Operation and Maintenance manual

CBD15/18/20J-Li-S

Walkie Electric Pallet truck

Warning Please read this manual before using.

Warning Operator should have skillful ability to use this truck and

compliance safety rules.

20200612 V02
1
 Introduction

In order to meet the needs of the national environmental protection request,To reduce
industrial pollution and improve productivity,we develop new series of CBD15/18/20J-Li-S
walkie Electric Pallet truck on the basis of absorption of the advantages of domestic &
overseas battery Pallet truck,they are especially suitable for cargo loading and unloading,
handling, stacking, etc for food, bank, light textile, station, port, logistics and other
enterprises.

This manual describes the technical parameters of the Pallet truck, working principle and
operation, maintenance, and other aspects.It can help operators use the Pallet truck more
reasonable, make its maximum effect.

It is hoped that Operator strictly abide the regulations and the precautions in this manual
when using the Pallet truck.Carefully use them so that your Pallet truck can be in the best
working condition for long period of time to maximize it’s effectiveness. And create better
economic benefits.

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 Catalogue
1.The General Introduction ...................................................................................... 1
2.Proper usage ............................................................................................................ 2
3.Introduction of the product...................................................................................... 3
3.1Model overview ................................................................................................ 3
3.2Model parameters .......................................................................................... 3
4.Control Mechanism diagram ................................................................................ 5
5.Operating principle ................................................................................................ 6
5.1Running system ................................................................................................ 6
5.2Steering system ................................................................................................ 6
5.3 Brake structure and brake schematic diagram............................................. 6
5.4 Operating System ............................................................................................ 8
5.5 Electric System ................................................................................................ 8
5.6 Hydraulic principle ......................................................................................... 8
6. Electrical schematic diagram .............................................................................. 9
7. Hydraulic Scheme ................................................................................................ 10
8. Operating Instruction ......................................................................................... 11
8.1 Operation ....................................................................................................... 11
8.2Emergency reverse function ......................................................................... 13
8.3 The use of the horn and the reversing horn ............................................... 13
8.4 Battery capacity display ............................................................................... 13
8.5 operation ........................................................................................................ 13
9. Safety operation and matters needing attention .......................................... 14
9.1 Repair and Maintenance ............................................................................... 14
9.2 Routine Maintenance .................................................................................... 15
9.3 Professional Maintenance Manual ............................................................... 15
9.4 Battery maintenance, charging and maintenance. ..................................... 18
10. Safety Caution ..................................................................................................... 22
10.1 General rule ................................................................................................. 22
10.2 Storage and transportation ........................................................................ 22
10.3 Check before using ...................................................................................... 23
10.4Safety operation regulation ........................................................................ 23
11. Service Manual ................................................................................................... 27
11.1 Troubleshooting .......................................................................................... 27
11.2 Preparation before repair .......................................................................... 28
11.3Check the amount of hydraulic oil .............................................................. 28
11.4 Complete repair,the preparation before using ......................................... 28

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 1.The General Introduction

CBD15/18/20J-Li-S is a Walkie type electric pallet truck.It adopts the advanced structure
such as ring rod lifting system and DC controller,at same time it is equipped with high
quality motor, lithium battery and pump station motor.It has the characteristics of superior
performance, convenient operation, flexible steering, reliable braking, good dynamic
performance, less noise, less pollution and beautiful appearance.

This series truck is suitable for working on the smooth ground in warehouse,if not,please
don’t use it.

The service environment：

a. Altitude does not exceed 1200 meters

b. temperature not over +40℃，not under +5℃；

c. when environment temperature at +40℃,the relative humidity can’t over 50%，At

low temperature，allow big relative humidity;

d. ground need hard and flat;

e. It is forbidden to use this car in corrosive environment such as flammable and

explosive or acid base.
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 2.Proper usage

Please using the electric pallet truck accord to this specification.

This is a tramp type electric pallet truck with autonomous control , lifting and lowering
is controlled by the handle button.

Improper use can cause personal injury or machine damage.Operators or operating

companies need to ensure proper using, at the same time ensure that the truck is only
operated by trained and authorized personnel.

The Truck needs to be used on a firm ,flat ,intact surface and suitable surface ,The truck
is designed for indoor use at room temperature from+5°C to +40°C

Use under light load without using permanent barriers or pits ,It is forbidden to operate
on the slops .During Operation ,The goods must be placed approximately at the center of the
truck’s load center

Lifting or Carrying people is strictly prohibited ,If carried goods .The goods must fall on
the lifting point 。

It is prohibited to use this truck on lifting or loading ramps.

The rated capacity is marked on the capacity label or nameplate.And the operator must
pay attention to the warming signs and safty instructions.

Operating lighting must be at lest 50LUX

Modification

Any modification that may affect the truck rated capacity,stability,or safety operations must
be approved in advance by the Truck’s original manufacturer or Its authorized Manufacturer
or its successor.This includes the effects of changes such as Braking ,steering ,Visibility,and
the addition of removable accessories.

After the manufacturer or its successor approves the modification or change ,The capacity
name plate ,Label,identification marks,operation and maintenance manual must be changed
accordingly

Truck damage caused by not following Instruction will lose its warranty.

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 3.Introduction of the product

3.1Model overview

This specification is for CBD-J series 1.5T Walike type electric pallet truck（follow as truck）.

The type is“CBD15/18/20J-Li-S—15/18/20 load capacity is 1.5/1.8/2.0T” meet the

requirement of JB/T8452-1996《Battery forklift model establishment method》,“J”is model
code.

3.2Model parameters

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Mode CBD15J-Li-S CBD18J-Li-S CBD20J-Li-S
Drive type ELECTRIC ELECTRIC ELECTRIC
Manner of operation Walike Walike Walike
Load Capacity Q (t) 1.5 1.8 2.0
Load Centre c (mm) 600 600 600
Distance between fork backrest and front
x (mm) 944 944 944
wheel
Wheel Base y (mm) 1243 1243 1243
Service Weight（with battery） kg 142 144 146 149 142 144 146 149 146 149
Tire material PU PU PU
Driving wheel size Φ×w(mm) Φ210×70 Φ210×70 Φ210×70
Balance wheel size Φ×w(mm) Φ80×60 Φ80×60 Φ80×60
Qty of wheel，Front/Rear（x=driving wheel
1x/4 1x/4 1x/4
）
Tread b11 (mm) 400/535 400/535 400/535
Lifting Height h3 (mm) 200 200 200
The height of handle in the operation position h14 (mm) 740/1160 740/1160 740/1160
Lowered fork height h13 (mm) 85 85 85
Overall Length l1 (mm) 1603 1603 1603
Body Length l2 (mm) 453 453 453
b1/ b2
Overall Width 550/685 550/685 550/685
(mm)
Fork Size s/e/l (mm) 50/150/1150 50/150/1150 50/150/1150
Fork Width b5 (mm) 550/685 550/685 550/685
Ground clearance under mast m2 (mm) 35 35 35
Aisle width for pallets 1000*1200 crossways Ast (mm) 1804 1804 1804
Aisle width for pallets 1000*1200 lengthways Ast (mm) 1854 1854 1854
Turing Radius Wa (mm) 1398 1398 1398
Driving Speed，load/unload (km/h) 4.2/4.5 4.2/4.5 4.2/4.5
Maximum gradeability load/unload (%) 5/10 5/10 5/10
Brake Type Electromagnetic brake
Drive Motor (kW) 0.75 0.75 0.75
Lift Motor (kW) 0.8 0.8 0.8
Battery，according to DIN 43531/35/36
no no no
A,B,C,no
Battery voltage/rate capacity (V/Ah) 24/20 24/30 24/40 24/60 24/20 24/30 24/40 24/60 48/20 48/30
Battery Weight（±5%） (kg) 6 7.8 10.2 13.2 6 7.8 10.2 13.2 10.2 13.2
Type of drive control DC DC DC
Noise level (dB(A)) ≤70 ≤70 ≤70

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Steering type Manual steering system

4. Control Mechanism diagram

The Truck with battery as power producer and controlled by electrical and hydraulic, trucks
can do some actions like walking, turning, pallet fork lift, etc.

Operating mechanism diagram:

1.Falling knob 2.Driving button 3.Lifting button 4.Emergency Reverse Button

5.Horn 6.Electricity meter 7.Falling button 8.Tortoise speed button

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 5.Operating principle

5.1Running system

The truck is powered by a battery, which is realized by controlling the AC motor on the drive
wheel.The speed of walking is realized by frequency conversion control motor speed, which
is controlled by the accelerator.

5.2Steering system

The steering of the moving car is driven by the handle lever through the handle lever to

drive the drive motor to realize the steering.

5.3 Brake structure and brake schematic diagram.

Braking performance depends on road conditions and vehicle load conditions.

5.3.1The brake function can be activated by the following ways：

⚫ Turn the travel switch (2) to "0" position or release the switch to make truck brake until
it stops.
⚫ With the driving switch (2) moving directly from one driving direction to the opposite
direction, the vehicle regenerates the brake until it begins to move in the opposite
direction.
⚫ The handle moves up and down to the braking area (' B ') and the truck brakes.If the
handle is released, the handle automatically moves to the upper braking area (' B ') and
the truck start braking until it stops.
⚫ Emergency Reverse button (4) can prevent the operator will be squeezed, when the truck
is facing an obstacle in (' Fw) direction .The body touch Emergency reverse button and
the truck deceleates or starts to move to (BW) for a distance and then stops .If the handle is
in the operating area and the truck is not moving, please consider that this button is still
working.

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5.3.2Braking operation principle：

As follow picture：The brake constitute by magnetic yoke 6 ,magnet exciting coil,7 , the
spring 2, the brake disc 5,the armature 1, the gear sleeve 4, the mounting screw 3,And so
on .The brake is mounted on the end cap of the motor and the mounting screw is adjusted to the
specified air gap value.

When magnet exciting coil 7 for brake on power，The coil generates a magnetic field to
to attract the armature 1 to the yoke assembly 6, and the armature 1 is disengaged (released)
from the brake disc 5.At this time, the motor drive shaft is normally started and operated
with the brake disc 5.When the magnet exciting coil 7 is de-energized, the magnetic flux
disappears, the armature 1 is released, and the spring 2 is pressed against the armature 1,
and the friction plate on the brake disc is pressed to generate frictional force for braking
purposes.

Brake schematic

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5.4 Operating System

The main working body of a moving truck is the fork, which relies on a fork to carry the

pallet or cargo for transport and short distance transportation.The expansion of the cylinder

is realized by the control of the operating handle, and the pressure oil is provided by the

pumping station.

5.5 Electric System

The electrical system includes walking and operation control.The truck use DC electric
control assembly.

The meter has a battery indicator.When the battery power is too low, the electric meter will
cut off the starting control line of the oil pump motor. The truck can only walk and can’t lift
the fork,, and the prompt should be charged immediately.

The motor of oil pump is the dc motor for 5 minutes, so the pump motor is not suitable for
long running.That is, the lifting movement should have time interval, can not continuously
carry on, otherwise would make the motor heating, even burn.

Special note: when the truck is used for a long time, the starter of the oil pump motor may
fail, and it can't be broken after being sucked or closed.The latter is not throw control handle,
the oil pump motor is kept in the rotation, should immediately stop at this moment, to cut off
the power supply (unplug battery plug-in), make the oil pump motor stop running, and
promptly replace the starter.

5.6 Hydraulic principle

The oil pump motor drives the gear pump to provide hydraulic power,lifting oil cylinder is
responsible of fork’s lifting and lowering,The control of the lift oil road is controlled by the
buttons on the operating handle,The lifting action is controlled by a single action oil circuit
on the valve block.This model of the hydraulic system pressure can only be adjusted on the
valve block, has been debugging good, before they go out after they leaving our factory,If not
the our company after-sales personnel or professional maintenance personnel are strictly
forbidden to adjust themselves, so as to avoid safety accident.

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6.Electrical schematic diagram

9
7、Hydraulic Scheme

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 8.Operating Instruction

Before operation, please familiarize yourself with the functions of the switches and buttons
on the dashboard.

8.1 Operation

Enter your
①、Plug in the lithium battery interface
password and press ok
②、Open the electric lock

Turn on the electric lock

with the key.

③、Fork lifting and lowering：

Lifting：Control the lift button on the handle.

Lowering：Hold the drop knob.

Lifting button
Lifting button Falling button

Falling button
Lifting button
Falling knob 11
 ④、Driving

Rotate the handle to the driving range;

A and C is brake range；

B is driving range；

Slowly rotate the accelerator to start the truck. (In order to be safe, fast acceleration is
prohibited.)

⑤、Brake

When the accelerator is released normally, the truck will stop until the brake is held in the
car through the regenerative braking of the motor.

When emergency braking, the operating handle is quickly turned to zone A or area C (figure
9), and the brake is carried to the death to realize the emergency braking function.

⑥、Parking
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Release the acceleration button to stop the moving truck and slow down the truck until the
brakes are on.

Lower the fork to the lowest position.Turn off the electric lock.

Park for a long time, then the battery power cord is pulled out.

8.2Emergency reverse function

The red button at the end of the handle is the emergency reverse button. When the body
is in contact with the emergency reverse button, the truck will stop immediately and drive
backward for a distance.This is a safety switch designed to prevent the vehicle from being
crushed when the operator encounters an obstacle.

Emergency reverse button

8.3 The use of the horn and the reversing horn

In order to drive safely, the truck is equipped with a driving horn.To remind others
when driving, press the horn button in the middle of the handle handle, and the horn will
ring to warn pedestrians.

8.4 Battery capacity display

The battery capacity of the forklift truck on the dashboard has capacity display function.

8.5 operation

（1）How to carry goods

slowly drive the truck to the items to be transported, insert the pallet fork and move
forward slowly, when the goods completely inserted into the goods after parking, control
handle upgrade button, the heavy lifting to a certain height, back slowly, don't touch the
adjacent goods, when the weight zone is put out the goods, and then walk handling.

（2）How to place the goods

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 When moving the goods close to the area of the goods, it will slow down. When the
moving truck is in a straight line with the goods, then the moving truck will slowly move
forward to the loading area to stop.Slowly press the lower lever, and once the load is held,
the fork will be lowered to the hollow position. When the fork is pulled out of the weight, the
back position will be confirmed without any obstacle.Wait for the fork to leave the weight
completely before carrying on a round of handling.

9.Safety operation and matters needing attention

The spare parts of the truck is not allowed to change without permission.All parts
supplied by the original manufacturer are subject to strict quality inspection.To ensure the
safety and reliability of the vehicle, please use the original parts.Replacement parts,
including all oils, must be collected and processed in accordance with local environmental
and health laws and regulations.

9.1 Repair and Maintenance

Maintenance technician: The maintenance and service should only be performed by

special personnel trained by the manufacturer. After the technician sent by after-sales
department of the manufacturer completed maintenance and servicing work, they should
sign on the service log.

Lifting of Truck: When the truck needs to be lifted for maintenance, the lifting device must
be safe and reliable, and strictly tied to the location of the lifting point. When the truck is
lifted, appropriate measures must be taken to prevent the vehicle from slipping or tipping
(wedges, wooden blocks can be used).

Cleaning Operation: Flammable liquid can not be used for cleaning the stacker. Before
cleaning, take safety precautions to prevent electric sparks (e.g. sparks caused by short
circuit). When operating the accumulator, connectors on it must be disconnected. Use soft
air suction or compressed air, non-conductive and anti-static brushes to clean electric and
electronic components.

Operation of Electric System: Operation on the electric system should only be performed
by specially trained personnel. Before performing any operation on the electric system,
precautions must be made to prevent electric shock. When operating the accumulator,
connectors on it must be disconnected.

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Welding operations: To prevent damage to electrical or electronic components, these
electrical components must be removed from the truck before taking any welding
operations.

Installation: When repairing or replacing hydraulic components, electric and electronic

components, make sure to install them back to their original positions.

Wheels:Quality of the wheels has significant effect on stability and driving performance of
the truck.Modification on wheels can be performed only with the approval from the
manufacturer. When replacing wheels, ensure that the truck is levelled as delivery
state(wheels must be replaced in pairs, i.e. replace right wheel together with left one).

Hydraulic oil pipe: The oil pipe must be changed every 6 years. When change the hydraulic
assembled parts, the oil pipe should be also changed.

9.2 Routine Maintenance

9.2.1 check the condition of each pole, cable and protective cover of the accumulator.

9.2.2 check whether the battery box is secure.

9.2.3 check whether the truck is oiled.

9.2.4 check the situation of fork, oil pipe and horn.

9.2.5 check the braking condition.

9.2.6 check the wear condition of driving wheel, load wheel and so on.

9.3 Professional Maintenance Manual

It is very important for safe operation of the truck to perform overall professional
maintenance. Failure in performing maintenance according to specified interval may cause
malfunction of the truck, and potential risk to human and equipment.

Maintenance periods listed in this manual apply to single shift a day under normal operation
conditions. If using in dusty environment, the ambient temperature varies remarkably or in
multi-shift situation, the maintenance period has to be shortened.

Maintain the truck according to following maintenance list. Maintenance periods are as
follows:

W1 = Every 50 work hours, but at least once a week.

M3 = Every 250 work hours, but at least once every three months

M6 = Every 500 work hours, but at least once every six months
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 M12 = Every 2000 work hours, but at least once every 12 months

Additional operations should be performed in trial run period:

(In initial 50 – 100 working hours or after two months)

— Check the nuts on the wheels, and tighten them if necessary.

— Check the hydraulic components for leakage, and tighten them if necessary.

—Replace the hydraulic filter.

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 Time interval(Month)●
Maintain list
W A B C

Brake 1.1 Check the air gap of the electromagnetic brake ●

2.1 Check the operation switch to show the function of the device ●

2.2 and components

Check alarm system and safety device ●

Electrical 2.3 Check the cable for damage and the terminal is secure ●

system 2.4 Check the function of the micro switch setting ●

2.5 Check controller and EPS controller ●

2.6 Cable and motor fixing ●

3.1 By observing the battery ●

Power
3.2 Visual inspection of battery charging plug ●
supply
3.3 Check if the connection of the battery cable is tight, and if ●
necessary, apply the electrode with grease.

4.1 Check the gearbox for abnormal noise ●

Driving 4.2 Check the running mechanism and grease, check the reset ●

system 4.3 function

Check theofdrive
the operating
wheel andhandle
bearing wheels for wear and ●

4.4 damage
Check wheel bearings and fixing conditions ●

5.1 Check if the frame is damaged ●

Whole
5.2 Check if the sign is complete ●
frame
5.3 Check the fixing of the mast ●

6.1 Check the function of the hydraulic system ●

6.2 Check hoses, pipes and connections for tightness, sealing and ●

6.3 damage
Check the cylinder and piston for damage, sealing and fixing ●

Hydraulic 6.4 Check the load chain settings and re-tension if necessary ●

movement 6.5 Visually inspect the mast rollers and check the wear on the ●

6.6 roller
Check faces
the forks and load handlers for wear and loss ●

6.7 Check the tank for oil level ●

6.8 Update hydraulic oil ●

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9.4 battery maintenance, charging and maintenance.

Any operation of the battery must be guaranteed to stop the truck and put it in a safe
position.

9.4.1 maintenance personnel.

Battery charging, maintenance and replacement must be operated by qualified

professionals.You must carefully read the manual, supply preparation and charging
requirements before preparing for the operation.

9.4.2 fire protection measures.

Smoking and open fire are strictly prohibited when operating the battery.Storage battery
and charge must be kept away from combustible materials, at least 2 meters above the
distance, the place of storage battery must be well ventilated and equipped with fire-fighting
facilities.

9.4.3 Battery type and usage note.

①、The battery type of the car is: lithium ion battery;Battery voltage 24V/48V;This
battery belongs to environmental protection battery, without chemical mercury and
cadmium.

②、Matters needing attention:

A) the battery USES the temperature environment 5 ~ 45;

B) the battery shall be charged and discharged once every three months during the long
period of suspension;

C) before using the new battery, or for the first time after storage, please recharge the
battery before use;

D) do not short-circuit the battery, which may permanently damage the battery;

E) do not burn or destroy batteries, which may cause the release or explosion of toxic
gases;

F) do not directly weld the battery;

G) do not allow the battery to be in a hostile environment, such as extreme temperature,

deep cycle, or frequent overcharge/discharge;

H) if the battery is hot, do not touch, until cooling;

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 I) when removing the battery pack, hold the plug with your hand instead of pulling the
cord;

J) after the battery is used, if the battery is hot and before recharging, please cool in the
ventilated environment;

K) do not put batteries in water or seawater;

L) do not try to separate, squeeze, impact the battery, the battery will heat or fire, the
lye in the battery will be harmful to the skin and eyes, and will damage the clothes;

M) keep the battery away from children.

9.4.4 Disposal of used batteries.

Scrap battery must be carried out in accordance with the relevant laws and regulations in
region recycling, storage provisions stipulated by the environmental protection area or
waste treatment area, and the work must be conducted by qualified professional company.

9.4.5 Specification of the accumulator

Battery Charger

Input：195/265VAC Output：
Rated Rated Capacity：
DC29V10A/DC58.4
Voltage:24V/48V 24V30AH/48V20AH 50/60Hz V5A

Uninsulated terminal poles on the accumulator should be protected with an insulated cover.
When connecting the accumulator and socket, make sure to stop the device and put the
switch at position “0”.When replace or install the accumulator, make sure the accumulator is
fixed securely in battery box.

9.4.6 Storage, transportation and installation of the accumulator

The device must be parked on the level ground steadily. To prevent short circuit,naked cable
ends and the terminal posts should be covered with insulated covers. When pulling out the
accumulator, properly arrange removed accumulator's connectors and cables without
blocking access of the accumulator.

9.4.7 Battery power indicator

Battery power display table:ten article showing represent 100% of the battery.

With the consumption of battery capacity, the glowing article shows will be from top to
down.

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The color of LED show the different states:

Name LED Color Parameter value

Green 70-100%
The standard battery
Orange 30-60%
remaining power
Red blinking 0-20%

Battery discharge on 70%,red lamp will blinking“Energy storage”.

Battery discharge on 80%,two lamp will blinking“run out of battery”,Need to charge the

accumulator.

9.4.8 Charging

Read the instruction manual carefully before recharging.

a）Must use Li-ion Charger specially designed by our company

b）Do not reverse charge the battery

c）Stop charging immediately when battery has obvious heat during charging .Then cool
it before charging

d）Please hold the handle when pulling charger connector,direct drawing of wire is not
allowed

9.4.9Disassembly and Installation of battery

Parking the truck before the battery is removed and installed

Disassembly & Installation battery step：

A：Turn off the car 。

B：Pull the power connector handle and unplug the power connector(Attention:When
pulling the power connector,Must hold the handle .Please do not pull the wire directly

C: Pull up the battery and pull the battery out of the car.

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 D：Insert the new battery into the battery mounting slot

E：Plug in the power connector.

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 10.Safety Caution

10.1 General rule

10.1.1 The operator must have a forklift operation qualification which proved by the
relevant departments of the training before driving truck.。

10.1.2 The operator must read the instructions before use all of the content, after fully
understand operation method can drive Truck.

10.1.3 truck must not carry passengers.。

10.1.4 Operators should pay special attention to when homework operating environment,
including other people nearby and fixed object.

10.1.5 Without the manufacturer's approval, shall not modify, add or remove tractor parts,
lest affect performance of tractor.

10.2 Storage and transportation

10.2.1 Use container or car to transport the truck should pay attention to at the time of
shipment:

○
1 Front and rear wheels with wedge, begin to pull up the parking system, prevent

sliding in the process of transportation;

○
2 Using the lasso, not placed in the weak structure of the truck；

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 ○
3 When moving the truck.Pay attention to keep the center of the moving truck in the

middle of two fork

○
4 During Transportation,Remove the Trailer and fix the tractor with a dedicated

strap for lifting according to the figure below。

10.2.2 When Truck doesn't work, should be parked in a dry ventilated cleaning warehouse,
Protect the truck from the sun and rain

And please note:

○
1 Turn off the Electrical lock and make the safety switch off,unplug the power plug

○
2 Begin to pull up the parking system, front and rear wheels with block mat;；

○
3 Such as discontinued for a long time, battery should be added once every 15 day

electricity.

10.3 Check before using

10.3.1 New car if there is any damage in transportation, please don't be put into use, and
promptly get in touch with the supplier, do proper processing.

10.3.2 New cars in the factory run parts has been filling lubricating oil.

10.3.3 Truck equipped with battery.The battery is charged before leaving factory.If leaving
the factory for a long time, may the battery is low.Before use should pay attention to
electricity meter shows that when the electricity meter display to the last two warning, must
charge at once.Every day before using, or before charging, should open the battery blocks,
check the liquid level height, such as liquid level is too low to add distilled water in
charge.Detail as (Battery charging and maintenance

10.4Safety operation regulation

10.4.1Requirement for operator: The Truck must be operated by a trained operator, He

can perform and operation demonstration on the user to move and mainpulate the cargo,
and can clearly guide the user how to operate the forklift.

10.4.2 Operator’s rights, obligations and responsibilities：Has been trained by the

operation of the vehicle, the driver must be clear of his rights and obligations; and he is

23
familiar with the contents of the relevant operating instructions. If the vehicle is pedestrian

type, the driver must also wear safety boots.

10.4.3 Prohibit unauthorized person to operate：The operator is responsible for the

vehicle,he need to prohibit unauthorized person to operate. Transport or lift person is also

forbidden.

10.4.4 Malfunctions and defects：If the vehicle has any malfunctions or defects,need to
inform administrator, If the vehicle cannot be safely operated (e.g.: wheel wear or brake
failure), then it must stop using until it is fully repaired.

10.4.5 Safe operation and environmental protection：inspection and maintenance must

be performed in accordance with the time intervals on the maintenance list.

Parts of the vehicle cannot be changed without any permission, especially safety devices. The

operating speed of the truck is not allowed to change.

All original spare parts have been verified by quality assurance department. To ensure the

safety and reliability of the operation of the truck must use only the manufacturer's spare

parts. The old parts, such as oils and fuels must be handled in accordance with the relevant

environmental protection rules.

10.4.6 Hazardous area: Hazardous area usually refers to the following range: vehicle or its

load lifting devices (e.g. fork or accessories) is dangerous for personnel when running or

lifting movements, or the ongoing regional transport loads. Typically, this range extends to

the load or truck accessories landing area.

Unauthorized personnel must be asked to leave the dangerous zone. As long as the situation

might cause some kind of damage, the driver must give a warning, if the driver asked the

person to leave but did not leave the hazardous zone, the driver must immediately stop the

vehicle.

10.4.7 High-risk environment：Working in high-risk environment, operator must have a

special design to be protected.

The vehicle was not specially designed for the high-risk environment.
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10.4.8 Safety devices and warning signs: Safety devices, warning signs and warning notes

described in the previous operating instructions must be taken seriously enough.

10.4.9Driving in public places: the vehicle is forbidden to drive in public places expect in

specified special areas.

10.4.10Distance between truck: keep an appropriate distance, avoid the front vehicle

suddenly stop.

10.4.11headroom: When the headroom is below the cargo or mast, it is forbidden to use

the vehicle.

10.4.12Using in the elevator and loading platform maneuvering: if there is sufficient

loading capacity, won’t affect the operation of the vehicle, and being agreed by the operator

of the vehicle, then the elevator and loading platform can be used for vehicle transport.

Before entering the elevator or loading station, operator must personally identify. The goods

must be placed in front and occupy an appropriate place, to avoid touching the wall of the

elevate when the vehicle enters the elevator. When personnel and vehicles take the elevator

together, person can enter only after the vehicle has safely entered, and person must leave

before the vehicle.

10.4.13 Driving aisle and working area: The vehicle must be operated on the specified
aisle, all non-related person must leave the work area, and cargo should be stacked in
designated places.

10.4.14 Operation Management：Driving speed must be adapted to local conditions. When

through the corners, narrow passage, swing doors and closed place, speed must be slowed

down. Drivers must be able to visually an adequate braking distance between vehicle and the

front vehicle, and he must remain in control of his vehicle. Sudden stop (unless urgent

needs), rapid U-turn, chased each other in the Aisle is not allowed. Do not pry out of the body

to operate the vehicle.

10.4.15 Visibility: The driver must look attentively at the direction of driving, to ensure the
front situation is clearly visible. When the vehicle is backing off, if the carriage of goods block
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the line of sight, a second person walk in front of the vehicle to give appropriate guidance
and warnings is necessary.

10.4.16 Pass through the ramp: Only a known ramp which should be clean, non-slip, and
with the vehicle technical availability was allowed to go through. The goods on the forks
must face uphill. It is forbidden to turn back, move diagonally or park on the ramp. The
operator must slow down when going through the ramp, and prepare to brake at any time.

10.4.17 Load capability on ground: when the vehicle is in operation, make sure the load

pressure of the body weight or wheels on the ground does not exceed the load capacity of the

ground .

10.4.18 Vehicle Change: Any possible changes or modifications for rated load, stability or

safe operation of the vehicle, must obtain prior written approval from origin manufacturers

or its successor. After vehicle manufacturer check and approve the changes, nameplates,

labels and markings of Operation and Maintenance Manual must be modified as well.

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 11.Service Manual

11.1 Troubleshooting

Fault Cause Treatment

The truck can't Check the battery connector，connected if

The battery connector is not connected
move necessary

Electric lock switch on “OFF” position Electric lock switch turn to “0”position

Emergency Stop Switch not open Open the Emergency stop switch

Check the battery charge，If it is

Battery power runs out
necessary to recharge

The vehicle being charge Interrupt charging process

The fuse is damaged Check the fuse

Goods can’t be The vehicle is not operating Handle according to the treatment
lifted up method listed in Vehicles cannot move”
Low hydraulic oil level Check hydraulic oil
The fuse is damaged Check the fuse

Overloading Pay attention to the rated capacity

The Up switch is in bad contact or Check up switch and replace if necessary
damaged
Goods can’t be Dirty oil blocks control valve Check hydraulic oil and clean control
lowered down valve,replace the oil if necessary
The solenoid valve for lowering is not Check or replace the valve for lowering
opened or is damaged
Can’t stop when Lifting micro switch is damaged Cu off the power and replace lifting micro
lifting switch
Moving in one The sensitive switch and the Check the sensitive switch in control
direction connecting cable are not lever and the connecting cable.
well-contacted.
The vehicle travels The related cable are not Check the battery indicator light and
very slow well-connected related cable
Controller is damaged. Change the controller
The car suddenly
started The handle which control the forward
Repair or change
or back is no reset.

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If above steps still can not solve problems, please contact after-sales service department of

the manufacturer and have the problems solved by specially trained technicians.

11.2 Preparation before repair

To prevent possible accidents during maintenance and repair work, following preparations

must be done:

— Park the device safely.

— Press the emergency stop switch and disconnect the connectors on accumulator.

11.3Check the amount of hydraulic oil

— A vehicle ready for repair or maintenance。

— Open the electrical box cover。

— Check the amount of hydraulic oil in the tank。

When checking the hydraulic oil level, the fork and mast must be lowered to the lowest
position.

11.4 Complete repair,the preparation before using

Use the device only after following operations have been completed.

— Clean the vehicle

— Check the brake.

— Check the emergency stop switch.。

— Check the horn.

Several electromagnetic brake tests need perform immediately after the test

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Note: the manufacturer reserves the right of interpretation.

If have change not notice additionally!

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