XILINX CTD12R-E Electric Pallet Stacker Instruction Manual

XILINX CTD12R-E Electric Pallet Stacker

Product Information: CTD12R-E Electric Pallet Stacker

The CTD12R-E Electric Pallet Stacker is a motor industrial vehicle designed to transport materials in a safe and effective manner. It has a load capacity of 1200kg and a load center distance of 1000mm. The driving model is electric, with the option of using storage battery, diesel, gasoline, or fuel gas as a power source.
The stacker has various driving models including manual, walking, stand driving, seat driving, and order picking. It has a service
weight of 800kg (with battery) and a maximum lift height of 3300mm.

Product Usage Instructions

Before operating the CTD12R-E Electric Pallet Stacker, it is important to read the instruction manual carefully. This manual includes information on correct operation, maintenance, and routine inspection. Please note that the manual may be in disagreement with practical product due to product innovation. In such cases, please contact the sales department for assistance.
It is important to adhere to ISO3691 Safety Specifications of Motor Industrial Vehicles when operating the stacker. Only trained personnel are allowed to operate the stacker.
The stacker has various driving models including manual, walking, stand driving, seat driving, and order picking. Please select the appropriate driving model for your needs.
The stacker has a load chart indicating its load capacity at different heights. Please refer to this chart when transporting materials.
The stacker has wheels made of rubber, high elasticity, pneumatic tyre, or polyurethane. Please pay attention to the wheel dimensions and number when operating the stacker.
The stacker has a mast that can be lowered or extended to lift materials. Please pay attention to the height of the mast and the operation handle when transporting materials.
Finally, please pay attention to the symbols in the instruction manual indicating potential dangers and safety precautions. These symbols are of great importance to your safety and others as well.

CTD12R-E Electric Pallet Stacker Operation Manual Parts Catalogue

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.

Warning!
Operators must strictly conform to ISO3691 “Safety Specifications of Motor Industrial Vehicles”. Untrained personnel are not allowed to operate the stacker.

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 CTD12R-E stacker is below 3300mm (including3300mm), the maximum load capacity is the rated capacity. Overloading is prohibited. 2.—-When the lifting height of CTD12R-E 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 1200kg.

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 symbolRegulations of the following symbols are of great importance to your safety and others as well. Please observe these regulations:

Danger

Indicates an impending danger. Deaths or severe injuries would be resulted without any precaution or avoidance. You must observe those requirements.

Warning

Indicates a potential danger. Deaths or severe injuries would be resulted without any precaution or avoidance. You must observe those requirements.

Caution

Indicates a potential danger. Moderate injuries would be resulted without any precaution or avoidance. You must observe those requirements.

Notice

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

Outline drawing

CTD12R-E Outline drawing
1

1.2 CTD12R-E Electric Pallet Stacker

1.1 Manufacturer(abbreviated)

1.2 Model

1.3

Driving model Electric(Storage battery), diesel, gasoline, fuel gas

Characteristics

1.4

Driving model Manual, Walking, Stand driving, Seat driving ,Order picking

1.5 Rated load

1.6 Load center distance 1.7 Front overhang

Weight

1.8 Tread 2.1 Service weight(with battery) 2.2 Axle load, front/rear, laden

2.3 Axle load, front/rear, unladen

3.1

Wheels (rubber, high elasticity, pneumatic tyre, polyurethane wheel)

Wheel chassis

3.2 Wheel dimension, front 3.3 Wheel dimension, rear

3.4 Additional wheel(dimension) 3.5 Wheel number, front/rear x = driving wheel 3.6 Tread, front

3.7 Tread, rear 4.1 Height of mast, lowered 4.2 Lift height 4.3 Max. height of mast, extended 4.4 Min. /Max. height of operation handle, in driving position

4.5 Height, lowered 4.6 Overall length

Dimension

4.7 Length to fork face 4.8 Overall width of truck body 4.9 Fork dimension

4.10 Overall width of fork 4.11 Wheelbase ground distance

4.12 Aisle width, with pallet 1000×1200 crosswise 4.13 Aisle width, with pallet 800×1200 lengthwise

Performance Data

4.14 5.1 5.2 5.3 5.4

Turning radius Traveling speed, laden/unladen Lifting speed, laden/unladen Descending speed, laden/ unladen Max. gradeability, laden/unladen

5.5 Traveling brake 6.1 Driving motor power 6.2 Lifting motor power

Motor

6.3 Battery voltage/rated capacity 6.4 Battery weight 6.5 Battery dimensionLXWXH

7.1 Noise level at operator’s ear, according to DIN12053

Q(kg) c(mm) x(mm) Y(mm) kg kg kg
b10(mm) b11(mm) h1(mm) h3(mm) h4(mm) h14(mm) h13(mm) l1(mm) l2(mm) b1(mm) s/e/l(mm) b5(mm) m2(mm) Ast(mm) Ast(mm) Wa(mm) Km/h m/s m/s %
kW kW V/Ah kg mm dB(A)

CTD12R-E Electric(Storage battery)

Walking

1200 600 790 1306 720 545/1055 515/205
PU

195×70 98×82 150×60

1x+1/4 523
1016-1416 2030/1780/2030 1600/2500/3000 2030/3000/3500
670/1300

80

1720

1800

651

1132-1532

40/100/1070(1150)

200-800

35

2410

2280

1490

4.5/5

0.09/0.14

0.12/0.10

6/15

EM brake

0.65

2.2

24/105

24/125

26X2

35X2

260X168X217 330×171×217

70

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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.

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. 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.
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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 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;
   4

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: 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
Ensure no people around the truck when driving backwards.
Notice
Driving through the narrow access shall be guided by working personnel.
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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. 2) Strictly forbid harsh driving
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 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.
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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.
2. 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.
3. 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.
4. 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.
5. 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.
6. 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 7

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. 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 adjustedcharging 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.
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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. 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.
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:
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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 5.2.1Accelerator 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 45°±35°(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:
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. The operator shall master the traveling speed according to site condition.The truck shall slow down and 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
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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. 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.
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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 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. 6.2.2The 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. 6.3 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. 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 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
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.
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7.1 Check point and check content:

No.

Check point

Check content

Braking system
Steering system

1 Operation handle 2 Brake clearance 3 Operation handle

When the operation handle is turned, with the handle switching between area A and B, there is a noise from the brake. The clearance between brakes should be kept between 0.2mm and 0.8mm.
Degree of tightness and rotary flexibility.

Hydraulic system

4 Oil pipe 5 Hydraulic oil 6 Lifting oil cylinder

Leakage or not. Appropriate oil quantity. Whether there is any oil leakage.

Wheels

7

Pins, screws and all Check all the fasteners of the truck’s wheels, i.e.

the fasteners

pins or screws, loose or not.

8 Wearing status

Compare the parameter lists, replace the wheel when its diameter reduces by 5%.

Storage battery

9 Charge 10 Electrolyte 11 Connecting line

Confirm the display state of the battery capacity. The solution level and density of electrolyte. The connecting line and socket shall be firm.

Horn

12 Horn

Instrument 13 Function

Others

14 Function

Press down the horn button to check whether the horn sounds. Turn on the switch of electric lock to check whether the instrument displays normally or not. Check that whether lifting, lowering, forward & backward movement and emergency reverse of the truck is normal, and if there is any abnormal noise.

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.

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.

13

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) Before service maintenance matters needing attention:
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 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
14

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

1

When the operation handle is turned, with the steering handle switching between area A and B, there is a noise from the brake.

Braking system 2 The oil dirt and dust on the turning gearwheel should be cleaned.

3

The clearance between brakes should be kept between 0.2mm and 0.8mm

Capability of electrolyte

4

Inspect the liquid level of electrolyte, pure water can be used 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 battery

6

Cover the lid, and flush with tap water.

Inspect the contactor

7

Burnish the coarse surface of contacts using sand paper.

9.6 The inspection and maintenance after 200 hoursMonthly

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 Whole truck
2 Horn

Abnormal or not. 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 system,

4 Brake clearance

The clearance between brakes should be kept between 0.2mm and 0.8mm.

braking

5 Operation handle

Degree of tightness and rotary flexibility.

system, hydraulic

6

Truck frame and Function and check cracks, lubrication and

fastener

tightness of fasteners.

system and lifting

7

Connecting rod and Function and check the cracks, bending,

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. 15

11 Electrolyte

Liquid levelspecific 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

Storage

battery,

16 Controller

charger and

electric

17 Driving motor

system

18 Lifting motor

19 Steering motor

Function
Function
Wearing status of carbon brush and selenium rectifier. Wearing status of carbon brush and selenium rectifier. Wearing status of carbon brush and selenium rectifier.

20 Fuse

Whether it is perfect or not

21

Wiring harness and connection terminals

Whether flexible and whether damaged or not.

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

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 hoursevery 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.

Contactor Burnish the coarse surface of contacts using sand paper. Replace according to the status when the function is not well.

Motor

Wearing status of carbon brush and selenium rectifier.

Brake

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

16

9.8 Maintenance for 1200 hoursevery 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.

Contactor

Burnish the coarse surface of contacts using sand paper. 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

Brake

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

Hydraulic system

Replace hydraulic oil. Check that whether there is any leakage in the lifting cylinder or not and replace the seals when necessary.

Fork wheel and bearings

Check the wearing condition, and replace them if necessary

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 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:

Items

Maintenance content

Maintenance period

Remarks

Bearings of fork wheel

Replacement

1200 hours

Fork wheel

Replacement

1200 hours

Seals

Replacement

1200 hours

Replace when finding out damage

Gear box

Replacing lubricant grease

1000 hours

Hydraulic oil

Replacement

1000 hours

High pressure oil pipe

Replacement

2000 hours Replace when finding

17

Strainer of hydraulic reservoir
Driving motor Steering motor Oil pump motor

Cleaning
Check for carbon brushes and bearings Check for carbon brushes and bearings Check for carbon brushes and bearings

1000 hours
1000 hours 1000 hours 1000 hours

out damage

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.
18

12. Common faults and trouble shooting:

No.

Faults

Possible causes

Trouble shooting

The fuse of control circuit is burnt out. Replace

The

stacker

can

notstart.(The contactor

does not work either)

The power switch is in poor connection or is damaged. Fuse of main circuit is blown. The switch of electric lock is in poor
connection or damaged.

Repair or replace Replace Repair or replace

The connection of the storage batteries is loose or has fallen off.

Tighten

The side-magnetic brake of the drive

1

wheel does not suck and the stacker is Repair or replace in a braked condition.

The walking motor carbon brush is worn

The stacker start.(The works.)

can not contactor

or bad contact between the steering device and the carbon-brush. The magnet- exciting coil of the stepper motor is broken or bad contact at the

Repair or replace Repair or replace

wire end.

Bad contact.

Repair or replace

There is a trouble at the MOSFET tube type circuit board.

Repair or replace

2

The stacker can only move forward or backward.

The contactor is in poor connection or burnt out.
There is malfunction in circuit board.

Repair or replace Repair or replace

3

The stacker can not stop Broken contact. The moving contact cannot Cut off the power at once

during traveling.

be reset.

and replace the contact

The erection bolt of the fine motion switch looses or is damaged.

Adjust or tighten the bolt or replace the fine motion switch.

4 The brake does not work The connecting wire of the side-magnet Tighten the bolt or repair

brake is loose or damaged

the side-magnet brake.

The braking plates of the side-magnet

brake are worn.

Replace the braking plates.

5

The steering has got stuck

The bearing of the steering device is damaged.
The bearing of the steering device lacks lubricant or there is too much dust

Replace the bearing Clean the bearing

The gear or bearing has got stuck

6

Difficult steering of the drive wheel, noise and the motor is overloaded.

because of foreign matters. There is a gap in the bearing installed The front wheel bearing is damaged.

Clean or replace the bearing
Adjust the clearance Replace the bearing

7

The forks cannot be lifted.

Overload

Reduce the load

The pressure of the overflow valve is too Adjust the pressure higher

19

low

Internal abnormal leakage in the lifting oil cylinder

Replace the seals

Insufficient hydraulic oil

Add appropriate quantity of filtered hydraulic oil

Insufficient voltage of the storage

battery

Charge the battery

The control handle is not horizontal or

vertical, the oil pump motor has not Improper operation

been turned on.

Damaged oil pump motor

Repair or replace

Damaged oil pump

Repair or replace

Damaged lifting button

Repair or replace

The electric lock is not unlocked or is damaged.

Repair or replace

11Seriously insufficient voltage in the cell. The internal mast is overloaded and
deformed

Recharge Repair or replace

The external mast is overloaded and deformed

Repair or replace

8

The forks cannot lowered after lifted.

be Dead mast roller Mast guiding rode is curved

Repair or adjust Repair or straighten

The oil return hole is blocked

Clean

The electromagnetic valve is out of control

Shoot the trouble

Damage of individual battery

Repair or replace

9

Reduced end voltage of the storage battery (after charged)

Low level of the electrolytic solution Foreign matters in the electrolytic solution

Add electrolytic solution Replace electrolytic solution

Driving wheel locating nuts loosen or Screw down the locating

10

The truck shakes while traveling.

come off. The balance wheel, driving wheel and the two front wheels are not in the same

nuts. Adjust bolts on the balance wheel to make the four

plane.

wheels in the same plane.

12.1 Adjustment methods of safety valve pressure 20

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 screw

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 9Mpa for truck with rated load of

1000KG and 11Mpa for truck with rated load

of 1200KG.

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

NO Programmer display code fault

Troubleshooting

1

BATTERY

4.5

DISCONNECT FAULT

The battery is not The battery is not connected

connected

Poor contact in the battery terminals

2 BRAKE OFF FAULT 3.4 Close brake failure

Electromagnetic brake coil is short circuit Electromagnetic brake driving is open circuit

3 BRAKE ON FAULT 3.2 Brake failure to open

Electromagnetic brake driving is open circuit Electromagnetic brake coil is short circuit

4

CURRENTSENSE FAULT

4. 1 Current detection fault

Motor or motor wiring shorted Controller fault

5

EEPROM CHECKSUM 4.3 FAULT

EEPROM fault

1. EEPROM Failure or malfunction

1)Motor voltage does not match the accelerator

6

HARDWARE FAILSAFE

4.2 Over voltage of motor

imput Motor or motor wiring shorted

Controller fault

Accelerator, key switch, or prohibit the

7 HPD FAULT

3.5 HPD fault

importation of several actions to implement operations in the wrong order

Adjust the accelerator improperly

8 MAIN FAULT

2.3 Main contactor fault

Main contactor is adhensive or open circuit The main contactor coil driver error

21

9 MAIN OFF FAULT

2. 1

Main contactor coil driver `turn off’fault

1. turn on the main contactor improperly

10 MAIN ON FAULT

2.4

Main contactor coil driver `turn on’fault

1. turn off the main contactor improperly

voltage>31V

11

OVERVOLTAGE FAULT

1.5 Over voltage of battery

Still connected to the charger when the vehicle is running

Poor contact

12 PRECHARGE FAULT 3.3 Precharging fault

Controller fault Low voltage

Speed potentiometer wiring is open circuit or

13 SPEED POT FAULT 1.3 Speed potentiometer fault short circuit

Speed potentiometeris open circuit

temperature>80C <-10C

14 THERMAL FAULT

1. 1 Over / under-temperature overload

cut off

drive in extremely harsh environments

eletromagnetic brake does not release normally

15 THROTTLE FAULT

1.2

Over voltage potentiometer

of

accelerator imput is open or short circuit. Potentiometer fault of accelerator

Choosing the wrong type accelerator

16

UNDERVOLTAGE FAULT

1.4 Low battery voltage

Battery voltage<17V Poor contact of battery or accelerator

17 WIRING FAULT

Incorrect operation of accelerator

3. 1

HPD fault time is over

ten seconds

faults happened in terminal or the mechanical

part of accelerator

14. Lists of accessories, spare parts and vulnerable parts

14.1 CTD12R-E accessories, spare parts and vulnerable parts

No.

Name

Use position

Type & specification

1 Key to the electric lock Unlock the electric lock

2

Fuse

Electric equipment

50A

3

Fuse

Electric equipment

125A

4

Sealing ring

Oil cylinder

UHS45

5 O type sealing ring

Oil cylinder

50X3.55

6

Composite ring

Oil inlet of cylinder

D14

7

Dustproof ring

Oil cylinder

DH40

8 O type sealing ring

Oil cylinder

UHS40

Quantity 2 1 1 1 1 1 1 1

Remarks

15. Structure diagram (explosion diagram) and principle diagram
22

of the major parts
Hydraulic Schematic Diagram (standard)
23

CURTIS 1212 Electric Schematic Diagram (standard)
24

16. Packing list

Consignee:

Packing List of CTD12R-E Electric Pallet Stacker
Ex-work No.:

Contract No.:

No.

Name

1

CTD12R-E electric pallet stacker

Quant Net weight

ity

(kg)

1

2

Accessory box

1

Ex-work Date: Dimension (L×W×H)

Remarks

A complete set.

Technical documents, accessories and spare
parts.

Note: 1. The following documents are in the file bag: Operation manual of CDDR Electric Pallet Stacker Packing list Qualification certificate
2.Accessories and spare parts

1 volume 1 copy 1 copy

No.

Name

Use position

Type & specification

Quantity

Remarks

1

Key to the electric lock Unlock the electric lock

2

2

Fuse

Electric equipment

50A

1

3

Fuse

Electric equipment

125A

1

4

Sealing ring

Oil cylinder

UHS45

1

5

O type sealing ring

Oil cylinder

50X3.55

1

6

Composite ring

Oil inlet of cylinder

D14

1

7

Dustproof ring

Oil cylinder

DH40

1

8

O type sealing ring

Oil cylinder

UHS40

1

25

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.

14.1.4.2 Stability

26

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. 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.
27

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 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
28

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; 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
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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 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.
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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. 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,
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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 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
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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 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.
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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; 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
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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.

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;

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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 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.
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Recording card of maintenance and upkeep process:

Items

Maintenance time

Maintenance Part

Material used

Maintenance personnel

Remarks

Customer advisement feedback:

Items

Occurrence time

Location of faults

Faults causes

Trouble-shooting

Remarks

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