Baoli CPD10 Installation and operating instructions

CPD10-30 DC
CPD10J-30J AC
Balanceweight Type Electric Forklift Truck
OPERATION & SERVICE MANUAL
KION Baoli (Jiangsu) Forklift Co., Ltd.
1-3T

PREFACE
Balance weight type electric forklift trucks are designed on the base of the advanced
features available from both local and foreign designs. These trucks are suitable to
handle, transport and stack goods in factories, mines, stations, ports, freight yards,
warehouses and used widely in food processing, textiles and other light industries. The
use of forklift trucks fitted with kinds of attachments will become extensive.
These forklift trucks feature a wide-vision mast system, full powered steering unit,
self-boost brake, stepless speed control, open type overhead guard and high quality
motor, battery, multifunction integration electric controller and large-screen combination
meter, so they have a lot of advantages such as good performance, easy operation, wide
vision, flexible steering, reliable braking, powerful and smooth power, low noise, no
pollution and beautiful appearance.
Newly designed AC system can control the torque intelligently, the standard soft
provides a complete toolkit to meet the demands of users, and it optimizes the operation
and reduces the producing cost of trucks. It adopts imported motors and electric
controllers, improving the reliability of trucks and making the performance more superior.
The combination meter based on User Interface makes the operation more easily and
conveniently.
This manual states the forklift truck’s specifications, operation, maintenance, 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
operating or maintaining the forklift trucks. The rules and notices in this 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.
The partial content in this manual might not correspond with the actual condition
because of technical improvement. Our products are subject to improvements and
changes without notice.

CONTENTS
Ⅰ. External view and specification ………………………………………………………… 1
Ⅱ. Safety instruction, operation & maintenance of electric forklift truck …………… 8
2.1 Shipping, loading, unloading and slinging of electric forklift truck ………………… 8
2.2 Storage of forklift truck ……………………………………………………………………… 9
2.3 Precautions before operation ……………………………………………………………… 9
2.4 Information of safety operation …………………………………………………………… 9
2.5 Periodic servicing and maintenance of electric forklift truck …………………………… 13
2.6 Brief operation instruction ………………………………………………………………… 16
2.7 Caution plates ……………………………………………………………………………… 20
Ⅲ. Construction, principle, adjustment & maintenance of electric forklift truck…26
1. Transmission system ……………………………………………………………………… 26
1.1 General description …………………………………………………………………… 26
1.2 Assembly of wheel hub …………………………………………………………………… 31
2. Brake system ……………………………………………………………………………… 32
2.1 General description ………………………………………………………………………… 32
2.2 Disassembly, assembly and adjustment of wheel brake ……………………………… 39
3. Steering system …………………………………………………………………………… 45
3.1 General description ………………………………………………………………………… 45
3.2 Adjustment and maintenance …………………………………………………………… 49
4. Electric system ……………………………………………………………………………… 51
4.1 General description ………………………………………………………………………… 51
4.2 Multifunctional integration control system (DC) ………………………………………… 56
4.3 SME AC electric controller assy ………………………………………………………… 58
4.4 Distribution and setting of sensor (AC) ………………………………………………… 58
4.5 AC microtron ……………………………………………………………………………… 61
4.6 LED instrument (DC) …………………………………………………………………… 62
4.7 SME compact meter (AC) ………………………………………………………………… 66

4.8 Harness ……………………………………………………………………………………… 72
5. Motor ……………………………………………………………………………………… 75
5.1 General description of DC motor ………………………………………………………… 75
5.2 SME three-phase AC motor ……………………………………………………………… 77
5.3 Inspection and maintenance of DC motor ……………………………………………… 78
5.4 Failure diagnosis of DC motor ………………………………………………… 84
6. Battery and charger ……………………………………………………………………… 85
6.1 Structure of battery ………………………………………………………………………… 85
6.2 Specification of battery and charger ……………………………………………………… 85
6.3 Usage and maintenance of battery ……………………………………………………… 86
6.4 Troubleshooting guide …………………………………………………………………… 90
6.5 Charger ……………………………………………………………………………………… 91
7. Hydraulic system …………………………………………………………………………… 94
7.1 General description ………………………………………………………………………… 94
7.2 Maintenance and adjustment of hydraulic system …………………………………… 104
8. Lifting system ……………………………………………………………………………… 109
8.1 General description …………………………………………………………………… 109
8.2 Maintenance and adjustment of lifting system ………………………………………… 112
Charging record card of electric forklift truck ………………………………………… 115
NOTE …………………………………………………………………………………………… 116
EC DECLARATION OF CONFORMITY…………………………………………………… 117

1
Ⅰ. External view and specification
External view of electric forklift truck

2
SPECIFICATION (CPD10 CPD15)
General
Model
CPD10
CPD15
Power type
Battery
蓄电池
Rated capacity
kg
1000
1500
Load center
mm
500
500
Dimension
Lift height
H
mm
3000
3000
Free lift height
H4
mm
162
162
Fork size
L×W
×T
mm
920×100×40
920×120×40
Fork outside spread (Min./Max)
B4
mm
200/968
200/980
Mast tilt angle
(forward/backward)
α/β
°
6/12
6/12
Front overhang
X
mm
429
436
Overall
dimension
Length to fork face
L1
mm
2056
2056
Overall width
B1
mm
1090
1090
Mast lowered height
H1
mm
1995
1995
Mast extended height
H3
mm
4042
4038
Overhead guard height
H2
mm
2162
2162
Min. turning radius
R
mm
1820
1820
Min. right angle stacking aisle width
RAX
A
mm
3370
3370
Performance
No load/
full load
Travel speed
km/h
13.5/11.5
13/11
Lifting speed
mm/sec
400/300
390/285
Max. grade ability
%
15
15
Service weight
kg
2900
3120
Max. pull force(full load)
KN
6
6.5
Chassis
Tyre
Front
mm
6.50-10-10PR
6.50-10-10PR
Rear
mm
5.00-8-8PR
5.00-8-8PR
Tread
Front
B2
mm
890
890
Rear
B3
mm
920
920
Wheelbase
Y
mm
1250
1250
Ground clearance
(No load / full load)
Mast
M
mm
110/95
Frame
F
mm
105/95
Power & Control
Battery
Voltage
V
48
48
Capacity
Ah
*400/440/480
Motor
Drive motor
KW/rpm
5.3/1700
Hydraulic motor
KW/rpm
8.2/1600
Controller
GE separate excitation controller

3
SPECIFICATION (CPD10J CPD15J)
General
Model
CPD15J
Power type
Battery
蓄电池
Rated capacity
kg
1500
Load center
mm
500
500
Dimension
Lift height
H
mm
3000
3000
Free lift height
H4
mm
162
162
Fork size
L×W×T
mm
920×100×40
Fork outside spread (Min./Max)
B4
mm
200/968
Mast tilt angle (forward/backward)
α/β
°
6/12
Front overhang
X
mm
429
Overall
dimension
Length to fork face
L1
mm
2056
Overall width
B1
mm
1090
Mast lowered height
H1
mm
1995
Mast extended height
H3
mm
4042
Overhead guard height
H2
mm
2162
Min. turning radius
R
mm
1820
Min. right angle stacking aisle width
RAXA
mm
3370
Performance
No load/
full load
Travel speed
km/h
15/13
Lifting speed
mm/sec
400/300
Max. grade ability
%
15
Service weight
kg
3120
Max. pull force(full load)
KN
6.5
Chassis
Tyre
Front
mm
6.50-10-10PR
Rear
mm
5.00-8-8PR
Tread
Front
B2
mm
890
Rear
B3
mm
920
Wheelbase
Y
mm
1250
Ground
clearance
(No load / full
load)
Mast
M
mm
110/95
Frame
F
mm
105/95
Power & Control
Battery
Voltage
V
48
48
Capacity
Ah
*400/440/480
Motor
Drive motor
KW/rpm
8/1600
Hydraulic motor
KW/rpm
10/2450
Controller
Italian SME AC Controller

4
SPECIFICATION (CPD20 CPD25)
General
Model
CPD20
CPD25
Power type
Battery
蓄电池
Rated capacity
kg
2000
2500
Load center
mm
500
Dimension
Lift height
H
mm
3000
Free lift height
H4
mm
140
Fork size
L×W×T
mm
1070×120×40
1070×120×45
Fork outside spread (Min./Max)
B4
mm
240/1040
Mast tilt angle (forward/backward)
α/β
°
6/12
Front overhang
X
mm
479
484
Overall
dimension
Length to fork face
L1
mm
2349
2381
Overall width
B1
mm
1152
Mast lowered height
H1
mm
2060
Mast extended height
H3
mm
4040
Overhead guard height
H2
mm
2159
Min. turning radius
R
mm
2050
2100
Min. right angle stacking aisle width
RAXA
mm
3715
3755
Performance
No load/
full load
Travel speed
km/h
12.5/11
12.5/10.5
Lifting speed
mm/sec
400/260
390/250
Max. grade ability
%
10
15
Service weight
kg
4160
4360
Max. pull force(full load)
KN
8
Chassis
Tyre
Front
mm
7.00-12-12PR
Rear
mm
18×7-8-14PR
Tread
Front
B2
mm
960
Rear
B3
mm
950
Wheelbase
Y
Y
1500
1250
Ground
clearance
(No load / full
load)
Mast
M
mm
120/100
Frame
F
mm
120/100
Power & Control
Battery
Voltage
V
48
48
Capacity
Ah
*630/700
Motor
Drive motor
KW/rpm
7.0/1400
Hydraulic motor
KW/rpm
8.6/1600
Controller
GE separate excitation controller

5
SPECIFICATION (CPD20J CPD25J)
General
Model
CPD20J
CPD25J
Power type
Battery
蓄电池
Rated capacity
kg
2000
2500
Load center
mm
500
Dimension
Lift height
H
mm
3000
Free lift height
H4
mm
140
Fork size
L×W×T
mm
1070×120×40
1070×120×45
Fork outside spread (Min./Max)
B4
mm
240/1040
Mast tilt angle (forward/backward)
α/β
°
6/10
Front overhang
X
mm
459
464
Overall
dimension
Length to fork face
L1
mm
2349
2381
Overall width
B1
mm
1265
Mast lowered height
H1
mm
2040
Mast extended height
H3
mm
4240
Overhead guard height
H2
mm
2125
Min. turning radius
R
mm
2050
2100
Min. right angle stacking aisle width
RAXA
mm
3715
3755
Performance
No load/
full load
Travel speed
km/h
14/12
Lifting speed
mm/sec
420/310
420/300
Max. grade ability
%
10
15
Service weight
kg
4160
4360
Max. pull force(full load)
KN
8
Chassis
Tyre
Front
mm
23×9-10-16PR
Rear
mm
18×7-8-14PR
Tread
Front
B2
mm
1040
Rear
B3
mm
950
Wheelbase
Y
mm
1500
1250
Ground
clearance
(No load / full
load)
Mast
M
mm
105/85
Frame
F
mm
140/120
Power & Control
Battery
Voltage
V
48
48
Capacity
Ah
*630/700
Motor
Drive motor
KW/rpm
8/1300
Hydraulic motor
KW/rpm
15/2200
Controller
Italian SME AC Controller

6
SPECIFICATION (CPD30)
General
Manufacturer
KION Baoli
Model
CPD30
Power type
Battery
蓄电池
Rated capacity
kg
3000
Load center
mm
500
500
Dimension
Lift height
H
mm
3000
3000
Free lift height
H4
mm
145
162
Fork size
L×W×T
mm
1070×125×45
Fork outside spread (Min./Max)
B4
mm
250/1100
Mast tilt angle (forward/backward)
α/β
°
6/10
Front overhang
X
mm
454
Overall
dimension
Length to fork face
L1
mm
2481
Overall width
B1
mm
1265
Mast lowered height
H1
mm
2040
Mast extended height
H3
mm
4273
Overhead guard
H2
mm
2125
Min. turning radius
R
mm
2230
Min. right angle stacking aisle width
RAXA
mm
3915
Performance
No load/
full load
Travel speed
km/h
13/12
Lifting speed
mm/sec
380/250
Max. grade ability
%
10
Service weight
kg
4850
Max. pull force(full load)
KN
10
Chassis
Tyre
Front
mm
23×9-10
Rear
mm
18×7-8
Tread
Front
B2
mm
1040
Rear
B3
mm
980
Wheelbase
Y
mm
1630
Ground
clearance
(No load / full
load)
Mast
M
mm
105/85
Frame
F
mm
140/120
Power & Control
Battery
Voltage
V
80
48
Capacity
Ah
*500/600
Motor
Drive motor
KW/rpm
10.2/1500
Hydraulic motor
KW/rpm
10/2000
Controller
GE separate excitation
controller

7
SPECIFICATION (CPD30J)
General
Model
CPD30J
Power type
Battery
蓄电池
Rated capacity
kg
3000
Load center
mm
500
500
Dimension
Lift height
H
mm
3000
3000
Free lift height
H4
mm
145
162
Fork size
L×W×T
mm
1070×125×45
Fork outside spread (Min./Max)
B4
mm
250/1100
Mast tilt angle (forward/backward)
α/β
°
6/10
Front overhang
X
mm
454
Overall
dimension
Length to fork face
L1
mm
2481
Overall width
B1
mm
1265
Mast lowered height
H1
mm
2040
Mast extended height
H3
mm
4273
Overhead guard height
H2
mm
2125
Min. turning radius
R
mm
2230
Min. right angle stacking aisle width
RAXA
mm
3915
Performance
No load/
full load
Travel speed
km/h
14.5/12
Lifting speed
mm/sec
420/280
Max. grade ability
%
10
Self weight
kg
4850
Max. pull force(full load)
KN
10
Chassis
Tyre
Front
mm
23×9-10
Rear
mm
18×7-8
Tread
Front
B2
mm
1040
Rear
B3
mm
980
Wheelbase
Y
mm
1630
Ground
clearance
(No load / full
load)
Mast
M
mm
105/85
Frame
F
mm
140/120
Power & Control
Battery
Voltage
V
80
48
Capacity
Ah
*500/600
Motor
Drive motor
KW/rpm
13/1500
Hydraulic motor
KW/rpm
22/2100
Controller
Italian SME AC Controller

8
Ⅱ. Safety instruction, operation & maintenance of electric forklift
truck
It is important for drivers and managers to remember the principle of “first safety” and
ensure the safety operation as the description of Operation & Service Manual. Please
read this manual thoroughly. This will give you a complete understanding of Baoli forklifts
and permit you to operate them correctly and safely.
2.1 Shipping, loading, unloading and slinging of forklift truck
2.1.1 Ship the forklift truck
(1) Apply the parking brake when shipping the forklift trucks by container or freight
car.
(2) Fix the mast and the balance weight with steel wire and use jacks to prevent the
forklift trucks from moving in the cabin.
(3) Pay attention to the overall length, width, height when loading, unloading and
shipping and conforming the regulations is necessary.
(4) Single transporting if necessary after disassembling the mast and balance weight.
2.1.2 Load and unload the forklift truck
(1) Use the plate with enough length, width and strength.
(2) Pull the parking brake and use jacks to stop the wheel.
(3) Fasten the plate on the center of the cabin, there must be no grease on the plate.
(4) The left and right height of the plate must be equal to make the loading and
unloading smooth.
(5) Don’t change the direction on the plate to prevent the danger.
(6) Reverse the truck slowly when loading the forklift on the freight car.
2.1.3 Sling the forklift truck
(1) Only the specially trained personnel can sling the truck.
(2) Sling points should be always at the positions specified in sling index plate.
(3) The slinging cable must be enough to hang the forklift truck.
(4) Disassembled parts of forklift truck must be slinged in appointed position.
Model
Mast
Balance weight
Dimension (mm)
Weight(kg)
Dimension(mm)
Weight(kg)
1.5T
1885×1094×485
530
1065×280×926.5
712
2.0T
1890×1040×470
750
1135×365×936.5
860
2.5T
1890×1040×470
750
1135×397×936.5
1030
3.0T
1935×1100×470
860
1135×397×936.5
1200

9
Notice:
Dismantling and slinging the component shall not be performed without the
approval of our company. Under special circumstances, the appointed sling position
should be used. The balance weight, fork and mast of the truck all have their
appointed hang up position. The above –mentioned weight is only for a reference,
which may be adjusted because of configuration difference or technology
optimization.
2.2 Storage of forklift truck
(1)Lower the mast to the lowest position.
(2) Turn off the key switch, place the levers in the neutral position. Disconnect the
power plug.
(3)Apply the parking brake.
(4) Wedge up the front and rear wheels.
(5) If the truck leaves unused for long time, build the wheels on stilts. Charge the
battery once a month.
2.3 Precautions before operation
(1) Check all the instruments.
(2) Check the tyre inflation pressure.
(3) Check all the levers and pedals.
(4) Check if the voltage of the battery is in normal limit. Check if the density and level
of the electrolyte is appropriate.
(5) Check for all the terminals and plugs.
(6) Check hydraulic oil, electrolyte and brake fluid for leakage.
(7) Check all connectors and fasteners for looseness.
(8) Check if all the lamps and signals are in normal state.
(9) Release the parking lever.
(10) Make trial of the mast for lifting and lowering, forward and backward tilting, and
the truck for steering and braking.
(11) The contamination level of the hydraulic oil should be lower than grade 12.
2.4 Information of safety operation
(1) The forklift truck belongs to special equipment. Only trained and authorized
operator shall be permitted to operate and service the truck.
(2) Wear the safety guards, such as clothing, shoes, helmet and gloves while
operating the truck.

10
(3) When the distance between the gravity center of loads and the fork arms is
500mm, the max. capacity is the rated capacity. When the distance exceeds 500mm, the
capacity shall be based on the load chart. Handle only loads within the allowable capacity
of the truck. The goods handled should not exceed the rated capacity of the truck.
(4) Operate your truck on a hard ground. Operate on other ground, the lift capacity
and travel speed must be decreased. Wipe off the oil and grease from the floor.
(5) Daily maintenance services should be done before or after using the truck.
Anytime you find that the truck is not functioning normally, operation of the truck should be
halted and check or repair at once.
(6) When operate one lever, pay attention not to shift another lever. Don’t operate the
lever at any position out of the driver seat.
(7) Don’t handle unfixed or loose goods. Be careful to handle bulky goods. To prevent
the collapse of stacked goods, tighten them. Forbid loading loose or little volume goods
without tray.
(8) If the truck is equipped with a load-handling attachment, its usage sphere will be
wider, but its allowable load and stability is reduced. The attachment and special device is
not to be diverted to any other purpose. It’s very dangerous to rebuild the attachment.
Please read the additional instruction we supplied and operate the truck following it
strictly.
(9) Fork can not be used to pull out any embedded goods, if necessary, the pulling
force should be estimated.
(10) Insert forks deeply under goods. Adjust fork’s distance according to the capacity
of goods. Make the loads distribute on the forks evenly to avoid tilt and slide of goods.
Don’t pick the loads with one fork tip.
(11) When handling bulky loads which restrict your vision, operate the forklift truck in
reverse or have a guide.
(12) When loading the goods, lower the forks to the floor. After the fork inserting
stacked goods, the fork arms should be in contact with the goods. Drive the truck with
mast tilting back for stabilizing the load. Before traveling, raise the forks for
200mm-300mm from the floor.
(13) While mast’s lifting and lowering, anyone is absolutely prohibited from standing
under the lifting rack or being lifted with forks. Never permit anyone to stand or walk under
upraised forks.

11
(14) When loading and unloading goods, keep the mast vertical and the truck is in
braking state.
(15) Because the rear wheels steer your truck, the rear end swings wide when you
turn. Use care in aisles and other tight places.
(16) During operation, pay attention to the performance and condition of machinery,
hydraulic, electric and speed adjuster.
(17) Connect the power source, turn on the key switch, select the position of
directional switch, check the truck for normal operation by turning steering wheel, depress
the accelerator pedal softly to keep proper acceleration.
(18) When the voltage drops below 43.2V (1-2.5t forklift truck) or below 72V (3t forklift
truck) during operation with load, it’s necessary to charge the battery or replace a full
charged battery at once.
(19) The shift distance of control valve lever can control the speed of the lifting or
descending of the goods. When the goods are lifted or descended, the initial speed
shouldn’t be too fast in either case.
(20) It is necessary to brake before tilting the mast forward or backward. It’s also
necessary to tilt forward slowly so as to prevent the goods from slipping off the rack.
(21) Tilt the mast of the high lift forklift truck as backward as possible when the truck
works. Use minimum forward and backward tilt when loading and unloading. It is
dangerous to travel or turn at high levels.
(22)On the high lift forklift truck with lifting height more than 3m, it is noted that the
goods on it will fall down, take the protection measures if necessary.
(23) The overhead guard is main part which is strong enough to meet safety standard,
and protect the operator from falling materials. It’s very dangerous to dismantle or rebuild
the overhead guard, because these conditions could lead to an accident.
(24) A load backrest shall be used as protection against back falling objects on the
fork. It’s very dangerous to dismantle or rebuild the load backrest, because these
conditions could lead to an accident.
(25) Load should be contacting with a load backrest. Do not handle the load which
exceeds height of a backrest. When loads go over the load backrest, there is a danger of
load’s falling against operator.
(26) The stability of the truck is influenced by the wind-force during outside operation,
you must notice specially.

12
(27) Be careful and slowly driving over a dock board or bridge-plate.
(28) When travel with load, don’t tilt mast forward, don’t do handling. Don’t brake
abruptly to prevent the bulk from slipping off the forks.
(29) Drive the forklift truck to the stacked goods at a low speed, at the same time, pay
much attention to sharp and hard objects near the goods, otherwise, the tyres will be
pricked.
(30) Pay attention to pedestrian, obstacle and bumpy road when driving. Pay
attention to the clearance over the forklift truck.
(31) Keep your head, hands, arms, feet and legs within the confines of the operator’s
compartment. Never allow other persons on the forklift truck.
(32) Crossing, turning and tilting shall not be taken on a slope. It could cause turning
sideways of the truck, it is very dangerous. On a slope, drive the truck with load forward to
ascend and backward to descend. When the truck goes down on a slope, drive slowly
with the brakes on. Make sure that the engine should not be shut down when traveling on
a slope.
(33) The starting, turning, driving, braking and stopping of the truck should be done
smoothly. When steering on the humid or slippery road, the truck should be decelerated.
(34) Operate the controls smoothly, don’t jerk the steering wheel. Avoid sudden stop,
acceleration, stop or turn. In the case of improper operation, the truck will turn over. In
case of this, the driver must keep calm, don’t jump off the truck. The driver must hold
tightly the control wheel with two hands; meanwhile, his body must incline in opposite
direction of truck’s turning over.
(35) The unloaded forklift truck with attachment should be operated as a loaded
truck.
(36) Check the chains periodically to make sure that good lubrication condition exists
between the chain elements, the degree of tightness between left and right chain is
identical. If the variation value of the chain pitch exceeds 2% standard value, it indicates
that the chains have been worn excessively, replace it immediately.
(37) Before the truck decelerating and stopping, don’t put it into reverse gear, so as to
ensure the safety of loading.
(38) Don’t make a sudden braking when the truck traveling with loads.
(39) When leaving, lower the forks on the ground and let the shift lever to neutral, cut
down the electric supply. If parking on a slope is unavoidable, apply the parking brake and

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block the wheels.
(40) When tilting the mast forward or backward to the limit or lifting the fork to the
maximum height, return the directional lever to neutral.
(41) 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.
(42) Tyres should be inflated according to the pressure valve specified in the marking
plate of “Tyre Pressure”.
(43) According to the Directive 2000/14/EC and based on EN12053 standard，when
the forklift truck during the test of lifting, traveling and idling, but the noise of the forklift
truck may fluctuate due to different operation and the influence of the external
environment.
(44) The driver feels the vibration of the forklift truck when operating and traveling the
forklift truck.According to ISO3691 and based on EN 13059 standard. The vibration of the
forklift truck fluctuates according to environment condition. In normal working condition,
the vertical direction acceleration mean value from the seat to the operator is referred to
the following table. But the vibration frequency felt by the driver depends on the working
condition (etc. road, operation method), so the actual vibration frequency must be
determined according to environment condition when necessary.
Model
The noise pressure level at
the operator’s position
The vertical direction acceleration mean
value from the seat to the operator
EN 12053
EN 13059
CPD10-15
69.1dB(A)
1.10(m/s2)
CPD20-25
78.3dB(A)
1.08(m/s2)
CPD30
63.9dB(A)
1.11(m/s2)
(45) Users select “Lengthening fork” in order to carry widening loads. Pay much
attention not to overload and observe the allowable load and the capacity chart on the
truck. Careful driving should be taken when traveling and turning.
(46) When operating the machine, observe and follow all markings on the machine.
The marking plates must be replaced if lost or damaged.
(47) The forklift truck must be used under the following environment: below an
elevation of 1000 meters and temperature between -15℃and 35℃, relative humidity is
95%. Careful operation must observe under other adverse circumstances.
(48) To prevent the fire, accident or other unpredictable event, prepare the fire
extinguisher in advance and operate it according to the instructions.
(49) You can’t change or add other working equipments on the truck without our
company’s permit, or the rated capacity and safety operation will be affected.
(50) Keep safety when serving on high position.

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2.5 Periodic servicing and maintenance of electric forklift truck
During operating the forklift truck, it is necessary to operate carefully, service and
maintenance periodically to make the forklift truck keep in good condition.
2.5.1 Handling a new forklift
The performance and service life of forklift depends heavily upon the way you
handle it during the break-in period. Drive with special caution while becoming familiar
with a new forklift. Retighten the fasteners after the replacing.
(1) Replace gear oil in the differential and reducer after the new forklift working for
100 hours. Retighten the fasteners after replacing.
(2) Readjust the clearance of the driving and driven gear in the reducer after the new
forklift working for 200 hours.
2.5.2 Cautions for starting
(1) The amount of hydraulic oil: The oil level should be at the middle position between
the upper and lower scale marks of oil level meter.
(2) Check if any leak or damage found on the piping joints, pumps and valves.
(3) Check the traveling brakes: The free stroke of brake pedal is 20-30 mm; when
achieving effective brake, the clearance between the front floor and the pedal should be
more than 20mm.
(4) Check the parking brake: The unload truck can park on stated ramp, when the
parking lever is pulled to the bottom.
(5) Check the meters, lamps, connectors, switches and electric circuit if they are
running properly.
2.5.3 Charging the battery
(1) Please refer to Manual of Battery about the initial charging and normal charging of
the battery.
(2) When the truck working with load, the voltage of the battery reduces to
43.2V(1-2.5t forklift truck), or to 72V(3t forklift truck), or the voltage of each cell drops
below 1.80V, the warner of battery capacity flashes, stop the truck until charge the battery
or replace a full charged battery.
(3) Measure the density, level and temperature of the electrolyte.
(4) After the battery is used, it should be charged immediately, the time left idle of the
battery must be less than 24 hours. You should try to prevent them from over being
discharged or over charged. Either way will affect their service time and functions.

15
Refer to Manual of Battery about charging method and maintenance.
2.5.4 Essentials of servicing
(1) Some critical components must be replaced according to demands periodically.
Use genuine parts only.
(2) Use genuine or recommended oil only when replacing or adding.
(3) If any damage or fault is found, the matter should be reported to the manager.
Only trained and authorized serviceman shall be permitted to service the truck. Do not
operate the truck until the truck has been repaired completely.
(4) Maintain the motor, electric controller and battery according to their manuals.
(5) Check all plugs once a month.
(6) Don’t wash the truck with a water syringe. Outdoor using the truck in rainy day is
forbidden.
(7) Clean the dust of photoelectric coupler of the hydraulic motor switch.
(8) Clean and dry the surface of the battery usually.
(9) Periodic maintenance must be done according to the following list after using the
forklift truck.
No.
Item
Contents
Period
(hrs.)
Remark
1
Bearing, steering wheel
Replace grease
1000
2
Bearing, drive wheel
Replace grease
1000
3
Steering link lever
Replace grease
1000
4
Parking brake lever
Add grease
200
5
Pin, foot brake
Add grease
200
6
Drive axle body
Replace gear oil
2400
7
Braking oil
Add
Whenever
necessary
8
Pin, tilting cylinder
Add lubricating grease
400
9
King pin of knuckle
Replace grease
1000
10
Hydraulic tank and filter
Clean
1000
11
Hydraulic oil
Replace
1000
12
Lift chain
Replace
3000
If damaged,
Replace it.
13
H. P. hose
Replace
3000
14
Switch, hydraulic motor
Clean photoelectric coupler
200
15
Brush, traction motor
Check
1000
16
Brush, hydraulic motor
Check
1000
17
Brush, P.S. motor
Check
1000