CDD14-ES CDD16-ES

STAND-ON PALLET STACKER

OPERATION MANUAL

HANGCHA GROUP CO.,LTD

 Foreword
Thanks for your purchasing our forklift truck.
CDD14-ES is our company’s new product. This manual is about how to use,
operation and maintenance . Please operator and whom in charge of the truck must
read the manual carefully before operate the truck.
We have the right to improve the truck, maybe there are some difference between
your product and the description in this manual.
If you have any questions please keep in touch with the sales department of E-P
Equipment or let the dealer know.

HANGCHA GROUP CO.,LTD

Address: NO.88 Donghuan Road, Economic Development Zone, Lin’an, Zhejiang, China
Tel:86-571-88926752/88926755/88926733
Fax:86-571-88926789
Net: www.hcforklift.com
Email: [email protected], [email protected]

ALL RIGHT RESERVED COPYRIGHT @2010.1 1st EDITION

HANGCHA GROUP Co.,Ltd
 WARNING!
TO PREVENT SETIOUS RISK OF INJURY TO
YOUORSELF AND OTHERS OBSERVE THE
FOLLOWING SAFETY INSTRUCTIONS.
These truck may become hazardous if adequate maintenance is neglected. Therefore,
adequate maintenance facilities, trained personnel and procedures should be
provided.

Maintenance and inspection shall be performed in conformance with the following

practices:

1. A scheduled planned maintenance,lubrication and inspection system should be

followed.

2. Only qualified and authorized personnel shall be permitted to maintain, repair,

adjust, and inspect truck.

3. Before leaving the truck:

– Do not park the truck on an incline.
– Fully lower the load forks.
– Set the key switch (4) to the "OFF" position and remove the key.
–Drawing back the emergency brake switch (11).
– Fold in the folding side arm

4. Before starting to operate truck:

– Be in operating position
– Place directional control in neutral
– Before operating truck, check functions of lift systems, directional control,speed
control,steering, warning devices and brakes.

5. Avoid fire hazards and have fire protection equipment present. Do not use open
flame to check lever, or for leakage of electrolyte and fluids or oil. Do not use open
pans of fuel or flammable cleaning fluids for cleaning parts.

6. Brakes,steering mechanisms, control mechanisms,guards and safety devices shall

be inspected regularly and maintained in legible condition.

7. Capacity, operation and maintenance instruction plates or decals shall be

maintained in legible condition.

8. All parts of lift mechanisms shall be inspected to maintain them in safe operating
condition.
9. All hydraulic systems shall be regularly inspected and maintained in conformance
with good practice. Cylinders, valves and other similar parts shall be checked to
assure that "drift" has not developed to the extent that it would create a hazard.

10. Truck shall be kept in a clean condition to minimize fire hazards facilitate detection
of loose or detective parts.

11. Modifications and additions which affect capacity and safe truck operation shall
not be performed by the customer or user without manufacturers prior written
approval. Capacity, operation and maintenance plates or decals shall be changed
accordingly.
 catalog
Correct use and application ....................................................................................1
1. Truck Description .................................................................................................2
1.1Assemblies .....................................................................................................2
1.2 Identification points and data plates ...............................................................5
1.3Specifications .................................................................................................7
2.Transport and Commissioning .............................................................................9
2.1Transport ........................................................................................................9
2.2Using the Truck for the First Time ...................................................................9
2.3During brake-in .............................................................................................10
3.Operation ............................................................................................................. 11
3.1Safety Regulations for the Operation of Forklift Trucks ................................. 11
3.2Starting up the truck ...................................................................................... 11
3.3Safety regulations for truck operation ...........................................................15
3.4 Collecting and depositing loads ...................................................................16
4.Battery Maintenance & Charging .......................................................................17
4.1 Safety regulations for handling acid batteries ..............................................17
4.2 Battery type & dimension .............................................................................18
4.3Charging the battery .....................................................................................18
4.4Battery removal and installation ....................................................................19
5.Forklift Truck Maintenance .................................................................................21
5.1Operational safety and environmental protection ..........................................21
5.2Maintenance Safety Regulations ..................................................................21
5.3Servicing and inspection ...............................................................................22
5.4Decommissioning the industrial truck ............................................................28
5.5Safety checks to be performed at regular intervals and following any unusual
incidents ............................................................................................................29
5.6Final de-commissioning, disposal .................................................................29
6.Troubleshooting ..................................................................................................30
 Correct use and application
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
supplied with the truck. The guidelines form part of these operating instructions and
must be observed. National regulations apply in full.
The truck described in the present operator manual is an industrial truck designed for
lifting and transporting load units.
It must be used, operated and serviced in accordance with the present instructions.
Any other type of use is beyond the scope of application and can result in damage to
personnel, the truck or property. In particular, avoid overloading the truck with loads
which are too heavy or placed on one side. The data plate attached to the truck or the
load diagram are binding for the maximum load capacity. The industrial truck must not
be used in fire or explosion endangered areas, or areas threatened by corrosion or
excessive dust.
Proprietor responsibilities
For the purposes of the present operator manual the “proprietor” is defined as any
natural or legal person who either uses the industrial truck himself, or on whose behalf
it is used. In special cases (e.g. leasing or renting) the proprietor is considered the
person who, in accordance with existing contractual agreements between the owner
and user of the industrial truck, is charged with operational duties.
The proprietor must ensure that the truck is used only for the purpose it is intended for
and that danger to life and limb of the user and third parties are excluded.
Furthermore, accident prevention regulations, safety regulations and operating,
servicing and repair guidelines must be followed. The proprietor must ensure that all
truck users have read and understood this operator manual.
Failure to comply with the operator manual shall invalidate the warranty. The same
applies if improper work is carried out on the truck by the customer or third parties
without the permission of the manufacturer’s customer service department.
Attaching accessories
The mounting or installation of additional equipment which affects or supplements the
performance of the industrial truck requires the written permission of the manufacturer.
In some cases, local authority approval shall be required.
Approval of the local authorities however does not constitute the manufacturer’s
Approval.

1
1. Truck Description
1.1Assemblies

Item Component Item Component

1 Folding operator pedal 5 Control Handle

2 Side arm 6 Emergency brake switch
3 Battery discharge indicator 7 Mast
4 Key switch 8 Lift mechanism

2
1.1.1Folding operator pedal
Folding operator pedal have two state: fold
and unfold. While the state of Folding
operator pedal changed the Travel speed
(Max) changed too. Because of gas spring
the folding operator pedal can fold
self-motion.

1.1.2Side arm
Travel speed (Max) will change when the
state of side arm is changed. Travel speed
(Max) is much higher when the side arm is
unfolded. The side arm can protect
operator when truck running in high speed.

1.1.3Battery discharge indicator

The LEDs (1) represent battery residual
capacity, The LCD (2) displays the
operating hours

Battery Discharge Indicator(1)

When the truck has been released via
the key switch, the battery charge
status is displayed.
The colours of the LEDs (1) represent
the following conditions:

LED colour value

Green Standard battery residual capacity 70-100%
Orange Standard battery residual capacity 50-60%
Flashing Red Standard battery residual capacity 0-20%
Battery Discharge for 70%, A flashing red show on storage battery charge warning.
Battery Discharge for 80%, Two flashing reds show on battery charge used up
warning, Lifting is now inhibited. The battery must be charged.
Operating hours display
Display range between 0.0 and 99,999.0 hours. Travel and lifting are logged. This is a
backlit display.
Power up test

3
On power up the display shows:
– the operating hours
– the charge status

1.1.4Key switch
Switches control current on and off.
Removing the key prevents the truck from being switched on by unauthorised
personnel.
1.1.5Control Handle

9 “Lower” button Lowers load forks.

10 “Lift” button Raises load forks.
11 Driving Controls the driving speed and direction
regulator
12 Warning signal Triggers a warning signal.
button
13 Collision safety Safety function which, when activated, forces the truck to
switch reverse for approx. 3 seconds and then cuts out until the
controller is briefly restored to neutral.
1.1.6Emergency brake swich
The supply current is interrupted, all electrical functions are deactivated and the truck
is automatically braked.

4
1.2 Identification points and data plates
Item Description

14 AC Power Decal

15 Operator Warning Decal

16 Truck data plate

17 “Never stand under the forks” warning

18 “Never stand or ride on forks for any reason” warning

19 “DO not operate this truck unless you are trained and authorized” warning

5
 1.2.1Truck data plate

For queries regarding the truck or ordering spare parts please quote the truck serial
Number SN.

6
1.3Specifications
Item Description Unit Parameter
1 Rated capacity Kg 1600
2 Load centre distance mm 600
(c)
3 Lift (mast-dependent) Max mm Remark①
(h1)
4 Raise lift speed(Max) Fully load mm/ 100
s
5 Travel speed(Max) Non-load Km/h 8.0
Remark②
6 Max. grade ability (5 Fully load % 8
min rating)
7 Turning radius Pedal folded (w1) mm 1665
Pedal unfold (w2) mm 2095
8 Ground clearance(m2) Min mm 30
9 Fork thickness （S） Max mm 60
10 Fork height（h8） mm 85
11 length Pedal folded (L2) mm 2003
Pedal unfold (L1) mm 2525
12 Dimensions width(b1) mm 850
13 height（h6） mm Remark①
14 Pedal height（h2） mm 140
15 Side arm height（h3） mm 1000
16 Control handle height Max (h5) mm 1160
Min (h4) mm 1500
17 Net weight （ including Kg 1050
battery）
20 Motor Travel KW 1.5
21 Raise lift KW 3.0
22 Wheel Loading Wheel /number Ф85х70/4
23 Driving wheel /number Ф230х75/1
24 Balance Wheel /number Ф130х60/2
25 Battery Type 2V-VCF
26 Voltage / capacity V/Ah 24/210
27 Brake distance Non-load mm 1
28 Wheelbase (Y) mm 1394
29 Distance between Fork (b11) mm 380
forks, outer
Remark:
① Particular parameter see the form1-1《parameter of Lift (mast-dependent) and
height》on page 8.

7
 ② The Travel speed(Max) is 6.0Km/h when the pedal folded or side arm folded.

Form 1-1 parameter of Lift (mast-dependent) and height

Lift (mast-dependent) 2600 2950 3150 3450 3750 4150 4450 4950
h1（mm）
Height h6 1844 2019 2119 2269 2419 2619 2769 3019
（mm）

8
2.Transport and Commissioning
2.1Transport
2.1.1Lifting the truck by crane
1.Only use crane lifting gear with
sufficient capacity.
2.Loading weight = net weight of truck
(+ battery weight for electric trucks).
3.Crane lifting gear get across fixed
hole(1) to Lifting the truck.
– Park the truck securely.(see 3.2.4
Parking the truck securely on page 14).
–Secure the crane slings to the
attachment points (1).
Raise the truck with the forks at the side
between the axles. Raise the truck
slightly and make sure it is securely
positioned on the forks. Necessary
adjust or secure the forks with stops.
Lower the truck slowly onto the ground
and prevent it from rolling away.

2.1.2Securing the truck during

transport
The truck must be securely fastened
when transported on a lorry or a trailer.
Keep pedal and side arm folded,avoid
them out of bodywork.
- The rope is used to fix the truck must
be firm enough.
- Check .
Both sides need to fix.
Loading must be carried out by staff
specially trained. In each case correct
measurements shall be determined and
appropriate safety measures adopted.

2.2Using the Truck for the First Time

Only operate the truck with battery current. Rectified AC current will damage the
electronic components. Cable connections to the battery (tow leads) must be less
than 6 m .
Preparing the truck for operation after delivery or transport

9
Procedure
– Check the equipment is complete.
– Check the hydraulic oil level.
– Install the battery if necessary, (see "4.4 Battery removal and installation" on page
19).
– Charge the battery, (see "4.3 Charging the battery" on page 18).
2.3During brake-in
We recommended operating the machine under light load conditions for the first stage
of operation to get the most from it. Especially the requirements given below should
be observed while the machine is in a stage of 100 hours of operation.
1. Must prevent the new battery from over discharging when early used.
2. Perform specified preventive maintenance services carefully and completely.
3. Avoid sudden stop, starts or turns.
4. Oil changes and lubrication are recommended to do earlier than specified.
5. Limited load is 70～80% of the rated load.

10
3.Operation
3.1Safety Regulations for the Operation of Forklift Trucks
Driver authorisation: The forklift truck may only be used by suitably trained
personnel, who have demonstrated to the proprietor or his representative that they
can drive and handle loads and have been authorised to operate the truck by the
proprietor or his representative.

Driver’s rights, obligations and responsibilities: The driver must be informed of

his duties and responsibilities and be instructed in the operation o f the truck and
shall be familiar with the operator manual . The driver shall be afforded all due rights .
Safety shoes must be worn with pedestrian operated trucks.

Unauthorised Use of Truck: The driver is responsible for the truck during the time it
is in use. He shall prevent unauthorised persons from driving or operating the truck.
It is forbidden to carry passengers or lift personnel.

Damage and Faults: The supervisor must be immediately informed of any damage
or faults to the forklift truck. Trucks not safe for operation (e.g. wheel or brake
problems) must not be used until they have been rectified.

Repairs: The driver must not carry out any repairs or alterations to the forklift truck
without the necessary training and authorisation to do so. The driver must never
disable or adjust safety mechanisms or switches.

Hazardous area: A hazardous area is defined as the area in which a person is at

risk due to truck movement, lifting operations, the load handler (e.g. forks or
attachments) or the load itself. This also includes areas which can be reached by
falling loads or owering operating equipment.

Unauthorised persons must be kept away from the hazardous area. Where there is
anger to personnel, a warning must be sounded with sufficient notice. If unauthorised
personnel are still within the hazardous area the truck shall be brought to a halt
immediately.

Safety Devices and Warning Signs: Safety devices, warning signs and warning
instructions shall be strictly observed.

3.2Starting up the truck

3.2.1 Preparing
Before the truck can be commissioned, operated or a load unit lifted, the driver must
ensure that there is nobody within the hazardous area.

11
Checks and operations to be performed before starting daily work
– Visually inspect the entire truck (in particular wheels and load handler) for obvious
damage.
– Visually inspect the battery attachment and cable connections.

3.2.2Switching on the truck

– Make sure the Emergency brake switch is depressed(6).

12
– Make sure the battery is connected
– Insert the key in the key switch ( 4 ) Warning!
and turn it to the right as far as it will go. Before operating the truck, check all
– Test the warning signal switch (6). controls and warning devices for
The truck is now operational. proper operation. If any damage of
The battery charge / discharge indicator fault is found, don’t operate truck until
(3) shows the available battery corrected.
capacity. 叉车任何损坏或失灵，未修理回复前
禁止启动叉车。
Test the braking operation of the control handle (5).
3.2.3Travelling, Steering, Braking
Never carry passengers.
Be extremely careful when driving and steering,especially when operating outside the
geometry of the truck.
Emergency Disconnect
–Drawing back the emergency brake switch (6).
All electrical functions are deactivated.
Emergency Stop
Automatic braking (emergency stop) occurs when the control handle (5) is
released–the tiller automatically reverts to the upper brake zone (B).
If the control handle moves slowly to the braking zone , the cause of this fault must be
rectified. If necessary, replace the recuperating spring.

13
Travel
Do not reach between the operator pedal and the truck panel when you fold up the
pedal.
We distinguish between two travel modes:
Truck with a folding operator pedal and moving handle.
– Pedestrian mode: Push the side arms in, fold up the operator pedal (1). The truck
can only be operated at the reduced travel speed.
– Rider mode: Push the side arms out, fold down the operator pedal (1). The truck can
be operated at maximum speed.
General:
– Set the handle (5) to the travel zone (F).
– Turn the controller (11) to the required direction (fwd. or rev.).
If the side arms are not folded out,the truck can only be operated at reduced speed.
Do not drive the truck unless the panels are closed and properly locked.When
travelling through swing doors etc. make sure that the doors do not activate the
collision safety button (13).
Travelling on inclines
Loads must always be carried at that end of the truck facing uphill.
Steering
In narrow bends the driver extends beyond the geometry of the truck.
– Move the tiller (5) to the left or right.
Braking
The brake pattern of the truck depends largely on the ground conditions. The driver
must take this into account when operating the truck.
The truck can brake in three different ways:
– by plugging
– by using the operating brake
– with the emergency brake switch (Emergency Disconnect)
By Plugging:
– When travelling, set the controller (11) to the opposite direction.
The truck brakes regeneratively until it starts to move in the opposite direction.
The rate of braking depends on the position of the controller.
Braking with the operating brake:
– Set the tiller (5) to one of the brake zones (B).
The drive motor brakes regenerative ( motor brake ) . Only when this brake fails to
achieve the necessary brake force is the mechanical brake ( magnetic brake) applied.
When the truck is idle the magnetic brake (magnetic brake) applies.
When the tiller is released it reverts to the upper braking zone (B).
Braking with the emergency brake switch:
–Press Emergency brake switch (11) .
The circuit is interrupted , all electrical functions are cut out and the truck
automatically brakes (magnetic brake).
3.2.4Parking the truck securely
When you leave the truck it must be securely parked even if you only intend to leave it

14
for a short time.
– Do not park the truck on an incline.
– Fully lower the load forks.
– Set the key switch (10) to the "0" position and remove the key.
–Drawing back the emergency brake switch (11).
– Fold in the folding side arm
Do not reach between the operator platform and the truck panel when you fold up the
folding platform.

3.3Safety regulations for truck operation

Travel routes and work areas : Only use lanes and routes specifically designated
fortruck traffic. Unauthorised persons must stay away from work areas . Loads must
onlybe stored in places specially designated for this purpose.

Driving conduct: The driver must adapt the travel speed to local conditions .
Thetruck must be driven at slow speed when negotiating bends or narrow
passageways ,when passing through swing doors and at blind spots . The driver must
always observe an adequate braking distance between the forklift truck and the
vehicle in front and must be in control of the truck at all times . Abrupt stopping
(except emergencies) , rapid U turns and overtaking at dangerous or blind spots are
not permitted. It is forbidden to lean out of or reach beyond the working and operating
area.

Travel visibility : The driver must look in the direction of travel and must always have
a clear view of the route ahead . Loads which affect visibility must be stored at the
rear of the truck.If this is not possible , a second person must walk in front of the truck
asa lookout.

Negotiating slopes and inclines :Negotiating slopes or inclines is only permitted if

such roads are clean and have a non-slip surface and providing such journeys are
safely undertaken in accordance with the technical specifications for the truck in
question. The truck must always be driven with the load unit facing uphill. The
industrial truck must not be turned , operated at an angle or parked on inclines or
slopes. Inclines must only be negotiated at slow speed, with the driver ready to brake
at any moment.

Negotiating lifts and docks : Lifts and docks must only be used if they have
sufficient capacity, are suitable for driving on and authorised for truck traffic by the
owner . The driver must satisfy himself of the above before entering these areas . The
truck must enter lifts with the load in front and must take up a position which does
not allow it tocome into contact with the walls of the lift shaft.
Persons riding in the lift with the forklift truck must only enter the lift after the truck
has come to a rest and must leave the lift before the truck.

15
3.4 Collecting and depositing loads
Before picking up a load , the driver must ensure that it is correctly palletised and that
the capacity of the truck is not exceeded. It is forbidden to collect long loads at an
angle.
– Fully insert the truck and the load handler underneath the load unit.
Lift
– Press the “Lift” (10) button until you reach the desired lift height.
Release the button as soon as you reach the limit position of the load handler.
Lower
– Press the “Lower ” button (9) until you reach the required lifting height.
Do not deposit the load in a sudden manner.
Nature of loads to be carried: The operator must make sure that the load is in a
satisfactory condition. Only carry loads that are positioned safely and carefully . Use
suitable precautions, e.g. a load guard , to prevent parts of the load from tipping or
falling down.

16
4.Battery Maintenance & Charging
4.1 Safety regulations for handling acid batteries
Park the truck securely before carrying out any work on the batteries.

Maintenance personnel : Batteries may only be charged, serviced or replaced by

trained personnel .The present operator manual and the manufacturer ’s instructions
concerning batteries and charging stations must be observed when carrying out the
work.

Fire protection :
– Smoking and naked flames must be avoided when working with batteries.
– Wherever a truck is parked for charging there shall be no inflammable material or
operating fluids capable of creating
sparks within 2 metres around the truck.
– The area must be well ventilated.
– Fire protection equipment must be
provided.

Protection against electric shock:

– Battery has high voltage and energy.
– Do not bring short circuit.
– Do not approach tools to the two poles of the battery，which can cause the sparkle.

Do not overuse battery:

– If you use up the energy of battery till the forklift immovability, you will shorten its
working hours.
– Shower for battery appears need for charge，please charge it quickly.

Inspection for electrolyte:

– Do not using forklift which is absent electrolyte.
– Inspection for electrolyte level every week.
– When electrolyte level is low，you must add distilled water to the level appointed.

Battery maintenance: The battery cell covers must be kept dry and clean. The
terminals and cable shoes must be clean, secure and have a light coating of
dielectric grease.Batteries with non insulated terminals must be covered with a non slip
insulation mat.

Warning!
1. Do not use dry cloth or fibre cloth to clean the battery，avoiding static to bring the
explosion.
2. Unfixing battery plug.
3. Cleaning with wet cloth.
4. Wearing glasses for protecting eyes rubber overshoes and rubber glove.
17
Battery Disposal:Batteries may only be disposed of in accordance with national
environmental protection regulations or disposal laws.The manufacturer’s disposal
instructions must be followed.

Before closing the battery cover make sure that the battery lead cannot be damaged.

Batteries contain an acid solution which is poisonous and corrosive . Therefore ,

always wear protective clothing and eye protection when carrying out work on
batteries . Above all avoid any contact with battery acid.

Nevertheless, should clothing, skin or eyes come in contact with acid the affected
parts should be rinsed with plenty of clean water-where the skin or eyes are affected
call a doctor immediately. Immediately neutralise any spilled battery acid.

Only batteries with a sealed battery container may be used.

The weight and dimensions of the battery have considerable affect on the operational
safety of the truck. Battery equipment may only be replaced with the agreement of the
manufacturer.

4.2 Battery type & dimension

Battery type & dimension as follow :
Tuck type Battery type Battery height Battery length Battery width
(mm) (mm) (mm)
CDD14-ES 24V-VCF 600 815 222

When replacing or installing batteries, ensure that the battery is correctly secured in
the battery compartment of the truck.

4.3Charging the battery

4.3.1Exposing the battery
Park the truck securely (See 3.2.4
Parking the truck securely Page 14).

– Drawing back the emergency brake

switch (3).
– Lift up the battery panel (2) using the
grip mould (1) and fold it back.

4.3.2Charging the battery

Safety regulations for Charging the battery

18
– To charge the battery, the truck must be parked in a closed and properly ventilated
room.
– When charging, the tops of the battery cells must be exposed to provide sufficient
ventilation.
– Do not place any metal objects on the battery .
– Before charging, check all cables and plug connections for visible signs of damage.
– It is essential to follow the safety regulations of the battery and charging station
manufacturers.

Charging step
– Check whether the condition is
according with "Safety regulations for
Charging the battery".
– Park the truck securely(See 3.2.4
Parking the truck securely Page 14 ).
– Expose the battery ( see 4.3.1
Exposing the battery Page 18 ).
– Remove the battery connector (29).
–Connect the battery plug (30) with the
charging lead of the stationary charger
(29) and turn on the charger.
4.4Battery removal and installation
4.4.1Changing the battery
⑴Undo the spring elements of the battery panel and remove the battery panel.

The truck must be parked on level ground. To prevent short circuits, batteries with
exposed terminals or connectors must be covered with a rubber mat. Place the
battery connector or the battery cable in such a way that they will not get caught on
the truck when the battery is removed.

When transporting batteries using a crane, ensure that the crane is of adequate
Capacity (the battery weight is indicated on the battery data plate on the battery
container). The lifting gear must exert a vertical pull so that the battery container is not
compressed. The hooks must be
attached to the eyes (4) of the battery in
such a way that they cannot fall onto
the battery cells when the lifting gear is
discharged.
– Park the truck securely(See 3.2.4
Parking the truck securely Page 14 ).
– Expose the battery ( see 4.3.1
Exposing the battery Page 18 ).
– Remove the battery connector (3).

19
 – Strap the crane lifting gear to the eyes (8).
–Drawing back the emergency brake switch.

When replacing a battery always use the same battery type. Extra weights must not
be removed and must remain in the same position.

– Installation is in the reverse order of operations. When reinstalling the battery,

heed the required installation position and make sure the battery is connected
correctly.
（2）remove the side panel
The truck must be parked on level
ground. To prevent short circuits,
batteries with exposed terminals or
connectors must be covered with a
rubber mat. Place the battery
connector or the battery cable in such a
way that they will not get caught on the
truck when the battery is removed.
–Remove the battery panel which on
the side, then pull out the battery.
Installation is in the reverse order of
operations.
After installing the battery again, check
all cables and plug connections for
visible signs of damage.
Before starting the truck, the battery panel must be firmly closed. Close the battery
panel carefully and slowly. Do not reach between the battery panel and the chassis.

20
5.Forklift Truck Maintenance
5.1Operational safety and environmental protection
– The servicing and inspection operations contained in this chapter must be
performed in accordance with the intervals indicated in the servicing checklists.

– Any modification to the forklift truck assemblies, in particular the safety

mechanisms, is prohibited. The operational speeds of the truck must not be changed
under any circumstances.

– Only original spare parts have been certified by our quality assurance department.
To ensure safe and reliable operation of the forklift truck, use only the manufacturer's
spare parts. Used parts, oils and fuels must be disposed of in accordance with the
relevant environmental protection regulations. For oil changes, contact the
manufacturer’s specialist department.

– Upon completion of inspection and servicing, carry out the activities listed in the
“Recommissioning (on page 27)” section.

5.2Maintenance Safety Regulations

Maintenance personnel
Industrial trucks must only be serviced and maintained by the manufacturer’s trained
personnel.
The manufacturer’s service department has field technicians specially trained for
these tasks. We therefore recommend a maintenance contract with the
manufacturer’s local service centre.
Lifting and jacking up
When an industrial truck is to be lifted, the lifting gear must only be secured to the
points specially provided for this purpose.
When jacking up the truck, take appropriate measures to prevent the truck from
slipping or tipping over (e.g. wedges, wooden blocks).
You may only work underneath a raised load handler if it is supported by a sufficiently
strong chain.
Cleaning
Do not use flammable liquids to clean the industrial truck.
Prior to cleaning, all safety measures required to prevent sparking (e.g. through short
circuits) must be taken. For battery-operated trucks, the battery connector must be
removed.
Only weak suction or compressed air and non-conductive antistatic brushes may be
used for cleaning electric or electronic assemblies.
If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical
and electronic components must be carefully covered beforehand as moisture can

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cause malfunctions.
Do not clean with pressurised water.
After cleaning the truck, carry out the activities detailed in the “ Recommission (on
page 27)” section.
Electrical System
Only suitably trained personnel may operate on the truck’s electrical system.
Before working on the electrical system, take all precautionary measures to avoid –
electric shocks.
For battery-operated trucks, also de-energise the truck by removing the battery
connector.
Welding
To avoid damaging electric or electronic components, remove these from the truck
before performing welding operations.
Settings
When repairing or replacing hydraulic, electric or electronic components or
assemblies, always note the truck-specific settings.
Tyres
The quality of tyres affects the stability and performance of the truck. When replacing
factory fitted tyres only used original manufacturer’s spare parts, as otherwise the
data plate specifications will not be kept.
When changing wheels and tyres, ensure that the truck does not slew (e.g. when
replacing wheels always left and right simultaneously).
Lift chains
Lift chains wear rapidly if not lubricated.
The intervals stated in the service checklist apply to normal duty use. More
demanding conditions (dust, temperature) require more regular lubrication.
The prescribed chain spray must be used in accordance with the instructions.
Applying grease externally will not provide sufficient lubrication.
Hydraulic hoses
The hoses must be replaced every six years. When replacing hydraulic components,
also replace the hoses in the hydraulic system.
5.3Servicing and inspection
Thorough and expert servicing is one of the most important requirements for the safe
operation of the industrial truck. Failure to perform regular servicing can lead to truck
failure and poses a potential hazard to personnel and equipment.
The service intervals stated are based on single shift operation under normal
operating conditions. They must be reduced accordingly if the truck is to be used in
conditions of extreme dust, temperature fluctuations or multiple shifts.
The following maintenance checklist states the tasks and intervals after which they
should be carried out. Maintenance intervals are defined as:
W = Every 50 service hours, at least weekly
A = Every 500 operating hours
B = Every 1000 operating hours, or at least annually
C = Every 2000 operating hours, or at least annually

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W service intervals are to be performed by the customer.
In the run-in period - after approx. 100 service hours - or after repair work, the owner
must check the wheel nuts/bolts and re-tighten if necessary.
5.3.1Maintenance Checklist
Standard ＝ ★
W A B C
Cold Store ＝ ☆
Brake 1.1 Check magnetic brake air gap. ★

Electrics 2.1 Test instruments, displays and control ★

switches.
2.2 Test warning and safety device. ☆ ★
2.3 Check fuse ratings. ★
2.4 Make sure wire connections are secure ★
and check for damage.
2.5 Test micro switch setting. ★
2.6 Check contactors and relays. ★
2.7 Frame leakage test ★
2.8 Test cable and motor attachments. ★
2.9 Check carbon brush wear, replace if ★
necessary.

Power 3.1 Visually inspect battery ☆ ★

supply 3.2 Check battery cable connections are ☆ ★
secure, grease terminals if necessary.
3.3 Check acid density, acid level and battery ☆ ★
voltage.

Travel 4.1 Check motor suspension. ★

4.2 Check the transmission for noise and ★
leakage.
4.3 Replace gear oil if service life exceeded
(10,000 hours).
4.4 Check travel mechanism, adjust and ☆ ★
lubricate if necessary.
Check tiller recuperating function.
4.5 Check wheels for wear and damage. ☆ ★
4.6 Check wheel bearings and attachments. ★

Truck 5.1 Test the operator’s platform and check for ★

design damage.
5.2 Check chassis for damage and screw ★
connections.
5.3 Check labels. ★

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 Standard ＝ ★
W A B C
Cold Store ＝ ☆

Hydraulic 6.1 Check operation, wear and setting. ★

operation 6.2 Check forks for wear and damage. ★
6.3 Test hydraulic system. ☆ ★
6.4 Check that hose and pipe lines and their ☆ ★
connections are secure, check for leaks
and damage.
6.5 Check cylinders and piston rods for ☆ ★
damage and leaks, and make sure they are
secure.
6.6 Check hydraulic oil level. ☆ ★
6.7 Replace hydraulic oil filter. ☆ ★
6.8 Replace hydraulic oil. ☆ ★
6.9 Check wheels for wear and damage. ★
Agreed 7.1 Lubricate truck in accordance with ☆ ★
performance Lubrication Schedule.
levels 7.2 Test run ★
7.3 Demonstration after servicing ★

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5.3.2 Lubrication Schedule

25
Fuels, coolants and lubricants

Handling consumables: Consumables must always be handled correctly. Follow the

manufacturer’s instructions.

Improper handling is hazardous to health, life and the environment. Consumables

must only be stored in appropriate containers. They may be flammable and must
therefore not come into contact with hot components or naked flames.

Only use clean containers when filling up with consumables. Do not mix consumables
of different grades. The only exception to this is when mixing is expressly stipulated in
the Operating Instructions.

Avoid spillage. Spilled liquids must be removed immediately with suitable bonding
agents and the bonding agent/consumable mixture must be disposed of in
accordance with regulations.

Code Description Used for

A HM46# Hydraulic system
B Grease, Polylube GA352P Lubrication
C GL-85W-90 Transmission

5.3.3 Maintenance Instructions

Prepare the truck for maintenance and repairs
All necessary safety measures must be taken to avoid accidents when carrying out
maintenance and repairs. The following preparations must be made:
– Park the truck securely (See 3.2.4 Parking the truck securely Page 14 ).
– Disconnect the battery to prevent the
truck from accidentally starting.
– When working under a raised lift truck,
secure it to prevent it from tipping or
sliding away.
( see 4.3.1 Exposing the battery Page
18 )

Removing the front panel

– Open the battery panel( see 4.3.1
Exposing the battery Page 18 ).
– Remove the two screws (1).
– Carefully lift off the front panel (2).

Replacing the drive wheel

The drive wheel must only be replaced by authorised service personnel.

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Checking the hydraulic oil level
– Prepare the truck for maintenance and
repairs ( See 5.3.3 Maintenance
Instructions Page26 ).
– Opening the front panel(See 5.3.3
Maintenance Instructions Page26).
– Check hydraulic oil level in hydraulic
reservoir .
There is oil level display on the level gauge
The Oil level depends on the lift height.
The oil level must be checked when the
load forks are lowered.
–If necessary add hydraulic oil of the
correct grade ( See 5.3.2 Lubrication
Schedule P26 ) .
Installation is the reverse order.
Check transmission oil level
– Prepare the truck for maintenance and repairs (See 5.3.3 Maintenance Instructions
Page26 ).
– Remove the front panel (See 5.3.3 Maintenance Instructions Page26).
– Turn the tiller to the right stop.
– Check the transmission oil level, it should be at the control plug level (See 5.3.2
Lubrication Schedule Page26).
– If necessary add transmission oil of the
correct grade (See 5.3.2 Lubrication
Schedule Page26).
Installation is the reverse order.
Checking electrical fuses
– Prepare the truck for maintenance and
repairs (See 5.3.3 Maintenance
Instructions Page26 ).
– Dismantle the front panel (See 5.3.3
Maintenance Instructions Page26).
– Check rating of all fuses in accordance
with table, replace if necessary.
Item To protect: Rating

1 Traction / Lift motor 200A

2 Controller 15A

Recommissioning
The truck may only be recommissioned after cleaning or repair work, once the
following operations have been performed.

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– Test horn.
– Test Emergency brake swich.
– Test brake.
– Lubricate the truck in accordance with the maintenance schedule.

5.4Decommissioning the industrial truck

If the industrial truck is to be decommissioned for more than two months , e.g.
foroperational reasons,it must be parked in a frost-free and dry location and
allnecessary measures must be taken before, during and after decommissioning as
described.

On decommissioning the truck must be jacked up so that all the wheels are clear of
the ground. This is the only way of ensuring that the wheels and wheel bearings are
not damaged.
If the truck is to be out of service for more than 6 months , further measures must be
taken in consultation with the manufacturer’s service department.

5.4.1Prior to decommissioning
– Thoroughly clean the truck.
– Check the brakes.
– Check the hydraulic oil level and replenish as necessary (See 5.3.3 Maintenance
Instructions Page26 ).
– Apply a thin layer of oil or grease to any non-painted mechanical components.
–Lubricate the truck in accordance with the maintenance schedule (See 5.3.2
Lubrication Schedule P26 ).
– Charge the battery (See 4.3Charging the battery P18).
– Disconnect the battery, clean it and apply grease to the terminals.
In addition, follow the battery manufacturer’s instructions.
– Spay all exposed electrical contacts with a suitable contact spray.
5.4.2During decommissioning
Every 2 months:
– Charge the battery (See 4.3Charging the battery P18).
Battery powered trucks:
The battery must be charged at regular intervals to avoid depletion of the battery
through self-discharge. The sulfatisation would destroy the battery.
5.4.3 Restoring the truck to operation after decommissioning
– Thoroughly clean the truck.
– Lubricate the truck in accordance with the maintenance schedule (See 5.3.2
Lubrication Schedule P26 ).
– Clean the battery, grease the terminals and connect the battery.
– Charge the battery (See 4.3Charging the battery P18).

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– Check transmission oil for condensed water and replace if necessary.
– Check hydraulic oil for condensed water and replace if necessary.
– Start up the truck (see 3.23.2Starting up the truck P11).

Battery powered trucks:

If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the operating
controls by applying them repeatedly.
Perform several brake tests immediately after re-commissioning the truck.
5.5Safety checks to be performed at regular intervals and following any
unusual incidents
Carry out a safety check in accordance with national regulations. HANGCHA has a
special safety department with trained personnel to carry out such checks. The truck
must be inspected at least annually (refer to national regulations) or after any unusual
event by a qualified inspector. The inspector shall assess the condition of the truck
from purely a safety viewpoint, without regard to operational or economic
circumstances. The inspector shall be sufficiently instructed and experienced to be
able to assess the condition of the truck and the effectiveness of the safety
mechanisms based on the technical regulations and principles governing the
inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by
possible improper use. A test report shall be provided. The test results must be kept
for at least the next 2 inspections.
The owner is responsible for ensuring that faults are immediately rectified.
A test plate is attached to the truck as proof that it has passed the safety inspection.
This plate indicates the due date for the next inspection.
5.6Final de-commissioning, disposal
Final, proper decommissioning or disposal of the truck must be performed in
accordance with the regulations of the country of application. In particular, regulations
governing the disposal of batteries, fuels and electronic and electrical systems must
be observed.

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6.Troubleshooting
This chapter is designed to help the user identify and rectify basic faults or the results
of incorrect operation. When locating a fault, proceed in the order shown in the table.
Fault Possible cause Action
Truck does – Battery connector not – Check the battery connector
not start. connected and connect if necessary.
－ Key switch in “0” position – Set key switch to “I”
－Battery charge too low – Check battery charge, charge
－Faulty fuse battery if Necessary
－Truck in charge mode – Test fuses
– Interrupt charging
Load can not – Charge capacity below 20 / – Charging the battery
be lifted 40% – Hydraulic oil level too – Check the hydraulic oil level
low – Note maximum capacity (see
– Excessive load data plate)

If the fault cannot be rectified after carrying out the remedial procedure, notify the
manufacturer ’ s service department ,as any further troubleshooting can only be
performed by specially trained and qualified service personnel.

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