Sovan's CBD25T User manual

CBD25T/CBD30
Electric Pallet Truck
Operation Manual
Parts Catalogue
2012-01

Welcome to choose “Sovan's” electric pallet truck!
We hope our electric trucks will bring great convenience to
your work!
Please read the manual carefully before operation.
This manual is a common manual. We reserve the right to modify
technology of the electric pallet truck. If there is anything in the
manual that is not consistent with the actual truck, the actual truck
should be considered correct and the manual is only for reference。
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Warning
Operators must strictly conform to ISO3691“Safety Specifications of Motor Industrial Vehicles”.
Untrained personnel are notallowed to operate the truck。
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Content
Brief introduction……………………………………………………………………..……1
Ⅰ.Technical parameters…………………………………………………..…………..2
Ⅱ.Structure description…………………………………………………………………4
Ⅲ.Safety norms……………………………………………………………………………..6
Ⅳ.Drive and operation………………………………………………………..………..11
Ⅴ.Storage battery and charge……………………………………………………..13
Ⅵ.Inspection before operation…………………………………………………....16
Ⅶ.Inspection after operation……………………………………………….……...16
Ⅷ.Periodic maintenance and repair………………………………………….….17
Ⅸ.The store and transportation of forklift…………………………………..22
Ⅹ.The tow of the pallet truck……………………………………………...........23
Ⅺ.The disassembly and assembly of some parts……………………….24
Ⅻ.Common fault and trouble shooting………………………………………..27
Appendix: Motor industrial vehicle—Safety norms………………………32

Brief introduction：
CBD25T/CBD30 series electric pallet truck is powered by storage battery, and driven by motor. This kind of truck
travels by means of gear drive. The fork is lifted by means of DC motor and hydraulic transmission, which
motivate hydraulic cylinder up and down to lift fork and goods together. As this truck is electrically driven for
traveling and lifting, it possesses many characteristics, such as labor-saving, high efficiency, stability in operation,
simple and easy operation, safety and reliability, little noise, environmental friendly, etc. And the driving mode for
this kind of truck is stand driving and steering operation of handle steering. This truck adopts 24V large capacity
battery cell, which greatly extends service time within one charge.
The kind of truck is applicable for goods transportation on hard and flat ground.
Allowed environment for using
a. Height above sea level shall not be over 1200m;
b. Ambient temperature shall not be higher than +40℃ and no lower than -25℃；
c. When the ambient temperature reaches +40℃, the relative humidity should not exceed 50%; at a lower
temperature, higher relative humidity is allowed；
d. Hard and flat ground。
e. It is prohibited to use the truck in a flammable, explosive or corrosive environment with acid and alkali.。
Description：
The instruction manual shall be kept by the operator, and shall be read by the operator until he gets a full
understanding.
The instruction manual is composed of correct operation, convenient and simple maintenance, and routine
inspection.
The instruction manual shall be carefully read before operation, for purpose of correct drive and suitable
maintenance to ensure safe and effective material transportation.
The instruction may be in disagreement with practical product due to product innovation.
The instruction manual shall be accompanied with in case of truck leasing or transfer.
Please come into contact with our sales department in case of any problem.
Description of symbol：Regulations of the following symbols are of great importance to your safety and others
as well
Danger
Indicates an impending danger. Deaths or severe injuries would be
resulted without any precaution or avoidance. You must observe
those requirements.
Warning
Indicates a potential danger. Deaths or severe injuries would be
resulted without any precaution or avoidance. You must observe
those requirements.
Caution
Indicates a potential danger. Moderate injuries would be resulted
without any precaution or avoidance. You must observe those
requirements.
Notice You shall pay attention to statements that are in direct or indirect
relation with personal security and truck maintenance.

1
Ⅰ.Technical parameters：
1． CBD25T/CBD30 Outline drawing：

2
2、Main technical parameter
Char
acter
istics
1.1 Manufacturer(abbreviated)
1.2 Model CBD25T CBD30
1.3 Driving model ：Electric(storage battery),
diesel, gasoline, fuel gas motor-driven motor-driven
1.4 Driving model （Manual, Walking, Stand
driving, Seat driving ,Order picking） Stand driving Stand driving
1.5 Rated load Q(kg) 2500 3000
1.6 Load center distance
c (mm)
600 600
1.8 Front overhang
x (mm)
933 933
1.9 Tread
Y (mm)
1491 1491
Weig
ht
2.1 Service weight(with battery) kg 860 860
2.2 Axle load, front/rear, laden kg 1240/2120 1360/2500
2.3 Axle load, front/rear, unladen kg 640/220 640/220
Whe
el
chas
sis
3.1 Wheels (rubber, high elasticity, pneumatic
tyre, polyurethane wheel) polyurethane
wheel
polyurethane
wheel
3.2 Wheel dimension, front φ250×80 φ250×80
3.3 Wheel dimension, rear φ82×173 φ82×173
3.4 Additional wheel(dimension) φ127×57 φ127×57
3.5 Wheel number, front/rear（x = driving wheel） 1X+2/4 1X+2/4
3.6 Tread, front
b
10(mm)
691 691
3.7 Tread, rear
b
11(mm)
455 455
Dime
nsion
4.4 Lift height
h
3(mm)
135 135
4.9 Min. /Max. height of operation handle, in
driving position
h
14(mm)
1041/1374 1041/1374
4.15 Height, lowered
h
13(mm)
82 82
4.19 Overall length
l
1(mm)
2143 2143
4.20 Length to fork face
l
2(mm)
923 923
4.21 Overall width of truck body
b
1(mm)
936 936
4.22 Fork dimension S/e/l(mm) 55x230x1220 55x230x1220
4.25 Overall width of fork
b
5(mm)
685 685
4.32 Wheelbase ground distance
m
2(mm)
27 27
4.33 Aisle width, with pallet 1000x1200 crosswise
A
st
(mm)
2343 2343
4.34 Aisle width, with pallet 800x1200 lengthwise
A
st
(mm)
2343 2343
4.35 Turning radius
W
a(mm)
1860 1860
Perfo
rman
ce
Data
5.1 Traveling speed, laden/unladen Km/h 7.5/8 6/6.5
5.2 Lifting speed, laden/unladen m/s 0.03/0.04 0.03/0.04
5.3 Descending speed, laden/ unladen m/s 0.05/0.045 0.05/0.045
5.7 Gradeability, laden/unladen % 6/8 6/8
5.8 Max. gradeability, laden/unladen % 8/20 8/20
5.10 Traveling brake regenerative
brake regenerative brake
Moto
r
6.1 Driving motor power kW 1.5 2.2
6.2 Lifting motor power kW 1.5 1.5
6.3 Battery voltage/rated capacity V/Ah 24/300 24/300
6.4 Battery weight Kg 300 300
6.5 Battery dimension（LXWXH） mm 810×212×665 810×212×665
8.4 Noise level at operator’s ear, according to
DIN12053 dB(A) 70 70

3
Ⅱ.Structure description：
1．Structure of the entire truck：
1 power switch； 2 lifting button； 3 horn button； 4 accelerator knob； 5 operation handle；
6 emergency reverse button；
7 multi-functional instrument 8 electric lock； 9 electric control unit； 10 driving unit； 11
platform； 12 steering power unit；
13 hydraulic power unit； 14 storage battery； 15 handrail； 16 handrail control box； 17 tool
pallet； 18 backrest

4
2 Function introductions
of instrument and
operational control
pieces:
⑴⑴ instrument:
1. battery capacity
indicator；
2. fault indicator；
3. low-speed
indicator；
accumulative working time
and fault code indicator
This instrument is a
combination of battery
capacity indicator, LCD hour
meter, fault code and
low-speed indicator, with
the battery capacity indicator of five segments of colorful LED display. When the storage battery is fully
charged, the five battery capacity indicators will be green. With battery capacity consuming up, the five
indicators will go out one by one. When battery discharges by 70% capacity, the last indicator will flicker
and shows “energy storage” alarm. When the battery discharges by 80%, the last indicator becomes red
and shows “energy exhaust”. After the external power supply is cut off, the internal battery can generally
keep storage memory of 10 years. The life service time for monitoring of this instrument is 99999.9 hours
recorded on LCD displays. Hour meter resets automatically and continue to time and display. Only if it is
connected to battery, LCD hour meter will start working. This instrument possesses high reliability under
extremely bad environment。
⑵Steering system:
The steering system mainly composes of operation handle, steering device shaft, support bearings,
potentiometer and steering power unit. The system is used to control travel direction of the truck。
⑶Braking:
the traveling brake of this truck is regenerative braking, with parking brake of electromagnetic brake.
When the accelerator is released during the traveling of the truck, the controller will carry out regenerative
braking at first. This kind of brake can turn the dynamic energy to electric energy which can be recharged to
battery. When the truck is stopped, the electromagnetic arrester will be out of power and braked again. This
type of regenerative brake with electromagnetic brake not only prolongs the service time of storage battery
but also reduces the wearing of the brake plate, which extends the service time of brake
The position of operation handle is divided
into 3 areas, i.e. area A , area B and area C which
have different operational functions separately.
area A： When the operation handle is in area A, the
truck will be in a state of braking.
Then acceleration knob for traveling can not work but
can only conduct lifting or lowering operation.
area B： When the operation handle is in area B, the
truck will be in a state of traveling. When the
accelerator knob is turned to one direction, the truck
will travel in this direction. When the accelerator knob
is turned in another direction, the truck will travel in
another direction. When the accelerator knob is
released during
truck traveling, regenerative braking will take effect, making the truck slow down to stop.
area C：When the operation handle is in area C, the truck will be in a state of traveling. When the accelerator
knob is turned to one direction, the truck will travel in this direction. When the accelerator knob is turned in
another direction, the truck will travel in another direction. When the accelerator knob is released during truck
traveling, the truck will be in a state of free sliding.

5
When the operation handle is placed in area B or area C, the truck can conduct traveling operation
as well as lifting operation. However, traveling and lifting operation can not realized at the same time, with the
traveling operation as the preferential function。
⑷Operation control:
1) Lifting and lowering operation: Press the lowering button of the forks, the forks will descend. While the
lifting button is pressed, the fork will rise。
1．Lifting button 2. Lowering button 3. Accelerator knob
4. Emergency reverse button 5. Horn 6. Slow-down button
2) Accelerator knob: It is used to control the travel direction and speed of the electric truck. Before
operation of the truck, firstly turn the operation handle to area C shown as above. When the handle is
placed in area A, the truck will be powered-off and braked. At this time, the truck can not drive. When the
operation handle is placed in area C and the acceleration knob is turned in one direction, the truck will
travel in that direction. Meanwhile the truck will be accelerated with the increasing of rotation amplitude
of the knob. When the
accelerator knob is turned in
another direction, the truck will
travel in another direction.
Likewise， the truck will speed
up with the increasing of
rotation amplitude of the knob.
3) Horn button ： Horn of the
truck will be turned on if you
press the button。
4) Emergency reverse button:
when the operation handle is
placed in area B and the
emergency reverse button is
pressed, the truck will travel in an opposite direction away from the operator immediately. This is a safety
switch which can avoid the operator from being squeezed under unexpected condition。
5) Slow-down button: When this button is pressed, the truck will travel at an extremely slow speed. This
button is applicable for operation on especially narrow field or on the condition that the truck needs to be
accurately located.。
6) Electric lock：It is used to control switching-on and switching-off of main power supply of the truck. Key
of the electric lock shall be kept by the truck driver or personnel who have been specially assigned. Be
sure to cut off the main power supply when you leave the truck, and take the key of electric lock, for fear
occurrence of accident due to operation carried out by others。
7) Power switch：It is used to control emergency power-off of the truck. Pulling up the switch, then main
power supply will be cut off, and inserting down represents switching-on. If your truck were out of
control due to some reason, please immediately pull up the switch to cut off power supply for sake of any
occurrence of accident。
As for the operation button on operation handle and handrail control case, the same buttons
have the same control function, which is convenient for easy operation。
1. Horn
button
2. Rise
button
3.Tortoise
climb button
4.Descend
button
5.battery
main switch

6
Ⅲ. Safety Norms：
Warning
Please pay attention to the following items first before operation of the truck：
⑴ This electric truck is only limited to utilization indoor with a hard flat floor. Operation in inflammable,
explosive environment or corrosive environment such as acid or alkaline condition shall be strictly
forbidden.
⑵ Only drivers who have received formal training or are authorized can be allowed to drive the truck.
⑶ Read this instruction carefully before operation so as to master the performance of the truck; check the
truck whether it is in its normal condition before each operation. It is forbidden to use faulty truck; repair
by untrained persons is forbidden as well.
⑷ Overloading operation is forbidden.
⑸ As for goods carrying and operation, center of gravity of the goods must be within range of the two forks.
It is forbidden to transport loose goods.
⑹ The truck shall travels slowly when forks pass in or out of pallet.
⑺ It is strictly forbidden to press the lifting or lowering button during the traveling of the truck. Meanwhile,
don’t switch lifting and lowering buttons rapidly or frequently, because rapid and frequent lifting or
lowering will cause damage to the truck and goods.
⑻ Don’t load heavy goods on the forks rapidly.
⑼ Don’t lay the goods on the truck for a long time!
⑽ It is strictly forbidden to make sharp turn on narrow aisle. When it is turning, slow down the truck so as
to ensure the safety of personnel and goods.
⑾ Descend the forks to the lowest position when the truck is not used.
⑿ It is strictly forbidden to put any part of the body under heavy goods and forks.
⒀ This truck is suitable to be used on flat ground or flat platform. Don’t put the truck on the slope for a long
time.
⒁ Overloading operation is forbidden. Otherwise the wheel will skid, resulting in the damage of wheel and
motor as well as danger of the human body and goods.
⒂ It is strictly forbidden to use the truck under stipulated voltage of 20.4V.
（16）It is strictly forbidden to conduct charge by connecting the plug to AC power directly。
1. Safety operation norms：
⑴Training of driver：
Notice
Even though each electric pallet truck may have the same technical parameters, there may
be differences on features of braking and acceleration as well. Never drive the truck until you get
familiar with all those operations。
⑵Wear of the driver during truck driving：
Notice
Please put on safety shoes and protective clothes. Do not wear clothes that are too loose
for sake of being caught, which would result in danger.
⑶ Rules that must be observed；
Notice
Never drive the truck when you are tired or un-concentrated, with an injection of drug, or
after a liquor drinking。
Safety rules and regulations shall be observed during operation or maintenance of the truck。

7
⑷ Safety of working place：
Notice
This kind of electric truck is only limited to utilization indoor with a hard flat floor. Operation
in inflammable, explosive environment or corrosive environment such as acid or alkaline condition
shall be strictly forbidden。
A Good roadway condition shall be kept and the traffic should be smooth.
B Sufficient light ray shall be ensured on working place.
C Fire extinguishing appliances shall be equipped in the places where truck and charging is operated.
The extinguishing appliances shall comply with the requirements of extinguishing fire of solid combustible
matter and electric apparatus.
D The value of truck noise mentioned in instruction is measured under the condition of new truck running on
flat, smooth and hard ground. If the traffic surface is bad or the tyre of truck is damaged, the noise may be
amplified.
⑸ Integrity of the truck shall be realized：
Warming
Don’t remake the truck
A Please observe safety rules and regulations of your working place during operation, inspection, and
maintenance of the truck.
B No modification or addition shall be made to the truck without written permission by our company. A
modification of the truck may have a negative effect on its safe operation。
⑹Prepare safety operation procedure：
Safety operation procedure shall be formulated with consideration of practical situations before
operation of the truck. Safety shall be taken into full consideration in preparation of the safety operation
procedure。
⑺Operation of truck under unsafe condition is strictly forbidden:
A A Operation under unsafe condition is forbidden, such as under conditions with uneven floor, or
impeded road. Goods lifting on slope is strictly forbidden
B Faulty truck is forbidden to use。
C Make sure a daily inspection of the truck would be taken. Please immediately repair or replace in case
of any abnormal conditions。
⑻Overloading operation of truck is forbidden:
Warning
Overloading operation of truck is forbidden. Overloading operation would
cause damage to the truck or bring harm to operator
⑼ Use suitable pallet：
The pallet shall be of suitable dimensions, neither too wide nor too large。
⑽ Electrical System Check：
Notice
Before checking the electrical system, turn off the key switches and the
emergency isolation switches。

8
2 Safety Operation Specification：
⑴ Check the safety condition around the truck
Notice
Before starting up the truck, please ensure that there is no person around it。
Notice
If the driver’s view is shielded by the bulky goods carried, please drive
backwards or drive under the guidance of other working personnel.
Notice
Ensure no people around the truck when driving backwards。
Notice
Driving through the narrow access shall be guided by working personnel。
Notice
At crossroad or other places impeditive for view, the driver shall not drive until there
is no person at both sides。
Notice
Keep concentration when operating truck。
Caution
The driving mechanism of truck is installed on the backside. Due to this
difference from common vehicles, the backside of truck swings comparatively fast
when turning around. For this reason, to prevent collision with other objects nearby
the backside of truck, do drive or turn slowly.
⑵ Strictly forbid harsh driving
Notice
Never start up, brake or turn abruptly.
Abrupt turning during traveling may cause the tilting of truck and result in serious accident.
Do decelerate and take care to turn。

9
Notice
Observe all items of safety rules on working place. Decelerate and sound horn
when travel by other truck or vehicles. Avoid driving in places with bad view。
Notice
Ensure to provide certain clearance between truck and entrance
（3） Never drive too close to roadside；
Notice
Ensure to provide enough distance between the truck and roadside or
platform edge。
When running on narrow road or platform, keep a certain safety distance with the edge against falling of the
truck.
Warning
Avoid turning or loading and unloading operation on slope;
otherwise the truck can go tilting。
3 Operation norms:
Notice
The truck can only carry goods under rated capacity。
1) Forbid overloading operation.
2) Forbid deflective transportation.
3) Passengers on truck must be forbidden.
4) Never push or pull the handle abruptly
5) Never use the truck as towing vehicle.
6) When transporting over-wide goods, the driver shall be extremely careful to turn slowly to keep balance
of the goods. Decelerate when ascent and descent, meanwhile, watch around for sake of safety.
The faulty truck for future repair must not be parked at places impeditive for traffic. Lower down the fork arms
to the lowest position and put on the warning board. Pull off the key
4 Important notice after operation：
1）Parking: Park the truck at appointed place. Never park the truck on slope.
Ensure the following points to be achieved before leaving away the truck.
a) Lay down the fork to the lowest position naturally；
b) Turn the steering wheel to the middle position；
c) Turn off the key switch。
2）Clean up the truck：
Notice
When cleaning up the electrical system, use compressed air but not
water.
3）Charge：
Warning
Open flame is forbidden to appear at the charge places, otherwise,
explosion or fire disaster can be caused。

10
Make a record of charge. As for the charge method, refer to the part about storage battery
operation。
Ⅳ.Drive and operation：
1．Prepare before operation：
Warning
Never use the faulty truck
a) Before operation, check the truck to make sure: whether oil leakage of hydraulic pipe exists, whether all the
supporting wheels work well, whether blocking phenomenon appears. Never use the faulty truck.
b) Check the charge quantity of storage battery. Never use the truck with empty batteries. Otherwise, the
lifetime of storage battery can be reduced greatly. More seriously, the storage batteries can be damaged。
c) Check the braking of truck and the ascent, descent, running forward and backward。
2. Driving：
⑴ Start-up：
Warning
When forking goods or moving goods, never rotate the accelerator knob
rapidly to speed up the truck abruptly。
Turn the switch of electric lock to ON position. When the operation handle is turned to area B or area C and
accelerator knob is rotated slowly, the truck will start gradually. The greater the accelerator knob is turned, the
faster the truck travels。
⑵ Decelerate：
The driving motor of the truck is AC motor. The running speed of motor is controlled by speed regulation actuator all
the time. So, if the accelerator knob is released slowly, the truck will slow down so as to decelerate. Then, the truck
will be in a state of sliding. When the operation handle is turned to area B, regenerative braking take effect. And the
truck will slow down until it stops.。
⑶ Turning：
Caution
The driving mechanism of truck is installed on the backside. Due to this difference
from common vehicles, the backside of truck swings comparatively fast when turning around.
For this reason, to prevent collision with other objects nearby the backside of forklift, do drive or
turn slowly。
The driver stands on the truck pedal in the right gesture and faces the forks. When the truck travels forward, if the
operation handle is rotated counterclockwise, the truck will turn clockwise. If the operation handle is rotated clockwise,
the truck will turn counterclockwise. When running backward, if the operation handle is rotated clockwise, the truck will
turn clockwise. If the operation handle is rotated counterclockwise, the truck will turn counterclockwise。
⑷ Braking：
Turn the operation handle to area B and release the accelerator knob, then braking of the truck can be realized.
While the operation handle is turned to area A, the truck will be in a state of braking, and traveling function will be cut
of。
⑸ Transportation operation：
Notice
Before operating truck, do check the following items: Ensure no goods falling and
damaged in the loading area.
Ensure no goods or objects impeditive for safety.

11
The following procedures shall be observed for goods transportation：
① Decelerate when approaching the goods area；
② Inspect safety condition around the stacking area；
③ Adjust position of the truck, placing it in front of place where goods locate；
④ Slowly start the truck, and insert fork arms to the bottom of goods as deeply as possible；
⑤ Press the lifting button, raising forks to a position with a distance of over 40mm between bottom of the pallet
and ground；
⑥ Start the truck and carry the goods to destination. Press lowering button and put the goods on the ground,
making the forks totally out of the bottom of the pallet. Then backward the truck slowly；
Ⅴ.Usage, maintenance and charge of storage battery
Schematic diagram of charging method
When it is necessary to conduct charging, please refer to the following operation methods，
1. Pull down the general power switch；2. Connect the charging plug of storage battery to output connector
of charger；3. Then link the input connector of charger to AC power system；4. Turn on the charger, and it starts
to charge after several seconds。
1 Initial charge
1．11 Initial charge shall be made for new battery, i.e. the first time charge. Clean up the surface of the
battery before the initial charge, and then check for damage to ensure reliable connection。
1．2 Open gas cap。
1．3When the charging equipment is able to operate normally, pour the sulfuric acid electrolyte with a
density of 1.260±0.005 (25℃) and a temperature of lower than 30℃ into the batteries. The electrolyte level
should be 15-25mm higher than the protective board. In order to reduce the temperature rise caused by
chemical reaction of the electrolyte and let the electrolyte fully penetrates into the pores of the polar plates and
the baffles, the batteries should be placed still for 3-4 hours, not exceeding 8 hours. The initial charging can only
be conducted when the electrolyte temperature reduces to below 35℃. (When necessary, the batteries can be
put into cold water for temperature reduction). After the still placement, if the electrolyte level reduces,
Warning
Hydrogen is aggregated in the battery box when charging. For this reason,
the charging condition shall be good ventilated. In avoidance of explosion and fire
disaster, open flame is forbidden 。

12
electrolyte should be added。
1．4 The sulfuric acid electrolyte is prepared with battery sulfuric acid complying with the state standard
GB4554-84 and distilled water. Never use industrial sulfuric acid and running water. The standard
temperature （25℃）and density of the electrolytic solution can be converted as follows:
D25＝Dt＋0.0007(t－25)
D25： the density of the electrolytic solution at 25℃
Dt：the density of the electrolytic solution at 25℃。
t：temperature of the electrolytic solution when testing the density。
1．5 Dry up the electrolyte spilled on the surface of battery. Connect the positive and negative poles of
batteries with those of D.C. power source (charger) respectively and then turn on the power. Charge with the
current of 40 A (the current of the first stage). After the charge voltage achieves 28.8V (12×2.4V=28.8V), switch
to the 20A current of the second stage for continuative charge. When charging, the temperature of electrolyte
shall never exceed 45℃. When the temperature raising up nearly to 45℃, reduce the current by half or stop
charging temporarily. After the electrolyte temperature reduce below 35℃, continue charging. However the
charge time need to be extended appropriately。
1．6 Fully charged basis：When the voltage during the second stage charging reaches 31.2V (12 ×2.6V =
31.2V), the variation of the voltage is no greater than 0.005 (V). The density of the electrolytic solution
reaches 1.280 ±0.005 (25℃), no apparent changes in 2 hours and there are fine air bubbles appear
violently, it can be deemed that the batteries are fully charged. The charged power capacity is 4-5 times of
the rated capacity and the charging time is about 70 hours.
1．8 In order to accurately control the sulfuric acid content of the electrolytic solution, the electrolytic
solution density of the batteries should be examined during the last period of charging. If there is inconsistence,
adjust with distilled water or sulfuric acid with a density of 1.40. The electrolytic solution density and the liquid
surface should be adjusted to the stipulated value within two hours in the charging state.
1．9 After the initial charging is completed, the surface of the batteries should be cleaned. Close the cover
of the open cover type liquid hole plug and then the batteries can be used。
2 Use and maintenance
2．1 In order to guarantee the service life of the batteries, the batteries in use should be fully charged.
Insufficiently charged batteries must not be used. During the process of use, close attention should be paid to the
discharge extent. Over discharge is prohibited---the voltage reduces to 1.7V per battery (when the total voltage
reduces to 1.7V×12 = 20.4V ). When the density of the electrolytic solution reduces to 1.17, discharging should
be stopped and charging should be conducted at once. The batteries should not be placed idle for a long period
of time. The supplementary charging frequently conducted during the process of use is called common charge.
2．2 Common charge: The first stage current of common charge is 40A and that of the second stage is 20A.
The charging method is the same as that of initial charge. The charged volume is 130-140 % of the discharged
volume and the charging time is about 10 hours。
2．3 The batteries in normal use should avoid over-charge, but over-charge must be properly conducted for
the batteries in following situation, i.e. balance charge。
a. The “lag-behind” batteries——batteries with a voltage lower than that of the other batteries in the
charging and discharging process and the batteries having been repaired for failure. (When balance charge is
conducted, the positive and negative poles of the “lag-behind” battery should be respectively connected with the
positive and negative ends of the charger, the DC power supply, and the charge should be conducted
independently.)
b. Balance charge should be conducted for the batteries in normal use every 2-3 months。
c. Balance charge should be conducted for the batteries that have not been used for a long period of time
before use.
2．4 Equalizing charge：
a. Charge with a 4A current。
b. When the charge voltage reaches 31.2V（12×2.6V=31.2V），and air bubbles occur in the electrolyte, the
current should be reduced by 50% (2A) and continue to charge.
c．When the batteries are fully charged, stop charging for 0.5 hour and charge again with 1A current for
one more hour.
d．Stop charging for another 0.5 hour and charge with a 1A current for another one hour。
e．Repeat according to item d till air bubbles occur violently in the batteries once the charger is switched on。
3 Keep and storage
The storage battery shall be kept in clean, dry and ventilated warehouse within the temperature range of
5 to 40℃. The valid storage period is 2 years. Safekeeping shall be made within storage period according
to the following requirements:
a. Avoid direct sunlight. The distance from heat source shall not less than 2m.

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b. Avoid contact with any harmful substance. No metal impurity shall fall inside the battery.
c. No inversion, no mechanical collision or heavy weight is permitted.
d. Storage with electrolyte is forbidden. Under special cases that the storage with electrolyte is necessary,
the density and solution level of electrolyte shall be adjusted to the specified value. Whenever one month
of storage period expires, a complementary charge shall be made with the common charge metho。
4、Operation of electrolyte
⑴Density check
The suction type densimeter shall be used to check density. During operation, avoid spilling out the
electrolyte, and do wear protection appliance.
⑵Operation besides check
Consult professional personnel, especially when complementing electrolyte (dilute sulfuric acid)。
⑶Electrolyte leakage
As for the electrolyte leakage resulting from storage battery tilting and damage, emergency treatment shall
be made at once (See emergency treatment item)
5、Operation of storage batteries during the final stage of their lifetime
⑴Operation of storage batteries during the final stage of their lifetime
When the lifetime of storage battery is about to terminate, the electrolyte in single battery reduces very fast.
For this reason, distilled water shall be complemented daily
⑵Treatment of waste battery
As for the waste battery, draw out the electrolyte and decompose the battery. It can be discussed that
whether the waste battery shall be recycled by the battery manufacturer.
6、Emergency treatment
⑴The electrolyte spills on skin: wash with large amount of water
⑵The electrolyte spills into eyes: wash with large amount of water, and then seek help from specialized doctor
⑶The electrolyte spills on clothes: take off clothes right away, wash with water, and then flush with week basic
soap solution.
⑷The electrolyte leakage: in case of electrolyte leakage outside, neutralize it with lime, strong carbonic acid
soda or carbonic acid soda, and then flush with large amount of water.
7、Charger
If the charger you use is full automatic type. It must meet with the following 2 requirements:
a. The output voltage of charger: 24V
b. The output current of charger: 40A
If the charger you use is semi-automatic or manually adjustable, please charge the battery pack according to the
requirements of use and maintenance mentioned in the second tip.
Ⅵ.Inspection before operation:
For the sake of safety operation and good situation of the electric truck, it is compulsory to check the truck
completely before operation. Contact the sales department of our company when founding problems
1 Check point and check content:
No. Check point Check content
Braking
system
1 Operation handle
When the operation handle is turned, with the
handle switching between area A and B, there is
a noise from the brake.
2 Brake clearance The clearance between brakes should be kept
between 0.2mm and 0.8mm.
Steering
system 3 Operation handle Degree of tightness and rotary flexibility.
Lifting
system
4 Oil pipe Leakage or not.
5 Hydraulic oil Appropriate oil quantity.
6 Lifting cylinder Whether there is any oil leakage.
Wheels
7 Pins, screws and all
the fasteners
Check all the fasteners of the truck’s wheels, i.e.
pins or screws, loose or not.
8 Wearing status Compare the parameter list, replace the wheel
when its diameter reduces by 5%.

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Storage
battery
9 Charge Confirm the display state of the battery capacity.
10 Electrolyte The solution level and density of electrolyte.
11 Connecting line The connecting line and socket shall be firm.
Horn 12 Horn Press down the horn button to check whether
the horn sounds.
Instrument 13 Function Turn on the switch of electric lock to check
whether the instrument displays normally.
Others
14 Truck frame, etc Damaged or not. If there is any crack.
15 Function
Check that whether lifting, lowering, forward &
backward movement and emergency reverse of
the truck is normal, and if there is any abnormal
noise.
Ⅶ.Inspection after operation:
After operation, the smudge on truck shall be wiped out. Besides, the following check shall be carried
out:
Keep visibility of all graphics context marks such as warning signs, nameplate and notice board. These marks
are able to instruct, caution and warn the operator to some degree.
The situation about deformation, distortion, damage or breakage
Add lubricating oil and grease if necessary.
Replace faulty components。
Ⅷ.Periodic maintenance and repair：
Comprehensive check for truck can avoid malfunction and ensure the service life. The hours listed in
maintenance procedures is based on the cases that the truck works for 8 hours per day and 200 hours per
month. For the sake of safety, maintenance shall be carried out according to maintenance procedure.
Notice
All the repair work shall be carried out by professional personnel
Please contact the sales department of our company if you need to adjust or replace the components。
1 Precautions during maintenance：
Notice
The components for replacement shall be produced completely by our
company. When replacing components of the truck, the components with the
same safety requirement with the original design shall be used.
The lubricating oil and hydraulic oil in use shall be recommended by our
company.
⑴ Places for maintenance：
Notice
The places for maintenance shall be appointed and can provide other
services such as hoisting and safety protection facility etc.
The places shall have level ground and good ventilation.
The places shall be equipped with fire-extinguishing devices。
⑵ Precautions before repair and maintenance：

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Notice
No smoking.
Arrange the self-protection work.
Wipeout the effusive oil in time.
Before adding lubricating oil, clean up the dirty oil or dust on the joint with
brush or cloth.
Except certain situation, turn off the key switch and pull off the power
socket.
Lower down the fork arms to the lowest point when carrying out
maintenance.
Ensure no goods on the truck when demounting the high pressure oil pipe.
Besides, the fork arms shall be descended to the lowest position, by this
way, the pressure of hydraulic system can be released.
For the reason that there are capacitors storing a little amount of electric
energy in circuit, so before contacting the binding post of the main circuit,
discharge at first.
Clean the electric section with compressed air, never flush with water..
2 Inspection and maintenance before the new truck put into operation
In order to follow the industry related regulations and ensure the absolute security to the truck in the
transportation, for new ex-factory truck, it is possible that there is no electrolyte inside storage battery before the
first use (except the inland sale).
The electrolyte of storage battery is prepared well before the truck leave the factory, and it is filled into the
storage battery by the professional personnel before the first use. First, place the truck to the site with good
ventilation, open the lid of storage battery box, and open all the top plastic lids of storage battery. The plastic pot
with storage battery electrolyte inside is raised using plastic funnel, and the electrolyte is poured into the storage
battery in a slow way until the liquid level can be seen. After all the storage battery is filled, conduct initial charge
to the storage battery timely according to the operation requirements of initial charge 5.1。
3 Daily inspection
Inspection of hydraulic oil level: lower the fork to the lowest position, look over the oil level from the oil window.
The distance between oil level and the bottom of oil tank is about 70mm, and oil charge is 1.5L.
Recommendatory trademark for the hydraulic oil should be chosen.
Check the capacity of storage battery: refer to the use and maintenance of storage battery。
4 The inspection according to the need
Clean the truck
Inspect and screw down each fastener
Inspect the damage state of wheels
5 The inspection and maintenance after 50 hours （Weekly）
Braking
system
1 When the operation handle is turned, with the steering handle switching
between area A and B, there is a noise from the brake.
2 The oil dirt and dust on the turning gearwheel should be cleaned。
3 The clearance between brakes should be kept between 0.2mm and
0.8mm.
Capacity of
electrolyte 4 Inspect the liquid level of electrolyte, pure water can be used for supplement if the liquid level is too low.
Capability
of
electrolyte
5 The specific gravity should be1.28g/ml after charged.
Clean the
storage
battery
6 Cover the lid, and flush with tap water.
Inspect the
contactor 7 Burnish the coarse surface of contacts using sand paper.

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6 The inspection and maintenance after 200 hours（Monthly）
Besides the weekly maintenance, the following maintenance should be carried out, and when the parts must be
adjusted and replaced, please contact with maintenance personnel of our company. (keep monthly maintenance
record)
）
No. Check point Check content
Whole truck
1 Whole status Abnormal or not.
2 Horn Sound
Steering
system,
braking
system
hydraulic
system and
lifting
system
3 Operation handle
When the operation handle is turned, with the
handle switching between area A and B, there is
a noise from the brake。
4 Brake clearance The clearance between brakes should be kept
between 0.2mm and 0.8mm。
5 Operation handle Degree of tightness and rotary flexibility.
6 Truck frame and
fastener
Function，and check cracks, lubrication and
tightness of fasteners.
7 Connecting rod and
wheel carrier
Function and check the cracks, bending,
deformation and lubrication condition.
8 Oil pipe Whether oil pipes leak or not.
9 Hydraulic oil Proper quantity of oil.
10 Lifting oil cylinder Whether there is any oil leakage or not.
Storage
battery,
charger and
electric
system
11 Electrolyte Liquid level，specific gravity and cleanness
12 Plug Function, whether it is damaged or not
13 Key switch Function
14 Contactor Contact performance and function
15 Inching switch Function
16 Controller Function
17 Fuse Whether it is perfect or not
18 Wiring harness and
connection terminals Whether flexible and whether damaged or not.
7 Maintenance for 600 hours（every three months）
During the maintenance every three months, the monthly maintenance process shall be repeated. When
the parts must be adjusted and replaced, please contact with maintenance personnel of our company。
Contactor
Burnish the coarse surface of contactor using sand paper
Replace according to the status when the function is not well
Motor Wearing status of carbon brush and selenium rectifier.。
Brake Clean the dirt and dust on friction plates of the brake, meanwhile check the
wearing status of the friction plates.