No, the speed of the EP Equipment CPD15/18/20FVD8(-C) should not be increased. The manual specifies that on descending gradients, the travel speed must be limited to 4.8 km/h or less for safety. This indicates that speed increases are not recommended and may pose safety risks.

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Summary of Contents for EP Equipment CPD15/18/20FVD8(-C)

Page 1 Operation Manual CPD15/18/20FVD8(-C) CPD15/18/20/25F8/18F8-H CPD18/20FVL Electric forklift truck Part No.508000004049 V3 10/2022...
Page 2 With business all over the world, EP has EP EQUIPMENT CO.,LTD. is one of the world’s thousands of employees and hundreds of agents leading companies manufacture, which design worldwide to provide our global customers with material handling equipment and provide related prompt local service.
Page 3 Foreword The present operation manual is designed to provide sufficient instructions for the safe operation of the industrial truck. The information is provided clearly and concisely. Our trucks are under ongoing development. EP reserves the right to alter the design, equipment and technical features of the system.
Page 4 Legal requirements for marketing Declaration EP EQUIPMENT CO., LTD. Address: No.1 Xiaquan Village, Lingfeng Street, Anji, Huzhou, Zhejiang We declare that the machine Industrial truck type: corresponding to these this operation manual Model: corresponding to these this operation manual Serial No.: corresponding to these this operation manual Fulfills all the relevant provisions of Directives −...
Page 5: Table Of Contents
Table of contents A Introduction...........................A1 1.1 Intended use ........................A2 1.2 Improper use ........................A3 1.3 Forklift truck handover .......................A3 B Truck description ........................B1 1.1 Application ..........................B1 1.2 Truck Assemblies .......................B2 1.2.1 Display(1) ........................B6 1.2.1 Display(2) ........................B6 1.2.2 Controls ........................B15 1.2.3 Components .........................B20 1.2.4 Cover and Seat......................B22 1.3 Standard version specifications ..................B26 1.3.1Performance data for standard truck ................B26...
Page 6 Table of contents 1.4.2 Drive wheels removal and installation ................G11 1.4.3 Check the gear or drive axle oil level................G13 1.4.4 Check the hydraulic oil level ..................G14 1.4.5 Check the electrical fuses....................G14 Decommissioning the trucks..................G15 1.5.1 Prior to decommissioning ....................G15 1.5.2 Restoring the truck to operation after decommissioning ..........G15 1.6 Final decommissioning, disposal ..................G15 Troubleshooting ......................H1 Appendix 1..........................
Page 7: A Introduction
Introduction The truck described in the present operator manual is an industrial truck designed for lifting and transporting load units. It must be used, operated and maintained according to the information in this operation manual. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property.
Page 8: Intended Use
a) arranges for the modification or alteration to be designed, tested and implemented by an engineer(s) expert in industrial trucks and their safety. b)maintains a permanent record of the design, test(s) and implementation of the modification or alteration. c) approves and makes appropriate changes to the capacity plate(s), decals, tags and instruction handbook.
Page 9: Improper Use
• When driving on public roads, the corresponding regulations must be observed, as well as country-specific restrictions for winter road conditions. • The operating company is responsible for adequate fire protection in the vicinity of the industrial truck. Industrial trucks may only be used to tow trailers if they are intended for this purpose by the •...
Page 10: B Truck Description
B Truck Description Application It is a four-wheel electric sit-down counterbalanced truck. It is battery-powered truck. With maximum economic efficiency, safety and driving comfort. These trucks are equipped with lead- acid battery For F8 and FVD8. The FVL series are equipped with lithium-ion battery. Customer can choose attachments randomly.
Page 11: Truck Assemblies
Truck Assemblies FVD8/F8 Fig3625-00011OM Drive wheel Combination light Battery behind panel Overhead guard Chassis Mast Counterweight Headlight Steering wheel Driver's seat Fork Warning light REV. 09/2022...
Page 12 FVD8/F8 Fig3625-00012OM Seat Tilting lever Steering wheel Emergency stop switch Attachment lever Key switch Side Combined lamp switch lever Steering column tilting angle Accelerator pedal adjuster Display Brake pedal Travel combination switch Caution light switch Lifting lever REV. 09/2022...
Page 13 Drive wheel Warning light Chassis Overhead guard Counterweight Mast Steering wheel Headlight Towing pin Forks Driver's seat Rear combination light REV. 09/2022...
Page 14 Steering wheel Attachment lever Side Key switch lever Combined lamp switch Accelerator pedal Steering column tilting angle Brake pedal adjuster Travel combination switch Display Lifting lever Hand brake lever Tilting lever Emergency stop switch REV. 09/2022...
Page 15: Display(1)
Display(1) 1.2.1 Orange Green Fig0000-00059OM KEY BOARD BUTTION:ENTER Save all changing KEY BOARD BUTTION:ROLL UP Change the digit marked by cursor KEY BOARD BUTTION:ROLL DOWN Change the digit marked by cursor KEY BOARD BUTTION:SET UP Shift cursor on previous digit KEY BOARD BUTTION:SET DOWN Shift cursor on following digit KEY BOARD BUTTION:OUT...
Page 16 CAUTION Too low battery power will influence the service life of the battery. Charge the battery when the capacity less than 20％ . The meanings of indicators: Low battery indicator The default system parameter setting residual power is below 10%, this lamp will illuminate.
Page 17 Seat indicator This lamp illuminates whenever the driver leaves the seat, indicating that the seat switch is OFF. At this point, the vehicle cannot move or lift. This feature requires the seat to be fitted with OPS. Fig0000-00066OM Service hour display Start the truck, the top right corner of the instrument displays the accumulated service hour,...
Page 18 1.2.1 Display (2) FVD8/FVL BATTERY DISCHARGE INDICATOR RED-ORANGE-GREEN (5) KEY BOARD BUTTON: OUT (4) KEY BOARD BUTTON: SET DOWN (3) KEY BOARD BUTTON: SET UP (2) KEY BOARD BUTTON: ROLL DOWN (1) KEY BOARD BUTTON: ROLL UP (*) KEY BOARD BUTTON: ENTER Fig0000-00144OM REV.
Page 19 PERFORMANCE CHOICE#1#2 START The display sends the chosen performance to traction and pump controllers via can; they will manage this information. MAIN PAGE WITH OR WITHOUT ALARMS If there are no alarms, the main page shows battery charge, traction hour meter and truck speed.
Page 20 Fig0000-00230OM Battery Indicator【1】 DIS00-UP display doesn’t calculate the remaining capacity of the battery. It just reads the battery information from the controller and shows the percentage with twenty grids. Fig0000-00231OM If the battery is fully charged and the controller verifies the capacity of battery is 100%, the display will show twenty grids as 100%.
Page 21 STEER ANGLE ( featuring Steering Angle feedback trcuk) 【2】 Below the battery indicator, there’s the information of steer angle . Fig0000-00234OM If the controller can update the steer angle information by can net, the display could show this onbelow the battery indicator. It’s showed through a moving grid. When the grid is in the middle, it means the steer angle is 0 deg, and the truck is moving straight.
Page 22 Information of accelerator【4】 The information of accelerator is consisting of two parts. One is pedal enable signal and another one is speed require signal. The left grid is used for pedal enable signal. When the pedal is released the display will show the information like picture below. When you push the pedal gently, the display will show the information like picture above.
Page 23 ICON EXPLANATION If this icon is showed on display, the truck is in normal high speed mode. This mode is the default mode, and can be selected by button 1 If this icon is showed on display, the truck is in low speed mode.
Page 24: Controls
1.2.2 Controls Steering When the steering wheel is turned right, the forklift will turn to the right; when the steering wheel is turned left, the forklift will turn to the left. The rear end of the forklift swings out when turning. WARNING This forklift truck adopts a fully hydraulic steering system.
Page 25 WARNING If parking on the slope is unavoidable, block the wheels with solid wedge. Horn button Press the horn button in the middle of steering wheel, the horn sounds. Travel Combination Switch Fig0000-00044OM For switching travel direction of truck: Forward (F) , Reverse (R) and Neutral (N).
Page 26 Light switch: Rotation type switch. Control the light through the knob on the head of combination switch. width light Headlight, width light Fig0000-00047OM Emergency stop switch In an emergency, press the red mushroom head button to cut off the vehicle's main power supply.
Page 27 Brake pedal Depressing the brake pedal will slow down or stop the forklift. CAUTION Do not depress the accelerator and brake pedals at the same time, as this will damage the drive motor. FVD8/F8 Accelerator pedal Accelerator pedal Brake pedal Slowly depress the accelerator pedal, the drive motor will start running and the Fig3218-00019OM...
Page 28 Lift lever Tilt lever lever Side shifter Lift lever Attachment lever Pull back to raise the forks. Push forward to lower the forks. The lifting speed depends on the distance that the lever is moved backward. The lowering speed is depends on the distance that the lever is moved forward.
Page 29: Components
1.2.3 Components Fork stopper Used when adjusting the spacing of the forks. Pull up the fork stopper and rotate it 90°, then adjust the forks to the desired positions according to the load to be handled. WARNING Fork spacing should be adjusted symmetrically to the truck centreline.
Page 30 Load backrest Load backrest is an important safety part that prevents loads dropping. It’s prohibited to dismantle and remould the load backrest. Never use truck without load backrest. DANGER Loads should be arranged so that they do not project beyond the edge of the truck loading surface and cannot slip, topple over or fall off.
Page 31 Fork assemble Caution light Place forks on the ground against the truck, lower the fork carriage to the lowest, drive the truck forward slowly, aim at the upper and lower slot of fork and the upper and lower beam and gap of fork carriage, fully lift the fork carriage, adjust the left and right position of forks.
Page 32: Cover And Seat
1.2.4 Cover and Seat Procedures to open the battery hood FVD8/F8 • Unlock the switch (1), then open the battery hood(2) . • With the help of air spring in the cover, the cover can be fully opened upward with small force.
Page 33 Adjust seat back Driver sits on. Pull forward or turn the seat back adjusting switch (1) , and adjust the back inclination. Release the switch, the seat back will be locked. Safety belt Fasten safety belt (3) before driving. It protects driver when accidents happen.
Page 34 Periodically check the safety belt Check if safety belt is damaged or cracked. Check if the metal pieces of safety belt(including anchor point) are worn or damaged. Check if lock catch for safety belt or traction machine functions normally. WARNING In any case, if there is damage or flaw etc.
Page 35: Standard Version Specifications
1.3 Standard Version Specifications Technical specification details in accordance with VDI2198. Technical modifications and additions reserved. 1.3.1 Performance data for standard truck Distinguishing mark Manufacturer Model designation CPD18FVL CPD20FVL Drive unit Electrics Electrics Operator type seated seated rated capacity Q KG 1800 2000 Load center distance...
Page 36: Dimensions
Tyre size, steering 16x6-8 16x6-8 wheels 2X/2 2X/2 Wheels, number driving/ steering (x=drive wheels) Tread, Driving wheels Tread, Steering wheels Dimensions Tilt of mast/fork carriage α/ β (°) forward/backward Height, mast lowered 2075 2075 Free lift (load backrest) Lift height 3000 3000 Height, mast extended...
Page 37 Performance data Travel speed, laden/ unladen km/h 13/ 14 13/ 14 Lifting speed, laden/ unladen m/ s 0.4/ 0.5 0.38/ 0.48 Lowering speed, laden/ m/ s 0.55/ 0.55 0.55/ 0.5 unladen Drawbar pull, laden/unladen N Max. drawbar pull, laden/ unladen (time) Max.
Page 38 Distinguishing mark Manufacturer Model designation CPD18FVD8 CPD20FVD8 Drive unit Electrics Electrics Operator type seated seated rated capacity Load center distance Load distance centre of drive axle to fork Wheelbase 1435 1435 Weight Service weight (include 3440 3540 battery) Axle loading, laden driving 4625/615 4955/585 side/loading side...
Page 39 Tyre size, steering 16X6-8 16X6-8 wheels Wheels, number driving/ 2x/ 2 2x/ 2 steering (x=drive wheels) Tread, Driving wheels Tread, Steering wheels Dimensions Tilt of mast/fork carriage α/ β (°) forward/backward Height, mast lowered 2112 2112 Free lift (load backrest) Lift height 3000 3000...
Page 40 Performance data Travel speed, laden/ unladen km/h 13/ 14 13/ 14 Lifting speed, laden/ unladen m/ s 0.27/ 0.43 0.26/ 0.43 Lowering speed, laden/ m/ s 0.44/ 0.435 0.44/ 0.435 unladen Drawbar pull, laden/unladen N Max. drawbar pull, laden/ unladen (time) Gradeability, laden/unladen 10.5/ 14.5 10.5/ 14.5...
Page 41 Tyre size, steering 5.00-8-10PR 5.00-8-10PR wheels Wheels, number driving/ 2x/ 2 2x/ 2 steering (x=drive wheels) Tread, Driving wheels Tread, Steering wheels Dimensions Tilt of mast/fork carriage α/ β (°) 6/ 12 6/ 12 forward/backward Height, mast lowered 2098 2098 Free lift (load backrest) Lift height 3000...
Page 42 Performance data Travel speed, laden/ unladen km/h 14/14.5 14/14.5 Lifting speed, laden/ unladen m/ s 0.3/0.45 0.3/0.45 Lowering speed, laden/ m/ s 0.45/0.44 0.45/0.44 unladen Drawbar pull, laden/unladen N ―― ―― Max. drawbar pull, laden/ 11000 11000 unladen (time) Gradeability, laden/unladen ――...
Page 43 Distinguishing mark Manufacturer Model designation CPD20F8 CPD25F8 Drive unit Electrics Electrics Operator type seated seated rated capacity Load center distance Load distance centre of drive axle to fork Wheelbase 1500 1500 Weight Service weight (include 3860 4030 battery) Axle loading, laden driving 5350/510 5930/600 side/loading side...
Page 44 Tyre size, steering 18X7-8 18X7-8 wheels Wheels, number driving/ 2x/ 2 2x/ 2 steering (x=drive wheels) Tread, Driving wheels 1045 1045 Tread, Steering wheels Dimensions Tilt of mast/fork carriage α/ β (°) 6/11 6/11 forward/backward Height, mast lowered 2180 2180 Free lift (load backrest) Lift height 3000...
Page 45 Performance data Travel speed, laden/ unladen km/h 13/ 13.5 13/ 13.5 Lifting speed, laden/ unladen m/ s 0.3/ 0.45 0.3/ 0.45 Lowering speed, laden/ m/ s 0.44/ 0.435 0.44/ 0.435 unladen Drawbar pull, laden/unladen N —— —— Max. drawbar pull, laden/ 17000 17000 unladen (time)
Page 46 CPD15,18, 20 FVD8 1.3.2 Dimensions Fig3615-00001OM REV. 09/2022...
Page 47 CPD15,18,20,25F8 Fig3815-00001OM REV. 09/2022...
Page 48 CPD18,20FVL REV. 09/2022...
Page 49: Identification Points
1.4 Identification points Helmet safety label Gas spring Hand brake label indicator label “Fill port”label The fork safety decals show the risk of serious injury or death when the forks are in a raised position. The tipover safety decal Anti-pinch label Emergency stop switch label No driving in the rain shows how to reduce the...
Page 50: Truck Data Plate
Truck data plate For queries regarding the truck or ordering spare parts please quote the truck serial number. Item Description Item Description PRODUCT NAME RATED CAPACITY MODEL TYPE LOAD CENTER SERIAL NO. MAX BATTERY WEIGHT MANUFACTURE DATE MIN BATTERY WEIGHT UNLADEN MASS UNLADEN MASS WITHOUT BATTERY BATTERY VOLTAGE...
Page 51: The Load Capability Chart
The load capability chart The capacity plate gives the capacity (Q) of the truck in kg for a vertical mast. The maximum capacity is shown as a table with a given load centre of gravity D (in mm) and the required lift height H (in mm). The capacity plate of the truck indicates the truck's capacity with the forks as originally supplied.
Page 52: C Safety
C Safety Before Operation Before using the truck, inspect the work area. It should be neat, well lit, adequately ventilated, and free from hazardous material. Aisles and roadways should be unobstructed and well ma- rked. Operators must know the classification for the truck and use the truck only in permissible areas.
Page 53 5. Protect yourself Operator must wear helmet, safety shoes and work(protective) clothes, whenever you operate and maintain the truck, handle the consumables etc. 6. Prevent explosion Because there will be explosive gas in the bosom of the battery, prohibit any flame or sparks nearby it strictly.
Page 54 Prohibit sudden stops, starts or sharp turns Operate the controls smoothly. Avoid sudden stops, starts or sharp turns. It is dangerous to make a sudden brake. for it may cause the truck to overturn. Fig0000-00021OM 12.Focus on the travelling route· Pay attention to the route of the truck, be sure to keep a clear view of it and look in the direction of travelling.
Page 55 15. Concentrating on your work Keep your mind on your work. Learn to estimate danger before it arises. 16.Mount and dismount properly Never mount or dismount the moving truck. Use the safety steps and safety handgrip and face the truck when mounting or dismounting the truck.
Page 56 22. Overhead guard and load backrest Safeguard protect you not to be hurt by the goods fallen. Load backrest can keep the load stable. It is forbidden to use truck without overhead guard or load backrest. Any additional bores or welding to the overhead guard on the overhead guard will compromise its rigidity.
Page 57 27. Tilt backwards when loaded Travel with load as low as possible and tilt back. If operating with steel pallet or the like, be sure to tilt back the mast to prevent it from slipping off the forks. Fig0000-00032OM 28.Watch for doorways and slow down at corners Watch for branches, cables, doorways, or overhangs.
Page 58 In the case of tip-over The stability of your truck is ensured if used properly and as intended. But once it tips over during unapproved applications or incorrect operation, always follow the instructions below: • Stay buckled up; Don’t jump; •...
Page 59 37. Check the ground of the work area Inspect the surface over which you will run. Look for holes, drop-offs, obstacles, and protrusions. Look for anything that might cause you the truck to lose control, or jolt. Clear away trash and debris. Pick up anything that might puncture a tire or let the load lose balance.
Page 60: Battery Safety
Battery Safety WARNING Batteries contain dissolved sulfuric acid for equiped lead-acid battery turck, which is poisonous and caustic. Batteries also can produce explosive gases • Remain aware of the following information. • Wear protective equipment (protective apron and gloves) and protective glasses when working with battery.
Page 61 EMC-Electromagnetic compatibility Electromagnetic compatibility (EMC) is a key quality feature of the truck. • EMC involves limiting the emission of electromagnetic interference to a level that ensures the troublefree operation of other equipment in the environment. Ensuring sufficient resistance to external electromagnetic interference so as to guarantee •...
Page 62: D Transport And Commissioning
D Transport and Commissioning Transport Use a truck or flatbed trailer to carry the forklift truck. • Lower the lift mast. • Pull on the hand brake lever. • Secure the front wheels and rear wheels with chocks to prevent slipping. •...
Page 63 • Loop the lifting straps around outer mast of the lift mast as shown; Fasten the sling onto the sling ponit (2) or towing pin (5) of counterweight; • Hang all sling ends on the lifting hook (1) of the hoist. •...
Page 64 Towing regulations When the truck needs to be moved, a tow rope or rod can be attached to the towing bar (1). A tow rope can also be attached to the base of the lift mast. CAUTION Braking can only be performed by the brake pedal or hand brake lever during towing.
Page 65: The Structure And Stability Of Truck
DANGER If the towing vehicle brakes, there is a risk that the truck will drive into the towing vehicle! If a rigid connection has not been used for power transmission in two directions during towing, the truck may drive into the towing vehicle when the towing vehicle brakes.
Page 66 WARNING combined gravity center Gravity center and stability truck gravity center Load gravity center The combined gravity center that is composed of the forklift center and the load gravity center determine the stability of lift trucks. When unloaded, the barycenter does not change;...
Page 67: Using The Truck For The First Time
Using the Truck for the First Time Only operate the trucks with battery current. Preparing the trucks for operation after delivery or transport. Procedures: Check whether is complete. • Check the hydraulic oil level. • Install the battery if necessary, (see Battery removal and installation" ) do not damage battery •...
Page 68: E Operation
E Operation Checks and operations to be performed before starting daily work Visually inspect the entire truck (in particular wheels) for obvious damage. • Visually inspect the battery attachment and cable connections. • • Check the mast , load backrest and forks for visible damage such as cracks. Check wheels for wear and damage.
Page 69: Switching On The Truck
Checking the emergency off function • Find a sufficiently large, open area in which nobody will be obstructed. • Accelerate the truck to walking speed. • Push the emergency off switch (2). • Actuate the parking brake. • The truck must decelerate and remain stationary. •...
Page 70: Loading
Steering A forklift is not like an ordinary vehicle, and it is rear-wheel steered, which means that the rear counterweight swings outward when turning. Decelerate when steering. Move the steering wheel counterclockwise, the truck turns left; move the steering wheel clockwise, the truck turns right.
Page 71 Lifting loads • Carefully approach the load to be lifted. • Apply the parking brake . • Set the mast vertical. • Raise the forks to the correct height for the load. • Drive the truck with forks spread as far •...
Page 72 • Reverse carefully and slowly until the load is outside the storage area. Fig0000-00328OM WARNING Do not get on the goods being loaded due to the danger of falling or being hit. WARNING Lift the goods, and make sure that they are within the load range of the truck to avoid toppling and falling.
Page 73: Parking The Truck Securely
Transport NOTE The consignor should secure the goods safely during transport. Attention should be given to appropriate stacking of the goods, to avoid damage to the packaging of the goods, the pallet etc. Responsibility for the safe loading of the goods lies with the transportation personnel.
Page 74 CAUTION If the truck is parked in an ambient tempeature of below -10℃ for extended period, the batteries will cool down. The electrolyte may freeze and damage the batteries. The truck will then not be ready for operation. WARNING An unsecured truck can cause accidents Parking the truck on an incline, without the brakes applied or with a raised load is dangerous and is strictly prohibited.
Page 75: Operator Daily Checklist
Operator daily checklist At the beginning of each shift, inspect your truck by using the EP Operator’s Daily Checklist. If necessary, refer to the Maintenance section of this manual for details on how to carry out this inspection. Check for damage and maintenance problems. Any necessary repairs must be completed before the truck is operated.
Page 76 Operator's Daily Checklist Date Operator Truck No. Department Runtime Meter Reading Daily Check Items O.K.(√) Remark Chassis, bodywork and fittings Check the condition and function of the driver's seat and seat belt. Check tire: Using a tire pressure gauge, measure the inflation pressure if necessary Chassis frame Checking the condition of tyres.
Page 77: F Battery Maintenance & Charging & Replacement
Battery Maintenance & Charging & Replacement Battery type & dimension Battery type & dimension as follow: Dimension Battery Voltage/ rated Charging Tuck type Charger type capacity (mm) time(h) Lead-acid 160A CPD18FVD8 48V/500AH 830*620*627 battery Lead-acid 160A CPD20FVD8 48V/500AH 930*620*574 battery Lead-acid 160A CPD15F8...
Page 78: Charging The Battery
Charging the battery • Check that the specific gravity of the electrolytes is at least 1.14 for FVD8/F8 series. • Charging the batteries shall only be carried out in adequately ventilated rooms and e.g. not in the offices or break rooms for FVD/F8 series. •...
Page 79 WARNING Damage to battery and charger! The charger must be matched to the battery in terms of voltage and charging capacity! Observe the correct combination of battery and charger to avoid overheating and fire hazard. Only use the charger that is suitable for the corresponding battery. WARNING The battery charging station should be plugged into a standard 380V, 3-phase, 50/60Hz walloutlet.The battery plug and socket may only be withdrawn or connected when the main...
Page 80 WARNING Output voltage, current and application range of the charger must match the battery, otherwise it will influence the volume and service life of the battery. Charging cable polarity must match the charger output terminal polarity. WARNING Recharge the battery in time. Do not keep the battery fully discharged or lower than 20%. Intermediate charging Lithium-ion battery systems offer the advantage that they can be recharged temporarily, allowing industrial trucks to be charged at any time.
Page 81 For FVD8/F8: Checking the battery condition, electrolyte level and specific gravity • Inspect battery for cracks, raised plates and electrolyte leaks. • Unscrew the battery cover and check the electrolyte level. • If the battery has an inspection tube, then the electrolyte level should be at the base of the tube.
Page 82: Battery Removal And Installation
Battery removal and installation Park the truck securely(See Parking the truck securely ) and turn off the power before removal and installation of the battery. Procedures for FVD8/F8 : • Park the truck on the flat ground, and pull on the hand brake; •...
Page 83 • Attach the lifting hook to the battery. • Sling the battery to a certain height with a hoist, then move it rightwards; • Place the battery to one side after lifting it away from the chassis. • Install according to the reverse order of removal.
Page 84 Removal procedures: The battery bracket aim side door,adjust battery to the frame by means of the interlocking Park the truck on the flat ground(1), pull out mechanism (3)interlock.and make it with the the power plug(2). bottom of the battery box at the same level height.
Page 85 Installation procedures: Remove guard of the battery bracket(4)the battery pulled into the battery box. The battery bracket aim side door, adjust the height of bracket to the frame by means of the interlocking mechanism(3) interlocking, and make it with bottom of the battery box at the same level height.
Page 86: G Truck Maintenance
Truck Maintenance Operational safety and environmental protection The servicing and inspection operations contained in this chapter must be performed in • accordance with the intervals indicated in the service checklists. • Only use original spare parts that have been certified by our quality assurance. Used parts, oils and fuels must be disposed of in accordance with the applicable environmental protection regulations.
Page 87: Servicing And Inspection
Settings When repairing or replacing hydraulic, electric or electronic components or assemblies, always note the truck specific settings. Hydraulic hoses The hoses must be replaced every six years. When replacing hydraulic components, also replace the hoses in the hydraulic system. Maintenance operations that do not require special training Simple maintenance operations such as checking the hydraulic fluid level or checking the battery electrolyte level (if necessary) can be carried out by persons with no special...
Page 88: 1Maintenance Checklist
1.3.1 Maintenance Checklist Maintenance ● interval Parking the truck secturely and cut off the power supply. Before Using wooden blocks to prevent wheel from moving. starting Clean the fork lift truck if necessary maintenance Check the time and date settings on the display unit; adjust if necessary.
Page 89 ● Maintenance interval ● Mast and tilt cylinders, Check fastening. ● Check the counterweight, motors, chassis, speed reduction gearbox, overhead guard and steering axle fastenings. Chassis ● Check and lubricate the other pins and swivel points. System ● Check the chassis for cracks or damages ●...
Page 90 ● Maintenance interval ● Test the release of brake pedal is normal ● Check the brake fluid level ● Test the release of emergency stop switch is normal Braking ● Test parking brakes is normal System ● Check the brake pump and piping connections for leaks ●...
Page 91: Lubrication Points
1.3.2 Lubrication Points Lubricant Improper operations may pose hazards to the operator's health and life, as well as to the surrounding environment. When storing or adding lubricant, use clean containers. It is strictly forbidden to mix different types and specifications of lubricants (except for those can be mixed under clear statement). CAUTION The use and disposal of lubricants must be carried out in strict accordance with the manufacturer's regulations.
Page 92 Table 1 Lubricants Code Type Specification Amount Position L-HM32 See Table 2.1 (Cleanliness grade Hydraulic for CPD15,18,20FVD8/ Anti-wear hydraulic oil 9, in compliance with System CPD18,20FVL NAS1638) L-HM46(Cleanliness grade 9, in See Table 2.1 Anti-wear hydraulic oil for CPD15,18,20,25F8 compliance with NAS1638) Sliding Surface Multi-purpose grease...
Page 93 Table 2.1 Application Amount of Hydraulic Oil - 2 Amount Lifting height Amount Amount (L)-CPD15,18, Amount Mast Series (mm) (L)-CPD15, (L)-CPD20, 20FVD8 (L)-TVL 18F8 25F8 2500 19.0 19.0 2700 19.6 29,28 19.6 3000 20.4 20.4 2-stage Full Mast 3300 21.3 21.3 3600 22.0...
Page 94 Table 2.2 Contact Surface Lubrication Table Code Position Steering axle Tilt cylinder connetor Fork Carriage Steel channel and rollers Contact surface REV. 09/2022...
Page 95: Maintenance Instructions
Maintenance Instructions Prepare the truck for maintenance FVD8/F8 and repairs All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made: • Park the truck securely (See section Parking the truck securely). •...
Page 96: Drive Wheels Removal And Installation
• Remove the five protectors (1) and unscrew the five nuts (2) on the steer wheel assem-bly (3); • Remove the steer wheel assembly (3) from the steer axle (4). Install according to the reverse order of removal. WARNING Tire is solid tire. When replacing wheels, be sure that the truck won't tilt.
Page 97 FVD8/FVL Drive Wheels CAUTION • Screw the nuts（1). • Tighten the nuts of steer wheels in order and mark with the torque: 180-220Nm. • Tighten the nuts of driving wheels in order and mark with the torque: 180-220Nm . • Turn the wheel to see if it is rotating smoothly, and if there is blocking or not.
Page 98 CPD15,18,20,25,30,35FVD8/ 1.4.3 Check the gear oil level CPD18,20FVL Pull on the hand brake and switch off the truck. Loosen the oiling port plug (2) and observe the oil level; If oil level is aligning with lower level of oiling port, it indicates that the oil level is normal;...
Page 99: Check The Hydraulic Oil Level
FVD8/F8 1.4.4 Check the hydraulic oil level WARNING Please follow the procedures for the safe handling of oil and lubricating grease. NOTE The oil level can only be checked after lowering the lift mast. • Open the battery hood(see page G9). •...
Page 100: Decommissioning The Trucks
Decommissioning the trucks If the forklift truck is to be used for over 2 months, it must be parked in a frost-free, clean and dry location. On decommissioning the truck must be jacked up so that all the wheels are clear of the ground.
Page 101: H Troubleshooting
H Troubleshooting This chapter is designed to help the user identify and rectify basic faults or the results of incorrect operation. When locating a fault, proceed in the order shown in the table. If the fault cannot be rectified after carrying out the remedial procedure, notify the manufacturer ’ s service department ,as any further troubleshooting can only be performed by specially trained and qualified service personnel.The manufacturer has a customer service department specially trained for these tasks.
Page 102 Fault Fault Symptom Troubleshooting Order * Troubleshooting Measures Hydraulic 1. The vehicle 1. Pump motor does not work: 1. Pump motor does not work: Failure cannot lift a. Parking brake switch and seat 1) Check if parking brake switch switch or its circuit connection and seat switch or the connec- failure tion of its circuit is normal;...
Page 103 Fault Fault Symptom Troubleshooting Order * Troubleshooting Measures Lift Failure 3. Slow Lifting of a. Overload 1) Refer to the rated capacity Vehicle marked on the nameplate; b. Hydraulic pipeline leakage 2) Check the pipe and hydraulic c. Valve failure: components for oil leaks;...
Page 104 Fault Fault Symptom Troubleshooting Order * Troubleshooting Measures Other Failures 1. Lights do not light a. Light failure or circuit not 1) Check the light and its circuit conducted connection; 2) Check Lighting combination b. Lighting combination switch or switch and its connection its circuit connection failure circuit;...
Page 105: Lead-Acid Battery Operating Instructions
APPENDIX 1 Lead-acid battery operating instructions REV. 09/2022...
Page 106 1.1 Safety and Warnings When operating on battery, you must wear protective glasses and protective clothing! Electrolyte contains sulfuric acid and is highly corrosive. If it accidentally comes into contact with the skin, wash immediately with plenty of water, if the situation is serious, immediately seek medical advice.
Page 107: Use Of Battery
1.2 Use of Battery 1.2.1 Pre-use Checks Check if the battery status is normal and also check for mechanical failures; Connect the battery connectors, make sure the contact is solid, the electrodes are connected properly, otherwise may cause damage to the battery, truck or charger; Check if the electrode bolt of each battery interface is tightened;...
Page 108: Temperature
1.2.4 Temperature Rated temperature of electrolyte is 30 °C. If the temperature is too high, it will reduce the service life of the battery; too low may reduce the battery capacity. When the temperature reaches the limit temperature of 55 ° C, it is prohibited to run the battery. 1.3 Maintenance &...
Page 109: Monthly Maintenance
There are two types of battery filler cap used proper electrolyte 合适的电 on battery cell: liquid level 解液液位 1) Filler cap with buoy Battery 电瓶 Add distilled water, red buoy will float until while rod appears under the red scale. WARNING Add only distilled water.
Page 110: Care
1.3.4 Care 1. Keep it clean Battery surface should be clean and dry to prevent the occurrence of leakage currents; Battery cables, terminals and connectors mu-st be tightened and clean, a small amount of special grease should also be applied. WARNING •Do not use a dry cloth or fabric to clean the surface of the battery, so that to prevent the occurrence of static electricity, resulting in explosion;...
Page 111 Battery Fault Analysis Fault Negative Phenomena Cause Handling Methods Insufficient 1. Low static voltage 1. Charger voltage and current 1. Adjust and repair the 2. Low density, cannot meet are set too low charger Battery the requirements after being 2. Insufficient initial charge 2.
Page 112 Battery Fault Analysis Fault Negative Phenomena Cause Handling Methods Electrode 1. Battery capacity drops 1. Insufficient initial charge 1. Over-discharge method during normal discharge 2. Long time of storage under 2. Repeated charging plate 2. Density drops to be lower the state of discharge method sulfation...
Page 113 Battery Fault Analysis Fault Negative Phenomena Cause Handling Methods Battery 1. Low static voltage below 2V 1. Electrode plate deformed and Battery needs to be 2. Electrolyte density is too low short circuit replaced Short 3. High temperature during 2. Spacer missing or broken Circuit charging during assembly...
Page 114: I Lithium Battery Operating Instructions
APPENDIX 2 Lithium-ion battery operating instructions REV. 09/2022...
Page 115: Lithium Battery Use And Maintenance Manual
Lithium Battery Use and Maintenance Manual Information on the conformity of lithium-ion batteries • The manufacturer of the lithium-ion battery declares that: the lithium-ion battery conforms with the provisions of the following EU directive 2014/30/EU and Electromagnetic Compatibility Regulations 2016 (SI 2016 No.1091) in accordance with EN12895. •...
Page 116: Safety And Warning
Accessories Do not use a charger that is not released by your manufacturer for lithium-ion battery. BMS (Battery Management System) The battery is permanently monitored by the BMS (Battery Management System). This provides the communication with the truck. The BMS continually monitors items such as the cell temperature, the voltage and the charge status of the cells.
Page 117 •Explosion or fire disaster is likely to occur; avoid short circuit! •Keep the battery away from all fire sources, heat sources and flammable or explosive materials. Fig0000-00004OM •Don’t knock over the storage battery! •Using lifting and delivery devices as specified. Prevent the storage battery cell, interface and connection cable from being damaged by the lifting hook! •If the materials leak out, do not inhale the fumes.
Page 118: Hazard Of Faulty Or Discarded Battery
1.3 Hazard of faulty or discarded battery Please monitor the battery status when in use and in storage. If you find any broken batteries, electrolyte leakage, abnormal expansion or pungent odors due to shipping damage or abnormal vibration, please stop use immediately and keep at least a 5 meter perimeter around the effected batteries.
Page 119: Instructions
Instructions Before the first use, charge battery completely with original charger. • • The lithium battery should be used at an ambient temperature of 0 ~ 40°C, do not use or store the battery near a fire source/heat source where the temperature exceeds the safety range;...
Page 120 Description Name When all 10 cells are on, it indicates that the battery is full; When the first cell and the second flash alternately, it indicates that the battery is low and must be charged. Energy display The battery remaining charge is displayed; “100%” indicates that the battery is fully charged.
Page 121: Lithium Battery Nameplate
Description Name Maximum cell Maximum value of cell voltage voltage No. of cell Identification No. of the cell with maximum voltage. Minimum cell Minimum value of cell voltage voltage Cell No. of minimum cell Identification No. of the cell with minimum voltage. voltage 1.4.2 Lithium Battery Nameplate...
Page 122: Charging
1.4.3 Charging • This battery can only be charged with the vehicle-specific charger, other chargers may cause battery damage. • The normal charging temperature range of the battery is: 5°C ~ 40°C, please do not charge in the environment beyond the normal temperature range; •...
Page 123: Storage
Storage Try to ensure that the battery or battery pack's power is ≥50% before long-term storage as the • battery has the function of self-discharge, be sure to charge the battery once every 2 months to ensure the battery power is ≥50%; The battery should be stored in a temperature environment of 0°C~40°C;...
Page 124: Instructions For Disposal
NOTE It is recommended that the original packaging is kept for any subsequent dispatch. A lithium-ion battery is a special product. Special precautions should be taken when: • Transporting a truck equipped with a lithium-ion battery • Transporting only the lithium battery A class 9 danger label must be affixed to the packaging for transport.
Page 125: Common Problems And Solutions
WARNING Don't bump, handle gently. Used cells and batteries are recyclable economic goods. In accordance with the mark showing a crossed rubbish bin, these batteries may not be disposed of as domestic waste. Return and / or recycling must be ensured as required by the Batteries Act (Act regarding the commissioning, return and environmentally responsible disposal of batteries and accumulators).
Page 126: Service
1.9.Service Daily Maintenance No. Maintenance content Method of operation Note Frequency Check if battery capacity Check instrumentation Make sure the battery is Everyday is too low SOC display not stored without charge for a long time. If the battery system needs to be put on hold for a long time, it is best to keep the battery in half power state...
Page 127 No. Maintenance content Method of operation Note Frequency Whether the external Perform a visual Make the wiring harness weekly wiring harness has worn, inspection fixed well imprint, creases and exposed line core Check that the surface of No dust, no water, no Clean surface if you found weekly lithium-ion battery looks...

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