BAOLI EQUIPMENT

Service & Maintenance Manual

EP15-N01 Electric Pallet Truck

EP15-N01 Version: 2015-06

 CONTENTS
FOREWORD .............................................................................................................................................. 2
1. GENERAL ........................................................................................................................................... 3
1.1 INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONS................................................. 3
1.2 MEASUREMENT CONVERSIONS .............................................................................................. 7
2. SPECIFICATIONS ............................................................................................................................ 11
2.1 LOCATION OF COMPONENTS ................................................................................................ 11
2.2 SPECIFICATION SHEETS ......................................................................................................... 12
2.3 LUBRICATION ........................................................................................................................... 14
3. ELECTRICAL SYSTEM ................................................................................................................... 15
3.1 ELECTRICAL DIAGRAM ........................................................................................................... 15
3.2 DRIVE WHEEL ........................................................................................................................... 16
3.3 PUMP STATION ......................................................................................................................... 16
3.4 BATTERY ................................................................................................................................... 16
3.5 CHARGER .................................................................................................................................. 18
3.6 CURTIS CONTROLLER............................................................................................................. 21
3.7 BATTERY INDICATOR .............................................................................................................. 32
3.8 REPLACING THE ELECTRICAL PARTS ................................................................................. 34
3.9 TOOL FOR REPAIRING THE PIN OF ELECTRICAL PLUG .................................................... 42
4. HYDRAULIC SYSTEM ..................................................................................................................... 43
4.1 HYDRAULIC FLOW DIAGRAM ................................................................................................. 43
4.2 INSTALLATION OF HYDRAULIC SYSTEM ............................................................................. 44
4.3 REPLACING OF THE PUMP STATION .................................................................................... 44
4.4 REPLACING OF THE CONTACTOR OF THE PUMP .............................................................. 45
4.5 REPLACING OF THE CARBON BRUSH .................................................................................. 45
4.6 REPLACIING OF THE CYLINDER ............................................................................................ 47
5. DRIVE WHEEL ................................................................................................................................. 48
5.1 REPLACING OF THE SENSOR ................................................................................................ 48
5.2 REPLACE OF THE BREAK ....................................................................................................... 49
5.3 REPLACE OF THE RIM ............................................................................................................. 50
6. CONTROL HANDLE ........................................................................................................................ 51
6.1 REPLACING THE CONTROL HANDLE ................................................................................... 52
6.2 REPLACING OF THE INTERLOCK SWITCH ........................................................................... 54
6.3 REPLACING OF THE AIR SPRING .......................................................................................... 54
7. CASTER WHEEL ............................................................................................................................. 55
7.1 OPERATION OF THE CASTER WHEEL .................................................................................. 55
7.2 ADJUSTING THE PRESSURE FOR THE DRIVE WHEEL....................................................... 55
8. TROUBLE DIAGNOSTICS............................................................................................................... 56
8.1 REGULAR MAINTENANCE ...................................................................................................... 56
8.2 TROUBLE SHOOTING .............................................................................................................. 58

1
 FOREWORD
Proper operation, maintenance, troubleshooting and repairs are necessary to preserve the performance
of the pallet truck over along period of time and ensure that fault and breakdowns do not occur. The
object of this service manual is to provide the information necessary especially in connection with the
performance of inspections and repairs mainly in the maintenance areas.

The majority of this pallet truck consists of steel, it can be completely recycled. Waste
material in conjunction with repairs, maintenance, cleaning or scrapping, must be collected and disposed
of in an environment-friendly way and in accordance with the directives of respective countries. Such
work must be carried out in areas intended for this purpose. Recyclable material should be taken care of
by specialized authorities. Environmentally hazardous waste, such as oil filters, batteries and electronics,
will have a negative effect on the environment, or health, if handled incorrectly.

All of the information reported herein is based on data available at the moment of
printing. Our products are constantly being developed and renewed, we reserves the right to modify our
own products at any moment without prior notice and incurring in any sanction. So, it is suggested to
always verify possible updates.

2
1. GENERAL

1.1 INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONS

Careless performing of the easy work may cause injuries. Take care to always perform work safely, at
least observing the following. It is of utmost importance that maintenance personnel pay strict attention
to these warnings and precautions to avoid possible injury to themselves or others, or damage to the
equipment. A maintenance program must be followed to ensure that the machine is safe to operate.
The specific precautions to be observed during maintenance are inserted at the appropriate point in the
manual. These precautions are those that apply when servicing hydraulic and larger machine
component parts.

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A

RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY
MANUFACTURED, IS A SAFETY VIOLATION.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE

FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBILITY OF THE
OWNER OR OPERATOR.

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LlSTED IN THIS SECTION

MAY RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY
VIOLATION.
 When carrying out any operation or maintenance, have trained and experienced personnel carry out
the work.
 When carrying out any operation or maintenance, carefully read out Operation and Maintenance
Manual.
 Read all the precautions given on the decals which are fixed to the machine.
 Be sure you fully understand the contents of the operation. It is important to prepare necessary tools
and parts and to keep the machine.

 Your safety, and that of others , is the first consideration when

engaging in the maintenance of equipment. Always be conscious of
weight. Never attempt to move heavy parts without the aid of a
mechanical device. Do not allow heavy objects to rest in an
unstable position. When raising a portion of the equipment, ensure
that adequate support is provided.

3
 It should be noted that the machines hydraulic systems operate at
extremely high potentially dangerous pressures. Every effort should
be made to relieve any system pressure prior to disconnecting or
removing any portion of the system. Relieve system pressure by
cycling the applicable control lowering button several times with the
motor stopped and ignition on, to direct any line pressure back into
the reservoir. Pressure feed lines to system components can then
be disconnected with minimal fluid loss.
 Remove all rings, watches and jewelery when performing any maintenance.
 Wear well-fitting helmet, safety shoes and working Clothes When
drilling grinding or hammering always. Wear protective goggles.
Always do up safety clothes properly so that they do. Not catch on
protruding parts of machines. Do not wear oily clothes. When
checking, always release battery plug. DO NOT WEAR LONG
HAIR UNRESTRAINED, OR LOOSE-FITTING CLOTHING AND
NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR
ENTANGLED IN EQUIPMENT.

 During maintenance do not allow any unauthorized person, to

stand near the machine.
 Flames should never be used instead of lamps. Never use a buring
flame to check leaks or the level of oil or electrolyte.

 Immediately remove any oil or grease on the floor of the operator’s

compartment or on the handrail. It is very dangerous if someone slips
while on the machine.

 Always use the recommended pure oil or grease, and be sure to use
clean containers.

 Oil is a dangerous substance. Never handle oil, grease or oily

clothes in places where there is any fire or flame. As
preparation for use of fire extinguishers and other fire- fighting
equipment.
 Keep the battery away from fire hazards. The generated gases
are explosive.
 Store all the oils in a specified place.
 Keep the flammable things away from the machine. Do not
smoke in the working site.
 Battery should always be disconnected during replacement of electrical components.

 Always use the grades of grease and oil recommended by NOBLELIFT

choose the viscosity specified for the ambient temperature.

4
 Exhaust gas is dangerous provide ventilation when working in a closed space.
 Avoid breathing dust that may be generated when handling components containing asbestos fibers.
Wear a gas mask if necessary.

 When working on top of the machine, be careful not to lose your

balance and fall.

 Hand a caution sign in the operator’s compartment (for example “Do

not start” of “Maintenance in progress”). This will prevent anyone
from starting or moving the machine by mistake.

 When welding on the machine or working on the electical system,

ALWAYS turn the key switch OFF and remove the battery plug
from the battery. Park the machine on firm, flat ground. Lower the
fork to the min. height and stop the motor.
 Sulfuric acid in battery electrolyte is poisonous. Ist is strong
enough to burn skin and eat holes in clothing. If you spill acid on
your clothes or skin, immediately flush it with large quantities of
water.
 When working on the battery, wear goggles or safety glasses. If
splashed into the eyes, flush with water and get medical attention
immediately.
 Battery terminals touched by metal objects can cause short circuit
and burn you. Keep tools away from the terminals.
 When disassembling and assembling the battery, make sure that
the battery terminals (+, –) are correctly connected.
 If water gets into the electrical system, abnormal operation or
failure can result. Do not use water or steam on sensors, connectors
and instruments in the cab.

 Do not handle electrical equipment while wearing wet gloves, or in wet

places, as this can cause electric shock.
 When working with others, choose a group leader and work according to his instructions. Do not
perform any maintenance beyond the agreed work.
 Unless you have special instructions to the contrary, maintenance should always be carried out with
the motor stopped. If maintenance is carried out with the motor running, there must be two men
present : one operating the pallet truck and the other one performing the maintenance. In such a
case, never touch any moving part.
 Before making adjustment, lubricating or performing any other maintenance, shut off all power
5
 controls.
 When removing parts containing O-ring Gaskets or seal. Make sure clean the mounting surface and
replace with new sealing parts.
 Thoroughly clean the machine. In particular, be careful to clean the grease fittings and the area
around the dipsticks. Be careful not to let any dirt or dust into the system.
 Use only approved, nonflammable cleaning solvents.
 When changing the oil or fitter, check the drained oil and filter for any signs of excessive metal
particles or other foreign materials.
 Always use NOBLELIFT genuine parts for replacement. ENSURE REPLACEMENT PARTS OR
COMPONENTS ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS.
 When checking an open gear case, there is a risk of dripping things in. Before removing the covers
to inspect such cases, empty everything from your pockets. Be particularly careful to remove
wrenches and nuts.

6
1.2 MEASUREMENT CONVERSIONS

Length
Unit cm m km in ft yd mile
cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
m 100 1 0.001 39.37 3.2808 1.0936 0.00062
km 100000 1000 1 39370.7 3280.8 1093.6 0.62137
in 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015
ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189
yd 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1mm=0.1cm, 1m=0.001mm

Area
Unit cm2 m2 km2 a ft2 yd2 in2
cm2 1 0.0001 – 0.000001 0.001076 0.000012 0.155000
m2 10000 1 0.000001 0.01 10.764 1.1958 1550.000
km2 – 1000000 1 10000 1076400 1195800 –
a 0.01 100 0.0001 1 1076.4 119.58 –
ft2 – 0.092903 – 0.000929 1 0.1111 144.000
yd2 – 0.83613 – 0.008361 9 1 1296.00
in2 6.4516 0.000645 – – 0.006943 0.000771 1
1ha=100a, 1mile2=259ha=2.59km 2

Volume
Unit cm3 = cc m3 l in3 ft3 yd3
cm3 = m l 1 0.000001 0.001 0.061024 0.000035 0.000001
m3 1000000 1 1000 61024 35.315 1.30796
l 1000 0.001 1 61.024 0.035315 0.001308
in3 16.387 0.000016 0.01638 1 0.000578 0.000021
ft3 28316.8 0.028317 28.317 1728 1 0.03704
yd3 764529.8 0.76453 764.53 46656 27 1
1gal(US)=3785.41 cm 3=231 in3=0.83267gal(US)

Weight
Unit g kg t oz lb
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 1 0.001 35.273 2.20459
t 1000000 1000 1 35273 2204.59
oz 28.3495 0.02835 0.000028 1 0.0625
lb 453.592 0.45359 0.000454 16 1
1 tonne(metric)=1.1023 ton(US)=0.9842 ton(UK)

7
Pressure
Unit kgf/cm2 bar Pa=N/m2 kPa lbf/in2 lbf/ft2
kgf/cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa=N/m2 0.00001 0.00001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
lbf/in2 0.07032 0.0689 6894.76 6.89476 1 144
lbf/ft2 0.00047 0.00047 47.88028 0.04788 0.00694 1
kgf/cm2=735.56 Torr(mmHg)=0.96784atm

Standard torque
The following charts give the standard torque specification of bolts and nuts.
Exceptions are given in the sections of “Disassembly and Assembly”

METER TABLE
Classification 4T, 5T 10T

10.9
Bolt type

Bolt size Torque kgf · m (lbf · ft) Torque kgf · m (lbf · ft)

M4 0.2 ± 0.02 0.4 ± 0.04

M5 0.3 ± 0.03 0.8 ± 0.08

M6 0.5 ± 0.05 1.4 ± 0.14

M8 1.2 ± 0.12 3.3 ± 0.3
M10 2.3 ± 0.23 6.5 ± 0.7

M12 4.0 ± 0.4 11.3 ± 1.1

M14 6.4 ± 0.6 17.9 ± 1.8

M16 9.5 ± 0.9 26.7 ± 2.7

M18 13.5 ± 1.4 38.0 ± 3.8
M20 18.6 ± 1.9 52.2 ± 5.2
M22 24.7 ± 2.5 69.4 ± 6.9
M24 32.1 ± 3.2 90.2 ± 9.0
M30 62.6 ± 6.3 176.1 ± 17.6
M36 108.2 ± 10.8 304.3 ± 30.4
M42 171.8 ± 17.2 483.2 ± 48.3
M45 211.3 ± 21.1 594.3 ± 50.4

8
INCH TABLE
4T, 5T 10T

Classification Bolt type

Bolt size Torque kgf · m (lbf · ft) Torque kgf · m (lbf · ft)
1/4 0.6 ± 0.06 1.7 ± 0.2
5/16 1.2 ± 0.12 3.0 ± 0.3
3/8 2.0 ± 0.20 5.6 ± 0.5
7/16 3.2 ± 0.32 8.9 ± 0.9
1/2 4.7 ± 0.47 13.4 ± 1.3
9/16 6.8 ± 0.68 19.0 ± 1.9
5/8 9.3 ± 0.93 26.1 ± 2.6
3/4 16.0 ± 1.60 45.1 ± 4.5
7/8 25.5 ± 2.55 71.6 ± 7.2
1 38.0 ± 3.80 106.9 ± 10.7
1-1/8 54.1 ± 5.41 152.2 ± 15.2
1-1/4 74.2 ± 7.42 208.9 ± 20.9
1-3/4 98.8 ± 9.88 277.8 ± 27.8
1-1/2 128.2 ± 12.82 360.7 ± 36.1

The torque specifications in above table shall not be applied to the bolts with nylon packings and nonferrous
metal washers, or the ones with specifically designated torque and standard.
H Newton meter : 1 N·m = 0.1kgf·m

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

The following torque shall be applied to the split flange bolts.
Diameter Flat width Torque
(mm) (mm) kgf·m N·m
10 14 6.7 ± 0.7 66.7 ± 6.8
12 17 11.5 ± 1 112 ± 9.8
16 22 28.5 ± 3 279 ± 29

9
APPROXIMATE CONVERSIONS

SI Conv Non–SI Conv SI

Unit Factor Unit Factor Unit
Torque
newton meter (N·m) × 8.9 = ln·in × 0.113 = N·m
newton meter (N·m) × 0.74 = lb·ft. × 1.36 = N·m
newton meter (N·m) × 0.102 = kg·m × 7.22 = lb·ft.*
Pressure (Pa = N/m2)
kilopascal (kPa) × 4.0 = in. H2O × 0.249 = kPa
kilopascal (kPa) × 0.30 = in. Hg × 3.38 = kPa
kilopascal (kPa) × 0.145 = psi × 6.89 = kPa
(bar) × 14.5 = psi × 0.069 = bar*
(kg/cm2) × 14.22 = psi × 0.070 =
2
newton/mm2 kgf/cm
= bar**
× 145.04 = psi × 0.069
megapascal (MPa) × 145 = psi × 0.00689 = MPa
(Pa=N·m2)
Power r (W = J/s)
kilowatt (kW) × 1.36 = PS (cv) × 0.736 = kW
kilowatt (kW) × 1.34 = HP × 0.746 = kW
kilowatt (kW) × 0.948 = Btu/s × 1.055 = kW
watt (W) × 0.74 = ft·lb/s × 1.36 = W
(W=J/s)
Energy (J = N·m)
kilojoule (kJ) × 0.948 = Btu × 1.055 = kJ
joule (J) × 0.239 = calorie × 4.19 = J
(J=N·m)
Velocity and Acceleration
2 2
meter per sec (m/s ) ×3.28 = ft/s2 × 0.305 = m/s2
meter per sec (m/s) × 3.28 = ft/s × 0.305 = m/s
kilometer per hour (km/h) × 0.62 = mph × 1.61 = km/h
Horse Power/Torque
BHP × 5252 R.P.M. = TQ (lb·ft) TQ Z R.P.M. 5252 = B.H.P.
Temperature
°C = (°F–32) ÷ 1.8 °F= (°C Z 1.8) + 32
Flow Rate
3
liter/min (dm /min) × 0.264 = US gal/minZ3.785 = l/min
Note : ( ) Non–SI Unit

10
2. SPECIFICATIONS

2.1 LOCATION OF COMPONENTS

1. Main cover 8. Key switch

2. Instruments cover 9. Emergency button
3. Tray 10. Fork chassis
4. Tiller 11. Load wheels
5. Safety (belly) button 12. Hydraulic cylinder
6. Accelerator (butterfly button) 13. Castors
7. Discharge indicator and charging 14. Drive wheel
indicating LED
CONTROL HANDLE

1. Raise/Lower buttons – Rocker switches

adjusting fork height.
2. FWD/BWD/REV travel button –Control
variable speed by turning knob
3. Emergency Reverse button – Emergency
reverse button or commonly known as the belly
button switch
4. Horn button
5. Indicator light – Indicates high/low speed
status. Green indicates high speed, red
indicates slow speed.
6. Shift button – Shift button for high speed and
low speed
11
 2.2 SPECIFICATION SHEETS
Type sheet for industrial truck acc. to VDI 2198
Weight Distinguishing mark

1.2 Manufacturer`s type designation EP15-N01

1.3 Power (battery ,diesel, petrol, gas, manual) Battery
1.4 Operator type Pedestrian
1.5 Load Capacity / rated load Q (t) 1.5
1.6 Load centre distance c (mm) 600
1.8 Load distance ,centre of drive axle to fork x (mm) 963
1.9 Wheelbase y (mm) 1217
2.1 Service weight kg 285
2.2 Axle loading, laden front/ rear kg 760/1026
2.3 Axle loading, unladen front/rear kg 222/64
3.1 Tires Polyurethane (PU)
xw
Tires, chassis

3.2 Tire size, front  252x89

3.3 Tire size, rear 
(mm)
xw 84x70/84x93
3.4 Additional wheels(dimensions) 
(mm)
xw  100x40
3.5 Wheels, number front/ rear(x=driven wheels) (mm) 1x +2/ 2or1x +2/ 4
3.6 Tread, front b10 (mm) 500
3.7 Tread, rear b11 (mm) 360
4.4 Lift h3 (mm) 120
4.9 Height of tiller in drive position min./ max. h14 (mm) 934/1205
4.15 Height, lowered h13 (mm) 85
4.19 Overall length l1 (mm) 1590
Dimensions

4.20 Length to face of forks l2 (mm) 440

4.21 Overall width b1 (mm) 700
4.22 Fork dimensions s/e/l (mm) 47 / 160 / 1150
4.25 Distance between fork-arms b5 (mm) 520
4.32 Ground clearance, centre of wheelbase m2 (mm) 34
4.34 Aisle width for pallets 800X1200 lengthways Ast (mm) 2145
4.35 Turning radius Wa (mm) 1480
5.1 Travel speed, laden/ unladen km/h 5.5 / 5.5
Performanc

5.2 Lift speed, laden/ unladen m/s 0.025 / 0.035

e data

5.3 Lowering speed, laden/ unladen m/s 0.045 / 0.030

5.8 Max. gradeability, laden/ unladen % 5/ 8
5.10 Service brake Electromagnetic
6.1 Drive motor rating S2 60min kW 0.9
Electric-motor

6.2 Lift motor rating at S3 5% kW 0.8

6.3 Battery acc. to DIN 43531/ 35/ 36 A, B, C, no No
6.4 Battery voltage, nominal capacity K5 V/ Ah 2x12 / 85
6.5 Battery weight kg 48
6.6 Energy consumption acc: to VDI cycle kWh/h 260 / 170 / 230
8.1 Type of drive control AC-speed control
Addition
al data

8.4 Sound level at driver`s ear acc. to EN 12053 dB(A) 67

12
13
2.3 LUBRICATION

Hydraulic oil

Hydraulic oil must have anti-wear qualities at least. It is not advisable to mix oils of
different brands or types, as they may not contain the same required additives or be of
comparable viscosities.

Name: Thickened hydraulic oil.

ISO Viscosity Grade #40 #30
Characteristics unit
At 40OC 57 48
Viscosity mm2/s
At 50OC 40 30
Viscosity index ≥150 ≥150
O
Flash point, Cleveland open cup C ≥160 ≥160
O
Pour point, Max C ≤-35 ≤-35
Density at 15 OC kg/m3 861.5
Copper corrosion(100OC, 3h) degree ≤1 ≤1
Foaming (93.5 OC) ml / ml ≤30/0 ≤30/0
Vickers vane pump test, loss of mass (on vanes after 100h) mg ≤100 15.3
Diameter of wear spot, 1200 r/min, 294N, 30min, 75 OC mm ≤0.5 ≤0.5

The oil for gear box

Name: Extreme pressure lithium-based grease, 1#.
Characteristics unit
Worked Penetration, 0.1mm 310--340
O
Dropping point, C ≥170
Extreme pressure (Timken OK) N ≥177
Similar viscosity (-10 OC, 10s-1) Pa.s ≤250
Corrosion preventive properties (52 OC, 48h) Grade 1
Wire points oil (100 OC, 24h) % ≤10

14
3. ELECTRICAL SYSTEM
3.1 ELECTRICAL DIAGRAM
WIRING DIAGRAM

Fuses EP15
FU1 : 10A
FU2 : 0.5A
FU01: 150A
FU02: 80A

15
3.2 DRIVE WHEEL

Type: 3EL-DC-0.75
Drive Motor
Model HS XQT-0.75-1DH1U
Rate voltage DC 24V
R.P.M 3200rpm
Rate output 1.0kw
Rate hour 60 min.
Rated current 45 A
Rated Exciting current 6.4A
Min Exciting current 3.5A
Insulation class F class
Electromagnetic Brake
Model G027-REB0908X-R
Rate voltage DC 24V
Rate Power 27W
Output Torque 8 N·M
Gear Box
transmission ratio i=1:30

3.3 PUMP STATION

Type: MR2-B-V1B-F4.5-PCMAV1Y-TK05C-F2
Item Specification
Rated voltage 24V
Rated output 0.8 kw
R.P.M 3000 rpm
Rated current 70 A
Rated hour 2 min.
Insulation class F class
IP Code IP54
Displacement 0.56cc/rec
Max. operating pressure 220bar

3.4 BATTERY

Rate Specification
Rated voltage 12V
Capacity (5 hours) 80Ah
Overall size (L*W*H) 260mm*168mm*226mm

25A DURATION OF DISCHARGING CURVE (ENVIRONMENTAL TEMPERATURE = 25OC)

16
100% DURATION OF DISCHARGING LIFE TEST CURVE ( ENVIRONMENTAL TEMPERATURE =
25OC)

CHARGING CURVE

17
3.5 CHARGER
Type: QQE192-8CH17-26A

MAIN PRODUCT SPECIFICATION

Output current
Max. output power battery capacity Input voltage Output voltage
range
240W 40AH-100AH 230Vac +28.2Vdc 8A

ENVIRONMENTAL CONDITION
No. Item Technical specification Unit Remark
1 Humidity 5%-95% With package
2 Altitude ≦3000 m Work normally
3 Cooling Natural convection cooling Working under full load

ELECTRICAL CHARACTERISTICS
1 Input characteristics
No. Item Technical specification Unit Remark
1.1 Rated input voltage 230 Vac
1.2 Input voltage range 180-264 Vac 230Vac
AC input voltage
1.3 47—63 Hz
frequency
264Vac input / start-up
in cold condition
1.4 Inrush current ≤100 A
/environmental
temperature is 25℃
1.5 Max input current 3.0 A Vin=180Vac, rated load
When input is on,voltage for fan is 12V When input voltage is off,there is no output
1.6 Fan function
voltage for fan
When input voltage is on, Relay output wire BN and BU are disconnected. When
1.7 Relay function
input voltage is off, Relay output wire BN and BU are connected.
2 Output characteristics
No. Item Technical requirements Unit Remark
2.1 Fast charge voltage 28.2 Vdc
2.2 Floating voltage 31 Vdc
2.3 Maintain voltage 27.6 Vdc
2.4 Constant current 8 A
2.5 Cross regulation ±3%
≥88% Vin=230Vac,rated load
2.6 Power efficiency

18
3 Protection characteristics
No. Item Technical requirements Unit Remark
Output over voltage
3.1 33 V Lockout
protection
The charger software limits the maximum output
Software over voltage
3.2 voltage to a level suitable for the connected battery
protection
system
When the internal temperature rises to 85℃，it turns
into pulse charge mode. The pulse mode charges
battery minutely with alternate currents 2A and 8A,
3.3 Thermal cutback
which will reduce charger internal temperature. When
the internal temperature drops to 60℃, the charger
comes back to previous charge mode.
Output current limiting
3.4 8 A @CC MODE
protection
Output short circuit Short circuit protection should be automatically recovery after
3.5
protection remove the condition
Electronic reverse The charger is electronically protected against permanent revers
3.6
battery protection battery connection
3.7 Cell short circuit timer Internal software protection
4 Charger(LED) indicator
No. Item Status LED Remark
1 Power on LED ( GREEN) ON
2 Power off LED OFF
3 Fast Charge LED (RED) ON
4 Floating Charge LED (ORANGE) ON
5 Full Charging LED (GREEN) ON

INPUT TERMINATOR DIAGRAM & DEFINITION

OUTPUT TERMINATOR DIAGRAM & DEFINITION

19
LED TERMINATOR DIAGRAM & DEFINITION

FAN TERMINATOR DIAGRAM&DEFINITION

RELAY TERMINATOR DIAGRAM & DEFINITION

20
3.6 CURTIS CONTROLLER

CURTIS 1311 HANDHELD PROGRAMMER

The Curtis 1311 handheld programmer provides programming, diagnostic, and test capabilities for the
controller. The power for operating the programmer is supplied by the host controller via a 4-pin Molex
connector.
The programmer includes a 7-line alphanumeric LCD display, rockertype keys for navigating through the
display and for modifying parameters (+/-), and three keys that can be used as bookmarks.
The 1311 programmer is easy to use, with self-explanatory functions. After plugging in the programmer,
wait a few seconds for it to boot up and gather information from the controller.
For experimenting with settings, the programmer can be left plugged in while the vehicle is driven.

The bookmark keys allow you to quickly go back to up to three selected items without having to navigate
21
back through the menu structure. To set a bookmark, press one of the bookmark keys for about three
seconds, until the Bookmark Set screen is displayed. To jump to a set bookmark location, quickly press
the appropriate bookmark key (1, 2, or 3). Note that the bookmarks are not permanently stored in the
programmer. They are cleared when the programmer is unplugged.
The bookmark keys can be used to make parameter adjustment easier. For example, in adjusting the
throttle deadband, you might set a bookmark at the Throttle % readout [Monitor > THROTTLE %] and
another at the Throttle Deadband parameter [Program > THROTTLE DB]; this way you can easily toggle
between the readout and the parameter.

Connect the 1311 handheld programmer to the truck and switch on the power, Program
parameter shown as below:
Menu 2 Menu 3 Menu 4 Menu 5 Value Min Max Unit

Mode
Settings
Mast Momentary On Off On
Switch Enable
PD control Off Off On
Enable
Motor type 1 0 32767
define
High Speed
Mode
Max Speed 4200 0 5000 rpm
Drive Current 100 5 100 %
Accel Rate 1.8 0.1 30 Seconds
Decel Rate 1.5 0.1 30 Seconds
Speed limitation
set
Mast High Max 2100 0 5000 rpm
Speed
Turning Switch Max 2100 0 5000 rpm
Speed
Arm close Standon 4200 0 5000 rpm
Max Speed
Arm close Wakier 4200 0 5000 rpm

22
 Max Speed
Arm open Wakier 4200 0 5000 rpm
Max Speed
Arm open Standon 4200 0 5000 rpm
Max Speed
Turtle Max Speed 2100 0 5000 rpm
Interlock brake
decel rate
Mast high Mode 3 0.1 30 Seconds
Mast low Mode 1 0.1 30 Seconds
Steer Angle
Speed
Reduction
Max Speed 4201 0 6000 rpm
Steer Angle Max 0 0 180
(Deg)-Left
Steer Angle 70 0 180
Deadband (Deg)-Left
Steer Angle 110 0 180
Deadband
(Deg)-Right
Steer Angle Max 180 0 180
(Deg)-Right
Full Turn Speed 30 0 100 %
Hydro Setting
Current set
Lower PD Max 0.7 0.0 2 Ampere
Current 1
Lower PD Min 0.35 0.0 2 Ampere
Current 1
Step1 Lower 0.35 0.0 2 Ampere
follow lift PD Max 1
Current
Step1 Lower 0.35 0.0 2 Ampere
follow lift PD Min 1
Current
Step2 Lower 0.35 0.0 2 Ampere
follow lift PD Max 1
Current
Step2 Lower 0.35 0.0 2 Ampere
follow lift PD Min 1
Current
Lift PD Max 0.68 0.0 2 Ampere
Current 1
Lift PD Min 0.02 0.0 2 Ampere

23
 Current 1
Pot input
Lift Pot Min 50 0 4095
Lift Pot Max 4050 0 4095
Lower Pot Min 50 0 4095
Lower Pot Max 4050 0 4095
Delay set
Pump to Lift 0.1 0.1 30 Seconds
Delay
Delay PD closed 1.5 0.1 30 Seconds
after Pump lift
Delay Lower 0.8 0.1 30 Seconds
after lift
Control 0 0 2
Mode
Select
0 - Speed
Mode
Express
Max Speed 3048 100 8000 rpm
Kp 20 0 100 %
Ki 20 5 100 %
Accel Rate 1.8 0.1 30 Seconds
Decel Rate 1.5 0.1 30 Seconds
Brake Rate 1 0.1 30 Seconds
Pump Enable Off Off On
1 - Speed
Mode
Speed Controller
Max Speed 3048 100 8000 rpm
Kp 20 0 100 %
Ki LS 20 5 100 %
Ki HS 30 5 100 %
Vel Feedforward
Kvff 0 0 500 Ampere
Build Rate 1 0.1 5 Seconds
Release Rate 0.4 0.1 5 Seconds
Acc Feedforward
Kaff 0 0 500 Ampere
Kbff 0 0 500 Ampere
Build Rate 1 0.1 5 Seconds
Release Rate 0.4 0.1 5 Seconds
Response
Full Accel Rate HS 3.6 0.1 30 Seconds
Full Accel Rate LS 1.8 0.1 30 Seconds
24
 Low Accel Rate 10 0.1 30 Seconds
Neutral Decel Rate 1.5 0.1 30 Seconds
HS
Neutral Decel Rate 3 0.1 30 Seconds
LS
Full Brake Rate HS 1 0.1 30 Seconds
Full Brake Rate LS 2 0.1 30 Seconds
Low Brake Rate 1.5 0.1 30 Seconds
Fine Tuning
Partial Decel 6 0.1 30 Seconds
Rate
HS (High Speed) 70 0 100 %
LS (Low Speed) 30 0 100 %
Reversal Soften 20 0 100 %
Max Speed Accel 1 0.1 30 Seconds
Max Speed 0.5 0.1 30 Seconds
Decel
Pump Enable Off Off On
2 - Torque
Mode
Speed Limiter
Max Speed 4000 500 8000 rpm
Kp 30 0 100 %
Ki 30 5 100 %
Kd 10 0 100 %
Response
Accel Rate 1 0.1 30 Seconds
Accel Release Rate 0.4 0.1 2 Seconds
Brake Rate 1 0.1 5 Seconds
Brake Release Rate 0.4 0.1 2 Seconds
Neutral Braking 10 0 100 %
Neutral Taper Speed 500 200 6000 rpm
Fine Tuning
Creep Torque 0 0 100 %
Brake Full Creep 50 25 100 %
Cancel
Creep Build Rate 0.1 0.1 5 Seconds
Creep Release 3 0.1 5 Seconds
Rate
Gear Soften 20 0 100 %
Brake Taper 1000 200 6000 rpm
Speed
Reversal Soften 20 0 100 %
Max Speed 10 0.1 30 Seconds
Decel
25
Restraint
Restraint 50 0 100 %
Forward
Restraint Back 50 0 100 %
Soft Stop Speed 0 0 500 rpm
Position Hold
Position Hold Enable Off Off On
Kp 10 2 100 %
Kd 15 0 100 %
Set Speed Settling 3013 0 5000 ms
Time
Set Speed Threshold 30 5 100 rpm
Entry Rate 50 5 100 %
Exit Rollback 50 0 100 %
Reduction
Current
Limits
Drive Current 100 5 100 %
Limit
Regen Current 100 5 100 %
Limit
Brake Current 100 5 100 %
Limit
EMR Current 100 5 100 %
Limit
Interlock Brake 100 5 100 %
Current Limit
Power Limiting
Map
PL Nominal Speed 500 100 4000 rpm
Delta Speed 500 50 1000 rpm
Drive Limiting Map
Nominal 90 0 100 %
Plus Delta 80 0 100 %
Plus 2xDelta 75 0 100 %
Plus 4xDelta 65 0 100 %
Plus 8xDelta 35 0 100 %
Regen Limiting Map
Nominal 100 0 100 %
Plus Delta 100 0 100 %
Plus 2xDelta 100 0 100 %
Plus 4xDelta 100 0 100 %
Plus 8xDelta 100 0 100 %
Throttle
Throttle Type 5 1 5
26
 Forward 0.5 0 5 Volt
Deadband
Forward Map 35 0 100 %
Forward Max 4.5 0 5 Volt
Forward Offset 0 0 100 %
Reverse 0.5 0 5 Volt
Deadband
Reverse Map 35 0 100 %
Reverse Max 4.5 0 5 Volt
Reverse Offset 0 0 100 %
Throttle Filter 10 2 125 Hz
HPD SRO Type 1 0 3
Sequencing 0.1 0 5 Seconds
Delay
VCL Throttle Off Off On
Enable
Brake
Brake Pedal Off Off On
Enable
Brake Type 5 1 5
Brake Deadband 0.5 0 5 Volt
Brake Map 50 0 100 %
Brake Max 4.5 0 5 Volt
Brake Offset 0 0 100 %
Brake Filter 10 2 125 Hz
VCL Brake Off Off On
Enable
EM Brake
Control
Brake Type 2 0 2
Pull In Voltage 100 0 100 %
Holding Voltage 80 0 100 %
Battery Voltage On Off On
Compensated
Set EM Brake On Off On
On Fault
Set Speed 30 5 100 rpm
Threshold
Release Delay 60 40 2000 ms
Set Speed 3013 0 5000 ms
Settling Time
Torque Preload 200 0 800 ms
Delay
Torque Preload On Off On
Enable
27
 Torque Preload 0 0 120 Seconds
Cancel Delay
EM Brake Fault 4 1 20
Motor Revs
Drivers
Main Contactor
Main Enable On Off On
Pull In Voltage 100 0 100 %
Holding Voltage 80 0 100 %
Battery Voltage On Off On
Compensated
Interlock Type 0 0 2
Open Delay 0.1 0 40 Seconds
Weld Check Enable On Off On
Main DNC Check On Off On
Enable
Main DNC Runtime 5 0 200 Volt
Threshold
Precharge Enable On Off On
Proportional
Driver
PD Enable Off Off On
Hyd Lower Enable Off Off On
PD Max Current 0 0 2 Ampere
PD Min Current 0 0 2 Ampere
PD Dither % 0 0 100 %
PD Dither Period 16 16 112 ms
PD Kp 10 1 100 %
PD Ki 10 1 100 %
Driver 3
Contactor Enable Off Off On
Pull In Voltage 100 0 100 %
Holding Voltage 80 0 100 %
Fault Checking
Driver 1 Checks On Off On
Enable
Driver 2 Checks Off Off On
Enable
Driver 3 Checks Off Off On
Enable
Driver 4 Checks Off Off On
Enable
PD Checks Enable Off Off On
External Supply Max 200 0 200 mAmper
e
28
 External Supply Min 0 0 200 mAmper
e
PWM Frequency 200 100 1000 Hz
Motor
Typical Max 4000 500 8000 rpm
Speed
Swap Encoder Off Off On
Direction
Swap Two Off Off On
Phases
Encoder Steps 64 32 256
Encoder Options
Encoder Solution 0 0 2
Encoder Fault
Setup
Fault Detection On Off On
Enable
Encoder Pulse Fault 0.5 0 3 Seconds
Detect Time
Fault Stall Time 5 0 10 Seconds
LOS Upon Encoder On Off On
Fault
LOS Max Speed 800 100 2000 rpm
LOS Max Current 400 100 650 Ampere
LOS Max Mod Depth 50 15 100 %
LOS Accel Rate 7 2 15 Seconds
LOS Decel Rate 3 2 15 Seconds
Temperature
Control
Sensor Enable On Off On
Sensor Type 3 1 5
Sensor Offset 0 -20 20 deg C
Temperature Hot 145 0 250 deg C
Temperature Max 160 0 250 deg C
MotorTemp LOS 800 100 3000 rpm
Max Speed
Battery
Nominal Voltage 24 24 84 Volt
Undervoltage 7 2 14 Volt
Cutback Range
User 125 115 200 %
Overvoltage
User 70 50 80 %
Undervoltage
Reset Volts Per 2.09 0.9 3 Volt
29
 Cell
Full Volts Per 2.04 0.9 3 Volt
Cell
Empty Volts Per 1.73 0.9 3 Volt
Cell
Discharge Time 34 0 600 Minutes
BDI Reset 75 0 100 %
Percent
Dual Drive
Dual Motor Off Off On
Enable
Dual Motor Slave Off Off On
CAN Node ID 2 0 127
Other
LOS Max Speed 800 100 8000 rpm
Master
Steer Angle Max 90 45 90
(deg)
Turn Accel Rate 5 0.1 30 Seconds
Critical Angle (deg) 70 45 90
Max Turn Speed 30 0 100 %
Inner Wheel Speed -100 -10 0 %
0
Steer Type 5 1 5
Steer Pot Min 0.5 0 5 Volt
Steer Pot Zero 2.5 0 5 Volt
Steer Pot Max 4.5 0 5 Volt
VCL Steer Enable Off Off On
Slave
Turn Accel Rate 5 0.1 30 Seconds
Critical Angle (deg) 70 45 90
Steer Fault Min 0.25 0 5.5 Volt
Steer Fault Max 4.75 0 5.5 Volt
Turn
Feedforward
Turn Accel Rate 5 0.1 30 Seconds
Turn Kvff 0 0 500 Ampere
Turn ff Build Rate 1 0.1 5 Seconds
Turn ff Release Rate 0.4 0.1 2 Seconds
Vehicle
Metric Units Off Off On
Speed to RPM 691.3 10 3000
Capture Speed 1 4500 0 8000 rpm
Capture Speed 2 4500 0 8000 rpm
Capture 22 1 1320
30
 Distance 1
Capture 100 1 1320
Distance 2
Capture 150 1 1320
Distance 3
Emergenc
y Reverse
EMR Enable On Off On
EMR Type 1 0 3
EMR Dir On Off On
Interlock
EMR Time Limit 5 0 30 Seconds
EMR Speed 1000 50 6000 rpm
EMR Accel Rate 1 0.1 3 Seconds
EMR Decel Rate 1 0.1 3 Seconds
Interlock
Braking
Enable On Off On
Decel Rate HS 0.5 0.1 30 Seconds
Decel Rate LS 0.5 0.1 30 Seconds
Interlock Brake 5 0 8 Seconds
Timeout
CAN
Interface
CANopen Off Off On
Interlock
CAN Node ID 1 38 0 127
CAN Node ID 2 39 0 127
CAN Node ID 3 40 0 127
CAN Node ID 4 41 0 127
Supervisor Node 70 0 127
ID
Baud Rate 0 -3 2
Heartbeat Rate 100 16 200 ms
PDO Timeout 100 0 200 ms
Period
Emergency 16 16 200 ms
Message Rate
Suppress 0 0 1
CANopen Init
Motor
Control
Tuning
Motor
Characterization
31
 Tests
Test Enable 0 0 1
Test Throttle 0 -1 1
Motor Poles 4 2 8
Max Test Speed 1000 500 3000 rpm
Max Test Current 80 20 100 %
SlipGain 3.85 0 200
Field Weakening
Control
FW Base Speed 1550 200 6000 rpm
Field Weakening 30 0 100 %
Weakening Rate 40 0 100 %
Min Field Current 0 0 800 Ampere
Motor Type 0 0 205
Reset 0 0 1
Controller

3.7 BATTERY INDICATOR

Type: CURTIS 803RB2448BCJ3010

Front View Rear View

TERMINAL ASSIGNMENT
Pin 7 or 8 = Battery +. Single voltage models: Pin 8 to battery +; Pin 7, open. Dual voltage models:
When vehicle voltage is the higher voltage of the 2 operating voltages, Pin 8 connects to battery +; Pin 7,
open. When vehicle voltage is the lower of the 2 operating voltages, Pin 7 connects to battery +, Pin 8,
open.
The discharge indicator uses Pin 7 or 8 for its battery state-of-charge measurements. Connection are to
be made as close as possible to battery to prevent voltage drops that will cause errors in discharge
indicator readings. The connection is not to be switched by the vehicle’s keyswitch.
Pin 5 = Battery –
Connect to battery ground as close to battery
32
as possible.
Pin 2 = Keyswitch. The keyswitch turns on and off the LED display of the battery discharge indicator.
Monitoring of the battery continues when Pin 2 is turned off and the display is not lit. The hour meter
display is unaffected by Pin 2, although it cannot accumulate more time as long as the keyswitch pin is
not energized. The control inputs HRM (+) and HRM (–) are enabled by the keyswitch. Pin 2 is
connected to the vehicle’s keyswitch.
Pins 1 & 6 = Hour Meter Control. In normal operation, Pin 1 or 6 is connected and the other is left open.
Only one of these pins is connected when using normal hour meter function. It is possible to or the hour
meter between the two inputs so that it accumulates the total time either system is on. Hour meter
control logic is detailed in Table 2.
Pin 6 = Hour Meter +. HRM (+) (for use with a switched positive voltage). Pin 6 connects to a high
voltage as defined in Table 1. to activate the hour meter. Leaving Pin 6 open or connecting it to a low
voltage gives control of the hour meter to the Hour Meter (–) input. See Table 2.
Pin 1 = Hour Meter –. HRM (–) (for use with a switched ground). Pin 1 connects to a low voltage level as
defined in Table 1 to activate the hour meter. Leaving Pin 1 openor connecting it to high voltage gives
control of the hour meter to the Hour Meter (+) input.
Pin 3 = Relay. Pin 3 connects in series with the lift coil circuit (or the circuit to be switched at empty). For
holding relay (J), Pin 3 must be electrically closer to battery + than Pin 4
Pin 4 = Relay. Pin 4 also connects in series with the circuit to be switched at empty.

HOUR METER CONTROL LINES & IMPEDANCE SPECIFICATIONS

Min. Impedance
Low Voltage (max.) Hight Voltage (min.)
HRM+ HRM-
5.0VDC 15.0VDC 80kΩ 20 kΩ

HOUR METER CONTROL LOGIC

Pin 1 (HRM-) Pin 6 (HRM+) Hour Meter Status
High Low Off
High Open Off
Open Low Off
Open Open Off
Low High On
Low Low On
Low Open On
High High On
Open High On

DISCHARGE ADJUSTMENTS
The followed table lists the voltages per cell under load that correspond to an empty indication on the
gauge (lockout point).

Setting K L M N O P Q R S T U

Volt/Cell
1.57 1.63 1.68 1.73* 1.78 1.82 1.84 1.86 1.89 1.91 1.93
at Empty
NOTE: “*” – factory setting

33
RESET TYPE/LEVEL (AFTER OR DURING RECHARGE)
CTR = Charge Tracking Reset: If the gage is connected to the battery during recharge, the gage will
track the battery charge level.
OCR = Open Circuit Reset: If the gage is disconnected from the battery during recharge, the gage will
retain the last indication. It will advance to full when reconnected only if the battery voltage is above the
OCR level. For standard (“B”) reset, OCR = 2.09 VPC (VPC = volts per cell.)

TROUBLESHOOTING
Problem Possible Causes
No display Terminals not connected or improper voltage
Instrument voltage does not match battery voltage, B+ connected
Stays at FULL
to the wrong terminal
Instrument voltage does not match battery voltage, or battery not
Will not reset
fully charged
Resets w/o charging battery Not connected directly to battery terminals
B+ connected to wrong terminal, or instrument voltage does not
EMPTY too soon
match battery voltage, or terminals not directly connected to battery

3.8 REPLACING THE ELECTRICAL PARTS

Lower the forks to the bottom before operation, shut down the emergency button and key
switch!
OPERATION OF THE COVER

STEP 1：Remove the fixing screws of the top cover STEP 2：Rotate the handle for 90°,then take
on electrical box with 8mm Allen wrench. down the top cover.

34
REPLACING OF THE CHARGER

STEP 1: Remove the input wire of the charger STEP 2: Remove positive pole input with 14mm
fixing the negative pole of the battery with 10mm wrench.
wrench.

STEP 3: Unplug the indicator light wire, power STEP 4: Remove 4 screws fixing the charger with
input wire, Self-preservation wire and connector opener.
of fan.

35
STEP 5: Remove the ground lead with 5mm Allen wrench, then you can replace the charger.

REPLACING OF THE FAN

Unplug the connector, and then remove 4 screws.

REMOVING OF THE BATTERY

Step 1: Press two springs of the battery cable tie, loosen it.

36
STEP 2: Take out the hook.

STEP 3: Remove the bolts fixing +/- pole with

10mm wrench.

REPLACING OF THE BATTERY INDICOTOR

STEP 1: Remove the fixing screws with 6mm Allen wrench.

37
 STEP 2: Unplug the connector of the indicator, remove 2 screws then you can remove it.
Instruction ：
① Blank
②、③ positive pole input through the key switch
④ positive pole output
⑤ negative pole input
⑥ Positive pole input through the micro switch of control handle
⑦ positive pole input
⑧ Blank

REPLACING OF THE KEY SWITCH

STEP 1: Cut off the ties with diagonal pliers, unplug the connector.

STEP 2: Remove the nut widdershins, then take

out the key switch.

38
REPLACING OF THE EMERGENCY BUTTON

STEP 1: Remove 2 screws fixing the emergency button with wrench.

Avoid losing the screws!

STEP 2: Remove 4 screws with 6mm Allen wrench.

STEP 3: Remove 2 screws fixing emergency STEP 4: Dismantle the black plug with hand on the
button with 3mm Allen wrench. emergency button.

39
 STEP 5: Remove B+ cable of the emergency
button with 14mm wrench, then you can remove it.

REPLACING OF THE FUSE ANG CONTACTOR

STEP 1: Open the protective cap of the fuse STEP 2: Remove the screws of the contactor with
holder, and then you can take out the fuse. 13mm spanner, and then remove cable13-6-,
J1-6- with nipper pliers.

STEP 3: Remove the fixing screws of the

contactor with wrench then you can remove it.

40
REPLACING OF THE CONTROLLER

STEP 1: Remove screws fixing +/- pole and 3 STEP 2: Remove 4 screws fixing the controller
wiring harness (U, V, W) with 5mm Allen wrench. with 5mm Allen wrench.

STEP 5: Take out the controller.

There is some thermal Silicone Grease

on the back of the controller!

41
3.9 TOOL FOR REPAIRING THE PIN OF ELECTRICAL PLUG
No. Figure Application

1 Tool for removal of pins / sleeves.

2 Tool for application of pins / sleeves

3 Tool for release of lock

Tool for application of secondary locking 2 –

4
pole

Tool for application of secondary locking 4 –

5
pole

6 Tool for removal of pins / sleeves

42
4. HYDRAULIC SYSTEM

4.1 HYDRAULIC FLOW DIAGRAM

INSPECTION OF HYDRAULIC OIL

External appearance Smell Condition Countermeasure
Clear and no discoloration Fine Fine Possible to use
Inspect the viscosity and if fine
Clear but the color becames bright Fine Mixed with other oil
it can be continuously used
Color changed like milk. Fine Mixed with air and water Separate water or replace oil.
Color changed into dark brown Bad Oxidized Replace oil.
Clear but there are small black
Fine Mixed with other particles Use after filtering.
spots

43
4.2 INSTALLATION OF HYDRAULIC SYSTEM

4.3 REPLACING OF THE PUMP STATION

STEP 1: Remove the cable FP fixing the contactor and cable E2 fixing the motor. Then remove cable
5-4-2-.J1-4- of contactor coil.

Lower the forks to the bottom before operation, The oil will spill over when operation;
Keep clean for the stacker and yourself!

STEP 2: Remove the hydraulic pipe joint with

19mm wrench.

Watch out for the hydraulic oil spilling,

check if the joint is dirty and clean it.

44
STEP 3: Remove the battery with 10mm wrench, remove 2 screws fixing the pump station with 17mm
wrench and then you can remove it.

4.4 REPLACING OF THE CONTACTOR OF THE PUMP

STEP 1: Remove the screw fixing the cable on the STEP 2: Loosen the screw of the hoop with
contactor with 13mm wrench. flathead screwdriver, all the parts is shown in
the picture.

4.5 REPLACING OF THE CARBON BRUSH

STEP 1: Remove 2 screws at the top of the pump station with 8mm wrench, and then remove the
Circlip.

45
STEP 2: Remove the carbon brush base, then the carbon brush will pop-up by the spring.

STEP 3: Remove the screws fixing the binding post of +/- pole with 10mm wrench, then you can
remove the carbon brush.

STEP 4: When installing carbon brush, you should

put the carbon brush into the carbon brush box,
and then press it into the neck.

46
4.6 REPLACIING OF THE CYLINDER

STEP 1: Remove the screws fixing the

connection plate with 5mm wrench.

STEP 2: Remove the locking plate, then remove the connecting shaft with wrench.

STEP 3: Remove the pipe joint with 17mm STEP 4: Remove the screws fixing the Ring rod
wrench. shaft with 4mm Allen wrench.

47
STEP 5: Take out the Ring rod shaft, the frame and electric box will be separated. Loosen the screw
of the hoop with 5mm Allen wrench, then you can remove the cylinder.

5. DRIVE WHEEL

5.1 REPLACING OF THE SENSOR

Lift up the truck before operating!

Take care of yourself!

STEP 1: Remove 4 screws fixing the motor with 2.5mm wrench.

48
STEP 2: Tilt the sensor with screwdriver, then you can take out the sensor and replace it.

5.2 REPLACE OF THE BREAK

No. Part name No. Part name

1 Gaiter 6 Spring
2 Friction plate 7 Carrier
3 Screw 8 Body magnetic
4 Break disk 9 Screw M5x45
5 Break anchor plate 1

STEP 1: Remove 6 screws with 6mm Allen

wrench, and then you can remove the break.

49
STEP 2: Remove the break pad.

5.3 REPLACE OF THE RIM

STEP 1: Remove the screws fixing 3 wiring STEP 2: Remove 10 screws fixing the rim with
harness (U, V, W) with 10mm wrench, then 5mm Allen wrench, then you can remove the rim
unplug the connector. and replace it.

50
6. CONTROL HANDLE

No. Part name No. Part name

1 Bushing, 23/19*17*10 8 Air spring
2 Handle mounting bracket 9 Handle cable
3 Shaft, 17 10 Micro switch Z-15GW2
4 Roll pin, 4x24 11 Screw, M4x25
5 Socket hex bolts M8x25 12 Cover
6 Elastic washer 8 13 Screw, M4x10
7 Socket hexa bolts M8X16 14 Tillerarm

51
 No. Part name No. Part name
1 Butterfly left or throttle switch left 16 Seesaw-left or toggle button left
2 Button for horn 17 Magnet holder for seesaw
3 Spring 18 Hinge spring
4 Bearing for camshaft 19 Contact base
5 Magnet 20 Belly switch cover
6 Spring for belly botton switch 21 Optional cover
7 Socket hexagonal Screw, M6X10 22 Seesaw right or toggle button right
8 Socket hexagonal Screw, M3X16 23 Tapping screw, ST4.2X25
9 Washer, 3 24 LED bicolor
10 Butterfly right 25 Housing for LED two parts
11 Edge Shaft 26 Spring RH throttle torsion
12 PCB-clip 27 Spring LH throttle torsion
Printed
13 Sensor for rocker lever 28
board
14 Upper-part
15 Lower-part

6.1 REPLACING THE CONTROL HANDLE

STEP 1: Remove 3 screws fixing the back cover of the handle with Philips screwdriver.

STEP 2: Unplug the connectors of the handle. STEP 3: Remove 2 screws fixing the driving
switch with 2.5mm Allen wrench.

52
STEP 4: Remove the driving switch axle.

STEP 5: Remove the screws fixing the PCB board unplug the connectors and then you can replace
the PCB board.

Don’t miss the shaft sleeve when removing the PCB board.

53
6.2 REPLACING OF THE INTERLOCK SWITCH

Step 1: Remove 4 screws on back cover of Step 2: Dismantle 2 screws fixing SA from the left
handle with 2.5mm Allen wrench. of the handle lever with 2.5mm Allen wrench.

6.3 REPLACING OF THE AIR SPRING

STEP 1: Remove the upper screws fixing the air STEP 2: Remove the below screws fixing the air
spring with 6mm Allen wrench. spring with 12mm wrench and then you can
remove the air spring and replace it.

54
7. CASTER WHEEL
7.1 OPERATION OF THE CASTER WHEEL

First, let the pallet truck to be slanting, then dismantle four screws. Note to help the nut when turning
the screws. Then you can dismantle the caster and replace it.

7.2 ADJUSTING THE PRESSURE FOR THE DRIVE WHEEL

After using some time, the drive wheel might wear off, the pressure for the drive wheel will not be enough,
and drive wheel can not bit into the ground and slip.
You can adjust it according to following steps:

STEP 1: Loose the four screws (do not need to STEP 2: Take away one or two piece washer.
dismantle them)

55
 8. TROUBLE DIAGNOSTICS

8.1 REGULAR MAINTENANCE

 Only qualified and trained personnel are allowed to do maintenance on this truck.
 Before maintaining, remove the load from the forks and lower the forks to the lowest position.
 If you need to lift the truck, follow chapter 4b by using designated lashing or jacking equipment.
Before working, put safety devices (for instance designated lift jacks, wedges or wooden blocks)
under the truck to protect against accidental lowering, movement or slipping.
 Please pay attention by maintain the tiller arm. The gas pressure spring is pre-loaded by
compression, carelessness can cause injury.
 Use approved and from your dealer released original spare parts.
 Please consider that oil leakage of hydraulic fluid can cause failures and accidents.
 It is allowed to adjust the pressure valve only from trained service technicians.
If you need to change the wheels, please follow the instructions above. The castors must be
round and they should have no abnormal abrasion.
Check the items emphasized maintenance checklist.

a. maintenance checklist
Interval(Month)
1 3 6 12
Hydraulic
1 Check the hydraulic cylinder, piston for damage noise and leakage 
2 Check the hydraulic joints and hose for damage and leakage 
3 Inspect the hydraulic oil level, refill if necessary 
4 Refill the hydraulic oil ( 12 month or 1500 working hours ) 
5 Check and adjust function of the pressure valve (1500kg +0/+10%) 
Mechanical system
6 Inspect the forks for deformation and cracks 
7 Check the chassis for deformation and cracks 
8 Check if all screws are fixed 
9 Check the push rods for deformation and damages 
10 Check the gearbox for noise and leakage 
11 Inspect the wheels for deformation and damages 
12 Inspect and lubricate the steering bearing 
13 Inspect and lubricate the pivot points 
14 Lubricate the grease nipples 
Electrical system
15 Inspect the electric wiring for damage 
16 Check the electric connections and terminals 
17 Test the Emergency switch function 
18 Check the electric drive motor for noise and damages 
19 Test the display 
20 Check, if correct fuses are used 
21 Test the warning signal 
22 Check the contactor(s) 
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23 Check the frame leakage (insulation test) 
24 Check function and mechanical wear of the accelerator 
25 Check the electrical system of the drive motor 
Braking system
26 Check brake performance, if necessary replace the brake disc or adjust 
the air gap
Battery
27 Check the battery voltage 
28 Clean and grease the terminals and check for corrosion and damage 
29 Check the battery housing for damages 
Charger
30 Check the main power cable for damages 
31 Check the start-up protection during charging 
Function
32 Check the horn function 
33 Check the air gap of the electromagnetic brake 
34 Test the emergency braking 
35 Test the reverse and regenerative braking 
36 Test the safety (belly) button function 
37 Check the steering function 
38 Check the lifting and lowering function 
39 Check the tiller arm switch function 
General
40 Check if all decals are legible and complete 
41 Inspect the castors, adjust the height or replace these if worn out. 
42 Carry out a test run 

b. Lubricating points
Lubricate the marked points according to the maintenance checklist. The required grease specification is:
DIN 51825, standard grease.

1. Turning bearing Joint

2. Support wheel bearings
3. Pump
4. Flange
5. Joint
6. Shaft
7. Load wheel bearings

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c. Check and refill hydraulic oil
The required hydraulic fluid- type is

 H-LP 46, DIN 51524

 Viscosity is 41.4 - 47
 Depending on the type the amount is 0,7L

Waste material like oil, used batteries or other must be probably disposed and recycled according to the
national regulations and if necessary brought to a recycling company.
The oil level height shall be in the not lifted position min.0.6L to 0.8L.
If necessary add oil at the filling point.

d. Checking electrical fuses

Remove the main cover.

Rate
FU1 10A
FU2 0.5A
FU01 150A
FU02 80A

8.2 TROUBLE SHOOTING

Trouble shooting
TROUBLE CAUSE REPAIR
Load weight too high Lift only the max. capacity,
mentioned on the ID-plate
Battery discharged Charge the battery
Lifting fuse faulty Check and eventually replace the
Load can’t be lifted lifting fuse
Hydraulic oil level too low Check and eventually refill hydraulic
oil
Oil leakage Repair the hoses and/or the sealing
of the cylinder
Oil leakage from air Excessive quantity of oil. Reduce oil quantity.
breathing
Battery is charging Charge the battery completely and
Truck not starts then remove the main power plug
operating form the electrical socket.
Battery not connected Connect the battery correctly

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 Fuse faulty Check and eventually replace fuses

Low battery Charge the battery

Combined emergency switch is De-activate the combined

activated emergency switch by insert and pull
the knob.
Tiller in the operating zone Move the tiller firstly to the braking
zone.

If the truck has malfunctions and can’t be operated out of the working zone, jack the truck up and go with
a load handler under the truck and safe the truck securely. Then move truck out of the aisle.

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