ep ICE301B User manual

Service Manual
Electric Forklift Truck
ICE301B

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

REV. 09/2020
TABLE OF CONTENTS
EP Equipment Co., Ltd.
EP Industrial Park, Xiaquan Village,
Dipu Town, Anji County, Zhejiang Province, P.R.China
www.ep-ep.com
Safety signs and instructions:
Please strictly adhere to these safety instructions to avoid personal injury.
Please pay attention to the important safety instructions.
Instructions.
FOREWORD
This Service Manual can help readers learn more about the truck system components,
maintenance and troubleshooting, and other related information. The operation and
maintenance personnel must read this Manual carefully before using the product. And when
vehicle is in use, be sure to follow the complete operation and maintenance information in
this Manual for vehicle maintenance.
Before using, please check if the pages of the Manual are clear and complete, so as not
to a󰀨ect your normal use because of incomplete information. If the contents of the Manual
have been illegible or damaged, which may a󰀨ect reading, please contact our company or
dealer for replacement.
With the constant update and improvement of our products, the equipment you are using
may be slightly di󰀨erent from what has been described in this Manual, therefore, we must
reserve the right to modify the appearance, conguration and technical specications. If you
have any questions, please contact our sales department or dealer.
i
Copyright
Copyright of Service Manual belongs to
EP Equipment Co., Ltd.
TABLE OF CONTENTS
1. INFORMATION & SPECIFICATIONS.................................1
1.1 After-sales Service Platform .............................................3
1.2 Introduction.........................................................................4
1.3 Common Tools ...................................................................5
1.4 General Tightening Torques .............................................6
2. MAINTENANCE ....................................................................9
2.1 Overview ........................................................................... 11
2.2 Maintenance .....................................................................12
2.2.1 Cleaning.........................................................................12
2.2.2 Inspection.......................................................................12
2.2.3 Lubrication......................................................................17
3. TROUBLESHOOTING........................................................19
3.1 Preparation Before Troubleshooting..............................21
3.1.1 Check the Voltage of Battery..........................................21
3.2 Troubleshooting Solutions of Common Faults..............22
4. DRIVING SYSTEM..............................................................33
4.1 Drive Wheel ......................................................................35
4.1.1 Removal and Installation................................................35
4.2 Drive Motor .......................................................................36
4.2.1 Removal and Installation................................................36
4.2.3 Checking and Testing.....................................................37
4.3 Drive Axle..........................................................................38
4.3.1 Removal and Installation................................................38
4.3.2 Component.....................................................................39
4.3.3 Gear Oil..........................................................................40
4.4 Di󰀨erential.........................................................................41
4.4.1 Removal and Installation................................................41
4.4.2 Component.....................................................................41
4.5 Gearbox ............................................................................42
4.5.1 Removal and Installation................................................42
4.5.2 Component.....................................................................42
4.6 Accelerator Pedal.............................................................43
4.6.1 Removal and Installation................................................43
4.6.2 Interface Description ......................................................43
4.6.3 Checking and Testing.....................................................44
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TABLE OF CONTENTS TABLE OF CONTENTS
5. STEERING SYSTEM ..........................................................45
5.1 Rear Steering Wheel .......................................................47
5.1.1 Removal and Installation................................................47
5.2 Steering Bridge ................................................................48
5.2.1 Removal and Installation................................................48
5.2.2 Component.....................................................................49
5.3 Steering Cylinder .............................................................50
5.3.1 Removal and Installation................................................50
5.3.2 Steering Cylinder Maintenance......................................50
6. BRAKE SYSTEM ................................................................51
6.1 Parking Brake...................................................................53
6.1.1 Removal and Installation................................................53
6.1.2 Adjustment .....................................................................53
6.2 Service Brake ...................................................................54
6.2.1 Removal and Installation................................................54
6.2.2 Air Discharge / Adding Brake Fluid.................................54
7. HYDRAULIC SYSTEM .......................................................55
7.1 Overview ...........................................................................57
7.1.1 Hydraulic Schematic Diagram .......................................58
7.2 Pump Motor & Gear Pump .............................................59
7.3 Multi-way Reversing Manual Valve ...............................60
7.3.1 Removal and Installation................................................60
7.3.2 Interface Description ......................................................61
7.4 Redirector .........................................................................62
7.4.1 Removal and Installation................................................62
7.4.2 Interface Description ......................................................62
7.5 Tilt Cylinder .......................................................................63
7.5.1 Cylinder Removal Precautions.......................................63
7.5.2 Cylinder Installation Precautions....................................64
7.5.3 Removal and Installation................................................65
7.5.4 Cylinder Maintenance ....................................................66
7.6 Refueling Cap ..................................................................67
7.6.1 Removal and Installation................................................67
7.6.2 Hydraulic Oil...................................................................67
7.7 Hydraulic Symbol .............................................................68
8. MAST ....................................................................................70
8.1 Wide-View Two-stage Mast ............................................72
8.1.1 Removal and Installation................................................72
8.1.2 Lifting Chains .................................................................73
8.1.2.1 Chain Adjustment ........................................................73
8.1.2.2 Chain Replacement.....................................................74
8.1.3 Mast Tubing....................................................................75
8.1.4 Lift Cylinder ....................................................................76
8.1.4.1 Cylinder Removal (with mast on the vehicle)..............76
8.1.4.2 Cylinder Maintenance .................................................77
8.1.4.3 Cylinder Installation.....................................................77
8.1.5 Built-in Side Shifter.........................................................78
8.1.5.1 Side Shifter Removal ..................................................78
8.1.5.2 Side Shifter Installation ...............................................78
8.1.6 External Side Shifter ......................................................79
8.1.6.1 Side Shifter Removal ..................................................79
8.1.6.2 Side Shifter Installation ...............................................79
8.2 Two-stage Full Free Mast ...............................................80
8.2.1 Removal and Installation................................................80
8.2.2 Lifting Chains .................................................................81
8.2.2.1 Chain Adjustment ........................................................81
8.2.2.2 Chain Replacement.....................................................82
8.2.3 Mast Tubing....................................................................83
8.2.4 Lift Cylinder ....................................................................85
8.2.4.1 Cylinder Removal .......................................................85
8.2.4.2 Cylinder Maintenance .................................................87
8.2.4.3 Cylinder Installation.....................................................89
8.2.5 Built-in Side Shifter.......................................................89
8.2.6 External Side Shifter.....................................................89
8.3 Three-stage Full Free Mast ............................................90
8.3.1 Removal and Installation................................................90
8.3.2 Lifting Chains .................................................................91
8.3.2.1 Chain Adjustment ........................................................91
8.3.2.2 Chain Replacement.....................................................92
8.3.3 Mast Tubing....................................................................94
8.3.4 Lift Cylinder ....................................................................96
8.3.4.1 Cylinder Removal .......................................................96
8.3.4.2 Cylinder Maintenance .................................................97
8.3.4.3 Cylinder Installation.....................................................98
8.3.5 Built-in Side Shifter.......................................................98
8.3.6 External Side Shifter.....................................................98
2-3 3-3
TABLE OF CONTENTS
SECTION PAGE
TABLE OF CONTENTS
SECTION PAGE

1
1
SAFETY WARNING
For your own safety and that of others, please observe the following safety instructions:
Thorough and normative maintenance is one of the most important prerequisites to ensure
stable and reliable operation of truck. Neglecting regular maintenance could easily lead
to the truck malfunction and failure, and potential threats to staff and operational safety.
Therefore, there must be adequate maintenance equipment, professional maintenance
personnel and a comprehensive maintenance plan in place.
Please perform the maintenance and inspections according to the following provisions:
To strictly enforce the truck maintenance, lubrication and inspection plans.
Truck maintenance, lubrication and inspection personnel must be approved by accredited
certication or evaluation agency.
The following operations shall be performed before you leave the truck:
- No parking on slopes.
- Fully lower the forks.
- Cut o󰀨 the power supply.
- Turn the switch lock to “STOP” and remove the key.
Prior to truck maintenance:
- Raise the drive wheel o󰀨 the ground, or cut o󰀨 the power supply connection.
- Use wooden wedges or other e󰀨ective xtures.
- When performing maintenance underneath the vehicle, make sure that the lifting device
or jack leg is secure.
- Park your vehicle in a safe and secure area.
Never use an open ame to check level of electrolyte, other oils or uids for leaks.
Keep the parking lot clean, well-ventilated and dry.
Regular checks and maintenance should be conducted to braking, steering, control, warning
and safety devices to keep them in good condition.
All nameplates and safety signs on the truck should be cleaned regularly to make them
clearly visible.
Regular checks and maintenance should be conducted to all the devices of lifting system to
ensure them to be safe for use.
The hydraulic system should be checked regularly based on usage. Hydraulic cylinders,
hydraulic valves and other hydraulic components should be ensured to be without leakage.
Regular checks and maintenance should be conducted to batteries, motors, controllers,
limit switches, protective devices, wires and connectors, and so on. Please pay particular
attention to the electrical insulation.
Park the truck in a clean environment to minimize the risk of re.
Without the permission of the manufacturer, users are not allowed to change or increase
the capacity of the truck. After having been changed under permission, the nameplates and
safety signs on the truck should also be changed accordingly.
The eld modication and installation of electrial accessories shall be carried out by trained
personal only.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
1. INFORMATION & SPECIFICATIONS

3
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INFORMATION & SPECIFICATIONS
1
2
NOTE: 1.1 After-sales Service Platform
Claims/Replacement Parts Service Platform:
In order to provide you with a fast and ecient
after-sales service, when you claim / order spare
parts or after-sales service upon maintenance,
please provide accurate truck model, vehicle
body serial number and part number.
After-sales Maintenance Service Platform:
iNOTE

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5
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INFORMATION & SPECIFICATIONS INFORMATION & SPECIFICATIONS
1 1
4
No. Name
1 Counter-weight
2 Warning Light
3 Overhead Guard
4 Steering wheel
5 Rearview mirror
6 Mast
7 Headlight
8 Headlight
No. Name
9 Load backrest
10 Forks
11 Steer wheels
12 Battery Hood
13 Chassis
14 Driver Seat
15 Drive wheels
16 Rear Combination Lights
This series are electric forklift trucks. Its impor-
tant structure is as shown in Fig3132-00003SM.
1.2 Introduction
-Please refer to the nameplate for rated load
capacity of the vehicle.
- The vehicle can only be used on the level gro-
und indoors, never use it on mezzanine or
balcony area.
WARNING
Truck can only be operated by single operator;
other personnel is forbidden from riding.
1.3 Common Tools
No. Name Remark
1 Hex Head Socket Wrench 8#~27# One Set
2 Phillips Screwdriver 2# One Piece
3 Slotted Screwdriver 2# One Piece
4 Sockets and Knobs One Set
5 Circlip Pliers One for holes and one for shaft
6 Hammer One Piece
7 Spreader, Crane One Pair
8 Cylinder Wrenches For removal and installation of cylinders
9 Diagonal Pliers One Piece
10 Cylinder Pliers One Piece
11 Grease Gun One Piece
12 Tiger Tooth Wrench 22#/27# One of Each
WARNING

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INFORMATION & SPECIFICATIONS INFORMATION & SPECIFICATIONS
1 1
6
Table 1.4.1 Screws/Bolts Performance Levels
Performance Level Material Specication (mm)
5.8 grade Low carbon steel M6 ~ M48
8.8 grade Quenched and tempered medium
carbon steel M6 ~ M48
10.9 grade Quenched and tempered medium
carbon alloy steel M6 ~ M48
12.9 grade Quenched and tempered medium
carbon alloy steel M6 ~ M48
Table 1.4.2 Metric Screws/Bolts Tightening Torque Table (n•m)
Nominal Diameter
(mm)
Performance Level
5.8 8.8 10.9 12.9
Proof Stress (MPa)
380 600 830 970
M6 7~8 10~12 14~17 17~20
M8 16~18 25~30 34~41 41~48
M8×1 17~20 27~32 37~43 43~52
M10 31~36 49~59 68~81 81~96
M10×1 35~41 55~66 76~90 90~106
M12 55~64 86~103 119~141 141~167
M12×1.5 57~67 90~108 124~147 147~174
M14 87~103 137~164 189~224 224~265
M14×1.5 144~170 149~179 206~243 243~289
M16 136~160 214~256 295~350 350~414
M16×1.5 144~170 228~273 314~372 372~441
M18 186~219 294~353 406~481 481~570
M18×1.5 210~247 331~397 457~541 541~641
M20 264~312 417~500 576~683 683~808
M20×1.5 294~345 463~555 640~758 758~897
M22 360~431 568~680 786~941 918~1099
M22×1.5 395~473 624~747 803~1034 1009~1208
M24 457~547 722~864 998~1195 1167~1397
M24×2 497~595 785~940 1086~1300 1269~1520
M27 669~801 1056~1264 1461~1749 1707~2044
M27×2 723~865 1141~1366 1578~1890 1845~2208
M30 908~1087 1437~1717 1984~2375 2318~2775
M30×2 1005~1203 1587~1900 2196~2629 2566~3072
M36 1587~1900 2506~3000 3466~4150 4051~4850
M36×3 1680~2011 2653~3176 3670~4394 4289~5135
M42 2538~3039 4088~4798 5544~6637 6479~7757
M42×3 2731~3269 4312~5162 5965~7141 6921~8345
M48 3813~4564 6020~7207 8327~9969 9732~11651
M48×3 4152~4970 6556~7848 9069~10857 10598~12688
12.9
10.9
8.8
5.8
1.4 General Tightening Torques
Screws or bolts used on the truck are of 8.8
grade or higher performance level.
When you are conducting truck maintenance,
you can refer to Table 1.4.1 and Table 1.4.2 to
select the suitable screws or bolts for replace-
ment.
-
-
CAUTION
The performance levels of screws or bolts are
marked on the heads of the screws or bolts.
If you nd the screws or bolts used on certain
position are not marked with performance
level, please select spare parts with perform-
ance level of at least 8.8 grade or higher level
for replacement.

9
2
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INFORMATION & SPECIFICATIONS
1
8
2. MAINTENANCE

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

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

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MAINTENANCE MAINTENANCE
2 2
Table 2.1 Inspection & Maintenance List (Continued)
Interval in days/months/years 7 d 60 d 90 d 6 m 1y
Interval in hours 50 250 500 1000 2000
Power Supply & Drive System
Check the position of various bearings for noise A
Check gear oil level A
Clean or replace the gear oil Replace once every 1000 hours
Check the gearbox for abnormal noise or leaks A
Check the drive wheel and steering wheel for worn or
damage A
Check and lubricate the wheel bearings A / L
Check the travel speed A
Hydraulic System
Check the functions of hydraulic system A
Check if the hoses, pipes and interfaces are fastened
or sealed securely, and check if there is damage A
Check the connections of pump motor connectors A
Check and tighten pump motor mounting bolts A
Check the gear pump xation and check for leaks A
Check the cylinders for leaks A
Check the cylinders for damages and check the xation A
Check the oil tank for leaks A
Check the hydraulic oil level A
Clean or replace the hydraulic oil Replace once every 2000 hours
Check and clean oil tank air lter A
Replace the oil tank air lter and lter A
Check the relief pressure A
A = Check / Adjust
Please refer to Inspection & Maintenance List
for regular inspection and maintenance of the
vehicles.
L = Lubrication
Under harsh conditions, the lubrication intervals
should be shortened by half.
Table 2.1 Inspection & Maintenance List (Continued)
Interval in days/months/years 7 d 60 d 90 d 6 m 1y
Interval in hours 50 250 500 1000 2000
Braking System
Check the braking functions A
Check the brake uid level A
Check the pump and piping connections for leaks A
Check the release of brake pedal is normal A
Check the braking distance of brake A
Mast System
Check the mast for damages A
Clean and lubricate the rolling surface of lift mast
column with grease A / L
Check and lubricate mast rollers A / L
Check the xation of lift mast A
Check the tubing on mast for connections and leaks A
Check the side shifter functions A
Check and lubricate the chains A / L
Check the lifting chains and chain guides for wear,
adjust and grease A
Check the fork carriages for wear and damage A
Visual inspection of rollers, sliders and stoppers A
Check the lifting and lowering speed A
Other
Check if the signs are clear and complete A
Check the chassis for cracks or damages A
Check the connections of bolts and nuts A
A = Check / Adjust
Please refer to Inspection & Maintenance List
for regular inspection and maintenance of the
vehicles.
L = Lubrication
Under harsh conditions, the lubrication intervals
should be shortened by half.

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MAINTENANCE MAINTENANCE
2 2
Table 2.1 Inspection & Maintenance List (Continued)
Interval in days/months/years 7 d 60 d 90 d 6 m 1y
Interval in hours 50 250 500 1000 2000
Other
Check tire pressure A
Check the xation of battery and battery tray A
Check the seat xation and adjustment functions A
Check the seat belt and functions A
Check the overhead guard and cabin A
Checking covering parts for damages A
Check if the optional features are functioning properly A
A = Check / Adjust
Please refer to Inspection & Maintenance List
for regular inspection and maintenance of the
vehicles.
L = Lubrication
Under harsh conditions, the lubrication intervals
should be shortened by half.
-
-
2.2.3 Lubrication
Improper operations may constitute hazards
to the operator's health and life, as well as to
the surrounding environment.
When storing or adding lubricant, use clean
containers. It is strictly forbidden to mix
di󰀨erent types and specications of lubricants
with each other (except for those can be
mixed under clear statement).
The use and disposal of lubricants must be
carried out in strict accordance with the manufa-
cturer's regulations.
Lubricant
Please see Table 2.2 for the lubricants used in
this truck.
CAUTION
2000-hour
1000-hour
Steering Axle
Gear Box
Bearing
Mast Pin Shafts
Mast Pin Shafts
Oil Tank
Bearing
Drive axle
Brake Fluid
Adding Grease
Changing
Hydraulic Oil Changing Gear Oil
Gear Oil Checks Brake Fluid Checks
Mast

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MAINTENANCE
2
Table 2.2 Lubricants
Code Type Specication Amount Position
AAnti-wear hydraulic oil L-HM46 See Table 2.3 Hydraulic
System
BMulti-purpose grease Polylub GA352P Appropriate amount Sliding surface
(See Table 2.4)
CHeavy duty gear oil 85W-90GL-5 4.5L (Align with oiling port) Drive Axle
DBrake uid ZSM207DOT3
After the gas within the
system is completely
discharged, add to 2/3 of
the oil cup
Brakes
Table 2.3 Application Amount of
Hydraulic Oil 1-2
Mast Series Lifting height
(mm)
Amount
(L)
Full Free
2-stage Mast
2000 30
2500 34
2700 34
3000 36
3300 36
3500 38
Wide-view
2-stage Mast
2000 30
2500 34
2700 34
3000 36
3300 36
3500 38
3600 38
4000 42
4300 42
4500 44
Table 2.3 Application Amount of
Hydraulic Oil 2-2
Mast Series Lifting height
(mm)
Amount
(L)
3-stage Mast
4300 38
4500 40
4800 42
5000 44
5500 46
6000 45
3. TROUBLESHOOTING

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TROUBLESHOOTING
3
20
NOTE: 3.1 Preparation Before Troubleshooting
-
-
-
-
Park the truck on level ground and block the
wheels with wooden wedges;
Fully lower the forks and press the emergen-
cy stop switch.
Turn o󰀨 the key switch;
Open the cover and check the controller.
-
-
Even if key switch is turned o, the controllers
are still energized.
Before checking or repairing the controllers,
make sure the battery plug has been
unplugged and the electrical circuit is
disconnected.
3.1.1 Check the Voltage of Battery
-
-
-
Unplug the battery plug;
Measure the battery voltage with a multim-
eter: black probe (-) connected to (-) terminal
of battery plug; red probe (+) connected to
the (+) terminal of battery plug. Read the
voltage reading on the meter.
Identify if the battery voltage is normal
according to the measured voltage.
As shown in the following table:
Battery Voltage Judgment
80V
65V~87.6V Normal
<65V or >87.6V Battery Fault
Enter TESTER Menu to check the battery
voltage.
If the battery voltage is still abnormal after being
charged: open the battery compartment, check
the voltage of each battery and its connection
circuit respectively:
1)
2)
Check if the voltage of single battery is
normal;
Check if the cables for connections between
each battery are normal, check for open circ-
uit and if the connection between connectors
is secure.
- Battery leakage check: disconnect the battery
connection, black probe (-) connected to
(-) terminal of battery plug; red probe (+)
connected to the chassis. Read the voltage
reading on the meter.
No voltage (0V): normal;
With voltage: battery leakage (remove battery
compartment, check each battery and cables)
CAUTION
CAUTION
i
NOTE

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TROUBLESHOOTING TROUBLESHOOTING
3 3
3.2 Troubleshooting Solutions of Common Faults
Table 3.1 lists the common faults that may occur and handling
methods. Mainly consists of the following items:
Table 3.1 Troubleshooting of Common Faults
Fault Fault Symptom Probable Causes Troubleshooting
Power supply
failure
1. Whole vehicle power
outrage
• Power supply failure
• Fuse failure
• Emergency stop switch or circuit
failure
• Key switch or circuit failure
1. Check the voltage of storage
battery
2. Check the fuses
3. Check key switch and its
circuit
4. Check emergency stop switch
and its circuit
Travel Fault
1. Forward and reverse
moving failures of
the vehicle, but other
functions are normal
• Parking brake switch and seat
switch or its circuit connection
failure
• Gearbox failure
• Travel switch or its circuit
connection failure
• Drive motor or its circuit
connection failure
• Controller failure
Controller failure error, carry out
troubleshooting according to the
fault code information on the
instrument.
1. Check if parking brake
switch and seat switch or the
connection of its circuit is
normal;
2. Check the gearbox;
3. Check the travel switch and
its connection circuit;
4. Check the drive motor and its
connection circuit;
5. Replace the controller.
2. The vehicle can
travel at low speed,
but cannot travel at
high speed
Failures due to external factors:
• Motor bearing blocked
• Gearbox bearing blocked
Failures due to internal factors:
• Drive motor speed encoder
failure
• Controller failure
Controller failure error, carry out
troubleshooting according to the
fault code information on the
instrument .
1. Remove the motor, check if
the motor rotation is normal;
2. Check the speed encoder
and its connection circuit;
3. Remove the gearbox, check
if the gear rotation is smooth
and if there is blocking;
4. Replace the controller
3. Drive axle Bearings
noise or jammed
• Bearing fatigue damage or
foreign 1. Replace the bearings
* Carry out trouble shooting in accordance with the order listed in the table, it can help you quickly
identify problems and resolve accordingly.
Travel Fault
4. Abnormal tyre
wear, cracking or
degumming
• Improper use
1. Replace the drive wheel;
2. Replace the rear steering
wheel.
5. Drive wheel slipping
or jumping • Wear 1. Replace the drive wheel
6. Vehicle sways while
running • Wheel lock nut loosening 1. Tighten the nuts
7. Brake performance
weakened or failure
• Insu󰀩cient brake uid;
• Brake master pump blocked;
• Brake pipeline leaks.
1. Add brake uid;
2. Replace the master pump;
3. Replace the brake pipeline.
Motor Fault
1. Motor does not
rotate
• Cable U, V, or W is broken;
• Loosening connections to cable
U, V or W ;
• Stator coil open circuit;
• Motor bearing damage;
• Speed encoder or its circuit
failure.
1. Replace the Cable U,V, or W;
2. Tighten the nut;
3. Check the stator coil;
4. Replace the motor bearing;
5. Check the speed encoder, if
neccessary replace it.
2. Motor is rotating
in slow speed and
reverse
• Cable connection error 1. Remove the cables and re-in-
stall;
3. Motor with abnormal
noise or vibration
• Uneven clearance between stator
and rotor;
• Bearing failures;
• Loosening xing screws on motor
housing.
1. Replace the drive motor or
pump motor;
4. Motor smoking or
burning smell
• Stator winding short circuit, motor
burnt
1. Replace the drive motor or
pump motor;
5. Motor temperature
too high, controller
failure
• Stator winding short circuit;
• Motor U, V and W terminals with
surface ;
• Bearing failure, resulting in
severe heating;
• Motor cooling duct blockage with
foreign body;
• Overload.
6. Refer to the rated capacity
marked on the nameplate;
Table 3.1 Troubleshooting of Common Faults
Fault Fault Symptom Probable Causes Troubleshooting
* Carry out trouble shooting in accordance with the order listed in the table, it can help you quickly
identify problems and resolve accordingly.

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

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Table 3.1 Troubleshooting of Common Faults (continued)
Fault Fault Symptom Probable Causes Troubleshooting
Lifting System
Failure
1. Slow Lifting of
Vehicle
• Overload
• Hydraulic pipeline leakage
• Valve failure:
• Gear pump wear, internal
leakage occurs
• Insu󰀩cient relief valve pressure
or blocked
1. Refer to the rated capacity
marked on the nameplate;
2. Check the pipe and hydraulic
components for oil leaks;
3. Wash or replace the valve
body
2. Slow Lowering of
Vehicle
• Solenoid valve blocking
• Valve body failure: throttle valve
failure or blocked
1. Wash or replace the solenoid
pool
2. Wash or replace the valve
body
3. Unstable Lifting /
Lowering of Vehicle
• Chain loosening;
• Poor lubrication between steel
channel and rollers;
• Improper adjustment of rollers, or
blocked.
1. Adjust the chain tension;
2. Check if the steel channel
grease is normal, clean and
relubricate steel channel and
rollers;
3. Adjust the side roller spacing
through roller screw; or
replace the roller.
4. Fork arm carrier or
mast tilt by itself.
• Tilt cylinder and ring abraded
excessively
• The hydraulic control valve spring
is inoperative.
1. Replace piston ring tilt
cylinder.
2. Replace it.
5. The fork arms carrier
moves up and down
sluggishly.
• Caused by piston jamming or
bent piston rod.
• Too much dirt is accumulated in
the cylinder.
1. Replace the faulty parts.
2. Strip it down and clean.
6. Forks are lifted or
lowered unsmooth.
• Carriage bracket assembly out of
adjustment.
• Insu󰀩cient clearance between
inner and outer masts or rollers
and mast.
• Biting foreign materials between
moving parts.
• Insu󰀩cient lubrication.
• Bent carriage bracket assembly.
1. Adjust clearance with thrust
metal and carriage side roller.
2. Adjust clearance with rollers.
3. Remove foreign materials.
4. Apply grease on contact sur-
faces of sliding parts.
5. Repair or replace.
* Under the circumstances of normal lifting and lowering, if failure occurs to any of other
hydraulic actions (forward/backward shifting, forward/backward tilting and left/right shifting),
perform troubleshooting to the corresponding control switch and its control circuit.
Table 3.1 Troubleshooting of Common Faults
Fault Fault Symptom Probable Causes Troubleshooting
Hydraulic
Failure
1. Noisy pump
• Insu󰀩cient oil;
• High viscosity of oil;
• Oil suction pipe air leak;
• Filters clogged by impurities;
• Hydraulic oil with foam;
1. Check the hydraulic oil level.
2. Replace the hydraulic oil.
3. Check the oil suction pipe.
4. Clean the oil inlet piping, re-
place the lter, if necessary.
5. See Fault 2.
2. Hydraulic oil with
foam
• Pump cavitation;
• There is water in the oil.
1. Check the amount of oil;
2. Check if the viscosity of hy-
draulic oil is normal;
3. Check the oil inlet piping for
air leaks;
4. Discharge and clean, and
replace with new hydraulic
oil.
3. Pump or oil
temperature is too
high
• Oil is too thin;
• Pump cavitation;
• Valve body internal relief.
1. Discharge and clean, and
add new hydraulic oil;
2. Check the oil inlet piping for
air leaks;
3. Replace the valve body.
4. Low System
Pressure
• Insu󰀩cient oil;
• Relief valve failur
• Pump wear, internal leakag
1. Check the hydraulic oil level;
2. See Fault 6;
3. Replace the gear pump.
5. On load, declined • Solenoid valve failure;
1. Check and clean the solenoid
valve spool.
2. Check the multi-way manual
valve and it installation.
6. Relief valve pressure
unstable or too low
• Pressure adjustment screw too
loose;
• Relief valve spring breakage or
deformation;
• Relief valve spool wear or
blocked.
1. Adjust to proper pressure
through hydraulic pressure
gauge.
2. Replace the relief valve.
3. Clean or replace the relief
valve.
* Carry out trouble shooting in accordance with the order listed in the table, it can help you quickly
identify problems and resolve accordingly.

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Table 3.1 Troubleshooting of Common Faults (continued)
Fault Fault Symptom Probable Causes Troubleshooting
Gear Pump
Fault
1. Gear pump does not
absorb oil or of small
ow
• Insu󰀩cient hydraulic oil;
• Pump body defects;
• Poor sealing with leakage;
• Oil lter clogging;
• Oil temperature is too high.
1. Replace the hydraulic oil;
2. Replace the gear pump;
3. Replace the sealing;
4. Clean or replace the oil lter;
5. Cool down the hydraulic oil.
2. Insu󰀩cient gear
pump output
pressure
• Pump body defects;
• Pump body with cracks or leaks;
• Impurities in the pump, oil lter
clogging;
• Low viscosity of hydraulic oil;
• Oil temperature is too high.
1. Replace the gear pump;
2. Replace the gear pump;
3. Replace the hydraulic oil and
clean the gear pump;
4. Replace the hydraulic oil with
higher viscosity;
5. Cool down the hydraulic oil
3. Too much vibration
and noise
• Pump body defects;
• Gear pump inlet tubing diameteris
too small;
• Oil lter clogging, or motorspeed
is too high;
• Motor and oil pump shaft
misalignment.
1. Replace the gear pump;
2. Replace the inlet tubing;
3. Clean the oil lter, adjust the
motorspeed to a lower value;
4. Remove and reinstall the
motor.
4. Oil leaks
• Pump body defects;
• Seal skeleton spring o󰀨;
• Shaft sealing surface scratche
1. Replace the gear pump;
2. Remove and reinstall the seal
skeleton;
3. Replace the shaft sealing.
5. Pump is not
functioning properly
or blocked
• Pump body defects;
• Poor alignment of pump
andmotor coupling;
• Impurities in the pump.
1. Replace the gear pump;
2. Remove and reinstall the gear
pump;
3. Remove and clean the gear
pump.
Redirector
Fault
1. Oil leaks • Redirector defects;
• Poor sealing with leakage;
1. Replace the redirector;
2. Remove and reinstall the
redirector, if neccessary
replace the redirector.
2. Redirector is not
functioning properly
or noise
• Redirector defects;
• Insu󰀩cient oil;
• There is air in the oil;
• High viscosity of oil.
1. Replace the redirector;
2. Add the hydraulic oil;
3. Discharge the air in the oil;
4. Replace the hydraulic oil with
lower viscosity;
* Carry out trouble shooting in accordance with the order listed in the table, it can help you quickly
identify problems and resolve accordingly.
Table 3.1 Troubleshooting of Common Faults (continued)
Fault Fault Symptom Probable Causes Troubleshooting
Lifting System
Failure
1. Lift roller does not
rotate
• Grease sti󰀨ened or dirt
accumulated on lift roller and
mast sliding surfaces.
• Improperly adjusted lift roller.
1. Clean and lubricate lift rollers.
2. Adjust.
2. Excessive mast
noise
• Insu󰀩cient lubrication.
• Improperly adjusted lift roller,
side roller and back-up metal.
• Rubber pad on lower of outer
mast is useless for container fork
lift truck.
1. Lubricate.
2. Adjust.
3. By adjusting shims and
rubber pad, piston rod is in
touch with bottom of cylinder
body after inner mast is in
touch with rubber pad.
3. Insu󰀩cient lift power
or no lift movement.
• Excessive wear occurs between
the oil pump body and gears,
causing too much clearance.
• The lifting jack piston Yx-ring has
worn, resulting in excessive inner
leaks.
• Springs of the multiple control
valve and its relief valve are
inoperative oil leaks.
• Excessive wear occurs of the
hydraulic control valve, resulting
in excessive oil leaks.
• Oil leaks occur between the
hydraulic control valve sections.
• Leakage occur in the hydraulic
pipe.
• The hydraulic oil temperature is
too high. Oil viscosity is too low
and the rate is insu󰀩cient.
1. Replace the worn parts or the
oil pump.
2. Replace Yx-ring.
3. Replace.
4. Replace.
5. Dismantle for regrinding the
joint surfaces and reassemble
the valve.
6. Tighten the joint nuts and
inspect the seal for damage.
7. Change the wrong hydraulic
oil or stop operation for
reducing the oil temperature.
Find out the reasons for high
oil temperature and eliminate
the trouble.
Manual Valve
Fault
1. The vehicle
cannot perform the
hydraulic control
instructions
• Valve failure;
• Valve seat blocked by large
impurities;
• External leakage:
i. sealing damaged;
ii. poor threaded connection;
iii. valve body defects;
• High viscosity of hydraulic oil;
• High frequency of use, service
life has expired already.
1. Replace the manual valve;
2. Remove and clean the valve
seat;
3. Replace the sealing;
4. Replace the screwed joint;
5. Replace the manual valve;
6. Replace the hydraulic oil with
lower viscosity;
7. Replace the manual valve;
2. Slow pace of
actuator
• Overow valve in the connection
block started;
• Valve seat leakage;
• Valve rod cannot push/pull to
bottom; the channel cannot be
fully opened;
• High viscosity of hydraulic oil;
• High frequency of use, service
life has expired already.
1. Restart the truck;
2. Replace the valve seat;
3. Clean the valve rod, if necc-
essary replace the valve;
4. Replace the hydraulic oil with
lower viscosity;
5. Replace the manual valve;

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Table 3.1 Troubleshooting of Common Faults (continued)
Fault Fault Symptom Probable Causes Troubleshooting
Steering Fault
1. The vehicle cannot
be steered (the
vehicle can travel)
• Steering potentiometer or its
circuit connection failure
• Redirector or the tubings
connection failure
• Steering bridge or the tubings
connection failure
• Pump motor failure
• Gear pump failure
• Pump controller failure
Controller failure error, carry out
troubleshooting according to the
fault code information on the
instrument .
1. Check the steering potentiom-
eter or its connection circuit;
2. Check if the mechanical
connection between steering
wheel and redirector is solid;
3. Check the redirector or the
tubings connection;
4. Check the steering bridge or
the tubings connection.
5. Check the pump motor or its
connection circuit;
6. Check the pump;
7. Replace the controller.
2. Steering Bridge
Abnormal Noise • Supporting bearing wear 1. Replace the bearing
3. Steering Bridge Oil
Leaks
• Oil seal wear or aged
• Not at of shim in limiting position
bolt
1. Replace the Oil seal
2. Grinding shim or replace it
4. Steering Bridge
Stuck • Support bearing damage. 1. Replace the bearing
5. High e󰀨ort for
steering of failure
to rotate steering
wheel
• Not enough oil supported by
pump
• Air enters in the line of steering
gear
• Not enough oil in tank
• Too low pressure setting of the
relief valve in the dividing valve
or blocking in valve
• Too high viscosity oil
• The steering fails to return to its
natural position due to breakage
of locking spring or insu󰀩cient
spring pressure
• Break or deform of swivel pin
• Break or deform of coupling
• Wrong in spring or safety valve
• Too much internal leakage in the
steering cylinder
• Deform of steering axle
1. Adjust control valve
2. Bleed the air
3. Fill oil
4. Adjust pressure or clear dirt
5. Replace wrong oil
6. Replace wrong spring
7. Replace it
8. Replace coupling
9. Replace spring
10.Replace seal or cylinder
11.Repair it
Table 3.1 Troubleshooting of Common Faults (continued)
Fault Fault Symptom Probable Causes Troubleshooting
Other Failures
1. Lights do not light
a. Light failure or circuit not
conducted
b. Lighting combination switch or
its circuit connection failure
c. Fuse failure
d. DC-DC converter failure
1. Check the light and its cir-
cuit connection;
2. Check Lighting combination
switch and its connection
circuit;
3. Check fuse and its connec-
tion circuit;
4. Check DC-DC converter
and its connection circuit.
2. Horn does not
sound
a. Horn switch or its circuit
connection failure
b. Horn failure
c. Fuse failure
d. DC-DC converter failure
1. Check the horn button and
its connection circuit;
2. Check the horn and its con-
nection circuit;
3. Check fuse and its connec-
tion circuit;
4. Check DC-DC converter
and its connection circuit.
* Carry out trouble shooting in accordance with the order listed in the table, it can help you quickly
identify problems and resolve accordingly.