CDDR

Electric Pallet Stacker

Operation Manual
Parts Catalogue

2010-06
 Welcome to choose “XILIN” electric pallet stacker!
We hope our electric stackers will bring great convenience
to your work!

Please read the manual carefully before operation

This manual is a common manual. We reserve the right to modify
technology of the electric stacker. If there is anything in the
manual that is not consistent with the actual stacker, the actual
stacker should be considered correct and the manual is only for
reference.
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Warning!
Operators must strictly conform to ISO3691 “Safety Specifications of Motor Industrial Vehicles”.
Untrained personnel are not allowed to operate the stacker.

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According to ISO 3691 “Safety Specification of Motor Industrial Vehicles”, load capacity and lifting height of our
CDD Electric Pallet Stacker are stipulated as follows:
1．——When the lifting height of CDDR stacker is below 2500mm (including2500mm), the maximum
load capacity is the rated capacity. Overloading is prohibited.
2．——When the lifting height of CDDR stacker is above 2500mm (excluding2500mm), the load
capacity is less than the rated bearing capacity. Take the following diagrams as a reference with
the rated loads of 1000kg, 1500kg and 2000kg:

1000kg

800kg

600kg 2500 mm
3000 mm
3300 mm
3500 mm
400kg 4000 mm

200kg
600 700 800 900 1000 mm

1.0T LOAD CHART

1500kg
1400kg

1200kg

1000kg

800kg

600kg 2500 mm
3000 mm
400kg 3300 mm
3500 mm
4500 mm
200kg 5000 mm
5600 mm
100kg
500 600 700 800 900 1000 mm

1.5T LOAD CHART

2000kg
1800kg
1600kg
1400kg

1200kg
1000kg
800kg
2500 mm
600kg 3000 mm
3300 mm
400kg 3500 mm
4500 mm
200kg 5000 mm
100kg 5600 mm
600 700 800 900 1000 mm
2.0T LOAD CHART
 Table of Contents

1．Configuration diagram and main technical parameter…………………….2

2．Brief introduction of structure……………………………..………….…………..7

3．Safety specifications…………………………..…….……………….……………….7

4．Initial operation ………………………………………………………………………..13

5．Use and operation instruction……………………………………………………..14

6．Use, maintenanc and charging of storage battery………………………....17

7．Inspection before operation …………………………….………..…………..20

8．Inspection after operation…………………………………….…….……………….21

9．Periodic maintenance and upkeep…………………………..……..…………….21

10. Storage, transportation, and loading&unloading ……………………………26

11．Replacement of storage battery…………………………..…………..............27

12．Common faults and troublshooting……….........................................27

13．
．Common faults signal and trouble shooting……………………….............30

14．Lists of accessories, spare parts and vulnerable parts……………….…..36

15．Structure and principle diagrams of major parts…………………………...37

16．
．Packing list……………………………………………….…….………………………...38

Appendix I Safety Specifications of Motor Industrial Vehicles………………...44

Appendix：《Safety Specifications of Motor Industrial Vehicles》

Brief introduction：
CDDR electric pallet stacker adopts storage batteries as the dynamic source and a AC motor as the
driving force, traveling through gear transmission. The lifting of the fork relies on the DC motor and
the hydraulic transmission system. The up-and-down movement of the oil cylinders lifts the fork and
the goods. As the traveling and lifting of the stacker are electrically driven, it possesses the
characteristics of energy saving, high efficiency, stable operation, easy operation, safety and
reliability, low noise and no pollution, etc.This stacker adopts 24V storage battery, which greaty
prolongs use time after one charging.

The stacker is applicable for goods piling and handling on hard and flat ground.

Allowed environment for using:

a. Height above sea level shall not be over 1000m;

b. Ambient temperature shall not be higher than +40℃ and no lower than -25℃;
c. When the ambient temperature reaches +40℃, the relative humidity should not exceed 50%;
at a lower temperature, higher relative humidity is allowed.
d. Hard and flat ground
e. It is prohibited to use the stacker in a flammable, explosive or corrosive environment with acid
and alkali.

Description:
The instruction manual shall be kept by the operator, and shall be read by the operator until he gets a full
understanding.
The instruction manual is composed of correct operation, convenient and simple maintenance, and
routine inspection.
The instruction manual shall be carefully read before operation, for purpose of correct drive and suitable
maintenance to ensure safe and effective material transportation.
The instruction may be in disagreement with practical product due to product innovation.
The instruction manual shall be accompanied with in case of truck leasing or transfer.
Please come into contact with our sales department in case of any problem.
Description of symbol：Regulations of the following symbols are of great importance to your safety and
others as well.

Please observe these regulations:

Indicates an impending danger. Deaths or severe injuries would be
Danger resulted without any precaution or avoidance. You must observe
those requirements.
Indicates a potential danger. Deaths or severe injuries would be
Warning resulted without any precaution or avoidance. You must observe
those requirements.
Indicates a potential danger. Moderate injuries would be resulted
Caution without any precaution or avoidance. You must observe those
requirements.

You shall pay attention to statements that are in direct or indirect

Notice
relation with personal security and truck maintenance.

1
1. Configuration diagram

1.1 CDDR configuration diagram

2
3
 1.2 Main technical parameters（
（CDDR Electric Pallet Stacker）
）
1.1 Manufacturer(abbreviated) Ningbo Ruyi Ningbo Ruyi
1.2 Model CDDR10-I(high standard) CDDR10-II（standard）
Driving model：Electric(Storage battery),
1.3 Electric(storage battery) Electric(storage battery)
Characteristics

diesel, gasoline, fuel gas

Driving model（Manual, Walking, Stand driving, Seat
1.4 walking walking
driving ,Order picking）
1.5 Rated load Q(kg) 1000 1000
1.6 Load center distance c(mm) 600 600
1.8 Front overhang x(mm) 697 697
1.9 Tread Y(mm) 1383 1383
2.1 Service weight(with battery) kg 1220/1245/1260/1270 1160/1185/1200/1210
Weight

2.2 Axle load, front/rear, laden kg 1470/1310 1440/1280

2.3 Axle load, front/rear, unladen kg 900/380 870/350
Wheels (rubber, high elasticity, pneumatic tyre,
3.1 polyurethane polyurethane
polyurethane wheel)
Wheel chassis

3.2 Wheel dimension, front φ250×70 φ250×70

3.3 Wheel dimension, rear φ80×84 φ80×84
3.4 Additional wheel(dimension) φ150×60 φ150×60
3.5 Wheel number, front/rear （x = driving wheel） 1x+1/4 1x+1/4
3.6 Tread, front b10(mm) 520 520
3.7 Tread, rear b11(mm) 404/525 404/525
4.2 Height of mast, lowered h1(mm) 1735/1985/2135/2235 1735/1985/2135/2235
4.3 Free lift height( optional) h2(mm) 1300/1550/1700/1800 1300/1550/1700/1800
4.4 Lift height h3(mm) 2500/3000/3300/3500 2500/3000/3300/3500
4.5 Max. height of mast, extended h4(mm) 2955/3455/3755/3955 2955/3455/3755/3955
4.9 Min. /Max. height of operation handle, in driving position h14(mm) 670/1300 670/1300

4.15 Height, lowered h13(mm) 90 90

Dimension

4.19 Overall length l1(mm) 1950 1950

4.20 Length to fork face l2(mm) 878 878
4.21 Overall width of truck body b1(mm) 820 820
4.22 Fork dimension s/e/l(mm) 60/180/1070(1150) 60/180/1070(1150)
4.25 Overall width of fork b5(mm) 570/695 570/695
4.32 Wheelbase ground distance m2(mm) 31 31
4.33 Aisle width, with pallet 1000x1200 crosswise Ast(mm) 2450 2450
4.34 Aisle width, with pallet 800x1200 lengthwise Ast(mm) 2420 2420
4.35 Turning radius Wa(mm) 1575 1575
5.1 Traveling speed, laden/unladen Km/h 5.8/6 5.8/6
Performance

5.2 Lifting speed, laden/unladen m/s 0--0.12/0--0.19 0.11/0.20

Data

5.3 Descending speed, laden/ unladen m/s 0--0.35/0--0.12 0.12/0.12

5.8 Max. gradeability, laden/unladen % 8/15 6/10
5.10 Traveling brake Electromagnetic brake Electromagnetic brake
6.1 Driving motor power kW 1.6(AC) 1.2(AC)
6.2 Lifting motor power kW 3 3
Motor

6.4 Battery voltage/rated capacity V/Ah 24/240 24/200

6.5 Battery weight kg 240 200
Battery dimension（LXWXH） mm 675×254×500 675×254×500
8.4 Noise level at operator’s ear, according to DIN12053 dB(A) 65 65
1.Parameters relating to h1、l、Q shall be calculated according to h1=3000mm and l=1070mm.
4
 CDDR Electric Pallet Stacker
1.1 Manufacturer(abbreviated) Ningbo Ruyi Ningbo Ruyi
1.2 Model CDDR15-Ⅰ(high standard) CDDR15-Ⅱ（standard）
Driving model：Electric(Storage battery), diesel,
1.3 Electric(storage battery) Electric(storage battery)
Characteristics

gasoline, fuel gas

Driving model（Manual, Walking, Stand driving, seat
1.4 walking walking
driving ,Order picking）
1.5 Rated load Q(kg) 1500 1500
1.6 Load center distance c(mm) 600 600
1.8 Front overhang x(mm) 697 697
1.9 Tread Y(mm) 1383 1383
2.1 Service weight(with battery) kg 1230/1245/1260/1270 1160/1185/1200/1210
Weight

2.2 Axle load, front/rear, laden kg 1470/1310 1440/1280

2.3 Axle load, front/rear, unladen kg 900/380 870/350
3.1 Wheels (rubber, high elasticity, pneumatic tyre, polyurethane polyurethane
3.2 Wheel dimension, front φ250×70 φ250×70
Wheel chassis

3.3 Wheel dimension, rear φ80×84 φ80×84

3.4 Additional wheel(dimension) φ150×60 φ150×60
3.5 Wheel number, front/rear （x = driving wheel） 1x+1/4 1x+1/4
3.6 Tread, front b10(mm) 520 520
3.7 Tread, rear b11(mm) 404/525 404/525
4.2 Height of mast, lowered h1(mm) 1735/1985/2135/2235 1735/1985/2135/2235
4.3 Free lift height( optional) h2(mm) 1300/1550/1700/1800 1300/1550/1700/1800
4.4 Lift height h3(mm) 2500/3000/3300/3500 2500/3000/3300/3500
4.5 Max. height of mast, extended h4(mm) 2955/3455/3755/3955 2955/3455/3755/3955
4.9 Min. /Max. height of operation handle in driving position h14(mm) 670/1300 670/1300
4.15 Height, lowered h13(mm) 90 90
Dimension

4.19 Overall length l1(mm) 1950 1950

4.20 Length to fork face l2(mm) 878 878
4.21 Overall width of truck body b1(mm) 820 820
4.22 Fork dimension s/e/l(mm) 60/180/1070(1150) 60/180/1070(1150)
4.25 Overall width of fork b5(mm) 570/695 570/695
4.32 Wheelbase ground distance m2(mm) 31 31
4.33 Aisle width, with pallet 1000x1200 crosswise Ast(mm) 2450 2450
4.34 Aisle width, with pallet 800x1200 lengthwise Ast(mm) 2420 2420
4.35 Turning radius Wa(mm) 1575 1575
5.1 Traveling speed, laden/unladen Km/h 5.8/6 5.8/6
Performance

5.2 Lifting speed, laden/unladen m/s 0--0.12/0--0.19 0.11/0.20

Data

5.3 Descending speed, laden/ unladen m/s 0--0.35/0--0.12 0.12/0.12

5.8 Max. gradeability, laden/unladen % 8/15 6/10
5.10 Traveling brake Electromagnetic brake Electromagnetic brake
6.1 Driving motor power kW 1.6(AC) 1.2(AC)
6.2 Lifting motor power kW 3 3
Motor

6.4 Battery voltage/rated capacity V/Ah 24/300 24/240

6.5 Battery weight kg 300 240
Battery dimension（LXWXH） mm 675×254×545 675×254×500
8.4 Noise level at operator’s ear, according to DIN12053 dB(A) 65 65
1. Parameters relating to h1、l、Q shall be calculated according to h1=3000mm and l=1070mm.

5
 CDDR Electric Pallet Stacker
1.1 Manufacturer(abbreviated) Ningbo Ruyi Ningbo Ruyi
1.2 Model CDDR20-Ⅰ(highstandard） CDDR20-Ⅱ（standard）
Driving model ： Electric(Storage battery), diesel, Electric(storage
1.3 Electric(storage battery)
Characteristics

gasoline, fuel gas battery)

Driving model（Manual, Walking, Stand driving, seat
1.4 walking walking
driving ,Order picking）
1.5 Rated load Q(kg) 2000 2000
1.6 Load center distance c(mm) 600 600
1.8 Front overhang x(mm) 697 697
1.9 Tread Y(mm) 1383 1383
2.1 Service weight(with battery) kg 1290 1230
Weight

2.2 Axle load, front/rear, laden kg 1740/1550 1710/1520

2.3 Axle load, front/rear, unladen kg 907/383 877/353
Wheels (rubber, high elasticity, pneumatic tyre,
3.1 polyurethane polyurethane
polyurethane wheel)
Wheel chassis

3.2 Wheel dimension, front φ250×70 φ250×70

3.3 Wheel dimension, rear φ80×84 φ80×84
3.4 Additional wheel(dimension) φ150×60 φ150×60
3.5 Wheel number, front/rear （x = driving wheel） 1x+1/4 1x+1/4
3.6 Tread, front b10(mm) 520 520
3.7 Tread, rear b11(mm) 404/525 404/525
4.2 Height of mast, lowered h1(mm) 1735/1985/2135/2235 1735/1985/2135/2235
4.3 Free lift height( optional) h2(mm) 1300/1550/1700/1800 1300/1550/1700/1800
4.4 Lift height h3(mm) 2500/3000/3300/3500 2500/3000/3300/3500
4.5 Max. height of mast, extended h4(mm) 2955/3455/3755/3955 2955/3455/3755/3955
4.9 Min. /Max. height of operation handle in driving position h14(mm) 670/1300 670/1300

4.15 Height, lowered h13(mm) 90 90

Dimension

4.19 Overall length l1(mm) 1950 1950

4.20 Length to fork face l2(mm) 878 878
4.21 Overall width of truck body b1(mm) 820 820
4.22 Fork dimension s/e/l(mm) 60/180/1070(1150) 60/180/1070(1150)
4.25 Overall width of fork b5(mm) 570/695 570/695
4.32 Wheelbase ground distance m2(mm) 31 31
4.33 Aisle width, with pallet 1000x1200 crosswise Ast(mm) 2450 2450
4.34 Aisle width, with pallet 800x1200 lengthwise Ast(mm) 2420 2420
4.35 Turning radius Wa(mm) 1575 1575
5.1 Traveling speed, laden/unladen Km/h 5.8/6 5.8/6
Performance

5.2 Lifting speed, laden/unladen m/s 0--0.12/0--0.19 0.11/0.20

Data

5.3 Descending speed, laden/ unladen m/s 0--0.35/0--0.12 0.12/0.12

5.8 Max. gradeability, laden/unladen % 8/15 6/10
5.10 Traveling brake Electromagnetic brake Electromagnetic brake
6.1 Driving motor power kW 1.6(AC) 1.2(AC)
6.2 Lifting motor power kW 3 3
Motor

6.4 Battery voltage/rated capacity V/Ah 24/300 24/240

6.5 Battery weight kg 300 240
Battery dimension（LXWXH） mm 675×254×545 675×254×500
8.4 Noise level at operator’s ear, according to DIN12053 dB(A) 65 65
1. Parameters relating to h1、l、Q shall be calculated according to h1=3000mm and l=1070mm.
6
2．
． Brief introduction of structure (See also the structure diagram

and the principle diagram of the major parts)

The stacker mainly consists of frame, mast, fork, lifting oil cylinder, operation handle, steering
device, driving wheel, storage battery pack, hydraulic power unit and control system for electrical
equipment, etc.

3. Safety Norms:

Warning:
Please pay attention to the following items first before operation of the truck:
1) This electric truck is only limited to utilization indoor with a hard flat floor. Operation in inflammable,
explosive environment or corrosive environment such as acid or alkaline condition shall be strictly
forbidden.
2) Only drivers who have received formal training or are authorized can be allowed to drive the truck.
3) Read this instruction carefully before operation so as to master the performance of the stacker;
check the truck whether it is in its normal condition before each operation. It is forbidden to use
faulty stacker; repair by untrained persons is forbidden as well.
4) Overloading operation is forbidden.
5) As for goods carrying and operation, center of gravity of the goods must be within range of the two
forks. It is forbidden to transport loose goods
6) The truck shall travels slowly when forks pass in or out of pallet.
7) It is strictly forbidden to press the lifting or lowering button during the traveling of the truck.
Meanwhile, don’t switch lifting and lowering buttons rapidly or frequently, because rapid and
frequent lifting or lowering will cause damage to the truck and goods.
8) Don’t load heavy goods on the forks rapidly.
9) Don’t lay the goods on the truck for a long time!
10) It is strictly forbidden to make sharp turn on narrow aisle. When it is turning, slow down the truck so
as to ensure the safety of personnel and goods.
11) Descend the forks to the lowest position when the truck is not used.
12) It is strictly forbidden to put any part of the body under heavy goods and forks.
13) This truck is suitable to be used on flat ground or flat platform. Don’t put the truck on the slope for
a long time.
14) Overloading operation is forbidden. Otherwise the wheel will skid, resulting in the damage of wheel
and motor as well as danger of the human body and goods.
15) It is strictly to use the truck under stipulated voltage of 20.4V.
16) It is strictly forbidden to conduct charge by connecting the plug to AC power directly.
17) It is forbidden to operate the stacker when the lift height of fork exceeds 500mm.

1 Safety operation norms:

⑴ Training of driver:

Notice
Even though each electric pallet stacker may have the same technical parameters, there
may be differences on features of braking and acceleration as well. Never drive the truck until you
get familiar with all those operations.

7
⑵ Wear of the driver during truck driving:

Notice
Please put on safety shoes and protective clothes. Do not wear clothes that are too loose
for sake of being caught, which would result in danger.

⑶ Rules that must be observed:

Notice
Never drive the truck when you are tired or un-concentrated, with an injection of drug, or
after a liquor drinking.
Safety rules and regulations shall be observed during operation or maintenance of the truck.

⑷ Safety of working place:

Notice
This kind of electric stacker is only limited to utilization indoor with a hard flat floor.
Operation in inflammable, explosive environment or corrosive environment such as acid or alkaline
condition shall be strictly forbidden.

a. Good roadway condition shall be kept and the traffic should be smooth.
b. Sufficient light ray shall be ensured on working place.
c. Fire extinguishing appliances shall be equipped in the places where truck and charging is operated.
The extinguishing appliances shall comply with the requirements of extinguishing fire of solid
combustible matter and electric apparatus.
d. The value of truck noise mentioned in instruction is measured under the condition of new truck
running on flat, smooth and hard ground. If the traffic surface is bad or the tyre of truck is
damaged, the noise may be amplified.

⑸Integrity of the truck shall be realized:

Warning
Do not make modifications on the truck.

A Please observe safety rules and regulations of your working place during operation,
inspection, and maintenance of the truck.
- Unauthorized truck modification is not permitted.
- No modifications or alterations to a powered industrial truck, which may affect, for example,
capacity, stability or safety requirements of the truck, shall be made without the prior written
approval of the original truck manufacturer, its authorized representative, or a successor
thereof. This includes changes affecting, for example braking, steering, visibility and the
addition of removable attachments. When the manufacturer or its successor approve a
modification or alteration, they shall also make and approve appropriate changes to capacity
8
 plate, decals, tags and operation and maintenance handbooks.
- Only in the event that the truck manufacturer is no longer in business and there is no successor
in the interest to the business, the user may arrange for a modification or alteration to a
powered industrial truck, provided, however, that the user shall:
a) arrange for the modification or alteration to be designed, tested and implemented by an
engineer(s) expert in industrial trucks and their safety;
b) maintain a permanent record of the design, test(s) and implementation of the modification
or alteration;
c) approve and make appropriate changes to the capacity plate(s), decals, tags and instruction
handbook;
d) affix a permanent and readily visible label to the truck stating the manner in which the truck
has been modified or altered together with the date of the modification or alteration, and the
name and address of the organisation that accomplished the tasks.
⑹ Prepare safety operation procedure:
Safety operation procedure shall be formulated with consideration of practical situations
before operation of the truck. Safety shall be taken into full consideration in preparation of the
safety operation procedure.

⑺ Operation of truck under unsafe condition is strictly forbidden:

a. Operation under unsafe condition is forbidden, such as under conditions with uneven floor, or
impeded road. Goods lifting on slope is strictly forbidden.
b. Faulty truck is forbidden to use.
c. Make sure a daily inspection of the truck would be taken. Please immediately repair or
replace in case of any abnormal conditions.
⑻ Overloading operation of truck is forbidden:

Warning
Overloading operation of truck is forbidden. Overloading operation would
cause damage to the truck or bring harm to operator.
⑼ Use suitable pallet:
The pallet shall be of suitable dimensions, neither too wide nor too large.

⑽ Electrical system check:

Notice
Before checking the electrical system, turn off the key switches and the
emergency isolation switches.

3．2 Safety Operation Specification:

⑴ Check the safety condition around the truck:

Notice
Before starting up the truck, please ensure that there is no person around it.

9
 Notice
If the driver’s view is shielded by the bulky goods carried, please drive
backwards or drive under the guidance of other working personnel.

Notice
Ensure no people around the truck when driving backwards.

Notice
Driving through the narrow access shall be guided by working personnel.

Notice
At crossroad or other places impeditive for view, the driver shall not drive until there
is no person at both sides.

Notice
Keep concentration when operating truck.

Caution
The driving mechanism of truck is installed on the foreside. Due to this
difference from common vehicles, the foreside of truck swings comparatively fast
when turning around. For this reason, to prevent collision with other objects nearby
the foreside of truck, do drive or turn slowly.

⑵ Strictly forbid harsh driving

Notice
Never start up, brake or turn abruptly.

Abrupt start-up or braking may cause the falling of goods.

10
 Abrupt turning during traveling may cause the tilting of truck and result in serious
accident. Do decelerate and take care to turn.

Notice
Observe all items of safety rules on working place. Decelerate and sound horn
when travel by other truck or vehicles. Avoid driving in places with bad view.

Notice
Ensure to provide certain clearance between truck and entrance.

（3） Never drive too close to roadside:

Notice
Ensure to provide enough distance between the truck and roadside or platform
edge.
When running on narrow road or platform, keep a certain safety distance with the edge against falling
of the truck.

Warning
Avoid turning or loading and unloading operation on slope;
otherwise the truck can go tilting.

3．
．3 Operation norms:

Notice
The truck can only carry goods under rated capacity.

1) Forbid overloading operation.

2) Forbid deflective transportation.
3) Passengers on truck must be forbidden.
4) Never push or pull the handle abruptly
5) Never use the truck as towing vehicle.
6) When transporting over-wide goods, the driver shall be extremely careful to turn slowly to keep
balance of the goods. Decelerate when ascent and descent, meanwhile, watch around for sake of
safety.
7) The faulty truck for future repair must not be parked at places impeditive for traffic. Lower down the
fork arms to the lowest position and put on the warning board. Pull off the key.
8) When protective devices suck as protective cover of mast is not mounted, it is forbidden to operate
the truck.
9) Take care to avoid the danger of wind force when loading goods.

Notice
Take care to avoid the danger of wind force when loading goods.

11
10）The operator shall master the traveling speed according to site condition.The truck shall slow down
and move at a low speed when turning, at a narrow aisle, passing by swing doors or places where view
impeded. And the truck shall keep enough distance with the forklift moving forward. Abrupt stop, sharp
turn and overtaking are forbidden at dangerous places or where view is impeded except accidents. It is
forbidden hold body or hands out of the driving cabin.
11）Driver’s view during operation: The driver’s view must keep in the traveling direction of the stacker
and pay attention to the condition on driving roads at all times. If the goods carried impeding driver’s
view, goods carried must be adjusted to the backward of driver’s view. If the goods can not be adjusted,
another operator shall be arranged and walk by the stacker so as to report the forward road condition for
the truck driver.
12）Upgrade or downgrade driving: The route of upgrade and downsgrade shall be specified driving
roads. The ground shall be kept clean, safe and reliable in accordance with technical performance
of the stacker. When the truck is moving upgrade with goods, the forks should be kept in the forward
position. While drving downsgrade, the stacker shall move backward. Turning, tilting
driving and parking is not allowed during upgrade and downsgrade moving. Make sure to slow down
when downgrade drving and always make prepare for braking.

13）Driving the stacker to elevator or charging platform: When it is necessary to drive the stacker to
elevator or charging platform, make sure that elevator or charging platform has enough loading capacity,
with the design structure applicable for bearing stacker. Meanwhile the elevator and charging platform
should be permitted by the equipment user. Checks must be carried out before operation. Before driving
into the elevator, the goods should be carried into the elevator first and select the suitable parking space
for the truck in order to avoid collision with walls during lifting. When there is other person needs to use
the elevator, they should place the stacker at first.Then they can come into the elevator afterwards.
When the elevator reaches the specified height, the personnel shall get out of the elevator at first.

14）Conditions for goods to be transported: The stackor operator should checke the goods carefully make
sure that there is not any risk. Before transportation of the goods, place and locate the goods. If there is
any possibility of falling or overturning of the goods during transportation, it should be mounted with
protective devices (such as protective guard).
3．4 Important notice after operation:
1）Parking: Park the truck at appointed place. Never park the truck on slope.
Ensure the following points to be achieved before leaving away the truck:
a. Lay down the fork to the lowest position naturally.
b. Turn the steering wheel to the middle position.
c. Turn off the key switch.
2）Clean up the truck:

Notice
When cleaning up the electrical system, use compressed air but not
water.
3）Charge:

Warning
Open flame is forbidden to appear at the charge places, otherwise,
explosion or fire disaster can be caused.

12
 Make a record of charge. As for the charge method, refer to the part about storage battery
operation.

4．
．Initial operation
4．
．1 Initial operation：
：
4．1．1 In case of dangerous conditions, the power can be cut off, and the battery plug must be
connected to the emergency parking plug of the stacker itself.

Warning
It is strictly forbiddent to operate the stacker without emergency
parking plug.

4．1．2 The stacker can only be driven by the battery power, but without rectified AC current which
may damage the electric parts of the truck. And length of battery cable (tow cable
) shall not be over 6m.
4．1．3If the stacker is driven by the external battery through a tow cable, it is forbidden to lift the
loads.
4．1．4Befor initial operation of the stacker, checks must be carried out as follows:
a) Check that whether the device is complete or whether the status is normal.
b)If the stacker has not been mounted with battery, it must be mounted with battery. Take care not to
damage the battery cable.
4．1．5The feature curve of charger shall be adjusted（charging curve）.
4．1．6 If the truck is not used for a long time, wheels placed on the ground will be pressed. Only after
the truck is put into operation for a short time, the wheel can come to the original shape.
4．
．2 Drive of the stacker without the driver of the stacker itself：
：

Warning
It is strictly forbidden to drag the stacker on the slope.

4．2．1 In case of dragging stacker during emergency operation, the electromagnetic brake must be
loosened.
4．2．2 When the stacker is placed at a specified place, the electromagnetic brake must be relocated
so as to make the stacker in a state of brake.

5．
．Use and operation instruction
The electric pallet stacker adopts storage batteries as the dynamic source for short distance goods
handling and stacking. Correct use and operation will bring great convenience to your work but
incorrect use and operation will damage the stacker or pose risk to you and your goods.

5．
．1 Before operation:

Warning
It is strictly forbidden to use faulty truck.

13
5．1．1 Before operation, please check if the truck is in normal condition: Is there any oil leakage in the
hydraulic pipes? Are the supporting wheels able to operate normally? Is there any block? The
trucks with problems are prohibited for operation.
5．1．2 Check if there is any electric power in the batteries with the method indicated in Fig.I. Pull the
general power switch out to turn on the general power supply, unlock the electric lock on the handle,
check the electric energy meter on the instrument panel of the truck. If the zero end grid is bright, it
indicates there is no electric power in the batteries and charging should be conducted at once. It is
prohibited to operate the truck without electric power as that will greatly reduce the service life of
the batteries and even damage the batteries.

There is no electric power in the Turn on the

electric door lock
batteries if this grid is bright. power

Turn off the power

supply

Fig.I

5．1．3 Check if the truck brake is normal. Check the lifting, dropping, forward and backward traveling
of the truck to see if the actions are normal. Check if the emergency reverse action of the truck is normal
with the method indicated in Fig.II:

slow-down

HORN

RISE
RISE

DROP DROP

Fig.II

14
 Warning
It is strictly forbidden to turn the accelerator knob fastly to speed up
the stacker abruptly during goods transportation.

Move the control handle to division A or division C as indicated in Fig.II and press the rise/lowering
button on th control handle to see if the lifting and lowering of the fork is normal. Then turn the control
handle to division B as indicated in Fig. II, slowly start the truck and press the handle to the horizontal
position to check that whether the truck can travel and brake normally.
Move the control handle to division B as indicated in Fig.II, press the emergency reverse button on top
of the control handle to ckeck that whether the truck can travel backward normally.
After the above check, if there is no failure in the truck, it can be put into operation; if there is some
failure, please repair it at once. It is prohibited to use trucks with problems.

5．
．2 In operation：
：
5．2．1
Accelerator knob: The accelerator knob is used for controlling traveling direction and speed of the
stacker. When it is for the traveling operation, turn the operation handle to B area indicated in the
above diagram. When the handle is in A or C area, the stacker is in a power-off status, and can not
travel. When the operation handle is in B area and the accelerator knob is turned in one direction, the
stacker wil travel in that direction. While the accelerator is turned in another direction, the stacker will
travel in another direction. Meanwhile the bigger the turning amplitude is, the faster the truck will
travel.
Note: A side-magnetic brake is installed on the shaft end of the driving wheel motor and there is a cam
and an inching switch installed on the rotary shaft of the rotary arm. Only when the rotary arm is at
30°±20°(as indicated in Fig. II), the stacker can be turned on and travel. Larger or less than the angle,
the stacker will be powered-off and braked. In that case, the stacker can lift goods. When lifting goods,
the stacker cannot travel. As indicated in Fig. II, when the operation handle is in division A or division C,
the stacker can only lift or lower but not travel; when the control handle is in division B, the stacker can
travel as well as lift or lower. The operation position of the handle will not be specially described in the
following descriptions, i.e. the stacker can only lift or lower but not travel when the handle is in division A
or C and the handle must be in division B when the stacker is traveling.

5．2．2 As indicated in Fig. II, there is a button on the operation handle which is used for slowing down
the stacker. When this “slow down” button is pressed as well as accelerate knob is turned, the stacker will
travel at a low speed. This state is best suitable for turning a corner, stacking and moving into and out of
the shelf while taking goods. When the “slow down” button is released and the accelerate knob is turned,
the stacker will travel at a normal speed.

5．2．3 Safety height：

The safety lift height for mast is about 1.8m (according to the assembled mast): If the mast is lifted to
a height which is over the safety height, the stacker will slow down to about 3km/h.
5．2．4 Operation of handling and stacking:

15
 Notice
Please check the following items before operation of the stacker:
Ensure no goods falling and goods damaged at loading and unloading area.
Ensure no goods or objects impeding for safety.

As indicated in Fig. II, pull out the general power supply switch, unlock the electric door lock, and drive
the stacker to the goods pile nearby. (The tip of the fork is 300mm from the goods pile). Press the
lowering button, adjust the height of the fork to a proper position, and insert the fork slowly and as deep
as possible into the pallet of the goods. Press the lifting button till the fork is 200-300mm from the ground.
Drive the stacker to the location of the goods shelf and stop slowly. (The tip of the fork is 300mm from the
goods shelf.) Press the lifting button and the fork rises to a proper height with the shelf (The bottom of
the pallet is about 100mm higher than the goods shelf). Move the goods slowly to the accurate position of
the shelf and press the lowering button to put the goods carefully on the shelf. Take the fork away from
the goods and drive the stacker slowly to make the fork out of the goods pallet. (The tip of the fork is
300mm from the goods shelf.) Lower the fork until it is 300mm from the ground and drive the stacker
away from the shelf. Attention should be paid to that there should be no obstacles around and when
turning, the speed should be reduced.

Caution
The driving mechanism of truck is installed on the foreside. Due to this
difference from common vehicles, the foreside of truck swings comparatively fast
when turning around. For this reason, to prevent collision with other objects nearby
the foreside of truck, do drive or turn slowly.

5．2．5 Operation of taking goods off the goods shelves：

As indicated in Fig. II, pull out the general power supply switch, unlock the electric door lock, and drive the
stacker to the goods shelf nearby. (The tip of the fork is 300mm from the goods shelf). Press the lowering
button, adjust the height of the fork to a proper position, and insert the fork slowly and as deep as possible
into the pallet of the goods. Press the lifting button to lift the goods till the bottom of the pallet is 100mm
from the goods shelf. Slowly drive the stacker and slowly move the goods out of the shelf (the tip of the
fork is 300mm from the goods shelf). Press the lowering button and the fork lowers to a height of
200-300mm from the ground. Drive the stacker away from the goods shelf until it reaches a desired
position and then slowly stop it. Press the lowering button to put down the goods, make the fork
completely away from the goods and move the fork slowly out of the goods pallet.

5．
．3 Abnormal situation handling during operation：
：

5．3．1When pressing the lifting button, the fork can rise but when releasing the lifting button, the fork is
still rising. The stacker is in a situation of out of lifting control. In that case, turn off the general power
supply switch to cut off the power supply at once. Drive the stacker to a safe position to lower the fork
manually and repair the circuit of the stacker.
5．3．2 If the brake is out of function when the stacker is in operation, the operation must be stopped at
once and repair the stacker.
16
5．3．3 When the stacker is moving forward and pushing the operator against a wall or other objects,
press the emergency reverse button on top of the operation handle and the stacker will
automatically move backward to avoid injuring the operator.
5．
．4 After operation：
：
After operation, the stacker should be parked in a fixed parking position and routine maintenance should
be conducted according to the stipulations in clause 6 and charging should be carried out.

6．
．Use, maintenance and charge of the storage batteries
Charging operation methods: This stacker is equipped with a fixed charger. And other built-in chargers
are also optional. When the fixed charger is used for charging, first open the side door to pull out the
socket connector to insert it into the socket joint of the fixed charger. Then insert the plug of fixed
charger into two phase AC power. Finally the charger will start charging after several seconds. When the
built-in charger is used for charging, first open the cover of battery case to take the charging plug out of
the battery case, then insert the charging plug into the two phase AC power. And the charging will start
after several seconds.

Warning
There is hydrogen gas accumulated in the battery case during
charging. Thus the charging environment requires good ventilation and
there should be no flame, otherwise explosion or fire may occur.

．1 Initial charge
6．
6．1．1 Initial charge should be conducted for batteries that have never been used, i.e. initial charge.
Before the initial charge, the surface of the batteries should be cleaned and the batteries should be
examined for damage. The bolts should be tightened to ensure reliable connection.
6．1．2 Open cover。
6．1．3 When the charging equipment is able to operate normally, pour the sulfuric acid electrolytic
solution with a density of 1.260±0.005 (25℃) and a temperature of lower than 30℃ into the batteries.
The liquid surface should be 15-25mm higher than the protective board. In order to reduce the
temperature rise caused by chemical reaction of the electrolytic solution and let the electrolytic solution
fully penetrates into the pores of the polar plates and the baffles, the batteries should be placed still for
3-4 hours, not exceeding 8 hours. The initial charging can only be conducted when the temperature of
the solution reduces to below 35℃. (When necessary, the batteries can be put into cold water for
temperature reduction). After the still placement, if the surface of the solution reduces, electrolytic
solution should be added.
6．1．4 The sulfuric acid electrolytic solution is prepared with battery sulfuric acid complying with
the state standard GB4554-84 and distilled water. Never use industrial sulfuric acid and running water.
The standard temperature （25℃）and density of the electrolytic solution can be converted as follows:
D25＝Dt＋0.0007(t－25)
Where: D25: the density of the electrolytic solution at 25℃
Dt: the actual density of the electrolytic solution at a temperature of t ℃.
t: temperature of the electrolytic solution when testing the density.
6．1．5 Sweep the electrolytic solution on the surface of the batteries and connect the positive and
the negative poles of the battery group respectively with the positive and the negative ends of the DC
power supply (charger). Turn on the power supply. First charge with 30 A (the first stage current,); when
the voltage reaches 28.8V (12 ×2.4V = 28.8V), change to the second stage current 15A and continue to
17
 charge. The temperature of electrolytic solution during the process of charging must not exceed 45℃ and
when it is close to 45℃, the charging current should be reduced by 50% or the charging should stop
temporarily. Wait till the temperature reduces to 35℃ to continue the charging. The charging time,
however, should be properly prolonged.
6．1．6 Fully charged basis: When the voltage during the second stage charging reaches 31.2V (12
×2.6V = 31.2V), the variation of the voltage is no greater than 0.005 (V); the density of the electrolytic
solution reaches 1.280 ±0.005 (25℃), no obvious variation in 2 hours and there are fine air bubbles
appear violently, it can be deemed that the batteries are fully charged. The charged power capacity is 4-5
times of the rated capacity and the charging time is about 70 hours.

6．1．7 In order to accurately control the sulfuric acid content of the electrolytic solution, the
electrolytic solution density of the batteries should be examined during the last period of charging. If
there is inconsistence, adjust with distilled water or sulfuric acid with a density of 1.40. The electrolytic
solution density and the liquid surface should be adjusted to the stipulated value within two hours in the
charging state.

6．1．8 After the initial charging is completed, the surface of the batteries should be cleaned. Close
the cover of the open cover type liquid hole plug and then the batteries can be used.

6．
．2 Use and maintenance
6．2．1 In order to guarantee the service life of the batteries, the batteries in use should be fully
charged. Insufficiently charged batteries must not be used. During the process of use, close attention
should be paid to the discharge extent. Over discharge is prohibited---the voltage reduces to 1.7V per
battery (when the total voltage reduces to 1.7V×12 = 20.4V). When the density of the electrolytic
solution reduces to 1.17, discharging should be stopped and charging should be conducted at once. The
batteries should not be placed idle for a long period of time. The supplementary charging frequently
conducted during the process of use is called common charge.

6．2．2 Common charge: The first stage current of common charge is 30A and that of the second stage
is 15A. The charging method is the same as that of initial charge. The charged volume is
130-140 % of the discharged volume and the charging time is about 12 hours.

6．2．3 The batteries in normal use should avoid over-charge, but over-charge must be properly
conducted for the batteries in following situations, i.e. equalizing charge.
a. The “lag-behind” batteries--- batteries with a voltage lower than that of the other batteries in
the discharging process and the batteries having been repaired for failure. (When equalizing
charge is conducted, the positive and negative poles of the “lag-behind” battery should be
respectively connected with the positive and negative ends of the charger, the DC power supply,
and the charge should be conducted independently.)
b. Equalizing charge should be conducted for the batteries in normal use every 2-3 months.
c. Equalizing charge should be conducted for the batteries that have not been used for a long
period of time before use

2．4 Equalizing charge：

a. Charge with a 4A current
b. When the charge voltage reaches 31.2V (12 ×2.6V = 31.2V) and air bubbles occur in the
electrolytic solution, the current should be reduced by 50% (2A) and continue to charge.
c. When the batteries are in the state of fully charged, stop for 0.5 hour and charge again
with a 1A current for one more hour.
d. Stop for another 0.5 hour and charge with a 1A current for another one hour.
e. Repeat according to item d till air bubbles occur violently in the batteries once the charger
is switched on.
18
6．
．3 Storage

Batteries should be stored in a clean, dry and well ventilated warehouse with a temperature of 5-40℃.
The valid shelf life is 2 years. The batteries should be kept according to the following requirements during
storage:
a. No direct sunshine on the batteries and at least 2m away from heat source.
b. Avoid contacting with any harmful substances. No metallic matters are allowed to drop
into the batteries.
c. The batteries should not be placed upright down and should not be impacted mechanically
or heavily compressed.
d. The batteries must not be stored with electrolytic solution. When it is required in special
situation that the batteries must be stored with electrolytic solution, the batteries should
be fully charged and the density and the liquid surface of the electrolytic solution should be
adjusted to the stipulated values. When the storage period comes to one month, the
batteries should be complementarily charged with the common charge method.

6．
．4、
、Operation of electrolyte

⑴ Density check
The suction type densimeter shall be used to check density. During operation, avoid spilling out the
electrolyte, and do wear protection appliance.
⑵ Operation besides check
Consult professional personnel, especially when complementing electrolyte (dilute sulfuric acid).
⑶ Electrolyte leakage
As for the electrolyte leakage resulting from storage battery tilting and damage, emergency treatment
shall be made at once (See emergency treatment item).
6．
．5、 、Operation of storage batteries during the final stage of their lifetime
⑴ Operation of storage batteries during the final stage of their lifetime
Add distilled water daily during the final stage of storage batteries.
⑵ Treatment of exhausted battery
As for the exhausted battery, draw out the electrolyte and decompose the battery. It can be
discussed that whether the exhausted battery shall be recycled by the battery manufacturer. The
waste electrolyte can be disposed according to relevant local regulations.
6．
．6、 、Emergency treatment
⑴ The electrolyte spills on skin
wash with large amount of water

⑵ The electrolyte spills into eyes

wash with large amount of water, and then seek help from specialized doctor.
⑶ The electrolyte spills on clothes
take off clothes right away, wash with water, and then flush with week basic soap solution.
⑷ The electrolyte leakage
In case of electrolyte leakage outside, neutralize it with lime, strong carbonic acid soda or carbonic
acid soda, and then flush with large amount of water.

6．
．7、
、Charger
If the charger you use is full automatic type. It must meet with the following 2 requirements:
a. The output voltage of charger: 24V
b. The output current of charger: 30A
If the charger you use is semi-automatic or manually adjustable, please charge the battery pack
according to the requirements of use and maintenance mentioned in the second tip.

19
7．
． Inspection before operation:
For the sake of safety operation and good situation of the electric truck, it is compulsory to check the
truck completely before operation. Contact the sales department of our company when founding
problems.

7．
．1 Check point and check content:
No. Check point Check content
When the operation handle is turned, with the
1 Operation handle handle switching between area A and B, there is
Braking
a noise from the brake.
system
The clearance between brakes should be kept
2 Brake clearance
between 0.2mm and 0.8mm.
Steering
3 Operation handle Degree of tightness and rotary flexibility.
system
4 Oil pipe Leakage or not.

5 Hydraulic oil Appropriate oil quantity.

6 Lifting oil cylinder Whether there is any oil leakage.

Pins, screws and all Check all the fasteners of the truck’s wheels, i.e.
7
the fasteners pins or screws, loose or not.
Wheels
Compare the parameter lists, replace the wheel
8 Wearing status
when its diameter reduces by 5%.
9 Charge Confirm the display state of the battery capacity.
Storage 10 Electrolyte The solution level and density of electrolyte.
battery
11 Connecting line The connecting line and socket shall be firm.

Press down the horn button to check whether

Horn 12 Horn
the horn sounds.
Turn on the switch of electric lock to check
Instrument 13 Function
whether the instrument displays normally or not.
14 Truck frame, etc Damaged or not. If there is any crack.
Check that whether lifting, lowering, forward &
Others backward movement and emergency reverse of
15 Function
the truck is normal, and if there is any abnormal
noise.

8．
．Inspection after operation:
After operation, the smudge on truck shall be wiped out. Besides, the following check shall be carried
out:
Keep visibility of all graphics context marks such as warning signs, nameplates and notice board. These
marks are able to instruct, caution and warn the operator to some degree.
The situation about deformation, distortion, damage or breakage
Add lubricating oil and grease if necessary.
Replace faulty components.
20
9．
． Periodic maintenance and repair:
Comprehensive check for truck can avoid malfunction and ensure the service life. The hours listed in
maintenance procedures is based on the cases that the truck works for 8 hours per day and 200
hours per month. For the sake of safety, maintenance shall be carried out according to maintenance
procedure.

Notice
All the repair work shall be carried out by professional personnel.

Please contact the sales department of our company if you need to adjust or replace the components.

9．
．1 Precautions during maintenance:

Notice
The components for replacement shall be produced completely by our
company. When replacing components of the truck, the components with the
same safety requirement with the original design shall be used.
The lubricating oil and hydraulic oil in use shall be recommended by our
company.
⑴ Places for maintenance:

Notice
The places for maintenance shall be appointed and can provide other services
such as hoisting and safety protection facility etc.
The places shall have level ground and good ventilation.
The places shall be equipped with fire-extinguishing devices.
⑵ Precautions before repair and maintenance:

Notice
No smoking.
Arrange the self-protection work.
Wipeout the effusive oil in time.
Before adding lubricating oil, clean up the dirty oil or dust on the joint with brush or
cloth.
Except certain situation, turn off the key switch and pull off the power socket.
Lower down the fork arms to the lowest point when carrying out maintenance.
Ensure no goods on the truck when demounting the high pressure oil pipe. Besides,
the fork arms shall be descended to the lowest position, by this way, the pressure of
hydraulic system can be released.
For the reason that there are capacitors storing a little amount of electric energy in
circuit, so before contacting the binding post of the main circuit, discharge at first.
Clean the electric section with compressed air, never flush with water.
When the truck requires high-position maintenance, the altitude safety protection
must be carried out for the repairing and maintenance personnel.

21
9．．2 Inspection and maintenance before the new truck put into operation
In order to follow the industry related regulations and ensure the absolute security to the truck in
the transportation, for new ex-factory truck, it is possible that there is no electrolyte inside storage
battery before the first use (except the inland sale).

The electrolyte of storage battery is prepared well before the truck leave the factory, and it is filled into
the storage battery by the professional personnel before the first use. First, place the truck to the site
with good ventilation, open the lid of storage battery box, and open all the top plastic lids of storage
battery. The plastic pot with storage battery electrolyte inside is raised using plastic funnel, and the
electrolyte is poured into the storage battery in a slow way until the liquid level can be seen. After all the
storage battery is filled, conduct initial charge to the storage battery timely according to the operation
requirements of initial charge 5.1

9．
．3 Daily inspection
Inspection of hydraulic oil level: lower the fork to the lowest position, and oil charge is 12L.
Recommendatory trademark for the hydraulic oil should be chosen.
Check the capacity of storage battery: refer to the use and maintenance of storage battery.

9．
．4 The inspection according to the need

Clean the truck

Inspect and screw down each fastener
Inspect the damage state of wheels

9．
．5 The inspection and maintenance after 50 hours （Weekly）
）

When the operation handle is turned, with the steering handle switching
1
between area A and B, there is a noise from the brake.
Braking
2 The oil dirt and dust on the turning gearwheel should be cleaned.
system
The clearance between brakes should be kept between 0.2mm and
3
0.8mm
Capability
Inspect the liquid level of electrolyte, pure water can be used for
of 4
supplement if the liquid level is too low.
electrolyte
Density of
5 The specific gravity should be1.28g/ml after charged.
electrolyte
Clean the
storage 6 Cover the lid, and flush with tap water.
battery
Inspect the
7 Burnish the coarse surface of contacts using sand paper.
contactor

22
9．
．6 The inspection and maintenance after 200 hours（ （Monthly） ）
Besides the weekly maintenance, the following maintenance should be carried out, and when the parts
must be adjusted and replaced, please contact with maintenance personnel of our company. (keep
monthly maintenance record)
No. Check point Check content

1 Whole status Abnormal or not.

Whole truck
2 Horn Sound
When the operation handle is turned, with the
3 Operation handle handle switching between area A and B, there is
a noise from the brake.

Steering The clearance between brakes should be kept

4 Brake clearance
system, between 0.2mm and 0.8mm.

braking 5 Operation handle Degree of tightness and rotary flexibility.

system, Truck frame and Function ，and check cracks, lubrication and
6
hydraulic fastener tightness of fasteners.
system and Connecting rod and Function and check the cracks, bending,
7
lifting wheel carrier deformation and lubrication condition.
system
8 Oil pipe Whether oil pipes leak or not.

9 Hydraulic oil Proper quantity of oil.

10 Lifting oil cylinder Whether there is any oil leakage or not.

11 Electrolyte Liquid level，specific gravity and cleanness

12 Plug Function, whether it is damaged or not

13 Key switch Function

14 Contactor Contact performance and function

15 Inching switch Function

Storage
battery, 16 Controller Function
charger and
Wearing status of carbon brush and selenium
electric 17 Driving motor
system rectifier.
Wearing status of carbon brush and selenium
18 Lifting motor
rectifier.
Wearing status of carbon brush and selenium
19 Steering motor
rectifier.
20 Fuse Whether it is perfect or not
Wiring harness and
21 Whether flexible and whether damaged or not.
connection terminals

23
Adjustment of the brake clearance:
1 Hollow screw 2 Fitting screw
3 Spring 4 Armature 5 Motor shaft
6 Spline housing 7 Friction plate
8 Electromagnetic coil 9 Mounting cover plate
10 Mounting screw
1. The structure of brake is shown as the figure.
After a period of use, performance of the brake will
decline due to the wearing and tearing of the brake
plate. Then it is necessary to adjust the clearance of
the brake. As indicated in the drawing, first use the
insert ruler to check the clearance between the brake
plate and magnetic steel. If the clearance is over
0.5mm, adjust it. Before the adjustment, clean the
dirt and dust on the friction plate. During adjustment, first loosen the fitting screw

2. Then adjust the length of the adjustment screws 1 and screw down the tightening screws. After the
adjustment, the clearance between brake plate and magnetic steel shall be kept between 0.2-03mm.
During the adjustment, make sure that the three tightening screws are adjusted evenly so as to ensure
that the clearance between brake plate and magnetic steel are distributed around equally. After the
adjustment, turn on the brake with 24v DC power. Then the brake will make clear sound.

9．．7 Maintenance for 600 hours（ （every three months） ）

During the maintenance every three months, the monthly maintenance process shall be repeated. When
the parts must be adjusted and replaced, please contact with maintenance personnel of our company.

Burnish the coarse surface of contacts using sand paper.

Contactor
Replace according to the status when the function is not well.

Motor Wearing status of carbon brush and selenium rectifier.

Clean the dirt and dust on friction plates of the brake, meanwhile check the wearing
Brake status of the friction plates.

9．
．8 Maintenance for 1200 hours（
（every six months）
）
During the maintenance for a half year, the maintenance process for three months shall be
repeated. When the parts must be adjusted and replaced, please contact with maintenance
personnel of our company.
Burnish the coarse surface of contacts using sand paper.
Contactor
Replace according to the status when the function is not well.

Motor Wearing status of carbon brush and selenium rectifier.

Decelerate box Replace the gear oil

Oil filter clean

Clean the dirt and dust on friction plates of the brake, meanwhile check the
Brake wearing status of the friction plates.
Replace hydraulic oil. Check that whether there is any leakage in the lifting
Hydraulic system
cylinder or not and replace the seals when necessary.
Fork wheel and
Check the wearing condition, and replace them if necessary
bearings
24
9．
．9 Recommended working medium:
⑴ Hydraulic oil:

A. When it is normally loaded, we advise:

Hydraulic oil: LHPISOVG46, in accordance with standard DIN51524T.2, the average sustained
temperature should between 40 degrees to 60 degrees.
B. When it is over loaded, we advise:
Hydraulic oil: LHPISOVG68, in accordance with standard DIN51524T.2, the average sustained
temperature is above 60 degrees.
C. When it is lightly loaded with low temperature, we advise:
Hydraulic oil: HLPISOVG32, in accordance with standard DIN51524T.2, the average sustained
temperature is below 60 degrees.
D. At the occasion with variable loading, we advise:
All the working conditions mentioned above can use the hydraulic oil LHPISOVG46 in accordance
with standard DIN51524T.2 for replacement. The viscidity of this lubricant is very high (mostly used
hydraulic oil).
If it is difficult to buy hydraulic oil, SAE20W/20 engine oil can be used to substitute HLP68 hydraulic
oil.
⑵ Gear oil：
Hyperbola gear oil 85W-90(GL-5)
⑶ Lubricating grease:
Lithium grease of type 3
All kinds of depleted hydraulic oil, gear oil and grease will pollute the environment. For this reason,
recycle the replaced working medium or treat according to local pertinent regulations

9．
．10 Maintenance period of consumables and partial parts:

Items Maintenance content Maintenance period Remarks

Bearings of fork
Replacement 1200 hours
wheel
Fork wheel Replacement 1200 hours
Replace when finding out
Seals Replacement 1200 hours
damage
Gear box Replacing lubricant grease 1000 hours
Hydraulic oil Replacement 1000 hours
High pressure oil Replace when finding out
Replacement 2000 hours
pipe damage
Strainer of hydraulic
Cleaning 1000 hours
reservoir
Check for carbon brushes and
Driving motor 1000 hours
bearings
Check for carbon brushes and
Steering motor 1000 hours
bearings
Check for carbon brushes and
Oil pump motor 1000 hours
bearings

25
10．
．The store, transportation and loading of truck:
10． ．1 The store of truck:
If the electric pallet stacker is not used for over two months, it should be placed in the room which is
in good ventilation, no frost, clean and dry; also the following measures should be taken:
Clean the truck thoroughly.
Lift the forks completely for several times, check it is normal or not.
Lower the forks to the lowest position.
Support the side near to driver of truck with square timber to lift the driving wheels of truck from the
ground.
Apply a layer of flimsy oil or grease on all the bared surface of mechanical parts.
Lubricate the truck.
Check the status of storage battery and electrolyte, and imbrue the non-acid lubricating grease to
the binding post of storage battery.
All the electrical contacts should be sprayed using appropriate contacts spray.
10． ．2 Transportation of truck:
If the truck needs to be transported for a long distance, support the side near to driver of truck with
square timber to lift the driving wheels of truck from the ground. The two front wheels of truck shall be
fixed stably by sphenoid wood block. Fasten the truck to transport vehicle with ropes.
10． ．3 Loading and unloading of truck:
Before loading the truck, check out the nameplate for the total weight of truck to choose
appropriate hoisting handling equipment. The hoisting of truck shall be kept level, and landing
shall be kept slow and stable. The personnel around shall watch for safety. One of the personnel
is responsible for conducting. If the other truck is used for loading and unloading, please watch
the bottom situation of the truck. Take care to insert the fork arms to the bottom, in avoidance of
damaging the driving wheel, balance wheel and forward wheel.

11．
．Replacement of storage battery
The replacement procedure of storage battery is as follows:
1. Open the side door of storage battery and take it down.
2. Pull down the socket connector of storage battery from the truck.
3. Pull out the pin of battery case to loosen the battery.
4. Pull out the storage battery from the side way and take the storage battery away with
special car or using hoisting method.
5. The mounting method of putting the storage battery back into the battery pack is
opposite to the above procedures.

Notice
Handle the storage battery gently during hoisting and transportation of the battery.
Otherwise it will cause damage to the battery or bring danger to human body.

26
12．
．Common faults and trouble shooting:

No. Faults Possible causes Trouble shooting

① The fuse of control circuit is burnt out. Replace
②The power switch is in poor
Repair or replace
connection or is damaged.
The stacker can
③ Fuse of main circuit is blown. Replace
notstart.(The contactor
④The switch of electric lock is in poor
does not work either) Repair or replace
connection or damaged.
⑤The connection of the storage
Tighten
batteries is loose or has fallen off.
① The side-magnetic brake of the drive
wheel does not suck and the Repair or replace
1 stacker is in a braked condition.
②The walking motor carbon brush is
worn or bad contact between the
Repair or replace
The stacker can not steering device and the
start.(The contactor carbon-brush.
works.) ③ The magnet-exciting coil of the
stepper motor is broken or bad Repair or replace
contact at the wire end.
④ Bad contact. Repair or replace
⑤ There is a trouble at the MOSFET tube
Repair or replace
type circuit board.
The stacker can only ①The contactor is in poor connection or
Repair or replace
2 move forward or burnt out.
backward. ② There is malfunction in circuit board. Repair or replace
Cut off the power at
The stacker can not stop Broken contact. The moving contact
3 once and replace the
during traveling. cannot be reset.
contact
Adjust or tighten the
①The erection bolt of the fine motion
bolt or replace the fine
switch looses or is damaged.
motion switch.
Tighten the bolt or
②The connecting wire of the
4 The brake does not work repair the side-magnet
side-magnet brake is loose or
brake.
damaged

③ The braking plates of the side-magnet Replace the braking

brake are worn. plates.
① The bearing of the steering device is
Replace the bearing
damaged.
The steering has got
5 ② The bearing of the steering device
stuck
lacks lubricant or there is too much Clean the bearing
dust

27
 ①The gear or bearing has got stuck Clean or replace the
Difficult steering of the
because of foreign matters. bearing
6 drive wheel, noise and
②There is a gap in the bearing installed Adjust the clearance
the motor is overloaded.
③The front wheel bearing is damaged. Replace the bearing
①Overload Reduce the load
②The pressure of the overflow valve is Adjust the pressure
too low higher
③Internal abnormal leakage in the
Replace the seals
lifting oil cylinder
Add appropriate
④Insufficient hydraulic oil quantity of filtered
hydraulic oil
⑤ Insufficient voltage of the storage
Charge the battery
The forks cannot be battery
7
lifted. ⑥ The control handle is not horizontal or
vertical, the oil pump motor has not Improper operation
been turned on.
⑦ Damaged oil pump motor Repair or replace
⑧ Damaged oil pump Repair or replace
⑨ Damaged lifting button Repair or replace
⑩ The electric lock is not unlocked or is
Repair or replace
damaged.
○,11Seriously insufficient voltage in the
Recharge
cell.
① The internal mast is overloaded and
Repair or replace
deformed
② The external mast is overloaded and
Repair or replace
deformed
The forks cannot be
8 ③ Dead mast roller Repair or adjust
lowered after lifted.
④ Mast guiding rode is curved Repair or straighten
⑤ The oil return hole is blocked Clean
⑥ The electromagnetic valve is out of
Shoot the trouble
control
① Damage of individual battery Repair or replace
Reduced end voltage of Add electrolytic
② Low level of the electrolytic solution
9 the storage battery (after solution
charged) ③ Foreign matters in the electrolytic Replace electrolytic
solution solution
①Driving wheel locating nuts loosen or Screw down the
come off. locating nuts.
The truck shakes while Adjust bolts on the
10 ②The balance wheel, driving wheel and
traveling. balance wheel to make
the two front wheels are not in the same
the four wheels in the
plane.
same plane.

28
12．
．1 Adjustment methods of safety valve pressure
The pressure of safety valves has already been
adjusted when the truck is ex-factory. Users shall
not adjust the pressure at will. Otherwise it will
bring danger to the truck’s hydraulic system and
safety. If the oil pressure is not in accordance
with specified value, please ask the professional Locknut
personnel to adjust according to the test methods
stipulated in the JB/T3300 standards as well as
the following methods:
Pressure adjusting
1 Screw out high pressure oil tube and install
pressure meter with capacity over 20Mpa at
the high pressure oil outlet.
2 Press lifting operation button to measure the
system pressure. The stipulated system pressure
is 11.5Mpa for truck with rated load of 2000KG
and 13.5 Mpa for truck with rated load of
2500KG.
3 If oil pressure is not in accordance with the
specified value, please loosen locknuts of the
overflow valves. Turn pressure screw left and
right until the pressure reaches the specified
value. When the screw is turned clockwise, the system pressure increases. While the screw is turned
counter-clockwise, the system pressure
decreases.
4 After the adjustment, please screw down the locknuts.

13．
．Common fault signal and troubleshooting

1230 controller fault code and diagnosis list

LED
1311 DISPLAY EXPLANATION POSSIBLE CAUSE
CODE
The speed sensor signal 1 Incorrect or ineffective speed sensor
1,2 motor speed encoder
can’t be detected. wiring.
2 Controller defective.
The motor speed is not in
Motor Failsafe Speed sensor malfunction.
the normal scope.
2 The electromagnetic brake of motor is
not loosened completely.
3 Insufficient braking torque.
4 P,I setting improper
5 Failsafe delay too short
1,3 Motor Overcurrent Motor overcurrent 1 Incorrect motor wiring
2 Controller defective.
Motor Output Fault Controller output abnormal 1 Incorrect motor wiring
2 Controller defective.
29
 1 Improper sequence of
1，4 Static Return To Off SRO sequencing error
KSI,INTERLOCK,F/R
2 Wrong SRO type selected.
3 Direction switch malfunction.
4 Sequencing delay too short.
Accelerator voltage is too
2，1 Throttle Wiper High 1 Accelerator is damaged.
high.
2 Wrong accelerator type selected.
2，2 EMR Wiring Open EMR wiring fault 1 EMR wire or check wire broken.
1 Incorrect sequence of accelerator and
2，3 High Pedal Disable HPD
KSI,INTERLOCK.
2 Wrong HPD type selected.
3 Accelerator malfunction
4 Key switch and INTERLOCK power-off.
5 Sequencing delay too short.
6 Wrong accelerator type selected.
Accelerator voltage is too
2，4 Throttle Wiper Low 1 Accelerator is damaged.
low.
2 Wrong accelerator type selected.
3，1 Multiplexer Fault Multiplexer malfunction Multiplexer malfunction
Misssing or welded main
3，2 Main Contactor 1 Main contactor coil open.
contactor.
2 Main contactor stuck closed
3 Welded main contactor
4 Main contactor driver shorted.
Precharge Precharge fault 1 Controller defective.
2 Low battery voltage.
3，3 Brake Fault Electromagnetic brake fault. 1 Brake coil shorted or open.
2 Brake driver fault.
4，1 Service Total Disable Total KSI timer has expired. Expired total KSI timer.
Total driving timer has
Service Driver Disable Total driving timer has expired.
expired.
Setted (KSI) service timer
Service Total Expired Setted (KSI) service timer has expired.
has expired.
Setted (driver) service timer
Service Driver Expired Setted (driver) service timer has expired.
has expired.

Battery Over voltage Battery voltage is too high. Battery voltage is too high.
4，2
Battery Under voltage Battery voltage is too low. 1 Battery voltage is too low.
2 Corroded battery terminal.
3 Storage battery is damaged.
Controller heatsink is too hot
4，3 Temperature Cutback 1 The power of controller is small.
or too cold.
2 Excessive load on vehicle fo a long time.
3 Abstraction of heat is bad.
30
 Mode switch is closed at
4，4 Anti Tiedown 1 Mode switch is adhesive.
startup.
2 Switch is in M2 position.
5，1 Hardware Failure Hardware failure Controller defective.
5，2 Software Failure Software failure Controller defective.
5，3 Parameters Corrupt Parameters corrupt. Controller defective.
2 .COMBI AC1 master microcontroller alarms overview

Machine
Master error Related slave status when Restart
Description Effect
code error code the test is procedure
done
Valve, pump
motor and
traction motor
CAPACITOR Power capacitors valve, lifting or
waiting for stop turning,
CHARGE voltage does not start-up traction
traction main contactor
increase request
open,
electromagnetic
brake the truck.

Valve, pump
motor and
traction motor
Motor output valve, lifting or
VMN LOW waiting for stop turning,
voltage lower start-up traction
traction main contactor
than expected request
open,
electromagnetic
brake V.
Valve, pump
motor and
traction motor
Motor output valve, lifting or
VMN HIGH waiting for stop turning,
voltage higher start-up traction
traction main contactor
than expected request
open,
electromagnetic
brake.
Valve, pump
motor and
traction motor
POWER MOS valve, lifting or
waiting for Power MOS tube stop turning,
SHORTED start-up traction
traction is shorted. main contactor
request
open,
electromagnetic
brake.

31
 Problem on the Valve, pump
hardware circuit motor and
which manages traction motor
COIL SHORT valve, lifting or
waiting for shortcircuit on stop turning,
HW KO start-up traction
traction main contactor main contactor
request
and open,
eletromagnetic electromagnetic
brake coil. brake.
Valve, pump
motor and
traction motor
Short circuit on valve, lifting or
COIL SHORTED waiting for stop turning, standby,
main contactor or traction
traction main contactor traction
brake coil. request
open,
electromagnetic
brake.
Valve, pump
motor and
Short circuit on
traction motor
the driver of start-up, valve, lifting or
DRIVER SHORTED waiting for stop turning,
main contactor standby, traction
traction main contactor
coil, which is not traction request
open,
able to close.
electromagnetic
brake.
Valve, pump
Driver of main motor and
CONTACTOR contactor coil is traction motor
valve, lifting or
DRIVER waiting for damaged(the stop turning,
standby, traction
DAMAGED traction switch of main main contactor
traction request
contactor is not open,
able to close.) electromagnetic
brake.

Valve, pump
motor and
traction motor valve,
CONTACTOR The main contactor coil
waiting for stop turning, lifting or
OPEN has been driven, but the start-up
traction main contactor traction
switch can not close.
open, request
electromagnetic
brake.
Valve, pump
valve,
CONTACTOR motor and
waiting for Main contactor lifting or
CLOSED traction motor start-up
traction malfunction traction
stop turning,
request
main contactor
32
 open,
electromagnetic
brake.
Valve, pump
motor and
traction motor start-up, valve,
AUX DRIVER
waiting for Circuit of electric braking stop turning, standby lifting or
SHRT
traction MOS tube is shorted. main contactor traction
open, marcia request
electromagnetic
brake.
Valve, pump
motor and
traction motor valve,
AUX DRIVER Driver of braking coil is
waiting for stop turning, Standby, lifting or
OPEN damaged.(not able to
traction main contactor traction traction
close)
open, request
electromagnetic
brake.
Valve, pump
motor and
Output of built in smart
traction motor valve,
POS AUX driver, which supplies Eb
waiting for stop turning, lifting or
SHORT coil positive, is high(= + start-up
traction main contactor traction
batt) when the tiller
open, request
switch is opened.
electromagnetic
brake.
Valve, pump
motor and
traction motor valve,
LOGIC Overvoltage/Undervoltage start-up,
waiting for stop turning, lifting or
FAILTURE #1 condition has been standby,
traction main contactor traction
detected. traction
open, request
electromagnetic
brake.
Valve, pump
motor and standby,
traction motor traction valve,
LOGIC
waiting for Motor voltage feedback stop turning, immediately lifting or
FAILTURE #2
traction circuits are damaged. main contactor after main traction
open, contactor request
electromagnetic close.
brake.

LOGIC waiting for Failure in the Valve, pump start-up, valve, lifting or
FAILTUR#3 traction high current HW motor and standby traction
33
 protection circuit traction motor request
stop turning,
main contactor
open,
electromagnetic
brake.
In standby Valve, pump
condition(no motor and
current applied traction motor
valve, lifting or
STBY I HIGH waiting for to the motor) the stop turning, start-up,
traction
traction current main contactor standby
request
feedbacks are in open,
the allowed electromagnetic
range. brake.
Start-up,
Valve, pump
standby
motor and
The battery
traction motor
WRONG SET voltage is too (traction valve, lifting or
waiting for stop turning,
BATTERY low. only traction
traction main contactor
（〈 0.8V or 〉 immediately request
open,
1.2V） after main
electromagnetic
contactor
brake.
close)
Valve, pump
motor and
Problem on the traction motor
start-up, valve, lifting or
ANALOG INPUT waiting for DA converter of stop turning,
standby, traction
traction master main contactor
traction request
microcontroller. open,
electromagnetic
brake.
Valve, pump
motor and
traction motor
start-up, valve, lifting or
ENCODER ERROR waiting for Problem on the stop turning,
standby, traction
traction decoder main contactor
traction request
open,
electromagnetic
brake.
Valve, pump
Input mismatch motor and
between traction motor start-up, valve, lifting or
TILLER ERROR waiting for
hard&soft switch stop turning, standby, traction
traction
input and tiller main contactor traction request
input. open,
electromagnetic
34
 brake.
Valve, pump
Master motor and
microcontroller traction motor
start-up,
WATCHDOG waiting for can not receive stop turning,
standby, Key re-cycle
FAULT traction signal from slave main contactor
traction
microcontroller open,
through CANBUS. electromagnetic
brake.

Main
Valve, pump
microcontroller start-up,
motor and
has detected that standby
traction motor
slave （ traction
HW FAULT waiting for stop turning,
microcontroller is immediately Key re-cycle
traction main contactor
not able to stop after main
open,
traction enable or contactor
electromagnetic
contactor/brake close）
brake.
enable.
Valve, pump
motor and
traction motor
NO CAN MSG unable to receive start-up,
waiting for stop turning,
N5 signal of slave standby, Key re-cycle
traction main contactor
microcontroller. traction
open,
electromagnetic
brake.
Valve, pump
Master
motor and
microcontroller
traction motor
WRONG has detected
waiting for stop turning,
SETPOINT wrong hydraulic continuous Key re-cycle
traction main contactor
function setpoint
open,
of slave
electromagnetic
microcontroller.
brake.
Valve, pump
Master
motor and
microcontroller
traction motor
has detected a
SAFTY FEEDBACK waiting for stop turning,
problem on the continuous Key re-cycle
traction main contactor
feedback of
open,
electromagnetic
electromagnetic
valve driver.
brake.

35
14．
．Lists of accessories, spare parts and vulnerable parts

14.1 Lists of CDDR （without full free lift）

）accessories, spare parts and vulnerable parts
Type & Quantit
No. Name Use position Remarks
specification y
Unlock the
1 Key to the electric lock 2
electric lock
With no
Charging plug and Matched with the
2 1 set charger for
socket charger
built-in type
Electric
3 Fuse 10A 2
equipment
Electric
4 Fuse 100A 1 standard
equipment
Electric standard/high-
5 Fuse 180A/425A 1
equipment standard
6 Sealing ring Oil cylinder UHS38 2
7 O type sealing ring Oil cylinder 45X2.65 2
Oil inlet of
8 Composite ring D16 2
cylinder
9 Dustproof ring Oil cylinder DH38 2

36
14.2 Lists of CDDR （with full free lift）
）accessories, spare parts and vulnerable parts
Type &
No. Name Use position Quantity Remarks
specification
Unlock the
1 Key to the electric lock 2
electric lock
With no
Charging plug and Matched with the
2 1 set charger for
socket charger
built-in type
Electric
3 Fuse 10A 2
equipment
Electric
4 Fuse 100A 1 standard
equipment
Electric standard/high-
5 Fuse 180A/425A 1
equipment standard
6 Sealing ring Oil cylinder UHS27 2
7 O type sealing ring Oil cylinder 45X2.65 2
8 O type sealing ring Oil cylinder 14X2.65 1
Oil inlet of
9 Composite ring D16 2
cylinder
10 Dustproof ring Oil cylinder DH27 2

15．
．Structure diagram (explosion diagram) and principle diagram

of the major parts

See attached diagram I for “The principle diagram of hydraulic system”
See Electric Instructions for “Instruction of the electric system”
See attached diagram II for “The explosion diagram”

37
 16．
．Packing list

Packing List of CDDR（

（without full free lift）
） Electric Pallet Stacker

Consignee: Ex-work No.:

Contract No.: Ex-work Date:

Net weight Dimension

No. Name Quantity Remarks
(kg) (L×W×H)
CDDR electric pallet
1 1 A complete set.
stacker
Technical documents,
2 Accessory box 1 accessories and spare
parts.

Note: 1. The following documents are in the file bag:

①Operation manual of CDDR Electric Pallet Stacker 1 volume

②Packing list 1 copy

③Qualification certificate 1 copy

2．Accessories and spare parts

Type &
No. Name Use position Quantity Remarks
specification
Unlock the electric
1 Key to electric lock 2
lock
Charging plug and Matched with the With no charger
2 1 set
socket charger for built-in type
3 Fuse Electric equipment 10A 2

4 Fuse Electric equipment 100A 1 standard

standard/high
5 Fuse Electric equipment 180A/425A 1
standard
6 Sealing ring Oil cylinder UHS38 2

7 O type sealing ring Oil cylinder 45X2.65 2

8 Composite ring Oil cylinder D16 2

9 Dustproof ring Oil cylinder DH38 2

Consigner：Ningbo Ruyi Joint Stock Co., Ltd

38
 Packing List of CDDR（
（with full free lift）
）Electric Pallet Stacker

Consignee： Ex-work No.：

Contract No.： Ex-work Date：

Net weight Dimension

No. Name Quantity Remarks
(kg) (L×W×H)
CDDRZ electric
1 1 A complete set.
pallet stacker
Technical documents,
2 Accessory box 1 accessories and spare
parts.

Note: 1. The following documents are in the file bag:

①Operation manual of CDDR Electric Pallet Stacker 1 volume

②Packing list 1 copy

③Qualification certificate 1 copy

2．Accessories and spare parts

Type &
No. Name Use position Quantity Remarks
specification
Unlock the electric
1 Key to electric lock 2
lock
Charging plug and Matched with the With no charger
2 1 set
socket charger for built-in type
3 Fuse Electric equipment 10A 2

4 Fuse Electric equipment 100A 1 standard

standard/high
5 Fuse Electric equipment 180A/425A 1
standard
6 Sealing ring Oil cylinder UHS27 2

7 O type sealing ring Oil cylinder 45X2.65 2

8 Composite ring Oil cylinder D16 2

9 Dustproof ring Oil cylinder DH27 2

Consigner：Ningbo Ruyi Joint Stock Co., Ltd

39
 A1
V1

P1

￠10X2

1Z

Hydraulic Principle Diagram (standard)

40
 Solenid Valve

Main
Motor

Hydraulic Principle Diagram (high standard)

41
 Standard Full Electric Pallet Stacker
标

42
43
High-equipped all-electric Pallet Stacker
Appendix 1
ISO3691

Powered industrial trucks—Safety code

The Second Part Safety Code of motor industrial trucks in service, operation and
maintenance
14 Safety rules for the user and driver
In order to use the motor industrial truck well, this part set up some rules. The 14.1 is applied
to the user, the 14.2 is for the driver.
14.1 Applied to the user
The users are the owner or the leaser individual or corporation of the truck.
14.1.1 The qualification of the driver
The driver of the motor industrial truck should be trained, pass examination and get the
operation qualification.
14.1.2 The truck working in flammable and explosive circumstance
Only the industrial motor truck getting the qualification of the national authoritative
department and getting the license of working in the flammable and explosive circumstance,
should work in the circumstance.
This kind of truck should be marked with proper stamp sign, and the relevant building or the
plant should be marked too.
The classification of the building or the field condition should agreed on by the user and the
national relevant authoritative department.
14.1.3 Passenger
Except for special seats, the vehicle can not carry passengers. The passengers are forbidden to
step on the ascent machine or the attachment, except for the following conditions:
The truck mounted working platform (except for the high-lift order picker):
A） The platform should be fixed on fork rack/ fork firmly.
B） If there is no ascent control device, when there is person on the platform, the driver
should leave the driving position.
C） When there is person standing on the platform with ascent control device, only this
ascent control device on the platform can be used.
D） The overall weight of the platform, the load and the people should not over the half of the
weight marked on the vehicle nameplate.
E） The platform on the truck should not be used to transport people. But if for the hand work,
the truck can be adjusted for operation in a small range.
14.1.4 The use of the forklift
14.1.4.1 The change of the capacity and nameplate of the truck
The truck in use shall not exceed the rated capacity stipulated by the factory.
Without the permit of the factory, any amendment of the design is forbidden, and should not
add any attachment on the truck, in order to prevent the influence of the capacity and
operation safety of the truck.
Any changing because of adding attachment should not reduce the security and accord to the
requirement of this rule. After adopting the attachment, the capacity of the truck, the operation
and the repair direction board, label or pattern should be altered correspondently.
The user should ensure all the nameplate and label in proper position, and maintain
handwriting clear.
44
14.1.4.2 Stability
The user should pay attention to section 6 of the code, which is about the stability of the truck
in the working conditions.
When operating correctly, the high lift truck accord with the section 6 is steady, but the incorrect
operating or the wrong maintenance could let the truck working unsteadily.
The factors that may influence the stability are: the condition of the ground and the floor,
gradient, speed, load, the weight of the storage battery, the dynamic force and the static force
as well as the judgment train conditions of the drivers.
When the truck is working in the condition differ to the regular working condition stated in the
section 6, should reduce the load.
When the truck mounted attachment working without load, it should be viewed as partial load.
14.1.4.3 The protection requirement and protection equipment
The truck should be painted with obvious color differing from the surrounding circumstance.
The driving type high –lift truck should be mounted with protection cabane, except for the
condition where the load could not drop onto the driver.
When convey the load maybe fall to the driver using high –lift truck, should adopt shielding
shelf with enough height, weight and the opening size is small enough to prevent the entire
load or part of them from falling onto the driver.
When it is necessary to denote the working condition, the truck should add caution device,
such as light or flash lamp.
In the permit of the factory, it is allowed to install turning hand hold on the steering wheel
formerly without it.
14.1.4.4 The transportation and storage of the fuel
The truck should refuel in the stated place. The fuel station should be ventilated, in order to
reduce the accumulation of the fuel gas to the least. In opening pit, subway entrance, and lift
well or other similar conditions nearby should not fill in the liquefied petroleum gas and replace
other dismountable liquefied petroleum gas container.
It is forbidden to smoke in the place of refuel, and should alarm using placard.
If the liquid fuel is not transport using pipeline, it should be transported using airtight container.
Only the personnel trained and appointed can fill or change the liquefied petroleum gas
container.
When store and transport the liquefied petroleum gas container, should fasten up the filling
valve, and the safety valve should connected to the vaporization room directly. When storing
the container, should screw the protective cap on the connection mouth.
Before filling and/or reusing, should inspect the container to ensure that it is vapor proof.
Especially pay attention to the valve and the connective part is vapor proof. The damaged
container should not be used. Only the permitted corporation could repair the liquefied
petroleum gas container.
14.1.4.5 The charging and changing of the battery
The battery charging station should set in the appointed area. The charging station should
prepare the equipment using for flushing and neutralizing the overflow electrolyte, the fire
control device, the measure avoiding the truck damage the charging device and the adequacy
ventilation facility blow away the fume off from the battery.
In the area of charging, it is forbidden to smoke and alarm with placard.
Only the personnel trained and permitted can change or charge the battery. The battery
repairing people should wear protective clothes.

45
 All the work of changing the battery should carried out according to the description of user’s
manual from the factory. When reinstall the battery, should adopt measures to make the
battery connecting, orientation and fixation correctly. Do not put tools and other metal
substance on the lidless battery.
Without the special approval (for example the truck factory), the electrical motor truck should
not change the battery with different voltage, weight or size.
It is obliged to use the battery stated by the factory. It is obliged to prepare the facility for
changing battery safely. When hanging up the battery using hoisting equipment, it is necessary
to use insulated steeve.
If adopting chain hoist, it is necessary to equip chain box. If adopting chain block, the lidless
battery should be covered by a piece of rubber blanket or other insulated materials, to prevent
the short circuit of chain and the connecting wire or connecting terminal between the battery
lattice.
14.1.4.6 The invalid or damaged truck
If finding the motor industrial truck existing insecurity factors, it should stop using and give
away on the spot. After repairing and recovery to the safety conditions, it can be reused.
14.1.4.7 Accident
Once the accident happens, for example the staff injures, the truck damages the building or the
equipment, firstly should organize salvage, do best to protect the accident field and report to
the governor.
14.1.5 Operating conditions
14.1.5.1 Channel and stacking field
The ground of the operating field should have enough carrying capacity, and it is necessary to
maintain it well not to influence the truck operating safely.
The transporting channel of the truck should have well visual field, and it is easy to turn, and no
grade, steep slope, narrow channel and low roof board. The outline or the borderline must be
clear.
In the road where it is easy to meet the stepping truck, the width of the channel should be
adjusted.
Advising the grade of the channel should not over 10%, the top and the bottom of the slope
should transit smoothly, to prevent the load vibration or the bottom of the truck from colliding
the ground.
When the grade is over 10%, installing a sign is advised.
If the truck is in operation (transport) and the load block off the sight, when the vehicle is
operating, the load should located on the backward of the truck operation direction.
For example: in some conditions (for example stacking and climbing), when the vehicle is
operating, the load is required on the forward of the vehicle operation direction. Then, the
driver should drive the vehicle carefully. It is necessary to attend: if the operation condition
require, should equip accessory (assistant) equipment or assistant.
The passage, road, runway, floor or slope should maintain good operating conditions, to
prevent the truck or the load from being damaged, and to prevent reducing the stability of the
vehicle.
In dangerous state, including the barrier danger on the top, should mark on the clear location.
The fire fighting passage, the upstairs passage and the fire fighting equipment should maintain
expedite.
14.1.5.2 Gangplank or transition board
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 All the gangplank or transition board should has enough safety coefficients to bear the truck
with load. On the gangplank or transition board should marked the max passing load
perpetually.
The gangplank or transition board should fixed firmly, to prevent the accidental move, vibration
or slide.
On the gangplank or transition board should equipped handing or other available equipment to
the effect of safety transport. On the conditions of possible, should set the fork hole or
suspending ear for moving goods.
The gangplank or transition board should have non-slip finishing.
On the both sides of the gangplank or transition board, should mounted the facility to prevent
the truck from going over it’s edge.
When the gangplank or transition board is fixed its location, should adopt measures to prevent
the reverse joint truck from moving suddenly.
14.1.5.3 Lighting
When the photometric brightness on the operating field is less than 32LX, the vehicle should
equipped auxiliary light.
14.1.5.4 The suspending of the truck
The sling should be tied to the lifting spot which the factory appointed.
14.1.5.5 The synchronizing operation of the truck
Conveying bulky or heavy load using two trucks simultaneously is a dangerous operating which
requires special care. And this kind of conditions should be taken as special conditions and
carried out under the supervision of the operator responsible for operation.
14.1.5.6 Elevator (lifter)
The elevator (lifter) for transporting the industrial truck can bear the overall weight of truck,
load and the drivers. This kind of elevator (lifter) must be appointed, and the drivers should use
the appointed elevator (lifter).
14.1.5.7 Operating on the road vehicle (trailer) and rail vehicle
Before the motor industrial truck drive to the road, the road vehicle should apply the brake and
wedging to prevent moving.
Exception: the road vehicle equipped with automatic snap lock type parking brake can not use
the wedge.
The industrial motor truck passing in and out without connect to the tractor, to prevent the
semi-trailer hold up can use support.
It is necessary to build up the operating communication and operating order, to prevent the rail
vehicle move accidentally when downloading.
The road vehicle (trailer) and rail vehicle should endure the overall weight of vehicle, load and
the drivers. It is necessary to inspect if the pavement is crushing, having holes or other
damage.
When the industrial truck is operating at high place or platform, should not use the industrial
truck to move other vehicles. Never open the door of the rail truck using industrial truck; expect
for equipped with special device and the driver has passed the train to use the device.
14.2 Applied to the driver
The safety operating of the industrial truck lies on the control manner of the driver ro a
considerable degree. The safety rules applied to the drives are as follows:
A） general rule;
B） transporting (lifting and stacking) rule;
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 C） operating (driving) rule;
D） the rule for the driver maintaining the truck.
Without regard to the rules maybe conduce:
A） the serious danger of damaging the driver or other personnel;
B） Damage the materials.
14.2.1 General rule
Only the personnel who have been trained and get the qualification of operation are permitted
to drive the industrial truck.
The motor industrial truck could not carry passengers, except for equipped with the facility for
the passengers sitting.
The driver should pay special attention to the operating circumstance, including the person
nearby other staves and fixed or moving substances, and it is necessary to watch out for the
passerby at any moment.
No matter whether there is load on the lifting part of the truck, it is forbidden anyone passing or
standing under the lifting part of the truck.
If the people, building, organization or equipment accident happens, it is necessary to report to
the relevant officer at once.
The driver should not change, add or demolish the truck components without the permission to
influence the performance of the truck .It is not allowed to install accessorial frame or handle
on the steering wheel ,except the factory has installed it.
The driver should use the truck in the using range. When operating high stacking job, convey
high and multi-piece piled goods using driving type high-lift truck, it is necessary to use the
truck with blind goods shelf and canopy guard shelf.
Exception: if there is no danger of the load fall down on the driver, the truck without blind
goods shelf can be used.
When operating high stacking job, convey high and multi-piece piled goods using walking type
truck, the blind goods shelf is necessary.
14.2.2 Load carriage (lifting and stacking) rule
14.2.2.1 Load
The industrial truck or the combination of the industrial truck and attachment only can convey
the load not over its rated load weight. The capacity of the industrial truck with attachment
maybe less than the one marked on the nameplate.
Any measure of enhancing the capacity of the truck is forbidden, for example the adding
people or balance weight.
In any conditions, especially when using the attachment, it is necessary to pay attention to the
operation, location, fixation and transportation of the load. The truck with attachment when
unloaded should be treated as with some capacity.
Only the rank stabilized or safety load can be conveyed, especially when convey the super long
or high load, should pay special care.
When convey the load which center of gravity is uncertain, operating the vehicle should special
carefully.
14.2.2.2 The loading and unloading of goods.
When loading the goods with forks:
A） The space between the forks should fit the width of the conveying load.
B） The fork should insert into the inner of the load as deep as possible. But pay attention to
not make the fork tip touch the substance except the load. Then the fork should lift to the
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 enough height to move the goods.
C） When conveying high and multi-piece piled goods, it is necessary to tilt the mast back
ward a little (if can tilt back) to stabilize the load, and should be careful specially.
When unloading the goods, it is necessary to descend carefully. If possible, tilt the mast
forward a little (or limited)in order to put ready the load and draw out the fork.
14.2.2.3 Stacking
When stacking, the mast should tilt backward to ensure the stability of the load, approach the
goods pile slowly.
When the truck approach and face to the goods pile, it is necessary to adjust the mast to the
vertical location, and lift the load a little higher than the height of the pile. Then running
backward the truck Or if using reach truck, extense the fork and descend it to unload the
goods.
After lifting, start the vehicle, no matter with or without load, it is necessary to operate the
brake carefully and placidly.
It is necessary to ensure that the stacking is firm.
After stacking, draw off the fork, and lower the fork to the operating height. After confirm there
is no block on the road, drive away the truck.
As for truck can tilt backward , it is necessary to use this function to stabilize the load.
14.2.2.4 Unpiling
The truck approaches the pile slowly, and stopped when the fork tip is 0.3 m far away from the
pile.
The space of the fork should adjusted to the width of the conveying load, and should check the
weight of the load, to make sure the load is in the lifting weight range of the truck.
It is necessary to lift the fork vertically and insert it to the bottom of the goods.
After lifting, start the truck, no matter the truck with or without load, it is necessary to operate
the brake carefully and placidly.
The fork should insert into the bottom of the load as possible. But pay attention to not make
the fork tip touch the substance except the load. Then lift the fork to the enough height to
move the goods.
Further lift the fork, make the goods away from the pile exactly. If the mast can tilt backward,
the fork should tilt back properly to stabilize the load. If it is reach truck, it is necessary to draw
back the fork.
After make sure the road is smooth, descend the load from the pile.
The fork should be descended to the operation height and the mast tilt backward mostly. After
make sure the road is smooth, drive the truck away placidly.
14.2.3 Running (driving) rule
14.2.3.1 General rule
The driver should drive the truck along the right side of the road, and the driver should see the
road clearly and attend other truck, passengers and safety space.
The drivers should abide by all the traffic rules, including the speed limit specified in the
factory.
It is necessary to hold a certain space with the front operating truck.
The driver should drive the truck with earnest and responsible attitude at any time. The sudden
starting, stopping and turn over at high speed are forbidden. Except for the requirement of the
operation conditions, advising the steering wheel should not put on the limiting position when
the vehicle is starting. If starting on the limiting position, it is necessary to operate carefully.
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 The load or the device that bears load must be kept at the operating height when the truck is
moving. If possible, the load shall be tilted backward when the vehicle is running. Except for
stacking operation, it is not permitted to lift the load. This regulation does not apply to truck
specially designed that can move with lifting load.
In operation (or called transport) state, if the load obstruct the driver’s sight, then when the
truck running, the load should be located in the back of the truck's moving direction.
Exception: Under some condition (such as stacking and climbing), the load should be located in
the front of the truck's moving direction when the truck is moving. At this moment, the driver
should drive the truck very carefully. If operating conditions requires, some subsidiary
(attached help) facilities or the other person’s lead can be adopted.
In crossroads and the occasion that would obstruct the driver’s sight, the driver must reduce
the speed of the truck, and issue sound signal.
When the truck is operating with load, the driver must control turning equipment and brake
system slowly and stably.
In crossroads and the occasion that would obstruct the driver’s sight or some dangerous
occasion, the truck must not exceed other truck moving at the same direction.
The driver must avoid the truck rolling over some fluffy object in order to avoid article damages
or personnel hurts.
It is forbidden that to put the arms , legs or the head in the columns of mast or between the
truck’s other moving components.
When the vehicle is running, the driver must not let his body outside the contour line of the
truck.
When turning, if there are some other trucks or pedestrians, the driver must issue warning
signal.
The driver must comply with all labels about ground load carrying capacity and requirements of
other instructive labels.
The driver must pay special attention to the load carrying capability of slopes and channels
leading to electric elevator.
14.2.3.2 Vehicle speed
The truck speed should coordinate with the status of person’s activity, visibility, road or the
ground conditions and load conditions of the running area. When the vehicle is moving on wet
and smooth road surface the driver must be very carefully.
Under any situation, the vehicle speed must be controlled within the range that the truck can
be stopped safely.
14.2.3.3 Running on the slope
When operating on the slope, the following regulations must be obeyed:
A) Moving up and down a slope slowly.
B) Except for the side loading and no lifted load truck, it may as well make the bearing load
device’s surface towards the downgrade direction.
C) Turning on the slope and bestride the slope are all forbidden.
D) When the vehicle is near the slope, high platform or platform edge, the driver must drive
carefully. The distance between the vehicle and the platform or platform edge must keep
at least a truck tyre width.
E) When the gradient is more than 10% during the truck’s running up and down the slope, if
possible, when the lifted load truck and flat stacking truck (except the side bearing load

50
 fork-lift truck, cross-country fork-lift truck , stride- truck and platform carrying vehicle)
moves, the load surface must be in a upgrade direction.
F) When the truck works on various slopes, the load and the load bearing device must tiltt
backward (if possible), and the driver can only elevate the load’s height that is enough for
running through the road surface and local barrier.
14.2.3.4 Get across a gap
It must be ensured that under hanging devices (such as: lamps, pipeline and fire extinguishing
system) there is an enough clearance height.
Before getting across the passage and door, it must be ensured that there is an enough gap
among the vehicle, the driver and the load.
14.2.3.5 Working in road truck and railroad vehicle
Before a motor-driven industry truck runs on (or run down) the road vehicle or railroad vehicle,
some necessary measures must be taken to prevent road truck and railroad vehicle from
moving.
Before a semi- trailer that is not linked with a tractor runs on the road truck or railroad truck ,it
must be ensured that the supporting part of the stilt of the semi- trailer is located at the
supporting position.
Before a motor-driven industry truck runs on the road vehicle or railroad vehicle, it must be
ensured that the floor board can endure all the weight of the industry vehicle, load and the
driver. Besides, it is required to check the plank to see if there are crashes, holes or other
damages.
When the industry truck works on high place or platform, it is forbidden to move other truck by
industry truck. It is also prohibited to close railroad truck’s door by industry truck except for one
case that the industry truck is equipped with a special device and the driver has also been
trained how to use this device.
If possible, the truck should cross over the railway virgule.
14.2.3.6 The truck operating on the gangplank or transition board
Before the motor industrial truck pass the gangplank or transition board, it is necessary to
make sure the firm of the board.
The overall weight of the truck should not excess the rated capacity of the gangplank or the
transition board.
When passing the gangplank or the transition board, the driver should drive the truck carefully
and slowly.
14.2.3.7 The use of the truck in elevator (lifter)
Before the motor industrial vehicle driving into the elevator (lifter), it is necessary to make sure
the elevator (lifter) can endure the over all weight of the truck, load and drivers.
Before allow the truck driving in or out of the elevator (lifter),all other personnel should leave
away from the elevator(lifter).
After the bridge box floor of the elevator (lifter) is even to the ground, the truck should slowly
driving in as the positive direction.
It should be the load go into the elevator (lifter) first not the driver, this is specially adopted to
the walking type truck.
After the truck driving into the elevator (lifter), it is necessary to put the control device in the
central position. switch off the power, and tighten the brake.
14.2.3.8 Parking
After the driver leaving, the carrying device must lower to the lowest position, put the control
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 device to the central position, switch off the power, and tighten the brake, stay steady the
vehicle to prevent accidental move or make bold by others without approval.
When parking the truck, the fire fighting passage, access stairs and fire fighting passages
should keep fluently.
The parking location of the truck should keep a safety distance to the railway.
14.2.4 The vehicle maintaining rule for the drivers
14.2.4.1 General rule
Before starting the truck, it is necessary to inspect the technical condition of the truck.
According to the different type of the truck, should pay more attention to some special location:
[for example: fuel oil system, alarm system, power system, brake, steering equipment, lighting,
wheel and air tire pressure (namely gas filled type) and lifting system (including lifting chain,
wire rope, limit switch and hydraulic cylinder).
If the truck is found to be repaired, or during the operation the defect develops, it is necessary
to report it to the superior in concern. It is forbidden to repair or adjust the truck by the truck
by the driver without permission.
The truck which fuel oil system is leaking could not be uses without repair.
14.2.4.2 Refuel
Before refuel, it is necessary to close the engine, brake the truck and the driver should leave
the truck.
The open flame and smoking is forbidden during refueling.
14.2.4.2.1 Liquid fuel (for example gasoline and diesel fuel)
The truck using liquid fuel should add fuel in the appointed places.
Before take away the refueling equipment, cover the filler cap and clear up the excessive fuel,
the engine could not start up.
14.2.4.2.2 Liquefied petroleum gas fuel (liquefied petroleum gas)
Only the personnel trained and appointed can refuel or change the liquefied petroleum gas
container.
The person charging for refuel liquefied petroleum gas should wear protective suit (that is to
say long sleeve unit and glove).
The pouring of the fixed type liquefied petroleum gas container and the pouring and change
of the liquefied petroleum gas container should be carried on the appointed place.
When transporting or conveying the liquefied petroleum gas container, it is necessary to be
careful, the container should not fall down, nor be thrown, rolling or draw. If it is necessary
to transport several containers one time, a proper transporting device should be adopted.
The liquefied petroleum gas container should not be filled in excessive.
Before filling the fuel, power off the engine, brake the truck, and the driver leave away the
truck.
It is necessary to using soap liquid to check the leak dictation.
The truck driven by liquefied petroleum gas could not park near the heat source, open flame
or the similar ignition, and not near to the open air pit, the entrance of the under crossing,
the elevator well or other similar place, and could not change the removable container in the
upper place.
Before fill fuel into all liquefied petroleum gas container and before the reuse of the
removable liquefied petroleum gas container, it is necessary to inspect if there is defect or
damage as follows:
A） the dent, scoring and groove of the pressure container;
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 B） the damage of any kinds of valve and fluid level gage;
C） the scraping in the safety valve;
D） the damage or the lose of the safety bonnet;
E） the leak in the connection of valve or screw-threaded joint;
F） The deterioration, damage or lose of the flexibility seal in the connection of prime or air
feed.
If finding the above defect and/or damage, the container should not be used until repaired.
The truck which is driven by liquefied petroleum gas is over night or stay indoor for a long
time and the liquefied petroleum gas container stayed on the truck, it is necessary to close
all of the feed valves on the container.
14.2.4.3 The charging and changing of the battery
The charging and changing of all the battery should be carried out by the personnel who has
been trained and appointed staves and proceed as the description of the user’s manual of the
battery or truck factory. As usual the driver can be appointed.
Before charging or changing battery, the truck should be located correctly and brake.
When charging, the exhaust cap should be in the correct position to prevent the electrolyte
spilling out, and make sure that the wind hole is in effect. Open the cover of the battery (or
separate room) to exhaust the gas and thermal.
In the battery charging area, should adopt measures to prevent open flame, spark or electric
arc. Smoking is forbidden.
The tools and other metal substance should put far away from the top of the battery without
cover.
The top of the battery should keep dry; the connection terminal should keep clean, wipe a little
vaseline and screw down correctly.
Without approval, the battery of different voltage, weight or size could not replace the former
one in the vehicle.
When reinstalling the battery, the battery should be put on the correct place.
Inspecting the liquid surface in the battery using open fire is forbidden.
When getting the solvent in the acid carboy, the acid carboy tilting device or siphon pipe could
be used. When diluting oil of vitriol confect the electrolyte, only adding the oil of vitriol into
water is permitted, not add water into oil of vitriol.
15 Maintenance
15.1 General description
Good performance of the motor industrial truck depends upon maintenance. Truck may
damage personal health and properties in case of maintenance neglect.
15.2 Maintenance items
The following items shall be carried on for all motor industrial vehicles shall be in accordance
with schedule, especially with maintenance instructions supplied by the manufacture.
Only professional and qualified maintenance personnel are allowed to go along with the
inspection, maintenance, modification and repair.
15.2.1 Brake set, steering mechanism, control mechanism, alarming device, lighting, adjustor, and
overload protection device for lifting shall be kept within safe operation condition.
15.2.2 Regular inspection shall be taken for components and members of lifting and inclination
systems, which shall be kept within safe operation condition.
15.2.3 Regular inspection shall be taken for safety protection shelf and safety devices, which shall be
kept within safe operation condition.
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15.2.4 Regular inspection and maintenance shall be taken for all the hydraulic systems.
Inspection must be taken for oil cylinder, valve, and other similar components to ensure that
internal leakage or external leakage would not develop into a dangerous condition.
15.2.5 Inspection and maintenance shall be taken for storage battery, driving motor, contactor and
controller, limit switch, protection device, lead wire and connecting assembly, which shall be
kept within safe operation condition. Special attention shall be paid to electrical insulation state.
15.2.6 Inspection for damage and leakage must be taken for exhaust gas system of internal
combustion truck, adjustor of carburetor, evaporator, and fuel injection pump.
Notice: hazardous substances may be produced by the internal combustion engine
in case of operation under close place. Sufficient ventilation is recommended in
that condition.
15.2.7 Check damaged condition of wheel tread, side face and wheel rim of the air-filled type
pneumatic tire. Pressure of the tire that is specified by the manufacture must be kept. Gas in
the tire shall be firstly be released before dismantling the air-filled type pneumatic tire from
separable rim.
15.2.8 Check the bonded condition between solid tire and metal wheel band or wheel rim. Foreign
matters on wheel tread of the tire shall be cleared if necessary.
15.2.9 Make sure that all the nameplates, indicator boards and labels (pattern) are clear and legible.
15.2.10 Inspection shall be taken for fuel oil system and auxiliary fittings to see if there is any leakage.
Soap bath shall be used for leakage inspection of liquefied petroleum gas system. truck must
leave the working site in case of any leakage in fuel oil system. And the truck cannot be put into
operation until all the leakages have been repaired.
Inspection must be taken before reuse of all the dismountable liquefied petroleum gas
containers or filling fuel into all the liquefied petroleum gas containers, to see whether there is
the following defective or damage:
A） Dent, scuffing, flute;
B） Damage of various valves or lever meters;
C） Scraps in emergency valve;
D） Damage or loss of emergency valve bonnet;
E） Leakage at connection of valve and thread;
F） Deterioration, damage, or loss of flexible seal at connections of gas filling or gas supply.
In case of occurrence of any defective or damage as above mentioned, no container would
be allowed to be used before repair.
15.2.11 Neither modification in design nor addition to the truck shall be taken without permission of the
manufacture for sake of weakening performance or operation security of the truck. Nameplate
and instruction manual shall be revised accordingly in that condition.
15.2.12 Special purpose truck or equipment that is designed for dangerous condition, or is permitted to
be used under dangerous condition, shall be paid special attention to, thus ensure the original
safe operation performance of the truck.
15.2.13 All the components that are used for replacement must be of the same model, or at least of the
same quality with the original part.
15.2.14 Industrial truck must be kept clean for sake of fire. Find loose or defective part in time. Keep
clean for lifting device, carrying device, wheel tread, foot pedal, and floor of the truck. No
grease, oil stain, or other dirty substances shall be kept.
15.3 Inspection
15.3.1 If any potential defective, abrasion, or damage is found in the vehicle after inspection, which
54
 would threaten safe performance, effective measure shall be taken. Truck cannot be put into
operation before repair.
15.3.2 Protective maintenance, lubrication and inspection shall be taken in accordance with schedule
for the truck. Data that are in demand of record shall be carefully kept.

Recording card of maintenance and upkeep process:

Maintenance Maintenance Maintenance
Items Material used Remarks
time Part personnel

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Customer advisement feedback:
Occurrence Location of
Items Faults causes Trouble-shooting Remarks
time faults

56