Foreword

Thanks for your purchasing our electric pallet truck.

This manual is about how to use, operation and maintenance CBD15-EM. 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
HANGCHA GROUP CO.,LTD. or let the dealer know.

HANGCHA GROUP CO.,LTD

Address:
Tel: 86-571- 88926772,
Fax: 86-571- 88926789
Net: www.hcforklift.com
Email: [email protected] , [email protected]

ALL RIGHT RESERVED COPYRIGHT 1st Dec. 2011 EDITION

 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 to the "OFF" position and remove the key.

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

1.1Application ......................................................................................................2
1.2 Assemblies ....................................................................................................3
1.2.1Control Handle ......................................................................................4
1.2.2Key switch.............................................................................................4
1.2.3Battery discharge indicator ....................................................................5
1.2.4Emergency brake switch .......................................................................5
1.3 Identification points and data plates ...............................................................6
1.3.1Truck data plate ....................................................................................7
1.4.Standard Version Specifications .....................................................................8
1.4.1Performance data for standard trucks ...................................................8
1.4.2Dimensions ...........................................................................................9

2.Transport and Commissioning ........................................................................... 11

2.1Transport ...................................................................................................... 11
2.2Using the Truck for the First Time ................................................................. 11
2.3During brake-in .............................................................................................12

3.Operation .............................................................................................................13
3.1Safety Regulations for the Operation of Forklift Trucks .................................13
3.2 Operate and run the truck ............................................................................13
3.2.1 Preparing ...........................................................................................13
3.2.2 Travel .................................................................................................14
3.3.3Lifting, transporting and depositing loads ............................................16
3.3.4Parking the truck securely ...................................................................17

4.Battery Maintenance & Charging .......................................................................18

4.1 Safety regulations for handling acid batteries ..............................................18
4.2 Battery type & dimension .............................................................................18
4.3Charging the battery .....................................................................................18
4.4Battery removal and installation ....................................................................19
4.5Battery maintenance .....................................................................................20
4.6 Battery Disposal ..........................................................................................21
5.Forklift Truck Maintenance .................................................................................22
5.1Operational safety and environmental protection ..........................................22
5.2Maintenance Safety Regulations ..................................................................22
5.3Servicing and inspection ...............................................................................24
5.3.1Maintenance Checklist ........................................................................25
5.3.2 Lubrication Schedule .........................................................................26
5.3.3 Maintenance Instructions ...................................................................27
5.4Decommissioning the industrial truck ............................................................29
5.4.1Prior to decommissioning ....................................................................29
5.4.2 Restoring the truck to operation after decommissioning .....................30
5.5Safety checks to be performed at regular intervals and following any unusual
incidents ............................................................................................................30
5.6Final de-commissioning, disposal .................................................................31

6.Troubleshooting ..................................................................................................32
 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
1.1Application
The truck is designed to transport goods on level surfaces. It can lift open bottom or
diagonal board pallets as well as roll cages beyond the area of the load wheels.
Suitable environment temperature is 5°C to 40 °C.
If a long time in less than 5 °C environment, cold storage or in the extreme conditions
of temperature and humidity changes in the use of forklift, you must install additional
special equipment, and obtain permission from the manufacturer.

2
1.2 Assemblies

Item Component Item Component

1 Control Handle 7 Lift Cylinder
2 Emergency brake swich 8 Chassis
3 Battery discharge indicator 9 Balance Stand
4 Key switch 10 Driving wheel
5 Cover(upper) 11 Cover (nether)
6 Plug

3
1.2.1Control Handle

11 ―Lower‖ button Lowers load forks.

12 ―Lift‖ button Raises load forks.
13 Travel switch Controls the driving speed and direction
14 Warning signal Triggers a warning signal.
button
15 Collision safety Safety function which, when activated, forces the truck to
switch reverse until the switch restored to neutral.

1.2.2Key switch
Switches control current on and off.
Truck power supply is break off when the key turn "2". Truck power supply is turn on
when the key turn "3".
The brake will release, when the key turn "1". The brake was clamped and you can't
move it when the power turn off. After the key turn "1", the brake released so that you
can move the truck. Once the truck in trouble please turn the key to "1" and then move
the truck to safety place before maintain.

Removing the key prevents the truck from being switched on by unauthorised
personnel.

4
1.2.3Battery 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:
– When the battery properly charged, the first LED lights. Along with decreases of
the battery charge , the LED lights have been light, each light a beacon.
– When the last second the LED flashes, indicating that access to "charge reserve
" (to use the 70% of electricity).
– When the last two LED flash alternately, indicating that the battery has voltage (to
use the 80% of electricity), battery needs charging.

The battery discharge indicator has a memory function, it can remember the battery
power after the power turn off, and next time the power has be turned on it will show
the power in it memory . If you want reset battery discharge indicator, please turn on
the key after properly charging .

Operating hours display(2)

Display range between 0.0 and 99,999.0 hours. Travel and lifting are logged. This is a
backlit display.

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

Time Indicator(3)
The time indication will flash, it means time begin.

Battery discharge indicator environment requirement：

Operation temperature : -25——+50℃
Store Temperature : -30——+70℃

1.2.4Emergency brake switch

The supply current is interrupted, all electrical functions are deactivated and the truck
is automatically braked.

5
1.3 Identification points and data plates

Item Description

1 Direction Decal On Control Handle

2 Truck Data Plate

3 Warning Decal

4 Key Switch Decal

5 Logo Decal

6
1.3.1Truck data plate

Item Description Item Description

1 Manufacturer logo 6 Fork length（mm）

2 Manufacturer 7 Battery nominate capacity（Ah）

3 Type 8 Weight including battery（kg）

4 Rated capacity（kg） 9 Serial no.

5 Fork width(mm)

For queries regarding the truck or ordering spare parts please quote the truck serial
number(9).

MODEL NUMBER EXAMPLE

CBD 15 – EM

Electric pallet truck Series label

Capacity: 15=1500 kg

7
1.4.Standard Version Specifications
Technical specification details in accordance with VDI 2198. Technical modifications
and additions reserved.
1.4.1Performance data for standard trucks
Item Description parameter Unit

Q Load capacity 1500 kg

C Load center 600 mm
laden 3.5 km/h
Travel speed
unladen 4 km/h
laden 0.051 m/s
Lifting speed
unladen 0.060 m/s
laden 0.052 m/s
Lowering speed
unladen 0.059 m/s

Maximum gradeability, S2 laden 3 %

5 min. unladen 10 %
Service brake Electromagnetic
Service weight Incl. battery 205 kg
Axle loading, laden operator/load side 605/1100 kg
Axle loading,
operator/load side 175/30 kg
unladen
Drive 0.65 Kw
Motor
Lift 0.84 Kw
Tyre type, operator/load side PU/ PU
Tyre size, operator side Ф210x70
Tyre size, load side 2xΦ80x60
Maintenance free
type
battery
Battery voltage/ rated
24/ 60 V/Ah
capacity (5h)
weight 30 kg
Sound level at operator's ear 74 dB(A)

8
1.4.2Dimensions
Item Description parameter Unit

X Load distance (Raised/ Lowered) 883/946 mm

Y Wheelbase 1250 mm
h3 Lift height 115 mm
b11 Tread load side 380 mm
h13 Fork height lowered 85 mm

Height of tiller arm in operating min 820 mm

h14
position max 1170 mm
l1 Overall length 1600 mm
l2 Length to face of forks 450 mm
b1 Overall width 560 mm
s Thickness 50 mm
e Fork dimensions Width 150 mm
l Length 1150 mm
b5 Fork spread 560 mm
m2 Ground clearance 35 mm
Wa Outer turning radius 1475 mm
1000×1200 pallet crossways 1929 mm
Ast Aisle width
800×1200 pallet lengthways 1779 mm

9
10
 2.Transport and Commissioning
2.1Transport
Lifting the truck by crane
1.Only use crane handling equipment gear
with sufficient capacity.
2.Loading weight > net weight of truck (+
battery weight for electric trucks).Loading
weight not only net weight of truck but also
the stock or the box.
3.Stock (box) should be big enough and
strong enough to bear hole truck.
– Park the truck securely.(see 3.2.4
Parking the truck securely on page 17).
– Make sure forks are positioned properly
for the pallet. Move forward slowly to insert
forks into the pallet as far as possible and then stop the truck.

Warning!
– To avoid break the fork be hurt when you move the truck to stock.
– In order to keep the truck out of be scraped,please move the truck void in
void and flat place.
– when you lowering the stock advert status of the place to avoid collapse.

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
Procedure
– Check the equipment is complete.
– Check the hydraulic oil level.
– Install the battery if necessary (where required), (see "4.4 Battery removal and
installation" on page 19) do not damage battery cable.
– Charge the battery, (see "4.3 Charging the battery" on page 18).
When the truck is parked the surface of the tyres will flatten. The flattening will
disappear after a short period of operation.

11
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. Please
charging when remain power less than 20%.
2. Perform specified preventive maintenance services carefully and c.ompletely.
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.

12
 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 of 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.

3.2 Operate and run 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.

13
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.

3.2.2 Travel
Do not drive the truck unless the panels are closed and properly locked.

Travel
Set the control handle to the travel range (M), and press the travel switch in the
desired direction (fwd. or rev.).
The more the control handle rotates，the speed is faster.

14
Steering
– Apply the control handle to the left or

right.

Braking
Emergency stop:
–Drawing back the emergency brake
switch (6).
All electrical functions are deactivated.

Automatic braking Warning!

When the control handle is released it If the control handle moves slowly or
automatically sets itself to the upper not at all to the upper brake zone, the
brake zone (B) and automatic braking truck must be taken out of service until
ensues. the cause of this fault is be rectified.
Replace the gas pressure spring if
necessary.

Regenerative braking
If the travel switch is set to "0", the truck Warning!
automatically brakes regeneratively. If the travel switch moves slowly or not
When the speed below 1Km/h, the at all to 0, the truck must be taken out
brake then applies and motor brake of service until the cause of this fault is
stop. be rectified.
Replace the control handle if
necessary.

Inversion braking
You can set the travel switch (13) to Warning!
the opposite direction when travelling. In hazardous situations set the control
The truck brakes regeneratively until it handle to the brake position or set the
starts to move in the opposite direction. travel switch (13) to the opposite
direction.

15
3.3.3Lifting, transporting and depositing loads
Unsecured and incorrectly positioned loads can cause accidents
·Instruct other people to move out of the hazardous area of the truck. Stop working
with the truck if people do not leave the
hazardous. Warning!
· Only carry loads that have been Before lifting a load unit the driver
correctly secured and positioned. Use must make sure that it has been
suitable precautions to prevent parts of correctly stowed and does not exceed
the load from tipping or falling down. the truck’s capacity.
· Do not transport witch bad Do not lift long loads at an angle.
handbarrow ( as truck and stock ) .
·Never stand underneath a raised load handler.
·Do not stand on the load handler.
·Do not lift other people on the load handler.
·Insert the forks as far as possible underneath the load.

Lift
Press ―Lift‖ button(12) until the height
you need. Warning!
Don't lift to tiptop, to avoid shorted life of
Lower oil cylinder.
Press ―Lower‖ button （ 11 ） until the
lowest position.

16
3.3.4Parking the truck securely
• Press ―Lower‖ button（3）, fully lower the
load handler. Warning!
• Turn off the key (1)switch and remove Parking the truck securely.
the key. Forbid parking on an incline.
• Press plug(2). Always fully lower the forks.
The truck is parked.

17
 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.

4.2 Battery type & dimension

Battery type & dimension as follow :
Tuck voltage/ rated Battery Battery Battery
Battery type
type capacity height (mm) length (mm) width (mm)
CBD15- Maintenance
24/ 60 215 260 169
EM free battery

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

4.3Charging the battery

Safety regulations for Charging the battery
– 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.
– Before start and finish charging to make sure power is turn OFF.

18
– 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 Page17 ).
– Remove the battery plug (1).
–Connect the battery plug (1) with the
charging lead of the stationary charger (2)
and turn on the charger.

4.4Battery removal and installation

Park the truck securely(See 3.2.4 Parking the truck securely Page 17 ) and turn off
the power before removal and installation battery.

Battery removal and installation steps:

a: Remove two screw(1), take out the Cover.
b: Remove four screw(2).

c: Remove 3 battery cable(3) as shown in figure.

d:Rotary operating handle(4) to the extreme
position. Warning！
e: pull electrical panel(5) a little out. Well place cables to avoid be
f: Turn the electrical panel(5) to the direction damaged when you removal and
as shown in picture until it can't cover battery installation battery.
at all.

19
g：Put battery(6) in or removal battery(6).

– Installation is in the reverse order of operations, pay attention on battery install

position and cable connection. Make sure the well place cables to avoid be damaged
when you removal and installation battery.

4.5Battery maintenance
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.

Battery maintenance:
The battery cell covers must be kept dry and clean. The terminals and cable shoes

20
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.

4.6 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.

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.

21
 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 29)” 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 connect cable must
be removed.
Only weak suction or compressed air and non-conductive antistatic brushes may be
used for cleaning electric or electronic assemblies.

22
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
cause malfunctions.
Do not clean with pressurised water.
After cleaning the truck, carry out the activities detailed in the ―Recommissioning
(on page 29)‖ 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 key.

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.

23
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
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.

24
5.3.1Maintenance Checklist
Maintenance
interval ●
W A B C
Brake Check magnetic brake air gap. ●

Electrics Test instruments, displays and control switches. ●

Test warning and safety device. ●
Make sure wire connections are secure and check for ●
damage.
Test micro switch setting. ●
Check contactors and relays. ●
Fix the motor and cable ●

Power Visually inspect battery ●

supply
Check battery cable connections are secure, grease ●
terminals if necessary.

Travel Check the transmission for noise and leakage. ●

Check travel mechanism, adjust and lubricate if ●
necessary.
Check control handle recuperating function.
Check wheels for wear and damage. ●
Check wheel bearings and attachments. ●

Truck Check truck frame for damage. ●

frame

Hydraulic Test hydraulic system. ●

operation
Check that hose and pipe lines and their connections are ●
secure, check for leaks and damage.
Check cylinders and piston rods for damage and leaks, ●
and make sure they are secure.
Check hydraulic oil level. ●
Replace hydraulic oil. ●
Check and clearn hydraulic oil filter. Replace it if ●
necessary.

25
5.3.2 Lubrication Schedule

26
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 Grease(contain Mus2) Lubrication and gear case
B HM46# Hydraulic system

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 17 ).
– Remove the key to prevent the truck from accidentally starting.
– When working under a raised lift truck, secure it to prevent it from tipping or sliding
away.

Removing the front panel

– Remove the two screws (1), remove
cover(2).
– remove other two screws(2).
– Carefully lift off the front panel (3).

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

Checking the hydraulic oil level

It is going to add hydraulic oil when you
Warning!
heard explosion sound from pipe during
Forbid adding hydraulic oil within
lifting.
impurity.

– Prepare the truck for maintenance and repairs ( See 5.3.3 Maintenance
Instructions Page27).
– Opening the front panel.
– Add hydraulic oil of the correct grade ( See 5.3.2 Lubrication Schedule P26) .
Add hydraulic oil till you cant hear explosion sound during lifting.
Installation is the reverse order.

Check transmission oil level

– Prepare the truck for maintenance and
repairs (See 5.3.3 Maintenance
Instructions Page27 ).
– Remove the front panel.
– Add transmission oil of the correct grade
to oil cup(See 5.3.2 Lubrication Schedule
Page26).
– add transmission oil every 1000 operating
hours, or at least annually.
Installation is the reverse order.

Warning!
Forbid adding transmission oil within
impurity.

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Checking electrical fuses
– Prepare the truck for maintenance and
repairs (See 5.3.3 Maintenance
Instructions Page27 ).
– Dismantle the front panel .
– Check rating of all fuses in accordance
with table, replace if necessary.

Item To protect: Rating

1 Traction / Lift motor 100A

Recommissioning
The truck may only be recommissioned after cleaning or repair work, once the
following operations have been performed.
– 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 Page27 ).
– Apply a thin layer of oil or grease to any non-painted mechanical components.

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–Lubricate the truck in accordance with
the maintenance schedule (See 5.3.2
Lubrication Schedule P26 ). Warning！
– Charge the battery (See 4.3Charging Charge every months:
the battery P18). – Charge the battery.
– Disconnect the battery, clean it and Battery powered trucks:
apply grease to the terminals. The battery must be charged at
In addition, follow the battery regular intervals to avoid depletion of
manufacturer’s instructions. the battery through self-discharge.
– Spay all exposed electrical contacts The sulfatisation would destroy the
with a suitable contact spray. battery.

5.4.2 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).
– Check hydraulic oil for condensed water and replace if necessary.
– Start up the truck (see 3.2.2Operate and run the truck P13).

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. EP 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

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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 － Key switch in ―OFF‖ position – Set key switch to ―I‖
not start. －Battery charge too low – Check battery charge, charge
battery if Necessary
－Faulty fuse – Test fuses
－Truck in charge mode – Interrupt charging
Load can – Hydraulic oil level too low – Check the hydraulic oil level
not be – Excessive load – Note maximum capacity (see
lifted 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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