CDDC Narrow aisle stacker

 Operation Manual
 Parts Catalogue
 Thank you for buying the CDDC electric pallet
stacker!
Hope it 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.

****************************************************** Wa
rning!
 Operators must strictly conform to ISO3691 1980 Safety Specifications of Motor
Industrial Trucks. Untrained personnel are not allowed to operate the stacker.

******************************************************
According to ISO 3691 Safety Specification of Motor Industrial Trucks, load capacity and
lifting height of the CDDC narrow aisle stacker are stipulated as follows:
1. When the lifting height of CDDC narrow aisle stacker is below 3300mm
(including3300mm), the maximum load capacity is the rated capacity. Overloading is
prohibited.
2. When the lifting height of CDDC narrow aisle stacker is above 3300mm
(excluding3300mm), the load capacity is less than the rated bearing capacity. Take the
following diagrams as a reference with the rated loads of 1500kg:
 Contents
Brief introduction................................................................................................................1

1． Structure diagram.....................................................................................................2

3． Safety Norms................................................................................................................4

4． Initial operation............................................................................................................9

5． Use and operation instruction.............................................................................9

6． Use, maintenance and charge of the storage batteries.................12

7． Inspection after operation................................................................................15

8． Inspection after operation................................................................................16

9． Periodic maintenance and repair..................................................................16

10 ． The store, transportation and loading of truck...................................20

11 ． Storage battery replacement.........................................................................21

12 ． Common faults and trouble shooting........................................................21

13 ． Instrument function description..................................................................26

14 ． Attachment, spare parts and wearing parts list...............................28

15 ． Structure diagram and schematic diagram..........................................28

16 ． Packing list................................................................................................................29
Brief introduction
The CDDC narrow aisle stacker uses batteries as the power source abd AC motors as the
power source, and drives the truck to move through gear transmission. The lifting of the forks
relies on DC motors and hydraulic transmission, driving the oil cylinder to move up and down
to lift the forks and goods. Because both the walking and lifting of the truck are electric, the
driving mode is side standing driving, and the steering is eletctric power steering. It has the
characteristics of labor-saving, high efficiency, smooth cargo operation, simple operation,
safety and reliability, low noise, and pollution-free. The truck uses a 24V high capacity
battery, greatly extending the usage time after a single charge.
This truck is suitable for cargo handling operations on hard and flat surfaces.

 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.

Instruction
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
Danger would be resulted without any precaution or avoidance.
You must observe those requirements.
Indicates a potential danger. Deaths or severe injuries
Warnin
would be resulted without any precaution or avoidance.
g
You must observe those requirements.
Indicates a potential danger. Moderate injuries would be
Cautio
resulted without any precaution or avoidance. You must
n
observe those requirements.

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 You shall pay attention to statements that are in direct or
Notice indirect relation with personal security and truck
maintenance.

1． Structure diagram
1.1 CDDC outline disgrame

2
1.2 Main technical parameters
1.1 Manufacturer(abbreviated)

3
 1.2 Model CDD15C

Driving model ： Electric(Storage battery), diesel,

1.3 Electric(battery)
gasoline, fuel gas
Characteristics

Driving model （ Manual, Walking, Stand driving, seat

1.4 Standing
driving ,Order picking ）

1.5 Rated load Q(kg) 1500

1.6 Load center distance c(mm) 600

1.8 Front overhang x(mm) 672

1.9 Tread Y(mm) 1386

2.1 Service weight(with battery) kg

Weigh

2.2 Axle load, front/rear, laden kg

2.3 Axle load, front/rear, unladen kg

Wheels (rubber, high elasticity, pneumatic tyre,

3.1 PU
polyurethane wheel)
Wheel chassis

3.2 Wheel dimension, front φ250×80

3.3 Wheel dimension, rear φ80×84

3.4 Additional wheel(dimension) φ150×47

3.5 Wheel number, front/rear （ x = driving wheel ） 1x+2/4

3.6 Tread, front b10(mm) 648

3.7 Tread, rear b11(mm) 405/530

4.2 Height of mast, lowered h1(mm) 2050/2210/2410/2710

4.3 Free lift height( optional) h2(mm) 1570/1740/1940/2240

4.4 Lift height h3(mm) 4500/5000/5600/6500

4.5 Max. height of mast, extended h4(mm) 5030/5510/6110/7050

4.9 Min. /Max. height of operation handle in driving position h14(mm) 2255

4.1
Height, lowered h13(mm) 90
5

4.1
Overall length l1(mm) 2010/2090
9

4.2
Length to fork face l2(mm) 940
0

4.2
Overall width of truck body b1(mm) 970
1

4.2 s/e/
Fork dimension 60/180/1070(1150)
2 l(mm)

4.2
Overall width of fork b5(mm) 570/695
5

4.3
Wheelbase ground distance m2(mm) 31
2

4.3
Aisle width, with pallet 1000x1200 crosswise Ast(mm) 2537
3

4.3 Aisle width, with pallet 800x1200 lengthwise Ast(mm) 2467

4

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 4.3
Dim Turning radius Wa(mm) 1653
5

5.1 Traveling speed, laden/unladen Km/h 8.5/8.5

Performance Data

5.2 Lifting speed, laden/unladen m/s 0.16/0.24

5.3 Descending speed, laden/ unladen m/s 0.35/0.22

5.8 Max. gradeability, laden/unladen % 8/15

5.1
Traveling brake EM brake
0

6.1 Driving motor power kW 2.2(AC)

6.2 Lifting motor power kW 3.2

Motor

6.4 Battery voltage/rated capacity V/Ah 24/400

6.5 Battery weight kg 330

6.6 Battery dimension （ LXWXH ） mm 654×254×760

8.4 Noise level at operator’s ear, according to DIN12053 dB(A) 75

1. Parameters relating to h1 、 l 、 Q shall be calculated according to h1=3000mm and l=1070mm.

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.

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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.
3.1 Safety operation norms:
1) 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.
2) 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.
3) 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.
4) 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

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 tyre of truck is damaged, the noise may be amplified.
5) Integrity 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.
B. Unauthorized truck modification is not permitted.
C. 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 plate, decals, tags and operation
and maintenance handbooks.
D. 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.
6) 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.
7) 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.
8) 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.
9) Use suitable pallet:

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 The pallet shall be of suitable dimensions, neither too wide nor too large.
10) Electrical system check:

Notice
Before checking the electrical system, turn off the key switches and the
emergency isolation switches.
3.2 Safety Operation Specification:
1) Check the safety condition around the truck:

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

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
Do not lift or lower goods when the truck is travelling.

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 trucks, 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.
2) Strictly forbid harsh driving

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 Notice
Never start up, brake or turn abruptly.
Abrupt start-up or braking may cause the falling of goods.
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 trucks. 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 truck.
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

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

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 Warning
Open flame is forbidden to appear at the charge places, otherwise, explosion or
fire disaster can be caused.
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.
4.1.3 If the stacker is driven by the external battery through a tow cable, it is forbidden to lift
the loads.
4.1.4 Befor 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.
4.1.5 The 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:

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 Warning
It is strictly forbidden to use faulty truck.
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.

Figure 1

5.1.3 Check whether the hydraulic support leg operates normally. (1) Operate the support leg
button at the integrated handle, the support leg will open and retract. Number 2 is the
horn button position, as shown in Figure1.

Figure 2

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5.1.4 Check whether the truck braking is normal; Check if the truck's lifting, lowering, and
forward and backward movement are normal. The method is shown in Figure 2:
1) Pull the joystick backward as shown in Figure 2 to lift the cargo fork, push it
forward to lower the cargo fork, and control the lifting speed;
2) Pull the joystick to the right as shown in Figure 2 to move forward; Turn to the left
to move backwards and control the front and rear travel speeds.
3) Return the joystick from the forward and backward driving positions to the middle
position as shown in Figure 2, and the truck should immediately brake.
Through the above inspection, if the truck has no faults, it can be put into use. If there
are faults, please repair them immediately. It is strictly prohibited to use faulty trucks.

Warning
It is strictly forbidden to turn the accelerator knob fastly to speed up the stacker
abruptly during goods transportation.
5.2 In operation
5.2.1 Note: The truck is equipped with a magnetic brake at the output end of the driving
wheel motor. The stacking truck can only operate when powered on, and can only lift
goods when powered off for braking. The truck cannot travel when lifting goods.
5.2.2 Handling and stacking operations

Note
Before starting to operate, the following items should be checked:
Ensure that no cargo falls or damages the cargo in the loading area.
Ensure that no goods or objects hinder safety.
As shown in Figure 1, pull out the main power switch to open the main power supply, open the electric
lock, and drive the truck to the vicinity of the cargo pile (the fork head is 300mm away from the cargo pile).
Use the operating handle shown in Figure 2 to lower the fork, adjust the height of the fork to the appropriate
position, and slowly insert the fork as deep as possible into the cargo tray. Use the operating handle to raise the
fork to a height of 200-300mm from the ground, Drive the truck to the shelf position and slowly stop the forks
at a distance of 300mm from the shelf. Then, operate the handle to raise the forks to the appropriate height of
the shelf (the bottom of the pallet is about 100mm higher than the shelf), slowly move the goods to the accurate
position of the shelf. Finally, operate the handle to lower the forks, carefully place the goods on the shelf, and
make the forks detach from the goods. Slowly start the truck, Move the fork out of the cargo pallet (the head of
the fork is 300mm away from the shelf), lower the fork to about 300mm away from the ground, and drive the
truck away from the shelf. During driving, attention should be paid to whether there are obstacles in the front,
back, left, and right sides. When turning, slow down and drive.

Warning
Unlike ordinary trucks, the driving mechanism is installed at the front of
the truck. When turning, the front part of the car swings faster. Therefore, when
the front part of the truck approaches other objects, it is necessary to drive or
turn slowly to prevent collisions.

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5.2.3 Operation of removing goods from shelves
Pull out the main power switch as shown in Figure 1, turn on the main power, open the
electric lock, and drive the truck to the vicinity of the shelf (the fork head is 300mm away
from the shelf). Lower the fork according to the operating handle as shown in Figure 2, adjust
the height of the fork to the appropriate position on the shelf, slowly insert the fork as deep
as possible into the cargo tray, lift the fork with the operating handle, and lift the goods to a
height of 100mm from the bottom of the cargo tray to the shelf. Slowly start the truck to
slowly move the goods out of the shelf (the fork head is 300mm away from the shelf), then
operate the handle to lower the fork to a height of 200-300mm from the ground, move the
truck away from the shelf, drive to the desired position, and slowly stop the truck. Finally,
operate the handle to lower the fork, place the goods down, use the fork to completely
detach from the goods, and slowly move the fork out of the cargo pallet.
5.3 Abnormal situation handling during operation
5.3.1 Pull the operating handle backwards to lift the fork, but when it is released and
returned to the middle position, the fork is still rising and is in a state of uncontrolled
rising. At this time, immediately press the main power switch to cut off the power
supply. In addition, move the truck to a safe position, manually lower the goods, and
inspect the truck's electrical circuit.
5.3.2 If brake failure is found during use, it must be immediately stopped and the truck
repaired.
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.
6.1 Initial charge
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

14
 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 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,

15
 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
6.2.4 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.
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.
6.4Operation of electrolyte
1) Density check

16
 The suction type densimeter shall be used to check density. During operation, avoid
spilling out the electrolyte, and do wear protection appliance.
2) Operation besides check
Consult professional personnel, especially when complementing electrolyte (dilute
sulfuric acid).
3) 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).
6.5Operation of storage batteries during the final stage of their lifetime
1) Operation of storage batteries during the final stage of their lifetime
Add distilled water daily during the final stage of storage batteries.
2) 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.
6.6Emergency treatment
1) The electrolyte spills on skin
Wash with large amount of water
2) The electrolyte spills into eyes
Wash with large amount of water, and then seek help from specialized doctor.
3) The electrolyte spills on clothes
Take off clothes right away, wash with water, and then flush with week basic soap
solution.
4) 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.
6.7Charger
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.

7． Inspection after operation

In order to operate safely and keep the truck in good condition, it is a statutory
responsibility to conduct a comprehensive inspection before operation. If any problems are
found, please contact our company's sales department.
7.1 Check point and contents
S/
Check Point Inspection content
N

17
 Pull the operating handle to switch the handle
between the walking area and the
1 Operating handle
Braking intermediate brake area, and the brake will
system make a clattering sound.
The brake clearance shall be maintained at
2 Brake clearance
0.2-0.8mm.
3 Operating handle Tightness and rotational flexibility.

Steering 4 Oil pipe Whether the oil pipe leaks oil.

system 5 Hydraulic oil Appropriate oil volume.

6 Lifting cylinder Oil cylinder for oil leakage.

Pins, screws and Check whether all pins, fasteners and screws
7
all Fasteners of all wheels of the truck are loose or fall off.
Wheel Compared with the parameter table, the
Friction loss
8 wheel shall be replaced when the diameter is
condition
reduced by 5%.
Determine the battery capacity display
9 Charging
status.
Battery
10 Electrolyte Electrolyte level, specific gravity.

11 Connecting line The connecting wire and socket shall be firm.

Check whether the horn rings after pressing
Horn 12 Horn
the horn button.
Open the electric lock switch and check
Instrument 13 Function
whether the instrument display is normal.
Frame and other
Other 14 No damage or crack.
structural parts
Check whether the lifting, forward, backward
15 Function and supporting legs are normal and whether
there is abnormal sound.

8． Inspection after operation

After completing the work, the dirt on the car should be wiped clean and the car should
be inspected in the following aspects:
Keep the warning signs, nameplates, warning signs, and other graphic and textual
markings of the truck complete and clear. These graphic and textual markings serve as
guidance, reminders, and warnings for operators.
Is there any deformation, twisting, damage or fracture.
Add lubricating grease according to the situation.
Replace faulty components.

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.

18
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.
1) 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.
2) 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.
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

19
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 Inspection as needed
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
1 switching between area A and B, there is a noise from the
brake.
Braking system The oil dirt and dust on the turning gearwheel should be
2
cleaned.
The clearance between brakes should be kept between 0.2mm
3
and 0.8mm
Capability of Inspect the liquid level of electrolyte, pure water can be used
4
electrolyte for supplement if the liquid level is too low.

Density of electrolyte 5 The specific gravity should be1.28g/ml after charged.

Clean the storage

6 Cover the lid, and flush with tap water.
battery

Inspect the contactor 7 Burnish the coarse surface of contacts using sand paper.

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
Whole 1 Whole status Abnormal or not.
truck 2 Horn Sound
No. Check point Check content
Steering 3 Operation handle When the operation handle is turned, with the
system, handle switching between area A and B, there
braking is a noise from the brake.

20
 The clearance between brakes should be kept
4 Brake clearance
between 0.2mm and 0.8mm.
5 Operation handle Degree of tightness and rotary flexibility.
system, Truck frame ， mast Function ， and check cracks, lubrication and
6
hydraulic and fastener tightness of fasteners.
system Connecting rod and Function and check the cracks, bending,
7
and 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 Wearing status of carbon brush and selenium
and electric 17 Driving motor
rectifier.
system
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 Whether flexible and whether damaged or
21
connection terminals not.
Adjustment of the brake clearance:
1. 1 Hollow screw 2 Fitting screw3 Spring
4 Armature 5 Motor shaft 6 Spline
The
housing
7 Friction plate 8 Electromagnetic coil
9 Mounting cover plate 10 Mounting screw
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.

21
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
Brake
wearing 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
Brake
check the wearing status of the friction plates.
Hydraulic Replace hydraulic oil. Check that whether there is any leakage in the
system lifting cylinder or not and replace the seals when necessary.
Fork wheel and
Check the wearing condition, and replace them if necessary
bearings
9.9 Recommended working medium:
1) 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

22
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.
2) Gear oil ：
Hyperbola gear oil 85W-90(GL-5)
3) 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:
Maintena
Items Maintenance content nce Remarks
period
Bearings of fork 1200
Replacement
wheel hours
1200
Fork wheel Replacement
hours
1200 Replace when finding
Seals Replacement
hours out damage
1200
Gear box Replacing lubricant grease
hours
1200
Hydraulic oil Replacement
hours
High pressure oil 2000 Replace when finding
Replacement
pipe hours out damage
Strainer of 1200
Cleaning
hydraulic reservoir hours
Check for carbon brushes and 1000
Driving motor
bearings hours
Check for carbon brushes and 1000
Steering motor
bearings hours
Check for carbon brushes and 1000
Oil pump motor
bearings hours

10 ． The store, transportation and loading of truck

10.1 Truck storage
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.

23
 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
truck 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 ． Storage battery replacement

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.

12 ． Common faults and trouble shooting

S/N fault reason Trouble shooting
1 ① The control circuit fuse is burnt
replace
out
② Poor contact or damage of
Repair or replace
The stacker does not power switch
work (contactor does ③ Main circuit fuse is blown replace
not work) ④ Bad contact or damage of
Repair or replace
electric lock switch
⑤ The battery connection is loose
tighten
or falls off
The stacker cannot ① The drive wheel side magnetic Repair or replace

24
 brake is not engaged, and the
truck is in braking state
② Swing accelerator damaged or
Repair or replace
screw loose
③ The excitation coil of traveling
be started (contactor
motor is broken or the wire end is Repair or replace
operates)
in poor contact
④ Bad contact of contactor
Repair or replace
contact
⑤ The MOSFET tubular circuit
Repair or replace
board is faulty
Stacker truck can ① Bad contact or burnt contactor Repair or replace
2 only move forward
② The circuit board is faulty Repair or replace
(or backward)
Emergency cut off
The stacker truck The contactor contact is
the power supply
3 cannot be stopped damaged and the moving
and replace the
during driving contact does not reset
contactor contact
① The wiring of the paramagnet Fasten the bolt or
brake is loose or the paramagnet repair the
4 Brake failure brake is damaged magnetic brake
② The brake pad of side Replace the brake
magnetic brake is worn pad
① Damaged stepping motor or
Repair or replace
loose set screw
5 Steering failure
② Steering motor damaged Repair or replace
③ Electric control is damaged Repair or replace
① The gear and bearing are Clean or replace
The driving wheel blocked by foreign matters the bearing
steering is heavy and ② Clearance during bearing Clearance
6
there is noise. The installation adjustment
motor is overloaded Replace the
③ Damage of front wheel bearing
bearing
7 Fork does not lift ① Use of overload Reduce load
② Excessively low pressure of
Raise the height
overflow valve
③ The lifting cylinder has
Replace seals
abnormal internal leakage
Apply appropriate
④ Insufficient hydraulic oil amount of filtered
hydraulic oil
⑤ The battery voltage is not
Battery charging
enough
⑥ Damaged solenoid valve Repair or replace
⑦ The oil pump motor is Repair or replace

25
 damaged
⑧ Damaged oil pump Repair or replace
⑨ Damaged solenoid valve Repair or replace
⑩ The electric lock is not opened
Repair or replace
or damaged
The battery voltage is seriously
charging
insufficient
① Inner gantry deformation due
Repair or replace
to overload
② Outer gantry deformation due
Repair or replace
to overload
The fork does not ③ Jamming of gantry roller Repair or adjust
8
drop after lifting Repair or
④ Bent gantry guide rod
straighten
⑤ The governor valve is blocked adjust
Troubleshoot the
⑥ Solenoid valve out of control
solenoid valve
① Individual single-circuit battery
Repair or replace
Reduced battery is damaged
9 terminal voltage Electrolyte
② Low battery level
(after charging) addition
③ Impurities in electrolyte Change electrolyte
① Pressure of pressure relay is
Raise the height
The hydraulic support too low
10 leg cannot be opened ② The electric control is
(or retracted) damaged or the program is Repair or replace
wrong
Reduce the
① The pressure of the pressure pressure of the
When the hydraulic
relay is greater than the pressure pressure relay or
support leg is fully
of the overflow valve, and the increase the
opened (or
relay is in the overflow state pressure of the
11 retracted), the pump
overflow valve
is still working and
The seal ring of the support leg Replace the
the lifting cylinder
oil cylinder is damaged sealing ring
does not lift
The three-way solenoid reversing
Clean or replace
valve is blocked
12.1 Controller fault code table
12.1.1 LED indicator display
The product is equipped with 2 LED indicator lights, which display different
information through different color light combinations. See Table 1 for details

Table 1

Display Description
Both LED light are OFF The controller is not powered on; Or the truck

26
 battery is exhausted; Or other serious faults.
Yellow LED is always ON The controller works normally
Yellow and red LED are ON Controller firmware is updating
simultaneously
The yellow and red LEDs are ON The controller has found a fault. The fault display
alternately code consists of 2 digits. The number of flashes
of the yellow light indicates the ten digits of the
code, and the number of flashes of the red light
indicates the single digits of the code.
12.2 Main controller fault code table
Table 2

Code Fault description Causes and trouble shooting

1 Feedback overspeed Contact the manufacturer in case of controller
failure.
2 Kernel running error Contact the manufacturer in case of controller
failure.
3 Long-time overload of Check whether the controller matches the motor
controller and motor and whether the controller is too small.
4
5 The position command Contact the manufacturer in case of controller
change after the electronic failure.
gear ratio exceeds the
maximum motor speed
6 In speed mode, the speed Contact the manufacturer in case of controller
command exceeds the failure.
maximum motor speed
7 In torque mode, the torque Contact the manufacturer in case of controller
command exceeds the failure.
maximum torque of the
motor
8 Loss of speed sensor No speed feedback detected. Treatment method:
Check the wiring between the speed sensor and
the controller;
Check whether the signal of the speed sensor is
normal;
Check the detection circuit of the controller.
9 Incorrect direction of speed The direction of speed sensor AB phase is
sensor inconsistent with the direction of motor UVW.
Solution (any of the following three methods):
Change parameter P3.0 encoder commutation;
Or any two-phase exchange position of controller
UVW;
Or speed sensor AB phase wiring exchange
position.

27
11 Motor 2-minute maximum The motor current exceeds the maximum current
current protection for 2 minutes for more than 2 minutes.
The motor is blocked; Check whether the brake is
opened and whether the drive mechanism is
blocked by foreign matters.
Improper setting of controller parameters, refer
to motor parameter adjustment for details.
12 Overcurrent of controller Wrong controller selection; Or controller failure,
contact the manufacturer.
13 Bus capacitor charging fault Contact the manufacturer in case of controller
failure.
14 Main contactor connection Check whether the main contactor is normally
failure connected.
15 Connection fault of Check whether the electromagnetic brake is
electromagnetic brake normally connected.
16 Battery voltage is too low Check the battery voltage; Or the controller
battery voltage level is set incorrectly.
17 Excessively high battery Check the battery voltage; Or the controller
voltage battery voltage level is set incorrectly.
18 Serious overheating of Controller protection, out of service.
power board
19 Serious overtemperature of Controller protection, out of service.
motor
20 The accelerator/brake pedal The input signal of accelerator pedal or brake
input is abnormal pedal is abnormal. Solution:
Check the connection between pedal and
controller;
Check whether the pedal is damaged;
Check the parameter settings of the controller
with respect to the pedal, especially the pedal
type. P91, P101).
21 Main contactor contact Check whether the main contactor is damaged,
fusion welding and replace the main contactor.
22 V output fault Short circuit of motor encoder; Or short circuit of
other 5V external equipment; Or controller
failure, contact the manufacturer.
23 MACID detection failed Repeated setting of CAN network ID number of
controller, reset.
24 Main contactor drive failure Check whether the main contactor is damaged,
and replace the main contactor.
25 Power module failure Contact the manufacturer in case of controller
failure.
26 Loss of CAN node The controller is configured in parameter P1 and
the interlock check is enabled in parameter P2. In
actual operation, no corresponding module is

28
 found.
Check the wiring between each module and the
working state of the module.
29 The temperature Contact the manufacturer in case of controller
measurement circuit inside failure
the controller is abnormal
31 The battery voltage is Battery power is insufficient, charge as soon as
slightly too low possible
32 Power board slightly Use of reduced load
overheated
33 Power version low Excessively low ambient temperature
temperature
34 The motor is slightly Use of reduced load
overheated
35 V output fault Short circuit of hand-held terminal power supply;
Or controller failure, contact the manufacturer
36 Drive3 connection failure Check Drive3 connection.
37 Drive4 connection failure Check Drive4 connection.
38 EEPROM parameter reading Contact the manufacturer in case of controller
and writing error failure

39 Parameter overrun error Parameter setting failure, contact the

manufacturer
40 Operation timing error The key signal is not in the original position after
reset (throttle switch, direction switch,
lifting/lowering and safety switch). Signal homing
and automatic alarm elimination.
41 Alarm for 20% of remaining Charging
power
42 Alarm for 15% of remaining Charging
power
12.3 Steering controller fault code table
Table 3

Code Description Causes and trouble shooting

1 Feedback overspeed Contact the manufacturer in case of controller
failure.
2 Kernel running error Contact the manufacturer in case of controller
failure.
3 Long-time overload of Check whether the controller matches the motor
controller and motor and whether the controller is too small.
4 Tracking overrun The target location differs greatly from the actual
location. Treatment method:
Check whether the motor is blocked.
8 Position command The set median value is greater than the maximum

29
 error and minimum dead band values. Treatment
method:
Check that the median value parameter should be
between the maximum and minimum values.
11 Motor 2-minute The motor current exceeds the maximum current
maximum current for 2 minutes for more than 2 minutes.
protection The motor is blocked; Check whether the brake is
opened and whether the drive mechanism is
blocked by foreign matters.
Improper setting of controller parameters, refer to
motor parameter adjustment for details.
12 Overcurrent of Wrong controller selection; Or controller failure,
controller contact the manufacturer.
13 Bus capacitor charging Contact the manufacturer in case of controller
fault failure.
14 Relay connection Check whether the relay is properly connected.
failure
17 Excessively high Check the battery voltage; Or the controller battery
battery voltage voltage level is set incorrectly.
18 Serious overheating of Controller protection, out of service.
power board
22 V output fault Short circuit of motor encoder; Or short circuit of
other 5V external equipment; Or controller failure,
contact the manufacturer.
23 MACID detection failed Repeated setting of CAN network ID number of
controller, reset.
24 Relay drive failure Check whether the relay is damaged and replace
the relay.
26 Motor short circuit Check motor winding for short circuit.
27 Error in centering Check whether the return switch is normally
installed.
28 Potentiometer input Input signal of potentiometer is abnormal. Solution:
abnormality Check the wiring between potentiometer and
controller;
Check whether the potentiometer is damaged;
Check the parameter settings of the potentiometer
related to the controller;
32 Power board slightly Use of reduced load
overheated
33 Power version low Excessively low ambient temperature
temperature
38 EEPROM parameter Contact the manufacturer in case of controller
reading and writing failure
error
39 Parameter overrun Parameter setting failure, contact the manufacturer

30
 error
40 Parameter S/N out-of- The serial number of imported parameter table is
limit error abnormal, contact the manufacturer.

13 ． Instrument function description

13.1 Function key description
Key description Reuse function
Up/P Move up /P gear
Down/turtle Move down/Very slow gear
Left/S Move left/S gear
Right/E Move right/E gear
Return/- Return/adjust-
OK/+ Confirm/adjust+
13.1.1 Home page switch
Press OK at the homepage into next page. Press Left/Right/Up/Down to move cursors to
certain places, and press OK to enter the wanted page, press Back to return.
13.1.2 Modes switch
There are 2 modes at the setting interface. Choose mode: the hightlight box
flashes at 1Hz frequency, which can be moved by pressing different keys to start
edit. Editing mode: press OK to start to edit language, background light,
protocols, etc, then press OK again to confirm and exit, then do another edition.
13.1.3 Set the language
Press Lef/Right/OK key to enter the page of language setting. The highlight box
flashes at 1Hz frequency, then press OK to edit the language. Move the cursor
left and right to choose thw wanted language and press OK to confirm. After
confirming, return to the previous page.
13.1.4 Backround light adjustment
Choose the backroung light adjust at setting page, and the highlight box flashes
at 1HZ frequency. Press Ok to edit the background light. There are 20 gears of
the background light, which shall be adjusted by pressing Right to increase, and
Left to decrease.
13.1.5 Administrator log in
Enter the administrator page and press OK to see the pin code page. Press Ok to
choose wanted numbers, ESC to exit, Delete to delete the input numbers. Press
OK to save the pin code and exit. Press OK again to input the correct pin code to
enter the page of setting protocols and baud rate values. If the pin code is not
recognized, returns to the previous page.
13.1.6 Set the protocol
Choose the protocol setting at setting page. The highlight box flashes at 1Hz
feequency.After the user inputs the right pin code, enter the editing mode.
Choose the wanted protocol by pressing Up and Down keys and press OK to save
the parameter.
13.1.7 Set the baud rate
Choose the baud rate setting at setting page. The highlight box flashes at 1Hz
feequency.After the user inputs the right pin code, enter the editing mode.

31
 Choose the wanted baud rate by pressing Up and Down keys and press OK to
save the parameter. Restart the system to make the modification effective.
13.1.8 Set the system time
Choose the time setting at setting page. The highlight box flashes at 1Hz
feequency. Set the wanted date/month/year by moving the cursor up in different
directions. Then press OK to edit the time. Press Up to increase the number,
Down to minor the number. Press OK again to finish setting the time and save
the parameter.
13.2 Instrument display description
13.2.1 Home
The main display content on the home page includes battery SOC level, etc. The battery
level display is divided into percentage display and battery symbol display. Due to different
product models, the interface display content may vary.
13.2.2 Historical Fault Interface
When an alarm occurs, the instrument will record the fault information and save it in non
volatile storage. The corresponding position in the alarm information column on the left side
of the screen will display the fault information, and the corresponding position in the
information column on the right side of the screen will display the fault time. The display
order is the order of the alarm occurrence. The most recent fault is displayed in the first line,
and the last one is displayed in the last line. A maximum of 6 alarm messages can be
recorded and displayed, More than 6 cycles of coverage.
13.2.3 System Settings
Set the Chinese and English language type, adjust the backlight brightness, select protocol
and baud rate, and set the time.

14 ． Attachment, spare parts and wearing parts list

Specificati
S/N Name Application QTY Remark
on
Power on electric
1 Electric lock key 1
lock
Charging plug Equipped with
2 1 set
and socket charger
3 Fuse Electrical part 10A 1
4 Fuse Electrical part 20A 1
5 Fuse Electrical part 250A 1
6 Sealing ring Oil cylinder UHS58 1
7 Sealing ring Oil cylinder UHS40 2
8 Sealing ring Oil cylinder UHS35 2
9 O sealing ring Oil cylinder 65X2.65 1
10 O sealing ring Oil cylinder 47.5X2.65 2
11 O sealing ring Oil cylinder 17X2.65 2
12 O sealing ring Oil cylinder 40X3.1 2

32
 13 Combination ring Oil pipe part D14 2
14 Combination ring Oil pipe part D16 2
15 Dust ring Oil cylinder DH58 1
16 Dust ring Oil cylinder DH40 2
17 Dust ring Oil cylinder DH31.5 2
Consignee：

15 ． Structure diagram and schematic diagram

See attachment 1 for the hydraulic schematic diagram
See the Electric Parts Manual for 12.-13.
See attachment 2 for the exploded picture

16 ． Packing list

Packing list
conwsignee ：
Ex factory No. ：
Contract No. ：
Ex factory date ：
Outside
Net
quanti dimension
No. Product weight(k remark
ty （ L×W×H
g)
）
CDDC narrow aisle
1 1 Complete truck
stacker
with technical
document,
2 Accessory bag 1
attachment and spare
parts

Note: 1. there are following documents in the bag

33
 ①CDDC narrow aisle stacker’s operation manual 1 copy
②Packing list 1 copy
③Certificate of qualification 1 copy
2 ． Accessories and spare parts
Specificati
S/N Name Application QTY Remark
on
Power on electric
1 Electric lock key 1
lock
Charging plug Equipped with
2 1 set
and socket charger
3 Fuse Electrical part 10A 1
4 Fuse Electrical part 20A 1
5 Fuse Electrical part 250A 1
6 Sealing ring Oil cylinder UHS58 1
7 Sealing ring Oil cylinder UHS40 2
8 Sealing ring Oil cylinder UHS35 2
9 O sealing ring Oil cylinder 65X2.65 1
10 O sealing ring Oil cylinder 47.5X2.65 2
11 O sealing ring Oil cylinder 17X2.65 2
12 O sealing ring Oil cylinder 40X3.1 2
13 Combination ring Oil pipe part D14 2
14 Combination ring Oil pipe part D16 2
15 Dust ring Oil cylinder DH58 1
16 Dust ring Oil cylinder DH40 2
17 Dust ring Oil cylinder DH31.5 2
Consignee:

34
Hydraulic schematic diagram

35
36
 Schematic Diagram
Record Card of Repair and Maintenance
Maintenance Maintenance Maintenance
Item Material used Remarks
time position personnel

Customer Feedback
Fault Troubleshooti
Item Time Cause User’s unit
position ng

37