROM VCM
131 LI CURR CUT PRO.
132 LI CURR LIM PRO.
133 LI CHARGING
134 LI WARNING TEMP
135 LI STOP TEMP
136 LI HIGH CURR
137 LI CELL VOL LOW
138 LI COMM INTER
139 LI CELL OVER DIS
140 LI TOT VOL HIGH
141 2F1 TIMEOUT
142 2F0 TIMEOUT
143 2F0 INIT. ERR.
144 2ND LEV INHIBIT
145 1ST LEV INHIBIT
146 AUTH. FAILED
147 0X1AA TIMEOUT
148 REM DEV INIT ERR
149 WR. SET TEMP MOT
150 ENCODER PHASES
86
163 ED SLIP MISMATCH
165 SHORT CIRCUIT KO
166 SHORT CIRCUIT
167 IMS ERROR
170 WRONG KEY VOLT.
177 COIL SHOR. EB.
178 MOTOR TEMP. STOP
179 STEER SENSOR KO
180 OVERLOAD
181 WRONG ENC SET
182 EVP2 COIL OPEN
183 EVP2 DRIV. SHORT
184 EVP2 DRIVER OPEN
185 TILLER ERROR
187 LIFT+LOWER
188 PUMP VACC NOT OK
189 PUMP INC START
190 PUMP VMN NOT OK
192 PUMP VACC RANGE
193 SMART DRIVER KO
87
194 AUX BATT. SHORT.
195 POS. EB. SHORTED
196 MOT.PHASE SH. （36/37/38）
197 WRONG SLAVE VER.
198 M/S PAR CHK MISM
199 PARAM TRANSFER
200 VDC OFF SHORTED
201 TORQUE PROFILE
202 VDC LINK OVERV.
203 HW FAULT MC
204 BRAKE RUN OUT
205 EPS RELAY OPEN
206 INIT VMN HIGH
207 INIT VMN LOW
208 EEPROM KO
209 PARAM RESTORE
210 WRONG RAM MEM.
211 STALL ROTOR
212 POWER MISMATCH
213 POSITIVE LC OPEN
214 EVP COIL OPEN
88
215 EVP DRIV. SHORT.
216 EB. COIL OPEN
217 PEV NOT OK
218 SENS MOT TEMP KO
219 PEB-PEVP NOT OK
220 VKEY OFF SHORTED
221 HANDBRAKE
222 SEAT MISMATCH
223 COIL SHOR. MC
224 WAITING FOR NODE
226 VACC OUT RANGE
227 HW FAULT
228 TILLER OPEN
229 HW FAULT EB.
230 LC COIL OPEN
232 CONT. DRV. EV
233 POWERMOS SHORTED
234 DRV. SHOR. EV
235 CTRAP THRESHOLD
236 CURRENT GAIN
89
237 ANALOG INPUT
238 HW FAULT EV.
239 CONTROLLER MISM.
240 EVP DRIVER OPEN
241 COIL SHOR. EVAUX
242 OPEN COIL EV.
243 THROTTLE PROG.
244 WARNING SLAVE
245 IQ MISMATCHED
246 EB. DRIV.OPEN
247 DATA ACQUISITION
248 NO CAN MSG.
249 CHECK UP NEEDED
250 THERMIC SENS. KO
251 WRONG SET BAT.
252 WRONG ZERO
253 FIELD ORIENT. KO
254 EB. DRIV.SHRT.
Software Version(Pump controller ACE3)
CAN
ALARM NAME
CODE
8 WATCHDOG
90
17 LOGIC FAILURE #3
19 LOGIC FAILURE #1
200 STEER SENSOR KO
201 WRONG ENC SET
202 VDC LINK OVERV.
208 EEPROM KO
209 PARAM RESTORE
210 WRONG RAM MEM.
212 W.SET. TG-EB XX
213 INPUT MISMATCH
227 OUT MISMATCH XX
229 NO CAN WR MSG.XX
230 SOFTWARE ERROR
235 CTRAP THRESHOLD
237 ANALOG INPUT
240 OUT MISMATCH PU
241 SP MISMATCH PUMP
242 SP MISMATCH XX
248 NO CAN MSG. XX
91
4.8.2 CombiACE2 NG (medium configuration)
Software Version
CAN CODE ALARM NAME
8 WATCHDOG
17 LOGIC FAILURE #3
18 LOGIC FAILURE #2
19 LOGIC FAILURE #1
30 VMN LOW
31 VMN HIGH
37 CONTACTOR CLOSED
38 CONTACTOR OPEN
53 STBY I HIGH
60 CAPACITOR CHARGE
62 TH. PROTECTION
65 MOTOR TEMPERAT.
66 BATTERY LOW
74 DRIVER SHORTED
75 CONTACTOR DRIVER
78 VACC NOT OK
79 INCORRECT START
80 FORW + BACK
92
86 PEDAL WIRE KO
119 WAIT DISP AUTH
120 NO CAN DISP
121 HW WRONG
122 0X1F0 INIT ERROR
130 0X1F0 TIMEOUT
132 BMS 10
133 BMS 09
134 BMS 08
135 BMS 07
136 BMS 06
137 BMS 05
138 BMS 04
139 BMS 03
140 BMS 02
141 BMS 01
142 2F1 TIMEOUT
143 2F0 TIMEOUT
144 2F0 INIT. ERR.
145 TH. PROT. PUMP
146 2ND LEV INHIBIT
93
147 1ST LEV INHIBIT
148 AUTH. FAILED
149 0X1AA TIMEOUT
150 REM DEV INIT ERR
151 WR. SET TEMP MOT
152 IIC BUS ERROR
153 ENCODER ERROR XX
154 OUT MISMATCH XX
155 SP MISMATCH XX
157 INPUT MISMATCH
163 ED SLIP MISMATCH
165 SHORT CIRCUIT KO
166 SHORT CIRCUIT
167 IMS ERROR
170 WRONG KEY VOLT.
177 COIL SHOR. EB.
178 MOTOR TEMP. STOP
179 STEER SENSOR KO
180 OVERLOAD
181 WRONG ENC SET
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185 TILLER ERROR
187 LIFT+LOWER
188 INT. CANBUSKO
189 PUMP INC START
190 PUMP VMN NOT OK
191 PUMP VACC NOT OK
192 PUMP VACC RANGE
193 SMART DRIVER KO
194 AUX BATT. SHORT.
195 POS. EB. SHORTED
196 MOT.PHASE SH. （36/37/38）
197 WRONG SLAVE VER.
198 M/S PAR CHK MISM
199 PARAM TRANSFER
200 VDC OFF SHORTED
201 TORQUE PROFILE
202 VDC LINK OVERV.
204 BRAKE RUN OUT
205 EPS RELAY OPEN
206 INIT VMN HIGH
207 INIT VMN LOW
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208 EEPROM KO
209 PARAM RESTORE
210 WRONG RAM MEM.
211 STALL ROTOR
212 POWER MISMATCH
213 POSITIVE LC OPEN
214 EVP COIL OPEN
215 EVP DRIV. SHORT.
216 EB. COIL OPEN
217 PEB NOT OK
218 SENS MOT TEMP KO
219 PEB-PEVP NOT OK
220 VKEY OFF SHORTED
221 HANDBRAKE
223 COIL SHOR. MC
224 WAITING FOR NODE
226 VACC OUT RANGE
227 HW FAULT
228 TILLER OPEN
229 HW FAULT EB.
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230 LC COIL OPEN
233 POWERMOS SHORTED
235 CTRAP THRESHOLD
236 CURRENT GAIN
237 ANALOG INPUT
240 EVP DRIVER OPEN
243 THROTTLE PROG.
244 WARNING SLAVE
245 IQ MISMATCHED
246 EB. DRIV.OPEN
247 DATA ACQUISITION
248 NO CAN MSG.
249 CHECK UP NEEDED
250 THERMIC SENS. KO
251 WRONG SET BAT.
253 FIELD ORIENT. KO
254 EB. DRIV.SHRT.
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4.8.3 INMOTION controller
Fault
Fault Remedy
code
ERROR: Acceleration pedal is activated when
20 Release acceleration pedal
starts.
ERROR: Direction switch is activated when
21 Shift direction switch to neutral gear
starts.
ERROR: front and rear direction switches are
22 direction switch failure
activated at the same time.
ERROR acceleration pedal analog quality
23 Acceleration pedal fault or recalibrate
exceeds range
analog quality
24 ERROR: acceleration pedal analog failure
ERROR : CAN communication of driver failure Check CAN bus or controller;
31
Or Instrument is disconnected.
32 ERROR: Low battery voltage Charging is needed.
34 ERROR: CPU inner failure It is suggested to change hardware test.
36 ERROR: Tilt switch is activated when starts. Restore tilt switch.
37 ERROR: Side shift is activated when starts. Restore side shift switch.
ERROR : Attachment switch is activated when
38 Restore attachment switch.
starts.
ERROR: Lifting switch is activated when
39 Restore lifting switch.
starts.
Lifting analog quantity is damaged or
40 ERROR: lifting analog quantity exceeds range.
recalibrate analog quality
ERROR: steering angle analog quantity exceeds steering angle analog quantity is
43
range. damaged or recalibrate analog quality
44 WARNING of traction driver speed protection Alarm of high truck speed
Check if encoder harness is poor
45 WARNING: fault of traction driver encoder
connected.
81 WARNING: low traction driver temperature Over low environment temperature
Traction driver temperature is over high
82 WARNING: high traction driver temperature
and its power is limited.
ERROR: traction driver temperature sensor
83 Change driver
failure
84 WARNING: low traction motor temperature Over low environment temperature
Traction motor temperature is over high
85 WARNING: high traction motor temperature
and its power is limited.
Traction motor temperature sensor is
ERROR: traction motor temperature sensor
86 abnormal and please check sensor or
failure
harness.
Traction motor speed encoder is
87 ERROR: traction motor speed sensor failure abnormal and please check encoder or
harness.
The input voltage connected to driver is
88 WARNING: high traction driver DC bus voltage
detected to be over high.
Charge the battery or check power
89 WARNING: low traction driver DC bus voltage
harness.
90 WARNIN: traction driver default value is loaded. Safe protection after refreshing
98
procedures. it will be ok after restart the
key switch.
WARNING : traction driver performance limiting Low battery quantity and truck
91
mode performance is limited.
Check if the output port harness is short
97 ERROR: traction driver output port failure. circuit or open circuit(such as main
contactor, backward relay and so on).
WARNING：traction driver over current or short
98
circuit Check power harness
101 ERROR: traction motor driver short circuit
102 ERROR: high traction driver temperature Cool driver
103 ERRO: high traction motor temperature Cool motor
104 ERROR: traction driver over current Check power harness
105 ERROR: overtime of traction driver precharging Change precharging resistance
Driver input voltage is overlow, please
110 ERROR: low traction driver DC bus voltage check battery voltage or check if
contactor is connected.
111 ERROR: high traction driver DC bus voltage
driver input voltage is overhigh, please
ERROR: high traction driver DC bus check battery voltage.
112
voltage( hardware monitor)
Check motor encoder and temperature
114 ERROR: interior power supply failure
sensor harness
121 WARNING: low pump driver temperature Overlow environment temperature
Pump driver temperature is high and its
122 WARNING: high pump driver temperature
power is limited.
123 ERROR pump driver temperature sensor failure Change driver
124 WARNING: low pump motor temperature Overlow environment temperature
Pump motor temperature is overhigh and
125 WARNING: high pump motor temperature
its power is limited.
Pump motor temperature sensor is
126 ERROR: pump motor temperature sensor failure abnormal and please check sensor or
harness.
Pump motor speed encoder is abnormal
127 ERROR: pump driver speed sensor failure
and check encoder or harness.
The input voltage connected to driver is
128 WARNING: pump driver DC bus voltage is high.
detected to be overhigh.
129 WARNING: pump driver DC bus voltage is low. Charge or check the power harness.
Safe protection after refreshing
130 WARNING: pump default value is loaded. procedure and it will be ok after restart
the key.
WARNING : pump driver performance is Battery quantity is low and charge the
132
limited. battery.
Check if output port harness has short
137 ERROR: pump driver output port failure
circuit or open circuit.
WARNING: pump driver over current or short
138
circuit. Check power harness.
141 ERROR: pump drive short circuit
142 ERROR: pump driver temperature is high. Cool driver.
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143 ERROR: high pump motor temperature. Cool motor.
144 ERROR: pump driver current calibrating failure Restart.
145 ERROR pump driver precharging overtime Change precharging resistance.
Driver input voltage is overlow and
150 ERROR: pump driver DC bus voltage low. check battery voltage or check if
contactor is connected.
151 ERROR: pump driver DC bus voltage high.
Driver input voltage is overhigh and
ERROR pump driver DC bus voltage high check battery voltage.
152
(hardware monitor)
Check motor encoder and temperature
153 ERROR pump driver interior fault.
sensor harness.
154 ERROR: pump driver speed control failure. Check encoder or harness.
BMS temperature is over high and it
157 BMS over temperature protection
need to be cool down.
BMS low battery voltage and charging is
158 BMS unit is over discharged.
needed.
BMS low battery voltage and charging is
159 BMS over voltage protection
needed.
163 BMS over current BMS output current is large.
BMS is charging and the truck does not
164 Charging protection
work.
BMS temperature is over high and it
156 Temperature protection
need to be cool down.
BMS limit output current and please
168 BMS current limit protection
check battery.
BMS cut output current and please check
169 BMS current cutout protection
battery.
Please check CAN, controller and
171 BMS communication error
battery.
4.8.4 HELI technology control system
The electronic control system has good compatibility and extended communication
performance, and has the function of programmable electronic control system parameters.
The instrument is compact, which can display analog and digital signals of all electronic
control systems, and can clearly display common information such as "electric quantity",
"truck speed", "accumulated running time" and "energy mode" of current operation. The
fault indication adopts code method to improve the maintenance efficiency. The
instrument can enter two modes: 1. Diagnosis mode, which can view the forklift system
parameters and the latest 10 fault information. 2. Calibration mode (turn off this mode),
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you can not only view various system parameters and fault information, but also modify
system parameters. In order to avoid the user's wrong adjustment of system parameters,
causing the forklift can not work normally, it is forbidden to open the function of
instrument calibration system parameters through the upper computer software.
Battery over voltage protection
 Fault code:1
 Fault level:1
 Fault reason: Through the internal measurement of the control unit, it is found
that the instantaneous battery voltage exceeds 63V.
 Remedy:
1. Check if the connection between the battery and electric control system is
well connected.
2. Check if the battery voltage level is normal.
3. Change the control unit.
Battery under voltage protection
 Fault code:2
 Fault level:1
 Fault reason: Through the internal measurement of the control unit, it is found
that the instantaneous battery voltage lower than 24V.
 Remedy:
1. Check whether the battery wiring is wrong and whether the positive and negative
electrode joints are seriously rusted.
2. Check the state of the battery: if the battery electrolyte is partially depleted, the
controller undervoltage protection fault may be triggered; or when the battery power
level is already very low, it needs to work with high current (for example, the oil
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pump motor and drive motor are working at full load), and the undervoltage
protection fault may also be triggered.
3. Replace control unit.
The accelerator is pressed before starting
 Fault code:3
 Fault level:1
 Fault reason: During the self-test of the system when the power is on (the main
circuit breaker is not closed), the driver presses the accelerator pedal in advance.
 Remedy:
1. If the fault code is caused by the driver stepping on the accelerator pedal in
advance during the system self-test when the power is on (the main circuit breaker is
not closed), please release the accelerator pedal and restart.
2. Check the value setting of accelerator pedal to see whether the minimum and
maximum voltage values of the accelerator pedal are set accurately. If not,
recalibrate it, and use the monitoring software or instrument of the upper computer
to set it.
3. Check whether the 42 pin terminal of the main harness control unit is
correctly connected with the accelerator pedal terminal. If there is no problem with
the wiring, step on the accelerator pedal through the upper computer monitoring
software and observe whether the pedal feedback voltage value is within the correct
range
K1-17(12V)
 K1-30 (grounding)
 K1-18 (pedal feedback signal input)
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Alarm of flash memory fault
 Fault code:5
 Fault level:1
 Fault reason: one or more than one parameter values of whole truck performance
or motor control in the control unit exceed the allowable range or error is found
when calibration (inconsistence between write and reading.) .
 Remedy:
1. Flash reloading default value: use FJ monitoring software, path: calibration >
enable Settings > "* restore system default value", change the "new value"
corresponding to this parameter to be "on", and the system will automatically call
out the default parameters when the system is powered off and powered on again.
2. If the alarm is still not released after scheme 1 is carried out, replace the
control unit.
Low voltage of precharging capacitor
 Fault code:6
 Fault level:1
 Fault reason: When the motor is working, it is found that the voltage level of the
precharging capacitor is lower than 70% of the battery voltage level in the same
period.
 Remedy:
1. After power on, wait for the contactor to contact before starting to work.
2. Check whether the main circuit breaker coil control connection terminal and
the main wiring harness connection terminal are correctly connected; the correct
connection mode is as follows:
 K1-29 (positive)
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K1-15 (negative)
3. Check whether the main fuse is in good condition.
4. Replace the main circuit breaker.
Drive motor power module is not saturated or over current
 Fault code:8
 Fault level:1
 Fault reason: The actual capacity of drive power module exceeds the limit value.
 Remedy:
1. Check whether there is a short circuit between the UVW three-phase cable
connection between the drive module and the motor (there is a short circuit between
the three-phase cables or between a phase cable and the truck frame), and check
whether the motor coil has burning smell.
2. Check whether the 26 pin connecting cable between the control unit and the
drive module is connected normally.
3. Disconnect the UVW cable of the power module, and use the high-grade
resistance gear of the multimeter to check whether the resistance value between the
+ / - B terminal and the UVW terminal of the module is symmetrical. If it is found
that the resistance value of one phase deviates greatly from other phases, the power
module can be judged to be burnt out and the power module needs to be replaced.
The charging of precharging capacitor is too fast.
 Fault code:9
 Fault level:1
 Fault reason: the voltage of precharging capacitor is increased to fast when the
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system is on power.
 Remedy:
1. Replace the main circuit breaker;
2. Replace power modules one by one to exclude drive and oil pump power
modules.
Alarm of overheating of oil pump motor power module
 Fault code:10
 Fault level:6
 Fault reason: the temperature of oil pump motor power module exceeds 90℃.
 Remedy:
1. The failure may be caused by insufficient heat dissipation. Check the heat
dissipation between the power module and the aluminum plate, as well as between
the aluminum plate and the frame. The even and appropriate heat conduction
silicone grease between the module and the aluminum plate, and between the
aluminum plate and the frame is the necessary guarantee for effective heat
dissipation.
Note: the temperature of the oil pump motor power module can be read through
the monitoring interface or instrument of Heli technology's upper computer
software.
2. If the heat dissipation measures of the above modules are normal, please
check whether the oil pump motor works normally, especially whether the lifting
potentiometer of the control valve’s lever and the control signals of each switch can
be reset normally; secondly, consider replacing the power module of the oil pump.
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Insufficient discharging of precharging capacitor when the system is started.
 Fault code:11
 Fault level:1
 Fault reason: when the system carries out self-check when the power is on, the
electric charge in the precharging capacitor fails to discharge sufficiently.
 Remedy:
1. Check whether the UVW connection cable between the oil pump motor and
the oil pump power module is well connected, and check whether the 26 pin control
cable between the oil pump power module and the control unit is connected
normally.
2. Replace the power module of oil pump motor.
3. Replace the main circuit breaker.
Alarm of battery low voltage
 Fault code:12
 Fault level:3
 Fault reason: The battery voltage is lower than the discharge protection value
(calibration > battery calibration > battery discharge protection value).
 Remedy
1. Charge the battery. Please note that if the battery voltage level is still lower
than the "battery reset value" (see calibration > battery calibration > battery reset
value) after charging, the fault code will not be eliminated. Only when the voltage
level of the battery after charging is higher than the "battery reset value" can the
fault code be eliminated and the forklift truck can work normally.
2. Measure the battery voltage. If the measured value is inconsistent with the
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"battery discharge protection value", replace the control unit.
Alarm of high temperature of drive motor
 Fault code:13
 Fault level:5
 Fault reason: The temperature measurement value of the drive motor is about to
reach the maximum allowable temperature value set by the user (calibration >
drive motor > drive motor over temperature protection point).
 Remedy:
1. First, check whether the connection between the motor temperature sensor
and the main harness is normal.
2. If the fault occurs when the motor is not hot:
1) Use a hand-held Multimeter in the resistance measurement mode to
measure the resistance between the two wires of the motor temperature sensor, and
compare it with the true value table of the motor temperature sensor. If the measured
value does not match the actual temperature of the motor, replace the temperature
sensor.
2) Replace control unit.
3. If the fault occurs when the motor is very hot:
1) If the temperature value read from the upper computer monitoring
software or instrument is consistent with the actual temperature of the motor, check
whether the motor casing is clean and whether the motor heat dissipation is normal.
2) Check whether the drive motor is working normally, whether there is brake
lock or other abnormal conditions.
Alarm of high temperature of oil pump motor
 Fault code:14
107
 Fault level:6
 Fault reason: The temperature measurement value of the oil pump motor is about
to reach the maximum allowable temperature value set by the user (calibration >
oil pump motor >oil pump over temperature protection point).
 Remedy
1. First, check whether the connection between the motor temperature sensor
and the main harness is normal.
2. If the fault occurs when the motor is not hot:
1) Use a hand-held Multimeter in the resistance measurement mode to
measure the resistance between the two wires of the motor temperature sensor, and
compare it with the true value table of the motor temperature sensor. If the measured
value does not match the actual temperature of the motor, replace the temperature
sensor.
2) Replace control unit.
3. If the fault occurs when the motor is very hot:
1) If the temperature value read from the upper computer monitoring
software or instrument is consistent with the actual temperature of the motor, check
whether the motor casing is clean and whether the motor heat dissipation is normal.
2) Check whether the motor is working normally, especially to check if the
oil pump motor continues working for a long time which is caused by the
potentiometer of control valve lever or switch single being unable to reset. Long
working time of oil pump motor will cause high temperature.
Current loss of drive motor
 Fault code:15
 Fault level:1
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 Fault reason: The phase current of drive motor is not zero when system is on.
 Remedy:
1. check if the connection of 26 pin connection cable between the power module
and control unit is well.
2. Replace the power module.
3. Replace the control unit.
Alarm of overcurrent of main circuit breaker coil
 Fault code:17
 Fault level:1
 Fault reason: the current of main circuit breaker coil is large.
 Remedy:
1. Check if there is external short circuit of main circuit breaker coil;
2. Replace the main circuit breaker;
The power module of drive motor is over heat.
 Fault code:20
 Fault level:5
 Fault reason: the temperature of drive motor’s power module exceeds 90℃.
 Remedy:
1. The fault may be caused by insufficient heat dissipation. Check the heat
dissipation between the power module and the aluminum plate as well as between
the aluminum plate and the frame. It is necessary to ensure the effective heat
dissipation by evenly and appropriately conducting silicone grease between the
module and the aluminum plate, and between the aluminum plate and the frame.
Note: the temperature of motor power module can be read by upper computer
109
software or instrument of Heli technology.
2. If the heat dissipation measures of the above modules are good, it is
necessary to check whether the drive motor works normally, and the abnormal motor
working will cause the power module to overheat; secondly, consider replacing the
power module.
The power module of oil pump motor is not saturated or over-current.
 Fault code:24
 Fault level:1
 Fault reason: the actual current of oil pump power module exceeds the limit
value.
 Remedy:
1. Check whether there is a short circuit between the UVW three-phase cable
connection between the oil pump module and the motor (if there is a short circuit
between the three-phase cables or between a phase cable and the frame), and check
whether the motor coil has burning smell.
oil pump module is connected normally.
3. Disconnect the UVW cable of the power module, and use the high-grade
resistance gear of the multimeter to check whether the resistance value between the
+ / - B terminal and the UVW terminal of the module is symmetrical. If it is found
that the resistance value of one phase deviates greatly from other phases, the power
module can be judged to be burnt out and the power module needs to be replaced.
Current loss of oil pump motor
110
 Fault code:36
 Fault level:1
 Fault reason: the phase current of oil pump motor is not zero when the system is
on.
 Remedy:
1. Check that the 26 pin connecting cable between the oil pump power module
and the control unit is correctly connected.
2. Replace the oil pump power module.
Output fault of control unit’s 5V voltage
 Fault code:37
 Fault level:1
 Fault reason: The voltage of K1-16 connector (5V output) of control unit is
lower than 4.3v.
 Remedy:
Check whether the 5V output is grounded and whether the motor encoder
wiring is correct.
The external devices using 5V output of control unit are excluded one by one.
Output fault of control unit’s 5V voltage
 Fault code:38
 Fault level:1
 Fault reason: The voltage of K1-17 connector (12V output) of control unit is
lower than 10.5v.
 Remedy:
111
1. Check whether the 12V output is grounded, which may be caused by wiring
errors of the following devices:
 Accelerator pedal
 Lifting sensor
 Steering sensor
 Instrument
2. Check the external devices using 12V output of control unit one by one.
The command level of oil pump motor is under activated state when the system is
started.
 Fault code:50
 Fault level:7
 Fault reason: When the system is started, the lifting potentiometer or tilt lever or
other auxiliary function switch signals have been activated.
 Remedy:
1. Reset all activated commands (including lifting potentiometer and each
switch signal).
2. Check if the voltage of the lifting potentiometer exceeds the set value, the
upper computer software of Heli technology can be used for recalibration
(calibration > lifting calibration).
Truck halt because of overheat of drive motor
 Fault code:61
 Fault level:1
 Fault reason: The temperature measurement value of drive motor exceeds the
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maximum allowable temperature set by the user. (calibration > drive motor >
drive motor over temperature protection point)
 Remedy: see the remedy for fault code 13.
The seat switch is not closed when starting.
 Fault code:63
 Fault level: warning
 Fault reason: When the system is powered on, the seat switch is not closed; or
after the main circuit breaker is closed, the seat switch is disconnected beyond
the time set by the parameter "seat switch delay" (menu calibration > time
setting > seat delay time).
 Remedy:
1. Check if the seat switch is poor connected or damaged.
Starting condition error
 Fault code:64
 Fault level: warning
 Fault reason: when the truck is started, the forward/backward switch is activated.
 Remedy:
1. Check whether the forward / backward switch is activated when the truck is
started.
2. If the direction switch is not activated, check whether the connection
terminal of the direction switch is correctly connected with the connection terminal
of the main harness. The monitoring software of Heli technology can be used for
auxiliary detection.
3. Replace the direction switch.
113
Truck halt because of overheat of oil pump motor
 Fault code:65
 Fault level: 1
 Fault reason: The measured temperature of the oil pump motor exceeds the
maximum temperature allowed by the user. (calibration > oil pump motor >
over temperature protection point of oil pump motor)
Truck halt because of overheat of drive motor’s power module
 Fault code:66
 Fault level: 1
 Fault reason: the temperature of drive motor’s power module exceeds 95℃.
Truck halt because of overheat of oil pump’s power module
 Fault code:68
 Fault level: 1
 Fault reason: the temperature of oil pump’s power module exceeds 95℃.
Temperature sensor fault of drive motor’s power module
 Fault code:71
 Fault level: 5
 Fault reason: The feedback value of the drive motor power module temperature
sensor is out of the measurement range.
 Remedy:
1. Check whether the 26 pin cable connection between the drive motor power
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module and the control unit is normal.
2. Replace the drive motor power module.
Temperature sensor fault of pump motor’s power module
 Fault code:72
 Fault level: 6
 Fault reason: The feedback value of the temperature sensor of the oil pump
motor power module exceeds the measurement range.
 Remedy
1. Check whether the 26 pin cable connection between the power module of oil
pump motor and the control unit is normal.
2. Replace the power module of oil pump motor.
Fault of oil pump’s encoder
 Fault code:73
 Fault level: 2
 Fault reason: the encoder (A or B)communication single is lost during the
working of oil pump motor.
 Remedy:
1. Check that the encoder is correctly connected to:
 Motor itself
 Grounding: K1-30 connector
 + 5V: K1-16 connector
 Channel A: K1-35 connector
 Channel B: k1-36 joint
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2. If the wiring is correct and well connected, replace the encoder.
Fault of drive motor’s encoder
 Fault code:74
 Fault level: 2
 Fault reason: the encoder (A or B)communication single is lost during the
working of drive motor.
 Remedy:
1. Check that the encoder is correctly connected to:
 Motor itself
 Grounding: K1-30 connector
 + 5V: K1-16 connector
 Channel A: K1-32 connector
 Channel B: k1-33 joint
2. If the wiring is correct and well connected, replace the encoder.
Temperature sensor fault of drive motor
 Fault code:77
 Fault level: 8
 Fault reason: The temperature of drive motor is higher than that of pump motor
and the temperature difference is higher than 70℃.
 Remedy:
1. Check whether the drive motor temperature sensor and the main wiring
harness are normal.
2. Replace the drive motor temperature sensor.
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Temperature sensor fault of oil pump motor
 Fault code:79
 Fault level: 8
 Fault reason: The temperature of pump motor is higher than that of drive motor
and the temperature difference is higher than 70℃.
 Remedy
1. Check whether the pump motor temperature sensor and the main wiring
harness are normal.
2. Replace the pump motor temperature sensor.
Temperature sensor fault of drive motor power module
 Fault code:80
 Fault level: 8
 Fault reason: the temperature of drive motor’s power module is higher than that
of pump motor’s power module and the temperature difference is higher than
70℃.
 Remedy:
driver module is connected normally.
2. Replace the drive power module.
Temperature sensor fault of oil pump motor power module
 Fault code:82
 Fault level: 8
117
 Fault reason: the temperature of oil pump motor’s power module is higher than
that of drive motor’s power module and the temperature difference is higher
than 70℃.
 Remedy:
oil pump module is connected normally.
2. Replace the oil pump power module.
CRC error
 Fault code:83
 Fault level: 1
 Fault reason: software version error
 Remedy:
1. Use the upper computer monitoring software of Heli technology to restore
the factory setting parameters (calibration > enable Settings > restore system default
values).
2. If the fault code still exists, replace the control unit.
Incorrect order for truck travelling
 Fault code:85
 Fault level: 9
 Fault reason: The acceleration pedal is pressed before shifting the direction
switch before truck travelling.
 Remedy: release the acceleration pedal, fist activate the direction switch then
press the acceleration pedal.
Steering sensor fault
118
 Fault code:91
 Fault level: 5
 Fault reason: The feedback voltage of steering sensor exceeds the calibration
range.
 Remedy:
1. Check that the following connections are correct:
 K1-17(12V)
 K1-30 (grounding)
 K1-31 (steering sensor feedback signal input)
2. If the wiring is OK, recalibrate the clockwise value, intermediate value and
counter clockwise value of the steering sensor (calibration > smart steering).
3. Replace the steering sensor and recalibrate.
Pedal acceleration fault
 Fault code:92
 Fault level: 2
 Fault reason: The accelerator pedal feedback voltage value > sum of half of the
difference between the set maximum and minimum value and the minimum
value, but the accelerator pedal switch is not closed at this time.
 Remedy:
1. Check the value setting of calibration >setting of accelerator pedal
calibration value, check whether the minimum and maximum voltage values of
accelerator pedal are set accurately. If not, recalibrate it, and use the monitoring
software of upper computer to set it.
2. Check whether the 42 pin terminal of the main harness control unit is
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correctly connected with the accelerator pedal terminal. If there is no problem with
the wiring, step on the accelerator pedal through the upper computer monitoring
software and observe whether the pedal feedback voltage value is within the correct
range.
 K1-17(12V)
 K1-30 (grounding)
 K1-18 (pedal feedback signal input)
3. Replace the accelerator pedal.
Fault of lifting potentiometer
 Fault code:93
 Fault level: 2
 Fault reason: The lifting potentiometer feedback voltage value > sum of half of
the difference between the set maximum and minimum value and the minimum
value, but the lifting switch is not closed at this time.
 Remedy
1. If the voltage of the lifting potentiometer exceeds the set value, the upper
computer software of Heli technology can be used for recalibration (calibration >
lifting calibration).
2. Replace the lifting potentiometer.
Short circuit of oil pump’s motor temperature sensor
 Fault code:94
 Fault level: 6
 Fault reason: The feedback resistance of oil pump motor temperature sensor
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exceeds the normal range and approaches to 0.
 Remedy:
1. Check whether the wiring between oil pump motor temperature sensor and
main harness is normal.
2. Replace the oil pump motor temperature sensor.
Short circuit of drive motor’s temperature sensor
 Fault code:95
 Fault level: 5
 Fault reason: The feedback resistance of the drive motor temperature sensor
exceeds the normal range and approaches to 0.
 Remedy:
1. Check whether connection between the drive motor temperature sensor and
the main wiring harness are normal.
Open circuit of oil pump’s temperature sensor
 Fault code:96
 Fault level: 6
 Fault reason: The feedback resistance of oil pump motor temperature sensor
exceeds the normal range and approaches infinity.
 Remedy:
1. Check whether the wiring between oil pump motor temperature sensor and
main harness is normal.
2. Replace the oil pump motor temperature sensor.
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Open circuit of drive motor temperature sensor
 Fault code:97
 Fault level: 5
 Fault reason: The feedback resistance of drive motor temperature sensor exceeds
the normal range and approaches infinity.
 Remedy
1. Check whether the connection between the drive motor temperature sensor
and the main wiring harness are normal.
Low capacitor precharging
 Fault code:98
 Fault level: 1
 Fault reason: The voltage increase of precharging capacitor is too low during the
self check of truck when starting.
 Remedy:
1. Check that the connecting cables between the control unit and the two power
modules are correct.
2. Replace the power modules one by one and clear the faults of the drive and
oil pump power modules.
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5 Hydraulic System
The hydraulic system consists of oil pump, control valve, priority valve, lift cylinder,
tilt cylinder, high & low pressure oil pipe an joint etc. The pump is driven directly by the
electromotor. The hydraulic oil flow to control valve through the pump and are distribute
to cylinders by the control valve.
5.1.1 Oil pump
The main parts of the gear oil pump for forklift are a pair of external gears mutually
meshed and their working principle is as shown in Figure 5-1.
Figure 5-1 Working principle of gear pump

(1) Oil suction cavity (2) Oil pressing cavity
A pair of meshed involute gear is mounted inside the housing, the two end face seals
of gear and gear separate the pump housing into two sealing oil cavities as shown 1 and 2
in the Figure When the gear of gear pump rotates in the direction shown in the Fig, the
volume of space shown by 1 (engaging part for gear disengagement) changes from small
to big and forms vacuum. The oil in the oil tank enters into oil suction cavity under the
action of atmospheric pressure to fill the intertooth space through the oil suction pipe of
pump. While 2 indicates that the volume of space (engaging part for gear entering)
changes from big to small and press the oil into pressure oil circuit, i.e.1 is oil suction
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cavity, 2 is oil pressing cavity and they are separated by meshing point of two gears. With
constant rotation of gear, the suction and discharge outlets of the pump continuously
absorb and drain oil.
Oil pump is to turn the mechanical energy of motor into hydraulic energy, so the oil
pump is the actuating unit of hydraulic system of the forklift.
The main pump consists mainly of a pump body, a pair of gears, lining plates and oil
seals. This pump uses pressure-balance type bearings and a special lubrication method so
as to minimum the clearance of the gear face. (See Figure 5-2)
Figure 5-2 Main pump

(1) Pump body (2) Driving gear (3) Driven gear (4) Front cover (5) Rear cover
(6) Lining plate (7) Seal ring (8) Ring (9) Oil seal (10) Snap ring
5.1.2 Control Valve
The external of the control valve as shown in Figure 5-3.
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Figure 5-3 Control valve
The control valve adopts two pieces and four body type. The hydraulic oil from
working pump distributes the high-pressure oil to the lifting cylinder or tilting cylinder
through the control of valve stem. There are safety relief and tilt-locking valves inside the
control valve. The safety relief valve is at the top of oil inlet of control valve to control
the pressure of the system. The tilt-locking valve is on the tilt valve block and is mainly
used to prevent the serious consequence due to wrong movement of control rod when the
tilt cylinder has no pressure source. The check valve is mounted between oil inlet and
inlet port of lifting valve block and between oil inlets of lifting and tilt valve blocks.
(1) Operation of the control valve
The control valve is operated with the valve levers. All valve levers are assembled
together with a shaft and the shaft is assembled on the valve joint plate with the bracket.
The valve levers operate the control valve with the joints. (See Figure 5-4)
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Figure 5-4 Operation of the control valve
As you see in Figure 5-5, the
mast lift up when you push the lift
lever forward, the mast fall down
when you pull the lift lever
backward. The mast tilt forward
when you push the tilt lever
forward, the mast tilt backward
when you pull the tilt lever
backward.
Figure 5-5 The symbol on the operation lever
(2) Setting pressure of the control valve (See Figure 5-6)
The pressure of the safety valve shall not be adjusted by non-professional personnel.
The adjustment shall follow following procedures:
a) Screw off the plug of the measuring hole on the inlet of the control valve. Install
an oil pressure gauge capable of measuring 25MPa.
b) Operate tilting lever and measure the pressure at the end of the cylinder stroke.
126
c) If the oil pressure is different with the specified value, loosen the locking nut of
the relief valve and turn the adjusting screw left and right until the pressure reaching the
specified value. Turn left when the pressure is high and turn right when the pressure is
low.
d) Tighten the nut after adjusting.
Figure 5-6
5.1.3 Lift cylinder
The lift cylinder is of single-acting piston type. It consists of cylinder body, piston,
piston rod, cylinder cap, cut-off valve and oil seals. The cylinder head is equipped with
bushing and oil seal and the bushing supports the piston rod and the oil seal keeps dust
off. (See Figure 5-7)
When the hoist valve of control valve is placed at lifting position, hydraulic oil
enters into the lower part of piston of hydraulic cylinder from pressure-gradient control
valve to selector valve to push rising of piston and lifting of the goods. When the hoist
valve of control valve is placed at descending position, the piston rod drops with the
action of goods, mast, fork carrier and piston itself, the hydraulic oil is pressed back to oil
tank. If the cut-off valve is mounted at the bottom of cylinder (See Figure 5-8), it can play
the role of protection if the mast rises when high-pressure pipe cracks.
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Figure 5-7 Lift cylinder
1. Bolt M16×1.5×40 2.washer 16 3.chain wheel 4. Snap ring 40
5. Chain wheel assembly 6.spacer bush 7. Bolt M12×1.25×25
8. Bolt M12×1.25×50 9.U type bolt 10.Nut M10×1.25 11.waher 10
12. washer 10 13. Pin B10×26 14. Adjusting block 15.Oil cylinder support block
16. Nut M12×1.25 17.Piston rod 18.dust proof ring 40×52×7/10 19.guide sleeve
20. Seal ring 40×50×6 21. Steel-backed bearing 4030 22.Shim 23. Screw M5×6
24. O ring d49.7×2.4 25. Cylinder body 26. Steel cable baffle ring
27.support ring 50×10×2.5 28. Valve assembly 29. Piston
30. Adjusting sleeveφ48×40.5 31.retaining plate 50×40×3
32.seal ring for hole 50×40×6 33.shim 34.sleeve 35.steel-cable baffle ring for hole
36.Spherical nut 37. Nut M14×1.5 38. Pin 3.2×30
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5.1.4 Cut-off valve
The cutoff valve is mounted at the bottom of the hoist cylinder (See Figure 5-8) to
prevent the goods from falling suddenly when the high pressure pipe is broken. The oil
from hoist cylinder passes through the hole A on the outer circumference of the spool
when returning to oil tank, if flow rate of oil through the hole is less than the setting value
of the valve and the pressure difference before and after spool smaller than spring force,
the spool will not move at this time and slide valve does not work. If the flow rate
through the spool hole exceeds the setting value due to high pressure pipe cracking or
other reasons, the pressure difference before and after spool will be larger than the spring
force and move the spool to the left. In this way, hole A is closed, only small amount of
oil flows out from the small clearance of spool and valve bush and the goods descends
slowly.
Flow less than the setting valve
Flow more than the setting valve

Figure 5-8 Working principle of the cut-off valve
5.1.5 Flow regulator valve
The flow regulator valve, located in the lift cylinder circuit to limit the descending
speed of loaded forks, has the construction as shown in Figure 5-9.
129
When the lift spool is placed in the “lift” position, the oil from the control valve
flows through the oil chambers A and B, oil holes C, D, E and F, and the chamber G to
the lift cylinder without any regulation. When the lift spool is placed in the “down”
position, the oil pusses the orifice plate and a pressure difference generates between the
chambers A and B, the pressure difference overcomes the force of the spring and moves
the valve core right, thus the oil flow being decreased by narrowing of the hole D and C,
and reduces the oil flow passing through the orifice plate.
Figure 5-9 Flow regulator valve

(1) Nipple (2) Spring (3) Ring seal (4) Snap ring (5) Spool
(6) Sleeve (7) Steel ball(8) Spring of the check valve (9) Valve body
5.1.6 Tilt cylinder
The tilt cylinder is of double-action and piston type hydraulic cylinder and is
mounted at both sides of mast with its piston rod end connecting with mast. The bottom
of tilt cylinder is connected through pin with connecting end of truck frame and mast, and
the forward and backward tilting of the mast are fulfilled by the motion of tilt cylinder.
The tilt cylinder consists primarily of piston, piston rod, cylinder body, cylinder base,
guide sleeve and seals. The piston, welded to the piston rod, is fitted with two Yx-rings
and one wear ring on its circumference. A bushing press-fitted to the inner side of the
guide sleeve supports the piston rod. The guide sleeve is with dust seal, snap ring,
Yx-ring and O-ring to prevent oil leakage and keep dust off. Fitted with them, the guide
130
sleeve is screwed into the cylinder body. When piston moves, oil enters from one port and
exits from the other. The piston rod is furnished with adjusting threads to adjust the
difference between the dip angles. (See Figure 5-10)
When the tilt lever is pushed forward, the high-pressure oil enters into the cylinder
body from the cylinder tail, moving the piston forward and causing the mast assembly to
tilt forward until 6 degrees. When the tilt lever is pulled backward, high-pressure oil
enters into the cylinder body from the guide sleeve and moves the piston backward,
tilting the mast assembly backward.
Figure 5-10 Tilt cylinder

(1) Ear ring (2) Dust ring (3) Snap ring (4) Yx-ring
(5) O-ring (6) Guide sleeve (7) Bushing (8) O-ring (9) Piston rod
(10) Cylinder body (11) Yx-ring (12) Wearing (13) Piston (14) Yx-ring
5.1.7 Oil tank
Oil suction filter, return oil filter and breather are fixed in the oil returning pipelines
to make sure the cleanness of the supplied oil.
5.1.8 Hydraulic oil circuit
The hydraulic system principle diagram see figure 5-11 and the hydraulic oil circuit
see figure 5-12.
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Figure 5-11 Hydraulic system principle diagram
1) Oil tank 2) Oil suction filter 3) Pump motor 4) Gear pump 5) Control valve
6) Steering unit 7) Steering cylinder 8) Flow regulator valve 9) Cut-off valve
10) Lift cylinder 11) Tilt cylinder 12) attachment cylinder 13) Return oil filter
Figure 5-12 hydraulic oil circuit
132
5.2 Maintenance，Fault Analysis and Remedies
5.2.1 Maintenance
Check if there is any seepage and serious oil leakage on the pipe fittings of hydraulic
drive system, hoist cylinder, tilt cylinder, oil pump, fully hydraulic steering gear and
steering cylinder before and after each shift. Check if the working oil inside work oil tank
is sufficient and check and clean the strainer mesh of oil filter mounted in the work oil
tank once every week. The first replacement time of the oil return filter is 300 hours (or
one and a half months), and the subsequent replacement cycle is 1200 hours (or six
months). The filter must be replaced when replacing the hydraulic oil.
Normally, change the oil in the work oil tank once every 1200-1500 hours of work
and mixed use of oils of different brand number is not allowed.
5.2.2 Troubleshooting
Trouble Cause Trouble shooting
1) Excessive wearing between the oil 1) Replace the wearable parts or oil
pump gear and pump body and pump.
wider-than-normal gap.
2) Wearing and wider-than-normal gap of 2) Replace with new piston sealing ring.
the piston sealing part in the lifting
cylinder, excessive inner leakage.
3) Failure of safety valve spring of control 3) Replace with new spring.
valve.
4) Excessive oil leakage due to wearing 4) Chromium plating the valve rod to
Insufficient between the control valve rod of control couple with the hole with the gap at
lifting
valve and valve body. 0.01～0.02.
capacity or 5) Oil leakage among valve bodies of the
unable to lift 5) Change the sealing ring, screw tight
control valve . the screw in sequence.
6) Oil leakage in hydraulic pipe. 6) Check to see whether there is damage
to the sealing ring or connecting nut and
screw tight the pipe joint.
7) Higher-than-normal temperature of 7) Replace the unqualified hydraulic oil,
hydraulic oil (should be ≤80℃), excessive stop operation to lower oil temperature
oil dilution and insufficient flow. and try to find the cause of over high oil
temperature.
8) Excessive load. 8) Lift load according to requirements.
1) Oil leakage due to wearing of ring seal 1) Replace the ring seal.
at fasteners.
Insufficient
2) Hydraulic oil is contaminated with air 2) Discharge air and add hydraulic oil.
pressure of
to form foam, air leakage at oil suction
oil pump
pipe-work, insuffi-
cient hydraulic oil.
133
3) Damaged ring seal inside the pump 3) Replace.
cover groove.
4) Wearing of the end face of bearing 4) Replace.
sleeve.
5) Oil pump gear wears. 5) Replace the oil pump.
6) Wrong rotation direction of oil pump. 6) Correct.
Trouble Cause Trouble shooting
1) Inner leakage of control valve.
1) Replace O-ring seal, repair valve rod
and reassign the coupling gap between
Excessive self 2) Inner leakage due to the damaged valve rod and hole to 0.01～0.02.
tilting of the O-ring seal of piston rod of the tilting 2) Replace.
tilting cylinder cylinder.
3) Oil leakage due to the damaged
YX-ring seal and O-ring seal in the pilot 3) Replace.
sleeve.
1) Select appropriate oil pump or check
1) Insufficient oil supply of oil pump,
to see if the oil pump is normal.
the slow-steering hand wheel feels
relatively light and the fast-steering
hand wheel heavy.
2) Discharge air in the system and check
2) Air in the steering system, foam in
the oil suction pipe-work.
oil, making irregular noise, the hand
wheel can rotate while the oil cylinder
can not keep continuous motion.
3) Check if the steel ball exists and if
3) Failure of the steel ball one-way
Heavy Steering there is dirty stuff blocking the steel
valve in the valve body, both the fast and
balls.
slow steering hand wheels are heavy,
also no pressure at steering.
4) Adjust pressure of the overflow valve
4) Pressure of the overflow valve is
or clean it.
lower than working pressure or the
overflow valve is blocked by dirty stuff,
light steering in case of light or no load,
heavy steering when adding load.
5) Use oil liquid with recommend-
5) Excessive viscosity of the oil liquid
ded viscosity.
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6. Lifting System
6.1 General Description of normal type lifting system
The lifting system is of the two-stage roller type with veritical up and down. It
consists of the inner mast, the outer mast, lifting cylinder and fork carrier.
6.1.1 Inner and Outer Masts
The inner and outer masts both are welded parts, and the weight is mainly supported
by the axle housing. The bottom of the outer mast is connected with the axle housing
through the support shaft. The middle part of the outer mast is connected with the frame
through the tilting cylinder, and can be tilted back and forth under the action of the tilting
cylinder. The channel steel of outer mast is C-type, the upper part is installed with main
roller and side roller, the channel steel of inner mast is JB type, the main roller and side
roller are installed at the bottom, and the inner mast makes the inner and outer mast keep
in the fixed relative position during the movement through the rolling of main rollers and
side rollers.
The maintenance of the roller and the side rollers on the inner and outer masts
belong to exalted maintenance. Please be careful.
135
Figure 6-1 inner, outer mast and accessories
6.1.2 Fork carrier
The fork carrier rolls in the inner mast through the main roller, which is fixed on the
main roller axle with snap ring, and the middle roller adopts composite roller; the main
roller shaft is welded on the fork carrier, and the side roller of vertical plate is fixed on
the fork carrier by bolts. The longitudinal load is borne by the main roller. When the fork
is lifted to the top, the upper roller is exposed from the top of the mast, and the transverse
load is borne by the composite roller and the lower side roller.
136
Figure 6-2 Fork carrier
6.1.3 Roller adjusting
The main rollers (6) are respectively installed at the upper end of the outer mast (2),
the lower end of the inner mast (2), and both sides of the upright plate of the fork carrier
(2); 4 composite rollers are respectively installed in the middle and both sides of the
lower end of the fork carrier.
The side rollers (6) are respectively installed on the upper end of the outer mast (2),
the lower end of the inner mast (2), and the fork carrier (2).
In addition to the composite rollers in the middle and lower end of the upright plate
of the fork carrier, the other main rollers only bear the load in the front and rear directions,
while the side rollers bear the side loads in the left and right directions. The main roller
137
and the side roller are used together to make the inner mast and fork carrier move freely.
Figure 6-3 Roller layout

Note: (a) The adjusting clearance of side roller is 0～0.5mm.
(b) Add grease on the surface of the main roller and the contact surface of the mast.
6.1.4 Maintenance
a. Adjust lift cylinder
The stroke of the rear lift cylinder must be readjusted when the lift cylinder, the
inner mast or the outer mast is replaced. As following:
(1) Place piston rod heads into the upper beam of the inner mast without shims.
(2) Slowly raise the mast to the maximum stroke of the oil cylinder and observe
whether the stroke terminals of the two oil cylinders are synchronized. If the two
cylinders stop at the same time, it indicates that the left and right cylinder travel is not
synchronized; add or decrease the shim at the top of the piston rod to make the stroke to
be synchronized; add an adjusting shim between the piston rod head and the upper cross
beam of the inner mast. The thickness of shim is 0.2mm and 0.5mm.
(3) Then lower the inner mast slowly to observe whether the stroke terminals of the
two cylinders are synchronized, which can refer to the adjustment method of lifting
synchronization;
(4) Adjust the tightness of lift chains.
138
The adjustment of lift cylinder also belongs to exalted maintenance. Please be
careful.
Figure 6-4 Installation drawing of rear lift cylinder

b. Adjust fork carrier’s height
(1) The truck should be stopped on horizontal ground. And ensure the masts erect.
(2) Lower the forks on the ground, adjust the set nut of tie-in on the upper of chains
to assure the distance A between main rollers and lower end of the mast channel steel.
Truck type A mm
1～2.0t(E) 36-41
2～2.5t 24-29
3～3.8t 19-24
(3) Make the mast assembly tilt backward when forks descended to the ground,
adjust the pulling force of lift chains and let the tightness of lift chains be equal.
Figure 6-5
139
c. Replacing rollers of the fork carrier
(1) Place a pallet on the forks and make the forklift stop on the horizontal ground.
(2) Make the forks and pallet descend to the ground.
(3) Take down tie-in on top of the chains. And take out chains from sheave. (See
Figure 6-6)
(4) Make the inner mast rise.
(5) Remove the fork carrier when the lift bracket disengaged from the outer mast.
(6) Replacing main rollers:
(a) Take apart all of snap ring from the lift bracket and take out main rollers.
(b) Fit the new main roller (the same type as the old one) on the fork carrier and
fastened with snap ring.
Figure 6-6
d. Replacing rollers of masts
(1) Take apart the fork carrier from the inner mast follows the way as c.
(2) Park the truck on the horizontal ground and lift up the front-wheel 250～300mm
from the ground.
(3) Pull parking brake level fully, and use a wedge to make back-wheel stationary.
(4) Take apart bolts which fastened lift cylinders and the inner mast. Hang up the
inner mast without losing shims of the piston rod heads carefully.
140
(5) Take apart bolts which jointed lift cylinders and the bottom of outer mast and
take apart the oil-pipe between two lift cylinders without loosing the nipple.
(6) Lower the inner mast and remove the main roller at the bottom of the inner mast.
(7) The main roller at the top of the outer mast will be exposed from the top end of
inner mast, then the main roller can be removed.
(8) Replacing main rollers
a) Take apart the upper main rollers without losing shims.
b) Fit the new main roller and shims together on the outer mast.
(9) Hang up the inner masts and let all rollers in the inner mast.
(10) Assembly the lift cylinder and the fork carrier as disassembly contrarily.
Note: the introduction in this manual is a general description. The specific structural
details of its structural parts and composite rollers shall be subject to the actual object. If
you have any technical questions, please consult the manufacturer.
6.2 Two stage full free lifting system
The two-stage full free lifting system is a two-stage roller type vertical lifting and
lowering system, which is composed of inner and outer mast, two rear lifting cylinders,
one front lifting oil cylinder and fork carrier.
6.2.1 Inner and outer mast
The inner and outer masts are welded parts, and the weight is mainly supported by
the axle housing. The connection of the mast with the axle and the mast is the same as
that of the two-stage normal type mast. The bottom of the outer mast is connected with
the axle housing through the support shaft, and the middle part of the outer mast is
connected with the mast through the tilt cylinder, and can tilt back and forth under the
action of the tilting cylinder. The channel steel of outer mast is C-type, the upper part is
installed with main roller and side roller, the channel steel of inner mast is JB type, the
141
main roller and side roller are installed at the bottom, and the inner mast makes the inner
and outer mast keep in the fixed relative position during the movement through the
rolling of main rollers and side rollers.
Figure 6-7 inner and outer mast and accessories
6.2.2 Fork carrier
142
The main rollers (6) are respectively installed at the upper end of the outer mast (2),
the lower end of the inner mast (2), and both sides of the upright plate of the fork carrier
(2). Combination roller (4), installed on middle part and lower end of fork carrier
respectively.
The side rollers (6) are respectively installed on the upper end of the outer mast (2),
the lower end of the inner mast (2), and the fork carrier (2).
In addition to the composite rollers in the middle and lower end of the upright plate
of the fork carrier, the other main rollers only bear the load in the front and rear directions,
while the side rollers bear the side loads in the left and right directions. The main roller
and the side roller are used together to make the inner mast and fork carrier move freely.
143
Figure 6-9 Roller layout
6.2.4 Maintenance
a Adjust lift cylinder
(1) Place piston rod heads into the upper beam of the inner mast without shims.
synchronization;
144
The adjustment of lift cylinder also belongs to exalted maintenance. Please be
careful.
Figure 6-10 Installation drawing of rear lift cylinder

(5) When the front cylinder needs to be replaced, the fork carrier needs to be
removed. The disassembly method is the same as c. take down the whole fork carrier, and
then dismantle and replace the front lifting cylinder.
to assure the distance A between main rollers and lower end of the mast channel steel.
Truck type A mm
1～2.0t(E) 36-41
2～2.5t 24-29
3～3.8t 19-24
145
Figure 6-11
Figure 6-12)
(6) Replacing main rollers:
Figure 6-12
146
from the ground.
(4) Take apart bolts which fastened lift cylinders and the inner mast. Hang up the
inner mast without losing shims of the piston rod heads carefully.
(5) Take apart bolts which jointed lift cylinders and the bottom of outer mast and
take apart the oil-pipe between two lift cylinders without loosing the nipple.
(6) Lower the inner mast and remove the main roller at the bottom of the inner mast.
(7) The main roller at the top of the outer mast will be exposed from the top end of
inner mast, then the main roller can be removed.
b) Fit the new main roller and shims together on the outer mast.
(9) Hang up the inner masts and let all rollers in the inner mast.
(10) Assembly the lift cylinder and the fork carrier as disassembly contrarily.
Note: the introduction in this manual is a general description. The specific structural
details of its structural parts and composite rollers shall be subject to the actual object. If
you have any technical questions, please consult the manufacturer.
6.3 Three stage full free lifting system
The three-stage full free lifting system is a three-stage roller type vertical lifting and
shrinking system, which is composed of inner, middle and outer three gantry, two rear
lifting cylinders, one front lifting oil cylinder and fork frame.
6.3.1 Inner, middle and outer mast
147
The inner, middle and outer mast are welded parts, and the weight is mainly
supported by the axle housing. The bottom of the outer mast is connected with the axle
housing through the support shaft, and the middle part of the outer mast is connected with
the frame through the tilting cylinder, and can tilt back and forth under the action of the
tilting cylinder. The channel steel of the outer mast is of C type, with the main roller and
side roller installed on the upper part; the channel steel of the middle mast is of JB type,
with a pair of main rollers and side rollers installed at the upper and lower parts
respectively; the channel steel of the inner mast is of JB type, with a pair of main rollers
and side rollers installed at the bottom. The inner mast makes the inner and outer mast
keep in the fixed relative position during the movement through the rolling of main
rollers and side rollers.
The maintenance of the upper main roller and side roller of the inner, middle and
outer door frame belongs to high-level maintenance, and attention should be paid to
safety.
Figure 6-13 Inner, middle, outer mast and accessories
148
6.3.2 Fork carrier

There are 10 main rollers, which are respectively installed at the upper end of the
outer mast (2), the upper end of the middle mast (2), the lower end of the middle mast (2),
the lower end of the inner mast (2), and both sides of the vertical plate of the fork carrier
(2). Composite rollers (4), respectively installed on both sides of the middle and lower
149
ends of the fork carrier.
There are 10 side rollers, which are respectively installed at the upper end of the
outer mast (2), the upper end of the middle mast (2), the lower end of the middle mast (2),
the lower end of the inner mast (2), and the fork carrier ( 2 ), as shown in Figure 6-15.
The composite roller(figure 6-16) in the middle of the vertical plate of the fork
carrier bear not only the load in forward and backward direction and also the load in
lateral, the other main rollers only bear the load in the front and rear direction, while the
side roller bears the lateral load in the left and right directions. The main roller and the
side roller are used together to make the inner mast and fork carrier move freely.
Figure 6-15 Rollers layout

Figure 6-16 Composite roller
150
6.3.4 Maintenance
a. Adjust lift cylinder
(1) Place piston rod heads into the oil cylinder support of middle mast without
shims.
synchronization;
The adjustment of lift cylinder also belongs to exalted maintenance. Please be careful.
(5) When the front cylinder needs to be replaced, the fork carrier needs to be
removed. The disassembly method is the same as c. take down the whole fork carrier, and
then dismantle and replace the front lifting cylinder.
151
Figure 6-17 Adjusting of rear lifting cylinder synchronization
to assure the distance A between main rollers and the mast channel steel, As shown in
Figure 6-18.
Truck type A mm
1～2.0t(E) 36-41
2～2.5t 24-29
3～3.8t 19-24
Figure 6-18
152
Figure 6-19).
(6) Replacing main rollers.
Figure 6-19
from the ground.
(4) Take apart the joints on top of the chain of the rear cylinder head and then
153
remove the chain from the chain wheel.
(5) Lower the inner mast until the rollers at the bottom of the inner mast and at the
top of the middle mast are exposed out.
b) Fit the new main roller and shims taken apart from step a).
(7) Remove the fixing bolts between the lifting cylinder and the middle mast. Lift
the inner and middle mast together, and pay attention not to lose the adjusting shims of
piston and rod head.
(8) Remove the connecting bolts between the lifting cylinder and the bottom of the
outer mast. Remove the lifting cylinder and the oil pipe between the two cylinders. Do
not loosen the oil pipe joint.
(9) Lower the inner and middle masts until the rollers on the lower part of the
middle mast and the upper part of the outer mast are exposed.
(10) Replace the main roller, the same as (6).
(11) Lift the inner and middle mast until all rollers enter the corresponding mast.
(12) Assemble the lifting cylinder and fork carrier according to the inverse steps.
Note: this introduction is a general description. The specific structural details of its
structural parts and composite rollers shall be subject to the actual object. If you
have any technical questions, please consult the manufacturer.
154
Appendix: Electrical schematic diagram of the lithium battery
Electrical schematic diagrams of the lithium battery is show as follows.
Figure A-1 is suited for lithium battery of 80V272Ah
Figure A-5 is suited for lithium battery of 80.5V202Ah
155
2 3 L .
5 6 7 8
3
2
Serial Number Mark Count Change Position Change Reason Sign Date
Charging + Change Log
QC-P- I~1QC-P+
Power supply 12V + A
Main circuit fuse Power supply 12 V-
Charging CAN H
Charging relay
Charging CAN L
Charging CAN GND_
S- CC2 signal Fast charge
JRCzM
~
LJRCzp- Temperature sensor Tl -
Heating fuse Heating film Temperature sensor T1+
Heating relay of charging

j Temperature sensor 12-
Temperature sensor T2+
Precharge relay
Charging-
a Heating relay of discharging
B
£
FD-P + FD-P- Precharge resistance
Discharging +
FDzP + l~IFD -
^ Vehicle CANJI
Vehicle CAN L
Discharging relay
BUS IN Discharging
BUS OUT BUS OUT
Discharging -
■ DC 12V-
DC 12V +
DC/DC module C
m= BUS IN
CC2 signal
nu
B2 ON gear signal DQ 12 V +
uolsjnEO
■
cp supply of as i2v+ i N Power supply of charging 12 V+

DC 12 V-
nu l alu uojla p
| Power supply of charging 12V-
_ 485B Instrument interface of 485 comunication
'p
tod
Vehicle CAN H
Vehicle CAN— L
DC 12V+ 2
-
Jacket type：AMP 174259 2
Terminal type：AMP 17166H
--
485A 3
.□
Charging CAN_ H
Charging CAN L
—
DC 12 V- 4 Buckle type: AMP 174260 7
Plug type：AMP 172888 2 D
B Ms
acneloA
- - - - uolpa cu
B+
V1+
V2+
V3+
Intranet CAN一H
Intranet CAN L
Temperature sensor T1 +
Temperature sensor Tl-
le—lol
Intranet CAN H
_
B (V V2 V3 ) 485A Intranet CAN L 2
'oinoion Part Marking 485B Charging CAN H
.witc
3 Debug interface
— dlob — dlD—Hl dlaz dl—jaz -

485GND Charging CAN L
Hi19 h D 4 Jacket type：AMP 282090 1
1
U uojl Vehicle CANJI 5
-J HU
+ + Vehicle CAN— L
dl ldl
+
3 s
!
+
dl CITG
+ d dl 6
nbue
3
£ 35 — —
H 3 3
E
^
A A
^
匕 >
New Drawing Number

a
B- ( V 1-V 2-V3- )
Shunt Lithium battery system for
Old Drawing Number Positive direction
lithium battery special vehicle
Figure A-1
Electrical schematic
Sign Sign Date Sign Date Phase marker Weight Scale F
Design itandardizatioi
Date Proofreading Craft

Check Approve Page: 1 of 1 first angle drawing c|(S)
2 3 / .
5 6 7 8
156
2 3 L .
5 6 7 8
：i
2
Charging + Change Log
fiCzP+
Power supply 12V+ A
QCzEd
-
~
Main circuit fuse Power supply 12V
_
Charging CAN H
Charging relay
Charging CAN—L
V3+ Charging CAN GND
JRCzP+ l~[JRCzP-
S
Heating
- fuse CC2 signal
Temperature Tl -
Fast charge
Heating film Temperature sensor T1 +
Heating relay of charging

Temperature sensor T 2+
Precharge relay
Charging -
Heating relay of discharging
a
FD-P+ I 1 FD-P- Precharge resistance — B
V1+
Discharging+
FD-P+ FD-P-
Vohiclo CANJ 1
Vehicle CAN L
Discharging relay
BUS IN Discharging
BUS OUT BUS OUT
Discharging -
DC 12V+
DC/DC module
DC 12V
- C
BUS IN
CC2 signal
ON gear signal DC 12V+
^
:□ Power supply of charging 12V+
uoj DC 12V
- -
uojpal
| Power supply of charging 12V
s 485B
;
Instrument interface of 485 communication
□ Vehicle CAN H
l cu
s uiEOU
DC 12V+ Jacket type：MIP 174259-2
tod
!
2
Vehicle CAN L 485A Teminal type：AMP 17166 H
- D
3
Charging CAN— H DC 12V Buckle type: AJIP 174260-7
.□ Charging CAN—L Plug type：AHP 172888-2
aCJ BM Temperature T1一
- - - - leloH uojpalcu
B+ ) Intranet CAN H
el o
V1
V2
Vs
>
Intranet CAN L
Temperature T1一 Intranet CAN一H
- -
>
B (VI V2 3 ) 485A Intranet CAN L 2
Common Part larking 485B

485GND
Charging CAN H
一
Charging CAN L
3
Debug interface
uo
— — dll— — diHZ diHZ - —
High-Side Drive Switch Jacket type：AMP 282090-1
Vehicle CAN H
luanu Eslnbue
5
: +
dd d
+ dl
+ CLI +
+
0 d
Vehicle CAN L 6
qlcx.CLj oo 8 — '
3 3
H H
'J —Jl
3
A
I
oA
E
New Drawing Number
O-
- - - -)
B ( V1 V2 V3
Figure A-2
Design
^
tandardizaLio:
i ：i
Check Approve Page: 1 of 1 first angle drawing
2 3 L 5 6 7 8
157
2 3 L .
5 6 8
3
2
Charging ^ Change Log
QCzEd
—
IQCZL+
Power supply 12V+ A
-
_
Charging CAN— H
Charging relay
Charging CAN—L
V3+ Charging CAN GND
JRCzP+J~IJRCzP-
S -
Heating fuse
CC2 signal
Temperature sensor Tl
-
Fast charge
Heating film Temperature sensor T1+
Precharge relay
Heating relay of charging Temperature sensor T2
-
Charging -
a
FD P+
- B
-
VI
Discharging+
FD P+
- m± -
Vehicle CAN H
Vehicle CAN L
Discharging relay
BUS IN Discharging
BUS OUT BUS OUT
Discharging-
DC 12V+
DC/DC module
m DC 12V - C
BUS IN
CC2 signal
nu
B 24 ON gear signal DC 12V+
l Power supply of charging 12V+
"
cu
uol DC 12V
- -
uojpal
| Power supply of charging 12V
s
; 485B Instrument interface of 485 comnunication
13
Vehicle CAN H
--
s unE Ou
ip DC 12V+
tod
!
2 Jacket type：AMP 174259 2
Vehicle CAN L 485A Terminal type：AMP 171661 1
- --
3
A□
Charging CAN— H
Charging CAN—L
DC 12V Buckle type: AMP 174260 7
Plug type: AMP 172888 2 D
BM Temperature sensor Tl-
- - - IES 20 uolpa cu
a le Intranet CAN H
B
I
一
lo
>
Intranet CAN L
- Intranet CAN H
B (V V2 485A Intranet CAN L 2
Common Part larking — 485B
— — — dlaz dl—az - —
I Charging CAN H 3
一
s de Dn•'e switch
485GND Charging CAN L 4 Debug interface
-
luajnu uoslnbue
Hi19 h Vehicle CANJ 1 5
Jacket type：AMP 282090 1
+ + Vehicle CAN L
+ +
dl + Id 6
g dig dl d 3
d 0
I
35 30 Hf 33
A A
E
New Drawing Number
O-
- ---
R ( V 1 V2 V3 )
Figure A-3
Design Standardizatio:
i ：i
Check Approve Page: 1 of 1 first angle drawing
2 3 L 5 6 7 8
158
2 3 L_ 5 6 7 8
3
2
_ Serial Number Mark Count Change Position Change Reason Sign Date
Bj
Charging+ Change Log
] -
Power supply 12V+ A
-
_
Charging CAN—li
Charging relay
Charging CAN—L
Charging CAN GND
JRC-P+I I.TRC-P-
S -
Heating fuse
CC2 signal
-
Fast charge
Heating film Temperature sensor T1+
Heating relay of charging l r«J-
•J
s Temperature sensor T2+
Precharge relay
Charging-
FD-P+
c>
FD-P- Precharge resistance
= .4
B
—：
Discharging+
FD-P+I IFD-P-
Vehicle CAN H
Vehicle CAN L
Discharging relay
BUS IN Discharging
BUS OUT BUS OUT
Discharging -
B ： DC 12V+
DC 12V
- C
DC/DC module
■rz BUS IN
. _
CC2 signal
-n
B 25+ ON gear signal DC 12V+
Power supply of charging 12V+
■
c:p •• ••• • «« Mb p
uo
| 4
DC 12V
-
nu 13 uolpc a s - | Power supply of charging 12V
-
; «»m
485B
!
rmtt G
Vehicle CAN一H Instrument interface of 485 communication
uiEO
BD DC 12V+
tod
type：AMP 174259-2
Vehicle CANT
!
~ 2 Jacket
485A Terminal type：AMP 17166H
CATIT 3
AO
Charging
Charging CAN L
_ DC 12V- Buckle type：A\IF 174260-7
Plug type: AMP 172888-2 D
a BM s Temperature sensor T1
B1-
B+
V l;
+
6
e uo Intranet C A N H
Intranet CAN—L
V 2+ lo pa
!

-
>
V + ;
3 Temperature sensor Tl Intranet CAN H
- --- le
ap
-
^
B (V V2 3 '
p
; 485A
~
Intranet CAN一L 2
hiion Part larking 01 485B Charging CAN H 3
. 485GND Charging CAN L Debug interface
luajnu uojlsmbue — — — -—
High -Side Drive S witch Vehicle CANJ 1 5
Jacket typo：AMP 282090- 1
+ + Vehicle CAN L 6
dig rl B dlHf d—loH diHZ diHZ dloA

+ +
dl 3
0
I
£ * 3
3
A
E
New Drawing Number
R- ( VI-VH> )
G -
Figure A-4
Design kandardizatioi
i ：i
Check Approve Page: 1 of 1 first angle drawing $
( )
2 3 4 5 6 7 8
159
(Isolation)
Main positive fuse
DC input+
DC output+
Diverter 1 detection+
Diverter 2 detection-
DC output-
Control signal
Heating relay+ DC input-
KEY-IN
BMS power supply+

BMS power supply-
Module voltage
Temperature data collection Vehicle CANH Vehicle debugging CANH
BMS AIO
Vehicle CANL Vehicle debugging CANH
A+
A-
Charging CANH Charging debugging CANH
Debugging port
Charging CANL Charging debugging CANL
CC2
Intranet CANH Intranet debugging CANH

Intranet CANL Intranet debugging CANL
Hall collection
Vehicle communication port

CAN1H
CAN1L 174257-2
Key switch
Precharge resistance Precharge relay
Discharge relay Discharge port:

Main positive
Amphenol socket
Main negative
Discharge port:
Heating relay- Amphenol socket
Charge port:
A+
A- 250A Chinese GB charging base
CAN2H
Charging relay CAN2L
CC2
Diverter DC+
DC-
CC1
PE
1P25S-202Ah(C370M1)
Figure A-5
160
(Isolation)
Main positive fuse
DC input+ DC output+
DC output-
Control signal
KEY-IN
BMS power supply+
BMS power supply-
Module voltage
BMS AIO
A+
A-
Debugging port
CC2

Hall collection

CAN1H
CAN1L 174257-2
Key switch
Discharge relay
Discharge port:
Main positive
Amphenol socket
Main negative Discharge port:

Heating relay-
Amphenol socket
Charge port:
A+
CAN2H
Diverter Charging relay CAN2L
CC2
Diverter DC+
DC-
CC1
PE
2P25S-404Ah(C093)
Figure A-6
161
(Isolation)
Main positive fuse
DC output-
Control signal
KEY-IN
BMS power supply+
BMS power supply-
Module voltage
BMS AIO
A+
A-
Debugging port
CC2

Hall collection

CAN1H
CAN1L 174257-2
Key switch
Discharge relay
Discharge port:
Main positive
Amphenol socket

Heating relay-
Amphenol socket
Charge port:
A+
CAN2H
CC2
Diverter DC+
DC-
CC1
PE
2P24S-542Ah(C098) Figure A-7
162
(Isolation)
Main positive fuse
DC output-
Control signal
KEY-IN
BMS power supply+
BMS power supply-
Module voltage
BMS AIO
A+
A-
Debugging port
CC2

Hall collection

CAN1H
CAN1L 174257-2
Key switch
Discharge relay
Discharge port:
Main positive
Amphenol socket

Heating relay-
Amphenol socket
Charge port:
A+
CAN2H
CC2
Diverter DC+
DC-
CC1
PE
2P25S-456Ah(C093M2)
Figure A-8
163
DC-DC:48V-12V (Isolation)
Main positive fuse
DC output-
Control signal
Heating relay+ IG-ON
DC input-
BMS power supply+
BMS power supply-
Debugging port
34S AIO
Debugging CAN0H
CAN0H
Debugging CAN0L CAN0L
Vehicle CAN1H CAN1H
Vehicle CAN1L CAN1L
A+
A-
Module voltage Charging CAN2H CAN2H
Temperature data collection
Charging CAN2L
CC2
CAN2L
Discharge port:
REMA female connector
CAN1H
CAN1L
MCU+
Discharge relay
MCU-
A+ Charge port:
A-
250A Chinese GB charging base
CAN2H
Heating relay- CAN2L
Charging relay
CC2
MCU+
MCU-
Diverter CC1
PE
1P25S-271Ah (C136)
Figure A-9
164
OPERATION &
SERVICE MANUAL
www.helichina.com
Add/No.668, FangXing Road, Hefei, China

Post Code/230000
Customer Service Hotline/4001-600761
Fokeli Print
S327-6-2022
Service Tel/+86-551-63648005,63689000
E-mail/heli@helichina.com All rights reserved

S327!6!2022 Operation & Maintenance Manual (English)

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S327!6!2022 Operation & Maintenance Manual (English)

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OPERATION &

1.Delivery of Forklift Truck ........................................................................................ 1

2.Storage of Forklift Truck.......................................................................................... 1

3.Precautions Before Operation .................................................................................. 1

4.Operation of Forklift Truck ...................................................................................... 2

5.Daily Maintenance of Forklift Trucks...................................................................... 3

6.Vehicle Identification Number position ................................................................... 5

7.Capacity chart .......................................................................................................... 6

Ⅱ. Main Specifications of Forklift Truck ............................................................................ 9

Ⅲ. Construction, Principle, Adjustment and Maintenance of Forklift Trucks ................. 17

1. Transmission System ............................................................................................ 17

2. Brake System ........................................................................................................ 21

4. Electric System ..................................................................................................... 43

5 Hydraulic System ................................................................................................. 123

6. Lifting System ..................................................................................................... 135

Appendix: Electrical schematic diagram of the lithium battery ..................................... 155

《OPERATION AND SERVICE MANUAL》&《OPERATION MANUAL》.

1.Delivery of Forklift Truck

with container or trucks.

(1) Apply the parking brake.

hoisting up the forklift truck.

and press the emergency button.

2.Storage of Forklift Truck

(1) Lower the mast to the lowest position.

(3) Wedged up the wheels.

the emergency button.

3.Precautions Before Operation

(4) The forward-reverse lever should be in neutral.

(5) Check all the levers and pedals.

(6) Complete the provisions before starting.

(7) Release the parking lever.

truck for steering and braking.

4.Operation of Forklift Truck

operating the truck.

damages or defects are found, operate it after repairing.

it evenly. Do not raise an object with one fork end.

(6) Travel with loads as low as possible and tilted backward.

to the clearance over forklift truck.

(10) Never permit anyone to stand or walk under upraised forks.

(14) Be careful and slowly driving over a dockboard or bridge-plate.

unavoidable, apply the parking brake and block the wheels.

5.Daily Maintenance of Forklift Trucks

(1) Inspection before startup

b) Check piping, joints, pumps and valves for leaks or damages;

(2) Oil used for forklift trucks

6.Vehicle Identification Number position

position is shown in the figure below.

Vehicle Identification Number position

It is forbidden to overload the forklift truck, otherwise overload may lead to

rated capacity are shown as follows.

（1）The actual capacity of forklift truck(The following figure is an example)

（2）The rated capacity chart of forklift trucks

1.5t (2-stage mast) 1.5t (3-stage mast)

1.8t (2-stage mast) 1.8t (3-stage mast)

2t (2-stage mast) 2t (3-stage mast)

2.5t (2-stage mast) 2.5t (3-stage mast)

3t (2-stage mast) 3t (3-stage mast)

3.8t (2-stage mast) 3.8t (3-stage mast)

External view of forklift trucks

Max. overall dimensions mm 1125×350×800 1125×350×800 1230×350×800 1230×350×800 1230×350×800

Max. overall dimensions mm 1150×620×960 1150×620×960 1150×560×980 1150×560×980 1150×705×980

Max. overall dimensions mm 1090×1405×1400 1090×1405×1400 1090×1405×1400 1090×1405×1400 1090×1405×1400

Max. overall dimensions mm 1038×500×2000 1038×500×2000 1165×520×2080 1165×520×2080 1165×520×2080