CPDS20 SM XC 1.3 X2.0t 3 W Electric Forklift Truck 202205 en NonCE

XC Series
Three fulcrum lithium battery forklift CPDS13/15/16/18/20-XCD4-SI

truck CPDS13/15/16/18/20-XCD6-SI
Service Manual
Original Instruction
HANGCHA GROUP CO., LTD.

05/2022
FOREWORD
We would like to express our deep gratitude for your purchase of HANGCHA Group's
three-fulcrum battery forklift truck.
XC series three - fulcrum lithium battery special balanced heavy forklift is a new product newly
developed by the company. It owns characteristics as beautiful shape, compact structure, small
size, low gravity, good stability, superior performance, flexibility ,dual motor front wheel drive,
steering lift common pump and small turning radius.
This manual briefly introduces the structural principles of XC series three fulcrum lithium battery
counterbalance forklift and some common faults.Relevant operators and maintenance personnel
must read the manual before use
With the continuous update and improvement of our products, the forklift in your hand may be
slightly different from some of the instructions in this operation and maintenance manual.
If you have any questions please keep touches with HANGCHA GROUP CO., LTD. sales
department or let the agents know.
Three fulcrum lithium battery forklift truck has been CE certified
Rated capacity(t)
Left traction electric Right traction Electric control
Model / Load center
control electric control of oil pump
(mm)
CPDS13-XCD4-SI
ACS80S-220C-35P ACS80S-220C-23P ACS80M-35P 1.3/500
CPDS13-XCD6-SI
CPDS15-XCD4-SI
CPDS15-XCD6-SI
CPDS16-XCD4-SI
CPDS16-XCD6-SI
CPDS18-XCD4-SI
CPDS18-XCD6-SI
CPDS20-XCD4-SI
CPDS20-XCD6-SI
© 05/2022 HANGCHA GROUP CO., LTD

CONTENT
Foreword
1 Driving system ..................................................................................................... 1
Reduction box ...................................................................................................... 1
Driving axle assemble removal and installation ....................................................5
Removing and installation of reduction box ..........................................................7
2 Steering system ................................................................................................. 30
Steering Device .................................................................................................. 30
Steering axle ...................................................................................................... 31
3 Brake system ......................................................................................................34
Braking Schematic ............................................................................................. 34
Service brake ..................................................................................................... 34
Brake master pump ............................................................................................ 35
Parking brake ..................................................................................................... 37
Fault and adjustment of brake system ................................................................38
4 Hydraulic system ............................................................................................... 39
Hydraulic system ................................................................................................ 39
Schematic diagram of the hydraulic system ....................................................... 39
Main components of hydraulic system ............................................................... 40
Gear pump ......................................................................................................... 40
Adjusting the pressure of the main relieve valve ................................................ 45
5 Lifting system .....................................................................................................48
Data ....................................................................................................................49
Trouble shooting and corrective action ...............................................................50
Tilting cylinder .................................................................................................... 51
Lifting Cylinder ....................................................................................................54
Mast Disassembly and Installation ..................................................................... 55
6 Electrical system ................................................................................................61
AC motor ............................................................................................................ 61
Instrument .......................................................................................................... 64
Electrical schematic diagram ..............................................................................74
1 Driving system
The drive system is mainly composed of drive motor, reduction box, tire and other components.
See Fig. 1.1 for the drive system diagram.
The front wheel is driven by two motors, that is, the left and right side drive wheels are driven by an
AC motor respectively.
Reduction gearbox is a two-stage reducer, of which one is a couple of cylindrical helical gears and
the other is planet gear at the wheel rim which contributes to its compact structure. Service brake
and parking brake share one wet brake, which lies in the reduction gearbox.
Drive motor
Reduction box
Tire
Fig.1-1 Drive system diagram
Reduction box
Data
D4 electric control model
Item Parameter
Weight (no oil included) About 40Kg
Oil mass Each side is about 0.35L

oils DEXRON Ⅲ-G00
Brake fluid DOT3 or DOT4
Stress of manipulation （6-8） MPa

Normal pressure(Maximum continuity) 8 MPa
Foot brake
Maximum pressure 10 MPa
Hydraulic cylinder brake fluid volume
1.71cm3
(under normal conditions)
Hydraulic cylinder brake fluid volume
3.71 cm3
(under maximum wear conditions)
Handle tension when operating hand
100 N
brake
Hand braking stroke 6 mm
Wear limit stroke 13 mm
1
Specifications for the overall product Data
Weight with oil up to 78 kg

Minimum storage temperature +5°C (+41°F)
Maximum storage temperature +40°C (+104°F)
Maximum operating temperature +80°C (+104°F)
Ambient temperature in operation -30 to +40°C

-30°C～+40°C
Gearbox
Gear ratios available 14.0 to 26.6
Maximum static wheel load 2850 kg (8818 lb 8 oz)
Maximum input speed 5000 rpm
Maximum output torque 1320 Nm
Wheel
Wheel dimensions Rim 6.5 F-10
Wheel 200/50-10
Rim 4.33 R-8
Wheel 18x7-8
Lubricant
Gearbox oil type
acc. to ZF lubricant list TE-ML17C
Gearbox oil quantity approx. 0.35 l
Fault
Method of
Trouble Probably cause
troubleshooting
The impact sound of running Gear clearance is too big. Adjust

and reversing reduction box is
large Too much worn of gear. Replace
Oil level is low. Add oil

Make gear noise during
operation Gear clearance is too big. Adjust
Too much worn of gear. Replace
The vehicle is not moving or

The friction sheet is damaged Replace
has insufficient braking power
2
Noises：
Type of noise Possible cause Rectification
High-pitch hitting Teeth of spur gear stage Check gear teeth of input pinion and spur
noise (depending damaged when mounting gear for damage （ Replace a damaged
on rpm) motor input pinion; if the spur gear is damaged,
you may carefully refile the gear teeth
using a diamond file。）
High-pitch,singing noise Mechanical engine Check motor dimensions and motor
connection defective motor connection and if necessary retighten
bearing defective input pinion to hub
Dull, grinding noise Defective wheel bearing Inspect wheel bearing, replace if
Incorrect bearing pretension necessary
of wheel bearing Check bearing pretension,correct if
necessary
Defective teeth in
Inspect planetary stage gear set and
planetary gear
wheel bearing, replace if necessary
Leaks, leaky points：
Location Possible cause Rectification
Bleeder Oil level too high Check oil level, correct if necessary
Housing cover Bolts not tightened to Check tightening torque, retighten bolts if
specified torque necessary
Gear shaft Radial shaft sealing ring Check radial shaft sealing ring, replace if
damaged or worn necessary
Brake lever Defective sealing ring Check sealing ring, replace if necessary
Screw plugs Screw plugs not tightened to Check tightening torque, if necessary
specified torque Incorrect or retighten bolts.
defective sealing ring
Remove screw plugs and use genuine ZF
mounted
sealing rings
Motor connection Defective motor O-ring Remove motor and replace O-ring
Motor Worn radial shaft sealing ring If necessary replace motor

on motor shaft
3
Drive with limited or no function
Defective connecting cable/loose

Replace/tighten connecting cable/
Carbon brushes (if fitted)
Motor Replace carbon brushes
fretted/worn
Replace motor
Insulation burned through
Replace motor/gearbox
Blocked motor/gearbox
Drive unit Carry out maintenance/repair to service
Service brake blocked
brake
Inadequate brake response
Air in hydraulic system Bleed or top up brake fluid

Worn brake discs Replace brake discs
Foot brake
Worn axial slide bearing Replace axial slide bearing
Ruptured brake cable Replace brake cable
Brake connection part
No.1 part：The hand brake cable connects the head. The wear limit of the connecting head of the
hand brake cable is 13 mm. Beyond this limit, it should be replaced
No.2 part：The connection port of the service brake oil pipe should be replaced when the brake oil
cylinder leaks.
No.3 part：：Air release screw plug. After adding brake fluid, the vent plug should be loosened to
vent. During brake commissioning, the exhaust plug is also used to remove gas from the brake
tubing and brake. Specific steps: when the brake is debugged, first tighten the vent plug and
continuously press the pedal hard until it feels very laborious to step forward. At this time, press
the pedal hard, loosen the vent plug and release the air bubbles, then tighten the vent plug and
loosen the pedal. These steps were repeated until no air bubbles appeared.The left and right
4
brakes operate according to the above requirements.
Oil plug and oil change of the reduction box
1.Oil filler plug 2.Observe the oil level plug 3.Observe the oil level plug
4.Oil discharge plug 5.Breather plug

Oil change steps:
1.Lift the forklift with a jack, pad solid wood blocks under the frame, unscrew the tire nuts, and
remove the tire assembly.
2.Place the container under the reduction box, screw plug 4 and remove the old oil.
3.Clean with a clean oil of the same specification, and wash the pollutants in the deceleration box.
4.Tighten oil discharge plug 4, inject clean oil of the same specification through refueling plug 1,
and add until oil level plug 2 overflows.
5.Tighten oil discharge plug 1 and observe oil level plug 2 to wipe out the spilled oil from the
deceleration tank.
6.Install the tire assembly and Split the tightening screws twice in diagonal order. The tightening
torque: 157Nm~176 Nm.
Driving axle assemble removal and installation

1. Raise front end of forklift truck and support frame with wooden blocks.Get the left and right
front tires off the ground.
2. Remove fork and mast assembles.
3. Remove the nut connecting brake tubing and gearbox; Remove the brake cable on the hand
brake pull rod; Remove the wiring from the motor
5
Caution
 Plug brake tube openings to prevent oil from flowing out.

4. Lift the reducer slightly gently with the lifting equipment to prevent the deceleration box from
falling down after removing the bolts connected to the frame
5. Remove the rim nuts and remove the rims and tires.
6. Remove bolts for reduction box and frame connections.
7. Lift out reduction box and motor

8. Remove reduction box and motor connection bolts and remove reduction box and motor
horizontally.
9. Driving axle disassembly and installation in reverse order, but to pay attention to the following
points：
─ When installing the motor, apply some grease to the motor spline, carefully send the
motor to the installation position, insert the bolt assembly(The meshing part of bolt tail
should be precoated with TaiLe 242 thread locking agent (or 222) to prevent
loosening).Split the tightening screws twice in diagonal order.
─ Discharge the old polluted oil in the reduction box, inject clean gear oil with the same
specifications, add until the oil overflow is observed at the oil plug port, wipe the spilled oil.
6
Removing and installation of
reduction box 5. Remove the 6 socket head cap bolts ○
3
Reduction box removal (M6×1) connecting the gearbox body ○

2 and
D6 electric control model the gearbox cover ○

1 . Put down the gearbox
1. Remove the adapter ○

1 body, and unscrew the 2 socket head cap bolts
When reassembling, it is necessary to replace (M6×1) on the edge of gearbox cover 1.
bearings, O-rings, piston seals, oil seals,

friction plates and matching plates.
2. Remove the hub cap ○

2 and remove the
lock nut ○
3 .
Caution: Be careful during disassembly to

avoid damaging parts.
6. Remove the carrier ○

1 , and remove the
planetary gear ○
2 connected to the carrier○
1 .
3. Remove the locking plate ○

4 and O-ring ○
5 ,
and then remove the rim assembly ○

6 .
7. Remove the snap ring○ 3 , thrust washer ○4

(t=1), 2 thrust washers ○ 5 (t=2), planetary
gear ○ 6 (Z=25), needle roller bearing○ 7 from
3 places on the carrier○ 1 . When the thickness
of thrust washer○ 5 is less than 1.6mm, it needs
to be replaced.
4.Remove the bearing○
7 .
8. Remove needle roller bearing ○

8 and thrust
7
washer ○
9 (t=2).
13. Unscrew 8 hexagon socket head cap

bolts○
5 (M6×1), bearing seat○
6 .
9. Remove bearing○
10 from carrier○
1 . Note: When disassembling, the return
spring ○
7 is easy to bounce, and the 4 return
springs should not be lost.
10. Remove the sun gear○

1
14. Remove 4 return springs ○

1 , remove 3
dynamic friction plates ○

2 , 3 static friction
plates○
3 , and pressure plate○
4 .
11. Remove the snap ring ○

2 from the sun
gear○
1 .

1 , snap ring ○
2 ,
spacer ○
3 , driven gear ○
4 (Z=22) from the
reduction box body.
12. Remove the driven gear ○

3 (Z=88) and
the bearing ○
4 .

2 , spacer ring ○
3 ,
snap ring○
1 and driven gear○
4 in sequence.
8
17. Remove the breathing plug○
5 (R1/8). 22. Remove the ring gear ○
3 (Z=64) and 6 flat
keys○
4 .
18. Remove the two snap rings ○

8 , brake
When the ring gear ○ 3 is difficult to

pins○
7 and remove the brake lever○
6 .
disassemble, tap the edge of the ring gear with
a long and sturdy object from the direction of
the arrow in the figure below to remove it.
19. Remove two hexagon socket head cap

bolts○
1 (M5×0.8).
Note: Be careful not to damage the oil seal or
the gears on the ring gear during the
disassembly process.
23. Remove the oil seal○
5 .
20. Remove the brake lever ○

2 and O-ring
seal○
3 .
24. Remove the outer ring ○

1 of the tapered
roller bearing. Note: Do not damage the rolling

contact parts during the removal process.
21. Remove the retaining ring ○

2 from the
transmission cover○
1 .
9
The difference in braking effect may lead to
longer braking distances or to the vehicle
breaking out to the side.
1.Brake disc set
2 of the tapered
25. Remove the outer ring ○
roller bearing. Note: Do not damage the rolling
contact parts during the removal process.
1.1 Remove the brake disc set from the

internal gear
3.
26. Remove the needle roller bearing○
1.2 Unclamp the housing from the assembly
fixture
2.Protective cap
2.1Release the protective cap from the wheel
shaft and remove manually
4 (G1/4) and 4
27. Remove 4 sealing plugs ○
O-rings○
5.

When changing the disc set in one
gearbox, the disc set of the gearbox on the
other side of the vehicle shall also be changed.
If this is disregarded,there may be a
pronounced difference in braking effect 3.Cylindrical pin
between the left-hand and right-hand gearbox. 3.1 Remove the cylindrical pin which secures
10
the grooved nut from the
wheel shaft . To do this, screw the thread of
Pinion-extractor with hammer stroke fully into
the cylindrical pin. Slide the hammer upwards
several times with enough
drive to pull out the cylindrical pin.
3.3 Place the housing on the press table with

the mating surface facing downwards.
3.2 Grooved nut

Undo the grooved nut from the wheel shaft
and remove manually.
4. Planet carrier
Caution ： Risk of accident and injury from
crushing. When pressing out the planet carrier,
do not place hands between the punch and the
tool.
4.1 Press the planet carrier out of the
housing.The punch of the hand lever press
and the tool shall be at right angles to each
other.
11
4.2 Remove the planet carrier from the
housing
Caution：it the jaws of the vice with protective

jaws (e.g. copper, aluminium or
brass) to prevent the surfaces from being
damaged.
Remove the 3 planetary gears
4.3 Remove O-ring from planet carrier by

hand.。
6. Gear shaft
Drive the wheel shaft out of the housing .
Secure the drive against falling from below
with your hand.
Clamp the housing in the assembly fixture.

Remove the spacers from the housing
7.Wheel shaft taper roller bearing

Caution ： If necessary, heat the taper roller
bearing to facilitate removal. Wear prescribed
5.Planetary gears protective equipment and use appropriate
Clamp the planet carrier in a vice. tools.
12
7.1 Remove the wheel shaft side taper roller
bearing from the wheel shaft . If necessary, 9. Wheel shaft sealing ring
heat the taper roller bearing. Drive the sealing ring downwards and
out of the housing by impacting it alternately
7.2 Remove the planet carrier side taper roller on opposite Sides.The shaft sealing ring is
bearing destroyed in the process. During reassembly,
a new shaft sealing ring shall be used.
8. Internal gear
10. Wheel shaft side bearing cup
Remove the 12 Torx bolts from the
Drive the wheel shaft side bearing cup of
internal gear，Remove the internal gear from
the taper roller bearing downwards and out of
the housing.If the internal gear is damaged, it
the housing by impacting it alternately on
shall be replaced as a complete unit.
opposite sides
11. Planet carrier side wheel shaft
Drive the planet carrier side bearing cup of the
13
taper roller bearing downwards and out of the
housing by impacting it alternately on opposite
sides
2. Install the ball bearing○

2 assembled above
to the reduction case body.
12. Wheel shaft sided sealing ring

Disassemble the sealing ring by using a
chisel. 3. Install 4 clutch pins○
5 and 2 parallel pins○
6 .
Pay attention to the direction of installing the

clutch pin○
5 , as shown in the following figure:
The sealing ring is destroyed in the

process. During reassembly, a new sealing
ring shall be used.
Gearbox assembling
D4 electric control model 4. Install the hole on the pressure plate ○
7
1. Install the ball bearing with retaining ring on 8.
through the clutch pin○
the driven gear○
1 in sequence
2 、 Spacer ○
3 , snap ring ○
4 . Note: Bearing
installation direction and the need to install a

snap ring.
5. Install the hole on the static friction plate○

1
through the clutch pin.
14
6. Install the dynamic friction plate○
2 .
9. Tighten 8 hexagon socket head cap bolts○

1
(M6×1) diagonally. Note: After tightening,

make sure that the 3 dynamic friction linings
Repeat steps 5 and 6, and install the static
can rotate smoothly and no air can enter.
friction lining and the dynamic friction lining at
intervals. After installing the 3 static friction
linings and the 3 dynamic friction linings, make
sure that the top one is the dynamic friction
lining.
7. Install 4 return springs○
3 .
Tightening torque 11Nm~15Nm
LOCTITE#262 or
Seal
equivalent
10. Install the ball bearing ○
2 on the driven
gear○
3 .
8. Align the hole on the bearing seat○

4 with the
clutch pin, place the return spring, and press

the return spring through the bearing seat ○
4 .
During the installation process, pay attention

11. Install the driven gear in mesh with the
to the gap.
transmission gear.
Note: When compressing the return spring, do
not pop the spring out.
12. Install snap ring○

2 on sun gear○
1 .
15
16. Install two thrust washers ○
5 , needle roller
bearings ○
7 , planetary gears ○
6 (Z=25), thrust
washers ○
4 (t=1), and snap rings ○
3 at three
places on the carrier○

1 .
Note: Do not forget to install the thrust washer

13. Install the sun gear ○ 1 , and align the sun
4 and the snap ring○
3 ; when the thickness t of
○
gear with the friction plate groove.
Note: When inserting the sun gear, tap lightly the thrust washer ○
5 is less than 1.6mm, it
so as not to damage the friction pads.
needs to be replaced.
Make sure that the snap ring○

2 is fully inserted
17. Install the tapered roller bearing outer
into the groove on the driven gear○
3 .
ring○
2 on the convex end of the reduction box
cover○
1 .
Note: Pay attention to the direction of installing

the outer ring of the tapered roller bearing○
2 ;
be careful not to damage the shaft hole

surface during installation.
14. Install the inner ring○
2 of the tapered roller
bearing on the carrier○

1 .
18. Install the oil seal○

3 .
Note: Pay attention to the installation direction

15. Install needle roller bearing ○
8 and thrust
of the oil seal ○
3 during installation; do not
washer ○
9 on carrier ○
1 (t=2.5). Note: The
damage the oil seal lip during installation.
needle roller of needle roller bearing ○
8 is
Liquid sealant ThreeBond#1104 or
installed facing the thrust washer○
9 .
equivalent
16
22. Install the retaining ring○
2 .
19. Turn over the reduction box cover ○

1 and
install the outer ring of the tapered roller 23. Install the needle roller bearing○
3 .
bearing○
4 . Note: Pay attention to the direction when
Note: Pay attention to the direction of installing installing the bearing, the marked end direction
the outer ring of the tapered roller bearing ○
4 ; is outside; do not directly knock the bearing in
be careful not to damage the shaft hole with a hammer.
surface during installation.
24. Install O-rings ○

4 (G1/4) and sealing
20. Align the groove on the ring gear○
5 (Z=64) plugs○
5 at 4 places on the gearbox cover.
with the groove on the reduction box cover○

1 ,
and then install it.

Note: When installing, pay attention to the
installation direction of the ring gear.
21. Install 6 flat keys○

1 in the groove between
25. Install two parallel pins ○

1 on the gearbox
the gearbox cover and the ring gear.
cover.
17
26. To install the carrier on the reduction box and tighten them.
body, it is necessary to correctly mesh the Tightening torque 11Nm~15Nm
planetary gear and sun gear on the carrier. Seal LOCTITE#262 or
equivalent
27. Draw a circle on the gearbox body with

liquid sealant.
Liquid sealant ThreeBond#1104 or 30. Install the inner ring○
3 of the tapered roller
equivalent bearing on the hub○

2 with 6 hub bolts.
31. Apply grease○

1 to the oil seal lip.
28. Install the gearbox cover to the gearbox Grease Industrial Lithium
body from above. Grease
Note: During installation, do not damage the
oil seal.
32. Install the hub○

2 .
Note: During the installation process, do not

damage the oil seal lip; after installing the hub,
29. Apply sealant to the 2 socket head cap make sure that it can be easily rotated.
bolts (M6 × 1, L=35), and tighten them in the

holes on the edge of the gearbox. After that,
turn the reduction box over, apply sealant to
the 6 socket head cap bolts○
1 (M6×1, L=20),
18
33. Install O-ring○
3 in the groove.
Note: Install O-ring○

3 completely in the groove,
do not protrude out of the groove.
34. Install the locking plate○

1 , and the contact
surfaces on both sides of the locking plate

should be smooth.
36. Fill the groove between the locknut ○

1 and
the carrier.
Note: Make sure the bottom of the slot is filled.
35. Tighten a temporary lock nut○

2 (M30×1.5),
and one bolt hooks spring balancer ○

3 among
the 6 hub bolts, so that when the hub is turned,

the force is in the tangential direction, and the
value of the force is between 60N~80N.
37. Install the hub cap○

2 .
19
38. Install the O-ring ○
2 in the brake lever○
1 , 42. Install breathing plug ○
1 (R1/8)
and then install the brake lever ○

1 on the Note: The breather plugs are not installed in
reduction box. the same position on the left and right
Note: When installing the brake lever, install gearboxes.
the small end outside. Sealant LOCTITE#572 or
equivalent
39. Tighten 2 hexagon socket head cap bolts○

5
(M5×0.8) on the diagonal,
Caution ： Be careful not to place your

40. Install the brake lever ○
6 hole towards the
hands or fingers between the punch and the
reduction box body, and install two stop
tool when working with the hand lever press.
rings○
8 and brake pins○
7 .
1.Wheel shaft sided sealing ring
Note: The brake levers are not installed in the
1.1 Place the wheel shaft sided sealing ring
same position on the left and right gearboxes.
onto the transmission housing(see picture).
Make sure that the sealing lip is facing
upwards.
41. Install adapter○

9 .
20
1.2 Drive up the sealing ring into the
3. Wheel shaft side bearing seat
transmission housing against the block.
3.1Clean the wheel shaft side bearing seat
of the taper roller bearing in the housing
2.Shaft sealing ring

2.1 Place the shaft sealing ring (103.130)
3.2 Drive the wheel shaft side bearing cup of
into the tool 4 .
the taper roller bearing into the bearing seat.
The inside of the bearing cup shall narrow to a
taper towards the bearing seat and the wide
edge of the bearing cup shall be positioned at
the bottom.
2.2 Drive the shaft seal into the bore by using

an assembly mandrel. The shaft seal has
reached its correct position as soon as its
upper surface has reached at least the lower
end of the bore's chamfer.
21
3.3 Coat the inner lip of the shaft sealing ring
with multipurpose grease.
Caution ： The inside of the bearing cup shall

narrow to a taper towards the bearing seat and
the wide edge of the bearing cup shall be
4. Planet carrier side bearing seat positioned at the bottom. Drive in the bearing
Drive the planet carrier side bearing cup cup until a dull metallic sound signals that the
of the taper roller bearing into the bearing bearing cup is resting
seat against the bearing seat.
5. Internal gear (Parts Kit available)

5.1 Manually slot the toothed disc into the
internal gear.
5.2 The opening of the ring shall be visible

(see arrow)
22
6.Gear shaft
6.1 Coat the Nilos ring with multipurpose
grease
Bolt on the internal gear with 12 Torx

bolts .
(1) Pretighten the bolts with a compressed-air 6.2 Slide the Nilos ring onto the
screwdriver in a crosswise pattern. wheel shaft
(2) Firmly tighten the bolts using a torque
wrench.
Caution：When tightening the bolts, note the
tightening torque of 79 N·m.
6.3 Fit taper roller bearing on gear wheel side

to gear shaft by hand.
5.3 Check whether it is still possible to move

the internal gear in a rocking motion after
tightening the bolts.
If it is possible, continue with work step
6.If it is not,Remove the internal gear again
and replace it or remove from the housing all 6.4 Press taper roller bearing on gear wheel
the parts which have so far been installed side onto gear shaft using lever press and tool
and replace the housing. 1

Plunger of lever press, tool and gear shaft
Caution:The rocking motion of the internal must align vertically with no offset.
gear is important for being able to compensate
for the oscillations generated by the planetary
gears.
23
Caution ： Risk of accident and injury from
crushing. When pressing the taper roller 6.8 Place the taper roller bearing onto the seat
bearing together with the gear shaft, do not of the wheel shaft
place hands in area between plunger and tool.

6.5 Grease the taper roller bearing
6.9 Press the planet carrier side taper roller

bearing onto the wheel shaft.The punch of the
6.6 Place the wheel shaft on the press table so
hand lever press, tool and taper roller bearing
that the wheel studs point downwards. The
shall be positioned vertically to each other.
wheel shaft shall stand on a suitable sleeve
and the wheel studs shall be clear of the table.
Unclamp the housing from the assembly
fixture.
6.7Fit the housing perpendicularly onto the Caution ： Risk of accident and injury from
wheel shaft.The mating surface of the housing crushing. When pressing the taper roller
shall face upwards. bearing onto the wheel shaft, do not place
hands between the punch and the tool.
6.10 Clamp the housing in the assembly

fixture.
6.11 Check the wheel shaft for smooth
running.
（ 1 ） It shall be possible to move the wheel
24
shaft easily by hand. Caution：It shall be ensured that the greatest
（ 2 ） In order that the taper rollers can align possible contact area of the depth gauge is
themselves correctly in the bearing races, a resting on spacer.
soft head hammer should be used to tap at （3）Adjust the depth gauge to the surface
various points around the wheel shaft. of the wheel shaft.
If the taper rollers are correctly aligned,
continue with work step 7.If they are not ，
Remove the wheel shaft again. Check both
bearings (wheel shaft side and planet carrier
side) for any damage which may have
occurred during the press fitting procedure.If
damage is found, remove the bearings and
（4）In the position, zero the depth gauge.
replace with new ones.
（5）Adjust the depth gauge to the surface of
the taper roller bearing
（6）Read off the difference between the
two settings.
（7）Repeat the measurement on the opposite
side.
Caution：The difference in measurement may
not exceed 0.5 mm.
7.Measuring and adjusting （8）Select spacers
Measuring the distance between the The thickness of the spacer set shall be
bearing surface of the taper roller bearing and the same as the difference between the
the surface of the wheel shaft measurements. A preloading on the wheel
（1）Rest spacer on the mating surface of shaft is then achieved. The preloading on the
the housing wheel shaft shall be between 3 and 7 N·m.
（2）Set the depth gauge onto spacer
8.Planet carrier
8.1 O-ring and press on planet carrier by hand.
25
8.2 Coat the toothing of the planet carrier and
8.5 Press the planet carrier into the wheel
the o-ring (103.180) with Klüberplex BEM
shaft .
34-132 (Klüber Lubrication)or Optimol White
Paste T.
（1）Make sure that the outer toothing of the

planet carrier and the inner toothing of the
8.3 Blow out the seating of the planet carrierin
wheel shaft mesh together correctly.
the housing with compressed air and fit the
（2）The punch of the hand lever press,
planet carrier.
tool and wheel shaft shall be positioned
vertically to each other without
deflection.
Clamp the housing in the assembly

fixture.
8.4 Place the housing on the press table so Caution：Risk of accident and injury from
that the wheel shaft is facing downwards. The crushing. When pressing in the planet carrier,
wheel shaft shall stand on a suitable sleeve do not place hands between the punch and the
and the wheel studs shall be clear of the table. tool.
8.6 Manually check the wheel shaft for

ease of movement in the Housing.It shall be
26
possible to turn the wheel shaft easily by hand.
9.2 Fit tool 14 to the wheel shaft and lock in
place with the screws
Tighten the grooved nut to a tightening
torque of 535 N · m.
9.Grooved nut
9.1 Fit the grooved nut to the wheel shaft.Fit
tool 2 to the grooved nut.Slightly tighten the
9.3 Remove tool 10 from the wheel shaft and
grooved nut with a compressed-air
check the wheel shaft for freedom of
screwdriver.
movement. The wheel shaft shall be easy to
turn in the housing
10.Wheel shaft drag torque

10.1 Check the drag torque on the wheel
shaft
（1）Attach tool 11 to the wheel shaft.
（2）Attach the torque wrench with transition
piece.
（3）Turn the wheel shaft with the torque
wrench.
（4）Read off the drag torque from the
torque wrench.
27
The drag torque shall be between 3 and 7 N
Notice：Use a chisel with a rounded edge only.
•m. If it is, continue with work step 10.2 ，If it is
A sharp edge may can damage the shoulder of
not，Correct the spacers as follows:
the slotted nut.
a.Drag torque too high ： The spacers
11.Cylindrical pin
chosen are too thick ， Remove parts back to
Insert the cylindrical pin into the wheel
work step 6 and redetermine the correct
shaft and drive it in.
spacer thicknesses。
b.Drag torque too low ： The spacers
chosen are too thin ， Remove parts back to
work step 5 and redetermine the correct
spacer thicknesses.
10.2 Drive the collar of the grooved nut by

means of a chisel (edge of the chisel must be
a radius of approx. 2.0 mm) into the recesses
of the planet carrier.
12. Protective cap

Fit the protective cap to the wheel shaft
and tap it lightly until it snaps into place.
28
13.3 Apply a pining by using tool 13 to
lock the planet gears
Notice ： The pining is done correcly as
soon as the axial play of the planet gear's
cylindrical roller bearings on the bolts has
dissappeared completely
13.Planetary gears ——(Parts Kit available)

13.1 Place a planet gear with pre-assembled
cylindrical roller bearing straight onto one of
the pins of the planet carrier
Notice ： Do not tilt the planet gear. Face

upwards the identification mark of the planet
gear.
13.2 Drive in the planet gear including the
cylindrical roller bearing until reaching the limit
stop. Use a hammer and a striking mandrel
(tool 12). Drive in the remaining two
pre-assembled planet gears by using the
same method.
29
2 Steering system
The steering system consists of steering device, steering axle and wheel assembly.
The steering device is composed of steering wheel assembly, steering tube device, locking handle
and the hydraulic diverter. See figure 2-1. Both the steering column and steering wheel can be put
forward and backward by an angle of 6° which can meet the requirements of different operators.
The steering axle assembly is composed of the steering axle, steering knuckle, steering hub,
steering wheels and steering cylinders. See figure 2-2.
Steering Device
It is composed of steering wheel, up shaft assembly, cardan joint, bottom shaft assembly,
bearing, circlip for shaft, bottom steering column, steering gear, priority valve, clamp lever and
hydraulic switch etc.; steering wheel can be put forward and backward as needed. See figure 2-1
Structure of Steering Device.
Figure 2.1 Structure of Steering Device
30
1.Steering wheel 4.Steering tube 5.Lock
2.Steering wheel nut 3.Washer
assembly assembly Handle
8.Lock sleeve
6.Snap ring 7.Lock shaft 9.Lock sleeve Ⅱ 10.Bolt
Ⅰ
11.Washer 12.Nut 13.Washer 14.Bolt 15.bush
20.Adjusting
16.Steering device 17.circlip 20 18.Dust cover 19.Bush
shim
21.Washer 22.Steering shaft
Steering axle
Housing 12 is fixed at the rear part of truck frame, and the acting force from ground is supported
by back-up bearing 11, 13. Nut 16 is used to adjust the preload of bearing 11, 13; hydraulic oil from
priority valve flows to cylinder component 17, pushes the movement of piston 21, piston 21 drives
the movement of rack 18, and axle seat assembly that meshed with rack 18 turns left and right,
which realizes the truck left/right movement, and the maximum turning angle is 86°.
Figure 2.2 Structure of the Steering Axle

1.Axle seat 7.Washer
2.gasket ring 3.grease seal 4.Bearing 5.rim 6.Bearing
assembly
14.End
8.Lock nut 9.Cover 10.Seal ring 11.Bearing 12.body case 13.Bearing
cover
17.Cylinder
15. O-ring 16.Nut 18.rack 19.seal ring 20.seal ring 21.Plunger
component
24.Combination 25.Outer
22.seal ring 23.Bolt
seal ring hexagonal plug
31
Use notice：
─ Cylinder leaks oil, check and replace seal ring 19, 20,22, and also check if the guide sleeve
and cylinder damage.
─ Check bearing 11, 13 and seal ring 10, 15 periodically; if damage, replace bearing and seal
ring timely; replace lubrication grease periodically.
─ Check bearing 4, 6 and oil seal 3 periodically; if damage, replace bearing and oil seal timely;
replace lubrication grease periodically.
─ Adjustment to preload of back-up bearing 11, 13: dismantle counterweight and its cover plate
etc., jack-up the rear part of the truck frame, screw down nut 16 until the kingpin cannot be
moved by hand, and then rotate nut 16 for 1/6～1/4 circles in opposite direction.
Condition Probable cause Corrective action
Damage or trouble of oil pump Replace

Failure to rotate
Priority valve is clogged or damaged. Clean or replace
steering wheel
Damaged hose or connector, block lines Replace or clean
Too low diverter valve pressure Adjust pressure
Air in oil lines. Exhaust air

Laborious operation
for steering The steering fails to turn to its natural position,
Replace spring flat
broken lock spring or insufficient spring pressure
Check piston for
Too much internal leakage in steering cylinder.
sealing
Oil is not sufficient in oil tank. Refill oil
Steering gear shaft/ rack damage Replace
Abnormal noise Hub bearing or supporting bearing damage Replace
Insufficient lubrication Fill lubricating grease
Suction piping or filter clogged. Clean or replace
Steering cylinder seal ring or pipelines or
Replace
connectors damage
Oil leakage
Seal ring of hub bearing or supporting bearing
Replace seal ring
damage
Steering angle of
left/right drive wheel Incorrect controller parameter Adjust
mismatching
32
Disassembly and installation of steering axle
Disassembly
1. Jack-up the forklift, support the truck frame with blocks and get the rear wheel off the ground.
2. Dismantle the rear cover plate.
3. Dismantle the truck frame and counterweight connected bolt(if the space for bolt removal is
not enough, first lift out the battery), and then lift out the counterweight.
4. Unscrew the rim nut, and dismantle the tire.
5. Unscrew the oil pipe joint that connects the steering cylinder, block the pipe with piston to
avoid oil outflow. Dismantle wire.
6. Dismantle rubber plate and truck frame connected bolt, and remove the rubber plate.
7. Dismantle steering axle and truck frame connected bolt, hoist out the steering axle backward.
8. To install the steering axle, reverse the order of disassembly, but pay attention to the
followings：
─ When installing tire, apply LOCTITE 222 glue to the thread, screw down the nut in three
times in symmetry cycle.
When installing the steering axle on the truck frame, get through the bolt from bottom to top, apply
LOCTITE 242 (222) LOXEAL to the final nut and thread meshing part, screw down the bolt in twice
33
3 Brake system
The braking system consists of the service brake and the parking brake. Service brake depresses
the brake pedal by foot while parking brake is braked by applying the brake handle. Both service
brake and parking brake function together with the wet brake located in the reduction gearbox.
Braking Schematic
Schematic diagram of drum brake braking principle
Service brake
Service brake system is composed of pedal mechanism, brake master pump, brake piping
and wet brake etc.
Pedal construction
Figure 3.1 Pedal construction
34
Steps for adjusting brake pedal:
1. Adjust the brake lamp switch to ensure that the point P on the pedal pad is 135mm ± 5mm
away from the front plate and tighten the bolt nuts;
2. Adjust the length of the brake master pump push rod so that the empty travel of point P in the
Q direction is 1mm~3mm, and lock the nuts;
3. When depressing the brake pedal 10～20mm gradually, the brake light switch is completely
connected, and release the foot to this state, brake light switch should be disconnected.
Brake master pump

The master pump contains a valve seat, check valve, return spring, primary cup, piston and
secondary cup, which are kept in place with stop washer and stop wire. The exterior of the cylinder
is protected from dust by means of a rubber dust cover. The piston is actuated through the push
rod by operation of the brake pedal. First, as the brake pedal, the push rod pushes the piston
forwards. The brake fluid in the cylinder flows back to the reserve tank through the return port until
the primary cup blocks up the return port. After the primary cup passes the return port, the brake
fluid in the cylinder is pressurized and opens the check valve, flowing through the brake lines to
the wheel cylinder. Thus, each wheel cylinder piston is forced outwards. This brings the brake
shoes into contact with the wheel drum and slows or stops the lift truck. Meanwhile, the cavity
caused behind the piston is filled with brake fluid led through the return port and inlet port to
lubricate the piston. When the brake pedal is released, the piston is forced back by the return
spring. At the same time, the brake fluid in each wheel cylinder is pressurized by the force of the
brake shoe return spring, thus returning into the master through the check valve. With the piston in
its original position, the fluid in the cylinder flows into the reserve tank through the return port. The
brake fluid in the brake lines and wheel cylinders has a residual pressure proportioned to the set
pressure of the check valve, which makes each wheel cylinder piston cup securely seated to
prevent oil leakage and eliminates of vapor lock developing when the lift truck is sharply broken.
35
Fig.3.2 Brake Master Pump
1.Lock nut 2.Push rod 3.Dust cover 4.Stop collar 5.Stop collar 6.Secondary cup
7.Piston 8.Primary cup 9.Spring 10.Check valve 11.Valve sea 12.Pump body
36
Parking brake
Parking brake is composed of handle, cable and wet disc etc. When to stop or park the forklift,
apply the hand brake to avoid the accidental move of the forklift. Generally, service brake is
adopted to brake the forklift during travelling, only when emergency brake is needed but the
service brake fails, then the hand brake is applied to stop the forklift.
When pulling the hand brake lever backward, cable shrinks. With the action of cable force, brake
rod 3 swings to the truck around the fulcrum and the other end of brake rod ejects the brake
cylinder, the clamping of friction plate generates frictional resistance thus prevents the tire rolling.
When pushing the hand brake lever forward(if there is button on the lever, it needs press this
button and meanwhile push the lever upward), brake rod 3 returns, with the action of spring, brake
cylinder piston shrinks, friction plates are loosened, then the frictional resistance disappears,
namely the parking brake force disappears.
1.Hand brake cable 2.Service brake oil pipe 3. Brake lever 4. Nut 5.Nut
Parking brake cable adjustment：

When pulling down the hand brake, braking force is insufficient, release nut 4, screw down nut 5 to
reduction gearbox direction, properly shorten the cable length between springs, after adjustment,
screw down nut 4.
When releasing hand brake, the forklift is still under the effect of parking brake force, release nut 5,
screw down nut 4 away from the reduction gearbox direction, properly lengthen the cable length
between springs, after adjustment, screw down nut 5.
Warning
 It is forbidden to substitute parking brake for service brake in travel, otherwise the parking
brake damages easily.
 Make sure braking force on left/right brake is equal when adjusting the parking brake cable.
37
Fault and adjustment of brake system
Condition Probable cause Corrective action
Oil leakage in brake lines Correct and replenish
Air in brake lines Bleed air.
Insufficient brake
Improper functioning of master cylinder Correct or replace
force
Clogged oil lines Clean
The friction sheet is worn or deformed Replace
Improper adjustment of the left and right

Adjust
brakes
Brake friction sheet is worn Replace

Unbalanced braking Eliminate air and
left and right, There is air or blockage in the brake line
cleaning
The forklift was
deflected to one Oil leakage of brake oil pipe Adjust and replace
side
The hydraulic cylinder piston leaks oil Replace
Parking brake cable length is improperly

Adjust
adjusted
·No free stroke of brake pedal Adjust
·Faulty piston cup Replace
·Weak or broken return springs Replace

Brake dragging
·Clogged master cylinder return port Clean
·Clogged oil lines Clean
Friction sheet deformation Replace
There is noise in the

The friction sheet is worn or deformed Replace
brake
38
4 Hydraulic system
Hydraulic system
Hydraulic system mainly consists hydraulic fuel tank, gear pump, priority valve, hydraulic
steering gear, control valve, steering cylinder, tilting cylinder, lift cylinders and hydraulic pipelines.
Schematic diagram of the hydraulic system
39
Main components of hydraulic system
Gear pump
TMG1 series hydraulic gear pump adopts backlash-free meshing, integral pump body, DU
bushing, powder metallurgy plate. It features in small pressure pulsation and low noise.
Major parameter：
Model: TMG1H20F2H6-R283D
Nominal displacement: 20 ml/r
Rated pressure : 20.6 MPa
Peak pressure : 22.6 MPa
Rated speed : 2000 r/min
Minimum rotative speed:500 r/min
Maximum speed of revolution:3000 r/min
Installation Instructions
– Before installation, make sure the rotation direction of gear pump can meet the system
requirement
– The coaxially between the gear pump axle and the motor axle must be less than 0.05mm,
– Connect the inlet and outlet connector, do not misconnect.
– Install the flanges and connectors. No bump ,scratch or burr, in case of oil or gas leakage and
noise-producing
– Avoid that there is no axial force or radial force on the gear pump axle. Install it smoothly
during the installation, no mounting or dismounting by force.
Operationand Maintenance
– Always follow the Instruction, never overload.
– Hydraulic oil requirement: summer, L-HM32 or similar viscosity hydraulic oil; winter & cold
storage, L-HV32 low temperature hydraulic oil;
– Starting for the first time, run without load to bleed the air in hydraulic system,until there is no
bubble.
– Keep the oil clean. Clean the oil tank and oil lines fully before refilling.
Inspect the oil cleanliness and strainers periodically, replace as necessary.
40
Fault and elimination：
Trouble Probable cause Corrective action
Low oil level in tank. Add oil to specified level.

No oil from oil
pump Clean oil line and tank. If oil is dirty,
Clogged suction pipe or strainer.
change.
Worn bearing damaged backup ring
Replace faulty parts.
and O-ring.
Readjust to specified pressure using
Maladjusted relief valve.
pressure gauge.
Low Retighten suction side pipe.
discharge
pressure on
oil pump. Add oil in oil tank.
Air in oil pump.
Check pump oil seal.
Do not operate pump until bubbles in

tank disappear.
Cavitation due to crushed suction Adjust or replace crushed hose and
hose or clogged strainer. clean strainer.
Air being sucked from loose suction
Retighten each joint.
side joint.
Replace with new oil having proper
Noisy oil
viscosity for temperature at which pump
pump Cavitation due to too high oil is to be operate.
viscosity.
To operate when oil temperature is
normal.
Bubbles in hydraulic oil. Determine cause of bubbles and remedy.

Faulty oil seal on pump, faulty
Oil leaking
O-ring or worn sliding surfaces on Replace faulty parts.
from oil pump
pump.
41
Hydraulic Steering Gear
Hydraulic steering, composed of servo valve and a pair of cycloid meshing pair, is a cycloid
hydraulic steering gear with rotating valve. It is flexible, effort-saving, reliable, owns less fault,
simple and compact structure, convenient layout, and achieves manual steering when the engine
stopped.
In the hydraulic steering gear, the spools, valve cover and body constitute the servo rotary valve,
which controls the oil flow; rotor and stator constitute cycloid meshing pair, plays a part in
measuring motor when the power steering that to ensure the oil quantity flowing into the fuel tank
and steering wheel angle is proportional and plays a part as a pump when manual steering;
linkage axle plays a part in transferring torque.
T A
LS
P B
Hydraulic Steering Gear parameter :
displacement（ml/r） 50
Sealed form of oil mouth O-ring seal
Note: The input torque shall not be greater than 1.4N.m.
Hydraulic Steering Gear common failures and troubleshooting measures
Fault Probable reason Phenomenon Corrective action
Combined part bolts

Retighten these bolts
loosen
Oil Combined face or journal
leakage Replace sealing ring
sealing ring damage
Gasket damage Replace gasket
Insufficient oil supply Turn steering wheel slowly is light

Check for oil pump work condition
from oil pump and turn fast is heavy.
Hard If there are bubbles in oil that give
steering out irregular noise when rotating Bleed the air in the system and
Air in the steering system
the steering wheel but the cylinder check for oil suction pipe leakage
stops-and-goes.
42
Fault Probable reason Phenomenon Corrective action
Oil level is lower than

Refill oil to specified position
specified position
oils are too viscous Use specified oil

Steering wheel is heavy when If the ball losses, install another
Ball check valve
turning fast or slowly, and no one. If the ball is blocked by dirt,
disorder.
pressure in steering system clean it.
The pressure of steering No load or light load steering is
Check out the reason, recover or
system is lower than work light, but much load steering is
improve system pressure
pressure heavy.
Steering wheel cannot return to the
Spring leaf broken Replace spring leaf
middle automatically
Dial pin or universal Pressure fluctuations increased
Replace dial pin or universal
driving shaft opening significantly, even worse ,cannot
Steering driving shaft
broken or deformed steer
failure
Teeth space engagement
Rotor or universal driving
Steering wheel rotates or moves between compact point teeth on
shaft opening broken or
from side to side freely universal driving shaft and on the
deformed
rotor.
No
Overlarge stator radial or Steer after misfire, steering wheel
human Replace stator
axial clearance turns but the cylinder keep still.
steering
Multiple unit valve
12
13
14
15
16
17
12
13
14
15
17 16
15
18
19
11
10
20 7 9
21 6
22 1,2,3 8
25
23
26 5
27 24 4
28
Multi-way valve connector

Hinged bolt tightening torque:
Thread size M10×1.5 M12×1.5 M16×1.5 M20×1.5 M22×1.5
Tightening 25~32 30~45 60~75 75~90 90~105
torque N m
43
Multi-way valve fault diagnosis and correction:

Loose of pressure-adjust screw. Readjusted and retighten.
Distorted or damaged
Pressure of relief valve is Replace.
pressure-adjust spring.
not steady or too low.
Worn or blocked relief valve core. Replace or clean.
Pump abated. Examine and repair pump.
Replace valve core and tilt
Fork tilt forward when Worn or damaged tilt lock valve.
lock valve as an assembly.
control lever is used
Broken tilting lock spring. Replace spring.
while engine is off.
Damaged tilt valve plunger O-ring. Replace O-ring.
Mast is unstable when Replace tilt relief valve
Malfunctioning tilt relief valve.
tilting forward. assembly.
Damaged or distorted
Replace spring.
reposition-spring.
Spool valve is not return Dirt exist between valve body and
Clean.
neutral position. spool valve.
Blocked control device. Adjusted.
Not coaxial parts at reposition Reinstall.，be coaxial
Damaged or distorted
Replace spring.
reposition-spring.
Spool valve is not return Dirt exist between valve body and
Clean.
neutral position. spool valve.
Blocked control device. Adjusted.
Not coaxial parts at reposition Reinstall.，be coaxial
Damaged O-ring. Replace.
Faulty seal of joint. Check and retighten.
Clean seal plate and retighten
Loose seal plate.
Leakage blots.
Loosed lock-nut of relief valve and
connect-nut between plate and Tighten.
plate.
Multi-way valve cannot Multi-way valve moves back and
Adjustment
move back and forth forth to adjust handle interference
44
Adjusting the pressure of the main relieve valve
The main relieve valve has been adjusted before leaving the factory, , it is not allowed to
adjust at will in general condition. Adjusting way is as follows:
(1) Park the truck on solid and smooth road, place in neutral, pull up the hand brake handle, tilt the
mast backwards to the end, and drop the fork to the ground. The vehicle power supply is turned off,
and the car key is removed.
(2) Open front soleplate, release the pressure mouth bolt of oil inlet pipeline in the multi-way valve,
and put in clean place. If hydraulic oil outflows, please protect the environment.
(3) Connect the pressure gauge. Notice:①Specification of gauge should be larger than 20Mpa.
②Taper thread at pressure mouth matches: Rc1/8R1/8; c. tightening torque is 20-22N•m.
(4) Start the forklift, place the mast in vertical, and the fork is 300mm from the ground.
(5) Read out the indication in the pressure gauge, and judge is the main safety valve of multi-way
valve is in normal scope.
2.0t~3.8t：18.5MPa±0.5 MPa
(6) If the pressure is not in the normal scope, please release the main safety valve locknut, and
adjust adjusting bolt.
If the indication is smaller than the normal scope, inner hexagon spanner the adjusting bolt in
clockwise (+) to increase main safety valve pressure.
If the indication is larger than normal scope, inner hexagon spanner the adjusting bolt in
counterclockwise (-) to decrease main safety valve pressure.
(7) Stable the pressure in normal scope for 30’s.
(8) Release pressure gauge, install the bolt, and the tightening torque is 20-22N•m. Drop the mast
to the ground and tilt backward to end.
(9) Retighten the tightening nut, and fix it on the front soleplate.
45
Steering Cylinder
Pressure oil from steering gear enters cylinder component 17, pushes the movement of piston 21,
piston drives rack 18 to move, rack 18 meshes with the gears of axle seat assembly 1, axle seat
assembly 1 moves left and right, thus realizes the forklift steering.
1.Axle seat 2.gasket 7.Washer

3.grease seal 4.Bearing 5.rim 6.Bearing
assembly ring
12.body 13.Bearin 14.End
8.Lock nut 9.Cover 10.Seal ring 11.Bearing
case g cover
17.Cylinder 19.seal 20.seal
15. O-ring 16.Nut 18.rack 21.Plunger
component ring ring
24.Combination 25.Outer
22.seal ring 23.Bolt
seal ring hexagonal plug
Remove the steering cylinder
1. Remove the steering bridge and the tires.
Attention:
 Unscrew the tubing joints at the left and right ends of the steering bridge and plug the
tubing opening to prevent oil from flowing out.
2. Remove potentiometer elements from steering bridge as shown below：
46
1
2
1 Bolt M4×35
2 Washer 4
3 5
4 6 3 Bracket
7
8 4 Nut M4
5 Screw M6×10
6 Washer 6
7 Potentiometer shaft
8 Nut M6
3. Unscrew nut 16, remove cover 14, sealing ring 15 and other components, remove shaft seat
assembly 1 and its bearing and sealing ring.
4. Remove the cylinder assembly 17 at the left and right ends of the cylinder, and remove the
sealing rings 19 and 20.
5. Remove tooth rack 18, unscrew bolt 23, and remove seal ring 22 and piston 21.
6. The disassembly order is reversed to the installation order, but the following are noted when
installation:
─ Rack 18 is in the relatively middle position of housing 12, and gears on the axle seat
assembly 1 correctly mesh with gears on rack 18.
─ Adjustment to the preload of back-up bearing11, 13: screw down nut 16 until the steering
main shaft cannot be moved by hand, rotate the nut 16 for 1/6～1/4 circles to the opposite
direction.
Fault diagnosis and analysis:
Fault Probable cause Correcting measures
The steering bridge makes an Gear wear Replace
abnormal noise Improper gear meshing Adjustment
Deviate to one side when Adjust the gear bar mounting
Steering wheel returns but the
mounting gears position
steering wheels deviate to one
Oil circuit blocking on the other Check, adjust, or replace it
side
side of wheel deviation
Oil leak or oil intermingle due Replace
to piston damage
The oil road was blocked Check, adjust, or replace it
The gear is damaged and Replace
When you turn the steering
deformed
wheel, the wheels don't turn
The gears were improperly Adjustment
engaged and stuck
The oil pressure is too low Adjust the oil pressure control
valve
Steering cylinder seal ring Replace
damage or pipeline or
Oil leak connector damage
Seal ring on back-up bearing
Replace the seal ring
or cylinder damage
47
5 Lifting system
The lifting system is mast, fork carriage, forks, load bracket, chain, lift cylinder, tilt cylinder and
pipeline. It is forklift truck work equipment, which performs loading and unloading. There are three
types for the fitted mast: duplex wide view mast, duplex full free lift mast and triplex full free lift
mast.
Mast type Height of the basic mast The height of optional mast
Wide view duplex mast 3.0 m 2.5 m ~4.5 m
Full free lifting duplex mast 3.0 m 2.5 m ~4.0 m
Full free lifting triplex mast 4.5 m 4.0 m ~6.5m
Figure 5-1 Vision of duplex mast
1.Outer mast 2.Inner mast 3.Load backrest 4.Carriage 5.Fork

6.Chain 7.Lifting cylinder 8.Tilting cylinder
Figure 5-2 Duplex full free lift mast

1.Outer mast 2.Inner mast 3.Chain 4.Free lift cylinder 5.Carriage
6.Fork 7.Lifting cylinder 8.Load backrest 9.Tilting cylinder
48
Figure 5-3 triplex full free lift mast
1.Outer 2.Middle 3.Inner mast 4.Front cylinder 5.Free lift cylinder 6.Carriage
mast mast chain
7.Fork 8.Chain 9.Lifting 10.Load backrest 11.Tilting cylinder
cylinder
Data
Inspection and adjustment
position Assy clearance Repair clearance
Mast to lift roller mm 0.1～0.8 0.2～1.0
gasket mm 0.5 / 1.0 / 2.0
Mast to support guide plate mm 0.1～0.8 0.2～1.0
gasket mm 0.5 / 1.0 / 2.0

Inner mast to carriage side
mm 0.1～0.6 0.2～1.0
roller
gasket mm 0.5 / 1.0 / 1.5
Lift chain deflection mm 25～30
Tightening torque of main components

position Tightening torque(N m)
Bearing covers of mast to drive
89～118（M14）
axle
Lock nuts of Tilting cylinder 89～118（M8）
Lifting cylinder bolt(head) 76～107（M12）
Lifting cylinder bolt（bottom） 22～29（M8）

Fixxing bolt of lifting cylinder （ U
14～18（M8）
type）
49
Trouble shooting and corrective action
Fault Probable cause Corrective action
Tilting cylinder and seal ring abraded Replace piston seal ring or tilting
Fork carriage or mast excessively cylinder.
tilts automaticly The valve control rod spring of multi-way valve
Replace
disorder
Fork carriage raises up piston jamming or piston rodbends Replace the damage parts.
and down
sluggishly. Too much dirt is accumulated in the cylinder. Clear
Adjust clearance between channel
Carriage assembly adjustimproperly
steel rail and side roller.
Insufficient clearance between rollers
Adjust clearance of rollers.
Fork carriage is lifted and inner and outer mast
or lowered Biting foreign materials between moving part. Remove foreign materials.
unsmoothly.
Apply grease on contact surfaces of
Insufficient lubrication.
sliding parts.（butter）
Inner mast deflection or carriage bends Repair or replace.
Forks are lifted Adjust lifting chains of both sides to
Improper adjustment of lifting chains
unevenly the same tightness
Grease stiffened or rollers get stuck by
Lifting roller cannot Clean and lubricate the rollers.
accumulated dirt
rotate
Improperly adjustment of lifting roller. Adjust.
Insufficient lubrication. Lubricate.

Side rollers on fork carriage adjust improperly. It
Adjust the rollers and side rolling
strikes the mast channel steel, when the
Too much noise on the adjusting gaskets
mast extended mast lowering.
By adjusting shims and rubber pad,
Rubber pad on lower of outer mast is out of work piston rod will touch the bottom of
for container forklift truck. cylinder body after inner mast is in
touch with rubber pad.
Excessive wear occurs between the oil pump Replace the worn parts or the oil
body and gears, causing too much clearance. pump.
The piston Yx-ring of lifting cylinder has been
Replace Yx-ring.
worn, resulting in inner leakage.
Springs of the multi-way valve and relief valve
Replace with a new spring
disorder
Excessive wearing of the hydraulic control valve
Replace
occurs, resulting in excessive oil leakage.
Insufficient lifting power Oil leaks occur between the hydraulic control After regrinding, reassemble and
or unable to lift
valve sections. rescrew the bolts in order
Tighten the joint nuts and check for
hydraulic pipeline leakage
damage of seal and connecting nuts
Change the faulty hydraulic oil or
High hydraulic oil temperature, low oil stop to reduce the oil flow, and
Viscosity and insufficient oil flow check for the reason of high oil
temperature trouble.
Overloaded Observe the lifting capacity limit.
50
Tilting cylinder
The pressure oil from the multi-way valve flows into the tilting cylinder and pushes the piston rod to
extend or shrink to achieve the mast forward or backward tilt.
Mast type Wide view duplex mast Full free lifting duplex Full free lifting triplex
mast mast
Mast forward / back 7°/6° 7°/6° 3.5°/5°
Structure of the tilting oil cylinder
1.grease 8.scraper
15.piston
cup seal
2.spherical 9.guide 16.seal
bearing sleeve ring
10.U-shaped
3.bolt 17.rider ring
seal ring
11.step
4.washer 18.nut
seal
5.nut 12.O-ring 19.cylinder
6.earring 13.O-ring 20.pin
7.piston 21.spacer
14.O-ring
rod bush
Tilting cylinder Removing and installing:

1. The mast is backward. Lower down the fork carriage thoroughly
2. Fix the outer mast with steel wire of crane. Prevent the mast falling after disassembling the
cylinders.
3. Screw out the bolts from the outer mast and pull out the pin.
4. Dismantle front baseplate, dismantle the pipeline connector on the tilt cylinder and the
connecting part with the truck frame, then take out the tilt cylinder.
5. Follow the reverse sequences of disassembly to install the cylinder. After installment, add
lubricating grease to the oil cups and earring 6 at the pin.
51
Caution
Pay attention to the following notes when disassembling the tilting cylinder.
 Fix the outer mast with steel wire of crane. Prevent the mast falling after
disassembling the cylinders.
 Keep away from the truck. Never stand on the fork carriage when it’s fitted with forks.
Disassembly of tilting cylinder parts

1. Retain the tilting cylinder with a jaw vice.
2. Drain out the remaining fluid in the cylinder by way of pulling the piston rod back and forth
when both inlets and outlets are open.
3. Screw out guide sleeve 9, pull out the piston rod 7 and its piston, seal ring out of the cylinder
19 through earring 6.
4. Unscrew earring bolt 3 and unscrew earring 6.
a) Pull out pin 20, unscrew nut 18, remove the guide ring, sealing ring, and piston.
Caution:
The removed dust ring and sealing ring must be replaced and shall not be reused。
Inspections on Key Components

– Check for deformation and the scratch and corrosion of the inwall. If the cylinder is badly
damaged or severely deformed, replace a new one. If the scratch or corrosion is not that
serious, polish it with”00”abrasive paper and lubrication oil.
– Check for the deformation of the piston rod and see if it is dent or with pocking marks and
corrosion.
– Light scars on the internal surface of the guide sleeve donot impact its performance. But if the
unilateral abrasion loss reaches 0.2mm ～ 0.3mm, the seal rings fails to function. Replace
timely.
– Check for the scars, cracks on the piston and check if the seal groove is damaged or not.
Keep the fit clearance of cylinder and pistion between 0.10mm ～ 0.15mm. The maximum
clearance should not exceed 0.2mm. Otherwise replace the piston.
– If any seal ring is found overworn, aged or scratched or flaw lip, replace them timely.
Installation and adjustment of tilting cylinder

– Clean up every part with gasoline and dry up with compressed air before installation. Smear
some hydraulic fluid on the cylinder inwall, piston and piston rod surfaces and the surfaces of
seals. (Hydraulic fluid should be some type as the working oil.)
– Follow the reverse sequences of the decomposition to assemble the cylinder. Keep an eye on
the installing direction of the seals. When the lip of seal ring passes through the inlet an outlet,
52
press it gently with a smooth pole, in case the chamfer edge of the inlet and outlet lip
damages the lip.
– After the piston is put in the cylinder, the movement in a whole stroke should be smooth and
no obstruction and not jammed.
Inspection and adjustment of the mast tilting angles.

– Keep the truck fully loaded and the mast in a vertical direction.。
– Lift the forks 300～500mm off the ground. Leave the range quadrant on the tangent plane
of the inner mast and read the angle.
– Tilt the mast forward to the end. Value of the quadrant angle is the forward tilting angle. Tilt the
mast backward to the end. Value of the quadrant angle is the backward tilting angle.
– If the angle is big or small, turn the earring on the top of the piston to reset and fasten with
bolts and nuts.
53
Lifting Cylinder
Pull backward the lift lever, pressure oil from control valve or electronic control lift manifold block
enters into the lower end of lift cylinder, pushes the piston rod to extend upward, thus drives the lift
of mast and fork carriage. Push forward the lowering lever, pressure oil from the lower end of
cylinder returns to oil tank through speed limit valve. The mast drops under gravity.Control the
mast drop speed by limiting the flow of the speed limit valve.
Structure of lifting cylinder:
2 7
3 8
5 9
4 10
11
12
13
16
14
15
2.Dustproof 5.Guide 6.Cylinder

1.Piston rod 3.Seal ring 4.O-ring
ring sleeve body
7.Steel cable 12.Valve
8. Piston 9. Support ring 10.Guard ring 11.Seal ring
bafflering pocket
13.Steel cable 14.Nipple
15.O-ring 16.Sleeve
baffle ring component
54
Disassembly of lifting cylinder with”00”abrasive paper and lubrication oil.
Operating procedures as follow: – Check for the deformation of the piston
– Tilt the mast forward to the end in order to rod and see if it is dent or with pocking
dismantle lift cylinder easily. marks and corrosion.
– Lower the lift cylinder to the end to – Light scars on the internal surface of the
compress the oil back to the tank. Close guide sleeve do not impact its
the electric switch. performance. But if the unilateral abrasion
– Dismantle the lower end rigid tube and loss reaches 0.2mm ～ 0.3mm, the seal
upper end hose of the lift cylinder. rings fails to function. Replace timely.
– Remove the cylinder fixed U bolt from the – Check for the scars, cracks on the piston
outer mast. and check if the seal groove is damaged
or not. Keep the fit clearance of cylinder
and piston between 0.10mm ～ 0.15mm.
The maximum clearance should not
exceed 0.2mm. Otherwise replace the
piston.
– If any seal ring is found over worn, aged
or scratched or flaw lip, replace them
timely.
– Dismantle the cylinder piston rod and
mast connected bolt. Installation and adjustment of tilting
cylinder
– Clean up every part with gasoline and dry
up with compressed air before installation.
Smear some hydraulic fluid on the
cylinder inwall, piston and piston rod
surfaces and the surfaces of seals.
(Hydraulic fluid should be some type as
the working oil.)
– Follow the reverse sequences of the
– Dismount the chain on the mast. decomposition to assemble the cylinder.
– Lift the inner mast with steel wire and take Keep an eye on the installing direction of
away the left and right lifting cylinders. the seals. When the lip of seal ring passes
through the inlet an outlet, press it gently
Remove the lifting cylinder parts with a smooth pole, in case the chamfer
1. Screw out the guide sleeve 5 with a edge of the inlet and outlet lip damages
hookwrench and take down scraper seal the lip.
and seal ring. – After the piston is put in the cylinder, the
2. Pull out piston rod 1 and its piston parts. movement in a whole stroke should be
3. Remove the steel cable baffle ring 13, smooth and no obstruction and not
valve pocket 12, seal ring 11 off the piston jammed.
8. – Conduct the exhaust and running tests
4. Dismantle nipple component 14 and seal after truck is assembled. Check for oil
ring 15 from the lift cylinder. leakage and the loosening bolts.
– Observe if the left/right lift cylinder stay in
Caution: the same level and lift synchronously, or
 The removed dust seal and sealing ring adjust the shims between the piston road
must be replaced and shall not be and inner mast support.
reused.
Mast Disassembly and
Inspections on Key Components Installation
– Check for deformation and the scratch
and corrosion of the inwall. If the cylinder
is badly damaged or severely deformed, 1. After screwing off the bolts from the middle
replace a new one. If the scratch or of the fork carriage and pulling out the fork
corrosion is not that serious, polish it locating pin, move forks to gap portion in
55
the middle of carriage bracket.
2. Tilt the mast forward and lower the forks

until they are off the fork carriage, then
back up the truck. 9. Remove nut bolts at both ends of outer
mast and drive axle connection.
Warning
 Keep the hands and feet off the forks.
Watch out when dismantling the forks.
Do not put hands for feet under the
forks or between the fork and carriage.
 Do not dismantle the fork from the
upper face of fork blade. Prevent any
damage caused by fork falling.
3. Tie up the carriage assy with steel wire

and crane it with lifting equipment. 10. Disassemble the mast assy.
4. Pull out the chain cotter pin attached to the 11. Following the revers sequences of
fork carriage, Screw out the nuts on ends disassembly to install the mast. Fork
of the chain and dismantle the chain from installation method : Forks directly face the
the carriage assy. truck and place on the ground, lower the
fork carriage to the lowest, truck travels
forward slowly, aims at the fork slot with
beam and gap on the fork carriage, fully lift
the fork carriage, adjust the fork position
and lock it.
Warning
 Forks, carriage and mast are heavy parts
and special care should be taken during
5. Dismount the carriage assembly from the
disassembly and installation.
inner mast.
6. Remove the rubber hose connector that
enters the speed limit valve of lift cylinder, Spare Parts Disassembly
and remove the oil return hose on the
upper end of left/right lift cylinder. Warning
7. Lift the inner and outer masts with steel  Be careful when disassembling the
wire mast as it is quite heavy.
8. Unscrew the bolts, pull out the pin shaft,
remove the bearing, and separate the tilt
Disassemble the lifting cylinder
cylinder from the outer mast.
– Place the mast flat on the ground. Screw
out the bolts on the piston rod of lifting
cylinder and U bolts on the outer mast and
the fastening screws.
56
Disassemble the inner mast
Tie up the inner mast with steel wire. Slide out
the inner mast with a lifting equipment
Inspection
– Check for damage of the roller and roller
holder and other involved parts
– Replace the damaged parts as necessary.
Assembly and adjustment
Warning
 Be careful when assembling as the
– Slide the inner mast and disassemble the inner and outer masts are quite
heavy.
lifting cylinder.
Mount the roller
Take out the rollers. Install the inner mast into the outer mast and
– Stretch out the inner mast from the bottom. mount the roller securely.。
Remove the retainer rings from the
composite rollers and take away the side
rollers. Prepare twoplectanes with about
10mm thickness and diameter at Φ53 and
Φ58 respectively. Cover the roller holder
with the two plectanes. Dismount the
composite rollers and main rollers with a
bearing puller.
Adjust the clearance between the roller and
– If there is no bearing puller, unclench the
mast channel.
rollers carefully. (even unclenching power for
– Name the distance between the rollers on
all directions). Otherwise, the rollers would inner mast and outer mast as L. And adjust
be damaged. as follow.
“L” dimension Unit：mm
Truck model
Class Ⅱ
Class Ⅲ
Max lifting 1t～
3Ton
2.5Ton
Height mm
2500～3300 368 328
3600 388 348
4000 418 378
4500 443 403
57
– Adjust the clearance A of left and right side
evenly with a thin washer and make it
0.1mm～0.6mm.
– Keep the clearance of rolling channel flange
within 0.8mm ～ 1mm. Do not adjust the
clearance. If it is over worn, replace the
rollers.
– Smear some lubricating grease on the
connecting surfaces of inner and outer
mast and also on the rollers and channel
rail. But in some areas with strong wind
and sand, carefully decide whether to
smear grease or not. Avoid the sand
sticking on the surfaces.
Clearance between the guide plate and mast

channel.
– Adjust the clearance B between guide plate
and inner mast column with a thin washer and
make it within 0.5mm ～ 1mm. Thin washer
might not be wanted as necessary. The
thickness of the washer should be around
0.2m.
Smear a layer of lubricating grease on the

guide plate and assemble the mast and lifting
cylinder on the forklift truck. Connect the oil
return tube and the high pressure tube.
58
Assemble the left and right cylinders and
adjust the cylinder position.
– Install the left and right cylinders into the
mast. Insert the locating pin to the location
hole which is on the bottom beam of the
outer mast.
– Set the upper end of the piston rod into
the cylinder holder of the inner mast.
Make all directions evenly positioned. If
there is height difference on left and right
sides, apply a washer between the
cylinder holder hole and the upper end of
the piston rod and adjust. Tighten the
bolts connecting the piston rod and the
mast.
Adjust the clearance of rollers on the fork
Adjust the lifting chain carriage assy
Install the fork carriage into the inner mast and – Measure the distance A between the two
channels of the inner mast. Collect the
mount the chain. Screw two bolts on each side
value on the top, central part, central
of the chain. Make the mast in a vertical beam of the inner mast and the bottom
direction and lower down to the end. Adjust the respectively.
nuts on the bottom of the chain and make the – Measure the space from left and right side
lower end of the fork carriage is about 74mm B、Bˊ、B" of rollers on fork carriage and
side roller of the composite roller
off the ground.
respectively.
– Calculate the difference values between A
and B, A and Bˊ, A and B" respectively.
Each difference value is the clearance
between the roller and inner mast
channel.
Evenly adjust the washers of each side roller
on left and right. Adjust the clearance to the
following range.
A-B = 0.2 mm～1mm
In order to adjust the tension of the chain,
A-B' = 0.1mm～0.8mm
lower the lifting cylinder until the forks is on the
ground. Adjust the chain nut (three nuts at A-B" = 0.1mm～0.8mm
each end) till length of C reaches to the rated
value when the finger presses the central part
of chain.
The length of “C” is around 25mm~30mm.
59
Thin adjusting washer：0.5mm、1mm。
– Use equal quantity of washers on left and
right sides.
– After the clearance is set. Slide the fork
carriage on the inner mast upward and
downward. Check if it is smoothly
operated.
60
6 Electrical system
The electrical system consists of the motor, controller, DC-DC converter, fuse, battery, lamp, wiring
harness, etc
AC motor
Parameters of motor
Rated Rated Rated Rated Freque
Insulatio Service
Type of work Model power voltage current speed ncy Phas
n grade time
kW V A r/min Hz e
Pulling motor
HPQ4.75 S2-60
（D4Electronic 4.75 55 69 1975 H 68.5 3
-80HC min
control models）
Pulling motor
YDQ5-4- S2-60
（D6 Electronic 5 53 77 2845 H 96..6 3
4820 min
control models）
YDB15-4 S3-15
Oil pump motor 15 53 223 2120 H 3
-4823 %
Caution
 AC motor has no commutator or brush, and is maintenance-free. But carry out daily
check and dedusting.
AC Motor maintenance
1. Motor must be maintained well so as to guarantee safety work and extend service life.
2. Motor installation and each fastener should be reliable.
3. Power cable should be correctly and firmly connected, no protrusion, no oil stain on the
insulation part, and keep dry.
4. Idle motion should be quick.
5. If there is any abnormal phenomenon, stop immediately, such as overheating or abnormal
noise. Operate until malfunction is corrected.
6. Do not disassemble the motor arbitrarily, follow the rules of Caution of Motor Disassembling;
7. Clean the surface of motor regularly, replace the grease of the motor bearing annually(working
temperature of grease is -40℃~+200℃)
8. Washing the motor case with high pressure liquid is strictly prohibited, in case of case
deformation.
9. To protect the motor shift, do not remove the motor by putting ropes on motor shift, during the
disassembling and assembling process.
Caution of AC motor disassembling：

1. Be careful of the outer coder, no strike and protect the connector of both signal wire. Do not
knock against coder gear when disassembling and inspecting the coder. Clear the gear before
assembling
61
2. Clear rust and other stain fully before assembling.
3. No part damages during the assembling
4. Wire connection should be correct and secure. No cutting-edge protrusion, no stain on
insulation, and keep dry
5. The motor rotor can rotate easily by hands.
Common fault and corrections:

Inspect the voltage of battery, switch, wire line, contact
Power failure terminal, motor connect terminal. Find out the causes and
correct
Check for the reason of fuse burnout and correct. Reinstall
Fuse burnout
a new fuse according to the motor capacity
Check for the connection of control circuit according to
Faulty connection of control circuit
electric schematic. find out the causes and correct
Inspect the coil by using multimeter, tramegger or indicator
Stator or rotor coil open circuit lights. If there is an open circuit, find out the open place
and reconnect.
Check for equilibrium of motor there phases, Check for
Short circuit or earth connection of
Motor fails earth connection of coil, find out the disorder place and
stator coil phases
to start correct
Recalculate the load, select the proper motor or lighten the
Overloaded or mechanical part gets
load, check if mechanical transmission mechanism gets
stuck
stuck and correct
Improper thermorelay or thermorelay
Select proper thermorelay and readjust according to motor
is adjusted small, or overflow relay is
rated electric current
adjusted small
Faulty connection of motor Δ to Ｙ,
causing the motor fail to start on Reconnect the motor according to the motor nameplate
heavy load
Recheck the head or tail port of stator coil, connect
Faulty connection of stator coil
correctly
Inspect the power line, motor connect terminal, fuse,
Starts on single phase switch, contact terminal, find out the disconnection and
correct
The sectional area of fuse is too
Rematch and replace a new fuse.
Fuse was small
burned A coil phase is shorten to the ground Disassemble and repair the motor coil
out, when
Overloaded or mechanical part gets Adjust the load to the rate value, and eliminate the
motor
stuck mechanical failure
starts
shorten circuit of connecting wires
Repair after finding out the shorten place
between battery and motor
The starting resistance of motor with Eliminate the shorted circuit or increase the starting
coils rotor is too small or shorted. resistance
62
Check for the voltage of power, ask power supply
Lower voltage of power
department for helps
Inspect the voltage of power, contactor, switch, one phase
Phase lack of power
disconnection ,find out the causes and correct
The head or tail port of motor is Power DC to the stator coil inspects the polarity of the coil.
misconnected or inner connection of Check the correct connection of the head or tail port of
Motor fails coil connects contrary coil, and reconnect.
to start Misconnect △to Y connection Change Y to △connection
and gives
Find out the open circuit place and repair, check the
out
contact condition of brush of coil rotor and collecting ring.
buzzing Coil of stator or rotor is shorted
Check open circuit of the staring resistance or big
noise after
resistance
power on
Overloaded or mechanical part got Release the load, eliminate the mechanical failure or
stuck replace the motor.
Tight installation or hard grease Reinstall, and replace the grease.
When polarity changing and
Select proper coil type and pitch. Lathe the rotor diameter
rewinding, the match of wedge and
improperly, Recalculate the parameters of coil.
groove select improperly
Misconnection of power wire and
Eliminate the fault connection, motor shell should connect
ground wire. Badly earth connection
to the protective ground wire securely.
of the motor
Charged
Wet coil and insulation aging Dry the coil and replace the insulation aged coil.
motor
shell Lead wire and terminal box interfere
Pack up or replace the extension line.
with the ground
Top end of the coil is connected to Find out the grounded place, pack up, insulate and paint,
the ground and add insulator into the end cover.
When the Cage rotor broken bar or break
Check broken bar or break welding place, and repair.
motor runs welding
with or One phase brush of cage rotor is Adjust the stress of brush, increase the contact surface of
without poor contacted brush and collecting ring.
load, the Collecting ring short circuiting device
current of cage rotor type motor contact Inspect and maintain or replace short circuiting device.
keep poorly
unsteadily One phase open circuit of coiled
Find out the open place and correct.
rotor
63
Instrument
The instrument installation position is located in the upper right corner of the
instrument rack.
Instrument interface
64
Function of the button
Basic function
Icon Name Function
Move the cursor up, or increase the selected number
Up key
by 1; Switch S mode (slow speed mode) in the main
interface;
Move the Move the cursor left; Switch P mode in the main
key left interface;
Move right Move the cursor right; Switch E mode on the main
key screen
Move the cursor down, or decrease the selected
Down key
number by 1;
Cancel the current content or return to the previous
Cancel key
menu;
No function in the main interface;
Confirm the current operation;
Enter key
Enter the menu mode in the main interface;
Body control shortcut keys

Icon Name Function
F1 Function key 1
F2 Function key 2 Drive the external relay,

the specific function
F3 Function key 3
according to the site use
F4 Function key 4 situation
F5 Function key 5
Combination key
Icon Name Function
Up key On the home screen, press Up and Down to view
the instrument information, including the

Down key instrument number, SIM card number, and
software version
65
Inmotion Controller
Summarize
International advanced closed-loop system and the advanced control technology are
integrated in the controller. Large screen clearly displays common messages as “power”, “speed”,
“total running hours”, “drive working time”, “lifting working time” and etc. Faults displayed by codes
improve the efficiency of maintenance. The peripheral components can also be detected by the
meter, and the functions of the handheld unit can be realized by the meter.
Actuating motor
The drive motor adopts a three-phase AC variable frequency motor with high power conversion
rate, no commutator and brush, and realizes maintenance-free.
Lift motor
The lifting motor adopts a three-phase AC variable frequency motor with high power conversion
rate, no commutator and brush, and realizes maintenance-free.
Safety & protection features
①Polarity protection of the battery
②Circuit connection protection
③All inputs are protected against connections errors
④Current overload protection
⑤It have detecting element, limit peak current
⑥Thermal protection
If the controller temperature exceeds 85°C, thermal protection will work; the maximum current
reduces in proportion to the thermal increase. Once the temperature exceeds 115°C, it will shut
down automatically and give a warning.
If the motor temperature exceeds 145°C, thermal protection will work; the maximum current
reduces in proportion to the thermal increase. Once the temperature exceeds 165°C, it will shut
down automatically and give a warning.
⑦Battery overdischarge protection
When the capacity of battery is low, there will be a buzzer alarm, the maximum speed and current
reduce greatly.
⑧External guard protection
Electric control is hermetical which can protect against dust and liquid into the body.
⑨Starting order protection
The drive request must be issued after the electric lock switch is closed and the vehicle is started.
⑩When electrical elements are damaged, the control can protect itself to avoid more
damage.
Operational features
①Close-loop control system make the vehicle speed follow accelerator, which make control
easily whether low speed or high speed.
②Two speeds and acceleration designs are available for more work situations.
③Regeneration technology makes direction change more smoothly.
④Three regenerative braking mode:
A. Regenerative brake from accelerator pedal release partly.
B. Regenerative brake from direction reverse
C. Regenerative brake from traveling downhill
Besides increasing driving security, it can recycle parts of electric energy, and prolong work hours
of every shift.
⑤Speed control during traveling downhill: motor speed lies on accelerator. If motor speed
exceeds the setting value of accelerator, the controller will brake automatically, which gives
an optimal protection of ramp.
Notice
– Maintain electric control ， must first cut off electrical source ， then hold 10-100ohmic
resistance join controller anode and cathode，release residual voltage in the capacitor, or else
66
you may meet tip-and-run danger.
– Magnetic and radiation have some effect to inverter，long time effect may mangle controller, So need
apart form magnetic and radiation.
Fault code of the controller

The controller is used together with the instrument. The fault code of the controller is shown in the
instrument section。
67
Fault code of the controller: The controller is used together with the instrument. The fault code
of the controller is shown in the instrument section.
Serial error
Analysis description Solution
number code
1 10 Operation sequence fault Reset all the traction controller switch
2 13 HPG controller EEPROM KO Reset key
Incorrect start Accelerator pedal switch Release pedal switch
3 20
active before key on
Incorrect start Forward switch or reverse Turn off the direction switch
4 21
switch active before key on
Forward switch and reverse switch Direction switch fault
5 22
active at the same time
6 23 Throttle analog value out of range Throttle fault or analog need to be calibrated
7 24 Throttle analog fault Throttle fault or analog need to be calibrated
HPG controller battery voltage low need

8 30 HPG controller battery voltage low
charge
Traction controller CAN communication Check CAN wire of controller and display
9 31
fault
10 32 BDI level is too low Need charge
11 33 DC motor voltage high Reset key
12 34 CPU fault Reset key
More than one pump functions are active Reset all the pump speed mode switchs
13 35
at the same time
Incorrect start Tilt switch active before
14 36 Reset tilt switch
key on
Incorrect start Side switch active before
15 37 Reset side switch
key on
Incorrect start Attachment switch
16 38 Reset attachment switch
active before key on
Incorrect start Lift switch active before
17 39 Reset lift switch
key on
18 40 Lift analog value out of range Lift analog fault or need to be calibrated
19 43 Steer analog value out of range Steer analog fault or need to be calibrated
1、Vehicle speed is too high alarm

20 44 Traction controller speed protection
2、Traction motor encoder fault
1、Traction controller encoder fault
21 45 Traction controller encoder fault 2、Traction motor speed sensor connection
wire is open
1、HPG conrtoller sensor fault
22 49 DC motor operating current is zero
2、Pump motor Open
1、Check power wiring
23 51 Slave traction controller short
2、Controller enable before contactor pull
DC bus voltage of Slave traction Battery need charge
24 52
controller is low cut back
1、HPG conrtoller over current
25 53 HPG conrtoller over current
2、Pump motor fault
26 54 Slave traction controller over current 1、Vehicle overload or Mechanical clamping
68
Serial error
number code
2、Slave traction motor speed sensor fault
DC bus voltage of Slave traction DC bus voltage of Slave traction controller is
27 55
controller is high cut back high cut back
DC bus voltage of Slave traction DC bus voltage of Slave traction controller is
28 56 controller is high cut back(Hardware high cut back(Hardware monitoring)
monitoring)
29 57 Slave traction controller precharge failed Replace the pre charge resistance
1、Slave traction motor temperature is high

Slave traction motor temperature is high need cool
30 58
cut back 2、Slave traction motor temperature sensor
fault
Slave traction controller temperature is Slave traction controller temperature is high
31 59
high cut back need cool
Slave traction controller temperature Slave traction controller temperature sensor
32 60
sensor fault fault
33 61 Slave traction motor controller fault change the Slave traction motor encoder AB
34 62 HPG controller temperature high HPG controller temperature high need cool
1、Slave traction motor temperature sensor is
Slave traction motor tenperature sensor fault
35 63
fault 2、Slave traction motor temperature sensor
connection wire is open
Open drain of Slave traction output open Check the wire of open drain of Slave traction
36 64
or short output open or short
Slave traction Internal power supply Slave traction motor temperature sensor or
37 65 speed sensor connection wire is open
error
38 66 HPG controller battery low HPG controller battery low need charge
Slave traction motor encoder fault
39 67 Slave traction motor encoder fault Slave traction motor speed sensor connection
wire is open
40 74 HPG controller driver shorted HPG controller driver shorted
41 76 HPG controller coil shorted HPG controller coil shorted
42 78 HPG controller vacc not ok

HPG controller vacc not ok
43 79 HPG controller incorrect start HPG controller incorrect start

44 81 Traction controller temperature is low Traction controller temperature is low alarm
45 82 Traction controller temperature is high Traction controller temperature is high alarm
Traction controller temperature sensor Traction controller temperature sensor fault
46 83
fault
1、Traction motor temperature is low
47 84 Traction motor temperature is low
2、Traction motor temperature sensor is fault
1、Traction motor temperature is high
48 85 Traction motor temperature is high
49 86 Traction motor tenperature sensor fault 2、Traction motor temperature sensor
connection wire is open
69
Serial error
number code
1、Traction motor encoder fault
50 87 Traction motor encoder fault 2、Traction motor speed sensor connection
wire is open
DC bus voltage of traction controller is 1、DC bus voltage high
51 88
high 2、The ramp is too steep
DC bus voltage of traction controller is
52 89 Need to charge or check power wiring
low
The default value of the traction
53 90 Reset key
controller is updated
54 91 Traction drive limit Battery low vehicle speed limit
Open drain of traction output open or Check the wire of open drain of traction output
55 97
short open or short
56 98 Traction controller over current or short Check power wiring
1、Check power wiring
57 101 Traction controller short
2、Controller enable before contactor pull
Traction controller temperature is high need
Traction controller temperature is high cool
58 102
cut back
1、Traction motor temperature is high need

Traction motor temperature is high cut
59 103 cool
back
2、Traction motor temperature sensor fault
1、Vehicle overload or Mechanical clamping
60 104 Traction controller over current
2、Traction motor speed sensor fault
61 105 Traction controller precharge failed Replace the pre charge resistance
DC bus voltage of traction controller is

62 110 Battery need charge
low cut back
DC bus voltage of traction controller is DC bus voltage of traction controller is high cut
63 111
high cut back back
DC bus voltage of traction controller is DC bus voltage of traction controller is high cut
64 112
high cut back(Hardware monitoring) back(Hardware monitoring)
Traction controller Internal power supply Traction motor temperature sensor or speed
65 114
error sensor connection wire is open
66 121 Pump controller temperature is low Pump controller temperature is low alarm
67 122 Pump controller temperature is high Pump controller temperature is high alarm
68 123 Pump controller temperature sensor fault Pump controller temperature sensor fault
1、Pump motor temperature is low
69 124 Pump motor temperature is low
2、Pump motor temperature sensor fault
1、Pump motor temperature is high
70 125 Pump motor temperature is high
70
Serial error
number code

71 126 Pump motor temperature sensor fault 2、Pump motor temperature sensor connection
wire is open
1、Pump motor speed sensor fault

72 127 Pump controller encoder fault 2、Pump motor speed sensor connection wire
is open
DC bus voltage of pump controller is DC bus voltage of pump controller is high
73 128
high
74 129 DC bus voltage of pump controller is low Check power wiring
The default value of the pump controller
75 130 Reset key
is updated
76 132 Pump drive limit Battery voltage low need charge
Check the wire of open drain of pump output

77 137 Open drain of pump output open or short
open or short
78 138 Pump controller over current or short Check power wiring

79 141 Pump controller short
Pump controller temperature is high cut
80 142 Pump controller temperature is high alarm
back
Pump motor temperature is high cut
81 143 Pump motor temperature is high alarm
back
82 144 Pump controller current calibration error Reset key
83 145 Pump controller precharge failed Replace the pre charge resistance
84 148 BMS fault, Parking BMS fault，Check the battery
85 149 BMS secondary fault
DC bus voltage of pump controller is low DC bus voltage of pump controller is low cut
86 150
cut back back
DC bus voltage of pump controller is DC bus voltage of pump controller is high cut
87 151
high cut back back
DC bus voltage of pump controller is DC bus voltage of pump controller is high cut
88 152
high cut back(Hardware monitoring) back(Hardware monitoring)
1、Reset key
89 153 Pump controller CPU fault 2、Pump motor temperature sensor or speed
sensor connection wire is open
1、Pump speed is too high alarm
90 154 Pump controller speed control fault
2、Pump motor encoder fault
BMS Temperature Warning，Reduce
91 156 BMS fault，Check the battery
Power
92 157 BMS Temperature Protection, Parking BMS fault，Check the battery
93 158 BMS Voltage Warning, Reduce Power BMS fault，Check the battery
94 159 BMS Voltage Protection，Parking BMS fault，Check the battery
Check display and controller CAN
95 161 Display CAN fault
connection
71
Serial error
number code
96 163 BMS Current Warning，Reduce Power BMS fault，Check the battery
BMS Feedback Current Protection，
97 164 BMS fault，Check the battery
Parking
Seat switch off after a period of time, the
98 165 Reset direction switch
direction of the request to reset
99 168 BMS indicates Limit Current alarm BMS indicates Limit Current alarm
100 169 BMS indicates cutoff Current alarm BMS indicates cutoff Current alarm
DC bus voltage of Slave traction

101 170 Need to charge or check power wiring
controller is low
DC bus voltage of Slave traction 1、DC bus voltage high
102 171
controller is high 2、The ramp is too steep
The default value of the Slave traction
103 172 Reset key
controller is updated
1、Slave traction motor temperature is low
104 173 Slave traction motor temperature is low 2、Slave traction motor temperature sensor is
fault
1、Slave traction motor temperature is high
105 174 Slave traction motor temperature is high 2、Slave traction motor temperature sensor is
fault
Slave traction controller temperature is Slave traction controller temperature is low
106 176
low alarm
Slave traction controller temperature is Slave traction controller temperature is high
107 177
high alarm
1、Vehicle speed is too high alarm
108 178 Slave traction controller speed protection
2、Slave traction motor encoder fault
109 180 BMS indicates brake Current alarm BMS indicates brake Current alarm
110 181 BMS CAN Error BMS CAN Error
111 182 BMS Fault Check BMS
Open drain of slave traction output open Check the wire of open drain of slave traction
112 185
or short output open or short
113 200 Proportional valve error Proportional valve error
114 201 Steer controller short Check power wiring
Steer controller temperature is high cut
115 202 Steer controller temperature is high need cool
back
1、Steer motor temperature is high need cool
116 203 Steer motor temperature is high cut back
2、Steer motor temperature sensor fault
117 205 Steer controller precharge failed Replace the pre charge resistance
DC bus voltage of Steer controller is low
118 206 Battery need charge
cut back
DC bus voltage of Steer controller is high DC bus voltage of Steer controller is high cut
119 207
cut back back
1、Steer motor encoder fault
120 210 Steer motor encoder fault 2、Steer motor speed sensor connection wire is
open
72
Serial error
number code
1、Steer motor temperature sensor is fault
121 211 Steer motor tenperature sensor fault 2、Steer motor temperature sensor connection
wire is open
122 212 Steer controller temperature sensor fault Steer controller temperature sensor fault
Steer controller Internal power supply Steer motor temperature sensor or speed
123 214
Check the wire of open drain of Steer output
124 217 Open drain of Steer output open or short
open or short
1、Steer motor temperature is low
125 218 Steer motor temperature is low
1、Steer motor temperature is high
126 219 Steer motor temperature is high
127 220 Steer controller temperature is low Steer controller temperature is low alarm
128 221 Steer controller temperature is high Steer controller temperature is high alarm
129 222 DC bus voltage of Steer controller is high DC bus voltage high
130 223 DC bus voltage of Steer controller is low Need to charge or check power wiring
Steer Controller Internal power supply Steer motor temperature sensor or speed
131 234
CHECK CAN WIRE OPEN AND CAN SPEED
132 241 HPG CONTROLLER CAN BUS KO
RATE
134 242 HPG controller battery over voltage HPG controller battery over voltage
133 243 HPG controller battery over voltage HPG controller key shorted
134 244 HPG controller watchdog error HPG controller watchdog error
135 245 Attachment switch status error Reset attachment switch status
HPG controller waiting for main
136 246 Turn off the pump conctactor parameter
contactor
73
Electrical schematic diagram
1.5mm215A
1.5mm215A FU4
DC转换器警
后方
DC FU5 大向
闪灯光开关（示宽）灯灯开
HT 光制开开关
FU6 SA1-2
1.5mm215A 器动关关
方向开关（倒车）灯 SF1 JK1 JK2 前
SA2-2 开进
喇灯光开关（转向）
关蓝
叭 SA1-1
JDQ1 继光
电大
器灯
JDQ2 继
电
RC1 器
SB2 SB1 HH
EL1-3 H1-3 EL2-3 H2-3 EL1-2 H1-2 EL2-2 H2-2 EL1-1 EL2-1 H1-1 H2-1 HU H1-4 H2-4 HF EL3
扶喇电
手叭喇
喇按叭
叭钮
按
钮
左左右右左左右右左右左右倒倒左右警后前 24V 24V
前后前后前后前后前前倒倒车车制制灯大进电电
转转转转示示示示大大车车蜂蓝动动灯蓝源源
向向向向宽宽宽宽灯灯灯灯鸣光灯灯光 1 2
灯灯灯灯灯灯灯灯器灯灯
FU2
FU1
ACS 35P ACS 35P

80V 80V
FU7 FU9
GG
MM PM
FU8
ACS 23P
80V
SM
IDD-43C DISPLAY
YB
CPDS13/15/16/18/20-XCD4-SI and CPDS13/15/16/18/20-XCD6-SI Electrical system principle diagram
74
Maintenance record
Date Maintain content Maintainer
75

CPDS20 SM XC 1.3 X2.0t 3 W Electric Forklift Truck 202205 en NonCE

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XC Series

Three fulcrum lithium battery forklift CPDS13/15/16/18/20-XCD4-SI

HANGCHA GROUP CO., LTD.

© 05/2022 HANGCHA GROUP CO., LTD

Fig.1-1 Drive system diagram

Weight (no oil included) About 40Kg

Oil mass Each side is about 0.35L

Brake fluid DOT3 or DOT4

Stress of manipulation （6-8） MPa

Specifications for the overall product Data

Weight with oil up to 78 kg

Ambient temperature in operation -30 to +40°C

The impact sound of running Gear clearance is too big. Adjust

Oil level is low. Add oil

Too much worn of gear. Replace

The vehicle is not moving or

Type of noise Possible cause Rectification

Location Possible cause Rectification

Motor Worn radial shaft sealing ring If necessary replace motor

Location Possible cause Rectification

Defective connecting cable/loose

Inadequate brake response

Location Possible cause Rectification

Air in hydraulic system Bleed or top up brake fluid

Brake connection part

Oil plug and oil change of the reduction box

4.Oil discharge plug 5.Breather plug

Driving axle assemble removal and installation

 Plug brake tube openings to prevent oil from flowing out.

7. Lift out reduction box and motor

Reduction box removal (M6×1) connecting the gearbox body ○

D6 electric control model the gearbox cover ○

1. Remove the adapter ○

When reassembling, it is necessary to replace (M6×1) on the edge of gearbox cover 1.

bearings, O-rings, piston seals, oil seals,

2. Remove the hub cap ○

Caution: Be careful during disassembly to

6. Remove the carrier ○

3. Remove the locking plate ○

and then remove the rim assembly ○

7. Remove the snap ring○ 3 , thrust washer ○4

8. Remove needle roller bearing ○

13. Unscrew 8 hexagon socket head cap

springs should not be lost.

10. Remove the sun gear○

14. Remove 4 return springs ○

dynamic friction plates ○

11. Remove the snap ring ○

15. Remove the snap ring ○

12. Remove the driven gear ○

16. Remove the snap ring ○

18. Remove the two snap rings ○

When the ring gear ○ 3 is difficult to

19. Remove two hexagon socket head cap

20. Remove the brake lever ○

24. Remove the outer ring ○

roller bearing. Note: Do not damage the rolling

21. Remove the retaining ring ○

1.1 Remove the brake disc set from the