Hyundai 15EST User manual

15EST
Electric Stacker
Operation Manual

Welcome to choose “HYUNDAI” electric pallet stacker!
We hope our electric stackers will bring great convenience
to your work!
Please read the manual carefully before operation
This manual is a common manual. We reserve the right to modify
technology of the electric stacker. If there is anything in the
manual that is not consistent with the actual stacker, the actual
stacker should be considered correct and the manual is only for
reference.
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Warning!
Operators must strictly conform to ISO3691 “Safety Specifications of Motor Industrial Vehicles”.
Untrained personnel are not allowed to operate the stacker.
************************************************************
According to ISO 3691 “Safety Specification of Motor Industrial Vehicles”, load capacity and lifting height of our
CDD Electric Stacker are stipulated as follows:
1．——When the lifting height of 15EST stacker is below 2500mm (including2500mm), the maximum
load capacity is the rated capacity. Overloading is prohibited.
2．——When the lifting height of 15EST stacker is above 2500mm (excluding2500mm), the load
capacity is less than the rated bearing capacity. Take the following diagrams as a reference with
the rated loads of 1000kg, 1500kg and 2000kg:
20 0k g
1400 kg
1200 kg
1000 kg
80 0k g
60 0k g
40 0k g
1500 kg
mm
60 0 70 0 80 0 10 00900 500
100k g
30 00 mm
33 00 m m
35 00 m m
25 00 m m
45 00 m m
5000 m m
56 00 m m
1.5T LO AD C HAR T

Contents
1．Outline drawing and main technical parameter………………………..…….1
2．Brief introduction of structure……………………………..………….…………..6
3．Safety specifications…………………………..…….……………….……………….6
4．Initial operation …………………………………………………………………………12
5．Use and operation instruction………………………………………………………12
6．Use, maintenanc and charging of storage battery………………………....16
7．Inspection before operation …………………………….………..……………..19
8．Inspection after operation…………………………………….…….……………….19
9．Periodic maintenance and upkeep…………………………..……..…………….20
10. Storage, transportation, and loading&unloading ……………………………25
11．Replacement of storage battery…………………………..………….............25
12．Common faults and troublshooting………........................................26
13．Common faults signal and trouble shooting………………………............28
14．Lists of accessories, spare parts and vulnerable parts……………….…..36
15．Structure and principle diagrams of major parts…………………………...37
16．Packing list……………………………………………….…….………………………...37
Appendix I Safety Specifications of Motor Industrial Vehicles………………...41

Appendix：《 Safety Specifications of Motor Industrial Vehicles》
Brief introduction：
CDDR electric pallet stacker adopts storage batteries as the dynamic source and a AC motor as the
driving force, traveling through gear transmission. The lifting of the fork relies on the DC motor and
the hydraulic transmission system. The up-and-down movement of the oil cylinders lifts the fork and
the goods. As the traveling and lifting of the stacker are electrically driven, it possesses the
characteristics of energy saving, high efficiency, stable operation, easy operation, safety and
reliability, low noise and no pollution, etc.This stacker adopts 24V storage battery, which greaty
prolongs use time after one charging.
The stacker is applicable for goods piling and handling on hard and flat ground.
Allowed environment for using:
a. Height above sea level shall not be over 1000m;
b. Ambient temperature shall not be higher than +40℃and no lower than -25℃;
c. When the ambient temperature reaches +40℃, the relative humidity should not exceed 50%;
at a lower temperature, higher relative humidity is allowed.
d. Hard and flat ground
e. It is prohibited to use the stacker in a flammable, explosive or corrosive environment with acid
and alkali.
Description:
The instruction manual shall be kept by the operator, and shall be read by the operator until he gets a full
understanding.
The instruction manual is composed of correct operation, convenient and simple maintenance, and
routine inspection.
The instruction manual shall be carefully read before operation, for purpose of correct drive and suitable
maintenance to ensure safe and effective material transportation.
The instruction may be in disagreement with practical product due to product innovation.
The instruction manual shall be accompanied with in case of truck leasing or transfer.
Please come into contact with our sales department in case of any problem.
Description of symbol：Regulations of the following symbols are of great importance to your safety and
others as well.
Please observe these regulations:
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.
Final installaton location of battery lock plate（the range of 180 degree in right Pic.）

1
1. Outline drawing
1.1 15EST Outline drawing

2
15EST Electric Stacker
Characteristics
1.1
Manufacturer(abbreviated)
HYUNDAI
1.2
Model
15EST
1.3
Driving mode
Electric
1.4
Driving mode
Pedestrian
1.5
Rated load
Q(kg)
1500
1.6
Load center distance
c (mm)
600
1.8
Load distance
x (mm)
677
1.9
Wheel base
Y (mm)
1420
Weight
2.1
Service weight(with battery)
kg
1090/1210/1230/1250/1415/14
60/1500
2.2
Axle load, front/rear, laden
1470/1310
2.3
Axle load, front/rear, unladen
kg
910/370
Wheel chassis
3.1
Tires
kg
Polyurethane
3.2
Tire size, front
φ250×70
3.3
Tire size. Rear
φ80×84
3.4
Additional wheel size
φ150×60
3.5
Wheel number, front/rear(x=driving)
wheel）
1x+2/4
3.6
Tread, front
b
10(mm)
580
3.7
Tread, rear
b
11(mm)
1040-1430
Dimension
4.2
Height of mast, lowered
h
1(mm)
1805/2055/2205/2305/2120/22
80/2480
4.3
Free lift height( optional)
h
2(mm)
1300/1550/1700/1800/1570/17
4.4
Lift height
h
3(mm)
2500/3000/3300/3500/4500/50
00/5600
4.5
Max. height of mast, extended
h
4(mm)
3025/3525/3825/4025/5100/55
4.9
Min. /Max. height of operation handle in
driving position
h
14(mm)
670/1300
4.15
Height, lowered
h
13(mm)
70
4.19
Overall length
l
1(mm)
1985
4.20
Length to fork face
l
2(mm)
915
4.21
Overall width of truck body
b
1(mm)
1170-1560
4.22
Fork dimension
s/e/l(mm)
40/100/1070
4.25
Overall width of fork
b
5(mm)
200—800
4.32
Wheelbase ground distance
m
2(mm)
35
4.33
Aisle width, with pallet 1000x1200
crosswise
Ast (mm)
2480
4.34
Aisle width, with pallet 800x1200
lengthwise
Ast (mm)
2465
4.35
Turning radius
W
a(mm)
1612
Performance
Data
5.1
Traveling speed, laden/unladen
Km/h
5.8/6
5.2
Lifting speed, laden/unladen
m/s
0--0.14/0--0.23
5.3
Descending speed, laden/ unladen
m/s
0--0.39/0--0.26
5.8
Max. gradeability, laden/unladen
%
8/15
5.10
Traveling brake
Electromagnetic brake
Motor
6.1
Driving motor power
kW
1.5(AC)
6.2
Lifting motor power
kW
3.2
6.4
Battery voltage/rated capacity
V/Ah
24/300
6.5
Battery weight
kg
260
Battery dimension（LXWXH）
mm
675× 254× 540
Additional data
8.4
Noise level at operator’s ear, according to
DIN12053
dB(A)
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.
3. Safety Norms:
Warning:
Please pay attention to the following items first before operation of the truck:
1) This electric truck is only limited to utilization indoor with a hard flat floor. Operation in inflammable,
explosive environment or corrosive environment such as acid or alkaline condition shall be strictly
forbidden.
2) Only drivers who have received formal training or are authorized can be allowed to drive the truck.
3) Read this instruction carefully before operation so as to master the performance of the stacker;
check the truck whether it is in its normal condition before each operation. It is forbidden to use
faulty stacker; repair by untrained persons is forbidden as well.
4) Overloading operation is forbidden.
5) As for goods carrying and operation, center of gravity of the goods must be within range of the two
forks. It is forbidden to transport loose goods
6) The truck shall travels slowly when forks pass in or out of pallet.
7) It is strictly forbidden to press the lifting or lowering button during the traveling of the truck.
Meanwhile, don’t switch lifting and lowering buttons rapidly or frequently, because rapid and
frequent lifting or lowering will cause damage to the truck and goods.
8) Don’t load heavy goods on the forks rapidly.
9) Don’t lay the goods on the truck for a long time!
10) It is strictly forbidden to make sharp turn on narrow aisle. When it is turning, slow down the truck so
as to ensure the safety of personnel and goods.
11) Descend the forks to the lowest position when the truck is not used.
12) It is strictly forbidden to put any part of the body under heavy goods and forks.
13) This truck is suitable to be used on flat ground or flat platform. Don’t put the truck on the slope for
a long time.
14) Overloading operation is forbidden. Otherwise the wheel will skid, resulting in the damage of wheel
and motor as well as danger of the human body and goods.
15) It is strictly to use the truck under stipulated voltage of 20.4V.
16) It is strictly forbidden to conduct charge by connecting the plug to AC power directly.
17) It is forbidden to operate the stacker when the lift height of fork exceeds 500mm.
3.1 Safety operation norms:
⑴Training 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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⑵Wear 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.
⑶Rules 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.
⑷Safety of working place:
Notice
This kind of electric stacker is only limited to utilization indoor with a hard flat floor.
Operation in inflammable, explosive environment or corrosive environment such as acid or alkaline
condition shall be strictly forbidden.
a. Good roadway condition shall be kept and the traffic should be smooth.
b. Sufficient light ray shall be ensured on working place.
c. Fire extinguishing appliances shall be equipped in the places where truck and charging is operated.
The extinguishing appliances shall comply with the requirements of extinguishing fire of solid
combustible matter and electric apparatus.
d. The value of truck noise mentioned in instruction is measured under the condition of new truck
running on flat, smooth and hard ground. If the traffic surface is bad or the tyre of truck is
damaged, the noise may be amplified.
⑸Integrity of the truck shall be realized:
Warning
Do not make modifications on the truck.
A Please observe safety rules and regulations of your working place during operation, inspection,
and maintenance of the truck.
- B Unauthorized truck modification is not permitted.
- No modifications or alterations to a powered industrial truck, which may affect, for example,
capacity, stability or safety requirements of the truck, shall be made without the prior written
approval of the original truck manufacturer, its authorized representative, or a successor
thereof. This includes changes affecting, for example braking, steering, visibility and the
addition of removable attachments. When the manufacturer or its successor approve a

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modification or alteration, they shall also make and approve appropriate changes to capacity
plate, decals, tags and operation and maintenance handbooks.
- Only in the event that the truck manufacturer is no longer in business and there is no successor
in the interest to the business, the user may arrange for a modification or alteration to a
powered industrial truck, provided, however, that the user shall:
a) arrange for the modification or alteration to be designed, tested and implemented by an
engineer(s) expert in industrial trucks and their safety;
b) maintain a permanent record of the design, test(s) and implementation of the modification
or alteration;
c) approve and make appropriate changes to the capacity plate(s), decals, tags and instruction
handbook;
d) affix a permanent and readily visible label to the truck stating the manner in which the truck
has been modified or altered together with the date of the modification or alteration, and the
name and address of the organisation that accomplished the tasks.
⑹Prepare 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.
⑺Operation 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.
⑻Overloading 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.
⑼Use suitable pallet:
The pallet shall be of suitable dimensions, neither too wide nor too large.
⑽Electrical system check:
Notice
Before checking the electrical system, turn off the key switches and the
emergency isolation switches.
3．2 Safety Operation Specification:
⑴Check the safety condition around the truck:

6
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.
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.
⑵Strictly forbid harsh driving
Notice
Never start up, brake or turn abruptly.

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

8
Notice
Take care to avoid the danger of wind force when loading goods.
10）The operator shall master the traveling speed according to site condition.The truck shall slow down
and move at a low speed when turning, at a narrow aisle, passing by swing doors or places where view
impeded. And the truck shall keep enough distance with the forklift moving forward. Abrupt stop, sharp
turn and overtaking are forbidden at dangerous places or where view is impeded except accidents. It is
forbidden hold body or hands out of the driving cabin.
11）Driver’s view during operation: The driver’s view must keep in the traveling direction of the stacker
and pay attention to the condition on driving roads at all times. If the goods carried impeding driver’s
view, goods carried must be adjusted to the backward of driver’s view. If the goods can not be adjusted,
another operator shall be arranged and walk by the stacker so as to report the forward road condition for
the truck driver.
12）Upslope or downslope driving: The route of upgrade and downsgrade shall be specified driving roads.
The ground shall be kept clean, safe and reliable in accordance with technical performance
of the stacker. When the truck is moving upgrade with goods, the forks should be kept in the forward
position. While drving downsgrade, the stacker shall move backward. Turning, tilting
driving and parking is not allowed during upgrade and downsgrade moving. Make sure to slow down
when downgrade drving and always make prepare for braking.
13）Driving the stacker to elevator or charging platform: When it is necessary to drive the stacker to
elevator or charging platform, make sure that elevator or charging platform has enough loading capacity,
with the design structure applicable for bearing stacker. Meanwhile the elevator and charging platform
should be permitted by the equipment user. Checks must be carried out before operation. Before driving
into the elevator, the goods should be carried into the elevator first and select the suitable parking space
for the truck in order to avoid collision with walls during lifting. When there is other person needs to use
the elevator, they should place the stacker at first.Then they can come into the elevator afterwards.
When the elevator reaches the specified height, the personnel shall get out of the elevator at first.
14）Conditions for goods to be transported: The stackor operator should checke the goods carefully make
sure that there is not any risk. Before transportation of the goods, place and locate the goods. If there is
any possibility of falling or overturning of the goods during transportation, it should be mounted with
protective devices (such as protective guard).
3．4 Important notice after operation:
1）Parking: Park the truck at appointed place. Never park the truck on slope.
Ensure the following points to be achieved before leaving away the truck:
a. Lay down the fork to the lowest position naturally.
b. Turn the steering wheel to the middle position.
c. Turn off the key switch.
2）Clean up the truck:
Notice
When cleaning up the electrical system, use compressed air but not
water.

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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 adjusted（charging curve）.
4．1．6 If the truck is not used for a long time, wheels placed on the ground will be pressed. Only after
the truck is put into operation for a short time, the wheel can come to the original shape.
4．2 Drive of the stacker without the driver of the stacker itself：
Warning
It is strictly forbidden to drag the stacker on the slope.
4．2．1 In case of dragging stacker during emergency operation, the electromagnetic brake must be
loosened.
4．2．2 When the stacker is placed at a specified place, the electromagnetic brake must be relocated
so as to make the stacker in a state of brake.
5．Use and operation instruction
The electric pallet stacker adopts storage batteries as the dynamic source for short distance goods
handling and stacking. Correct use and operation will bring great convenience to your work but
incorrect use and operation will damage the stacker or pose risk to you and your goods.

10
5．1Before 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.
5．1．3Check 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:
There is no electric power in the
batteries if this grid is bright.
electric door lock
Turn on the
power
supply
Turn off the power
supply
Fig.I
Low speed button
Horn
Lift button
Speed controller
Emergency reverse button
Accelerator
Fig.II

11
Warning
It is strictly forbidden to turn the accelerator knob fastly to speed up
the stacker abruptly during goods transportation.
Move the control handle to division A or division C as indicated in Fig.II and press the rise/lowering
button on th control handle to see if the lifting and lowering of the fork is normal. Then turn the control
handle to division B as indicated in Fig. II, slowly start the truck and press the handle to the horizontal
position to check that whether the truck can travel and brake normally.
Move the control handle to division B as indicated in Fig.II, press the emergency reverse button on top
of the control handle to ckeck that whether the truck can travel backward normally.
After the above check, if there is no failure in the truck, it can be put into operation; if there is some
failure, please repair it at once. It is prohibited to use trucks with problems.
5．2 In operation：
5．2．1
Accelerator knob: The accelerator knob is used for controlling traveling direction and speed of the
stacker. When it is for the traveling operation, turn the operation handle to B area indicated in the
above diagram. When the handle is in A or C area, the stacker is in a power-off status, and can not
travel. When the operation handle is in B area and the accelerator knob is turned in one direction, the
stacker wil travel in that direction. While the accelerator is turned in another direction, the stacker will
travel in another direction. Meanwhile the bigger the turning amplitude is, the faster the truck will
travel.
Note: A side-magnetic brake is installed on the shaft end of the driving wheel motor and there is a cam
and an inching switch installed on the rotary shaft of the rotary arm. Only when the rotary arm is at
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:

12
Notice
Please check the following items before operation of the stacker:
Ensure no goods falling and goods damaged at loading and unloading area.
Ensure no goods or objects impeding for safety.
As indicated in Fig. II, pull out the general power supply switch, unlock the electric door lock, and drive
the stacker to the goods pile nearby. (The tip of the fork is 300mm from the goods pile). Press the
lowering button, adjust the height of the fork to a proper position, and insert the fork slowly and as deep
as possible into the pallet of the goods. Press the lifting button till the fork is 200-300mm from the ground.
Drive the stacker to the location of the goods shelf and stop slowly. (The tip of the fork is 300mm from the
goods shelf.) Press the lifting button and the fork rises to a proper height with the shelf (The bottom of
the pallet is about 100mm higher than the goods shelf). Move the goods slowly to the accurate position of
the shelf and press the lowering button to put the goods carefully on the shelf. Take the fork away from
the goods and drive the stacker slowly to make the fork out of the goods pallet. (The tip of the fork is
300mm from the goods shelf.) Lower the fork until it is 300mm from the ground and drive the stacker
away from the shelf. Attention should be paid to that there should be no obstacles around and when
turning, the speed should be reduced.
Caution
The driving mechanism of truck is installed on the foreside. Due to this
difference from common vehicles, the foreside of truck swings comparatively fast
when turning around. For this reason, to prevent collision with other objects nearby
the foreside of truck, do drive or turn slowly.
5．2．5 Operation of taking goods off the goods shelves：
As indicated in Fig. II, pull out the general power supply switch, unlock the electric door lock, and drive the
stacker to the goods shelf nearby. (The tip of the fork is 300mm from the goods shelf). Press the lowering
button, adjust the height of the fork to a proper position, and insert the fork slowly and as deep as possible
into the pallet of the goods. Press the lifting button to lift the goods till the bottom of the pallet is 100mm
from the goods shelf. Slowly drive the stacker and slowly move the goods out of the shelf (the tip of the
fork is 300mm from the goods shelf). Press the lowering button and the fork lowers to a height of
200-300mm from the ground. Drive the stacker away from the goods shelf until it reaches a desired
position and then slowly stop it. Press the lowering button to put down the goods, make the fork
completely away from the goods and move the fork slowly out of the goods pallet.
5．3 Abnormal situation handling during operation：
5．3．1When pressing the lifting button, the fork can rise but when releasing the lifting button, the fork is
still rising. The stacker is in a situation of out of lifting control. In that case, turn off the general power
supply switch to cut off the power supply at once. Drive the stacker to a safe position to lower the fork
manually and repair the circuit of the stacker.
5．3．2 If the brake is out of function when the stacker is in operation, the operation must be stopped at
once and repair the stacker.

13
5．3．3When 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.
6．1 Initial charge
6．1．1 Initial charge should be conducted for batteries that have never been used, i.e. initial charge.
Before the initial charge, the surface of the batteries should be cleaned and the batteries should be
examined for damage. The bolts should be tightened to ensure reliable connection.
6．1．2 Open cover。
6．1．3When the charging equipment is able to operate normally, pour the sulfuric acid electrolytic
solution with a density of 1.260± 0.005 (25℃) and a temperature of lower than 30℃into the batteries.
The liquid surface should be 15-25mm higher than the protective board. In order to reduce the
temperature rise caused by chemical reaction of the electrolytic solution and let the electrolytic solution
fully penetrates into the pores of the polar plates and the baffles, the batteries should be placed still for
3-4 hours, not exceeding 8 hours. The initial charging can only be conducted when the temperature of
the solution reduces to below 35℃. (When necessary, the batteries can be put into cold water for
temperature reduction). After the still placement, if the surface of the solution reduces, electrolytic
solution should be added.
6．1．4 The sulfuric acid electrolytic solution is prepared with battery sulfuric acid complying with
the state standard GB4554-84 and distilled water. Never use industrial sulfuric acid and running water.
The standard temperature （25℃）and density of the electrolytic solution can be converted as follows:
D25＝Dt＋0.0007(t－25)
Where: D25: the density of the electrolytic solution at 25℃
Dt: the actual density of the electrolytic solution at a temperature of t ℃.
t: temperature of the electrolytic solution when testing the density.
6．1．5 Sweep the electrolytic solution on the surface of the batteries and connect the positive and
the negative poles of the battery group respectively with the positive and the negative ends of the DC
power supply (charger). Turn on the power supply. First charge with 30 A (the first stage current,); when
the voltage reaches 28.8V (12 × 2.4V = 28.8V), change to the second stage current 15A and continue to
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.

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charge. The temperature of electrolytic solution during the process of charging must not exceed 45℃
and when it is close to 45℃, the charging current should be reduced by 50% or the charging should stop
temporarily. Wait till the temperature reduces to 35℃to continue the charging. The charging time,
however, should be properly prolonged.
6．1．6 Fully charged basis: When the voltage during the second stage charging reaches 31.2V (12
× 2.6V = 31.2V), the variation of the voltage is no greater than 0.005 (V); the density of the electrolytic
solution reaches 1.280 ± 0.005 (25℃), no obvious variation in 2 hours and there are fine air bubbles
appear violently, it can be deemed that the batteries are fully charged. The charged power capacity is 4-5
times of the rated capacity and the charging time is about 70 hours.
6．1．7 In order to accurately control the sulfuric acid content of the electrolytic solution, the
electrolytic solution density of the batteries should be examined during the last period of charging. If
there is inconsistence, adjust with distilled water or sulfuric acid with a density of 1.40. The electrolytic
solution density and the liquid surface should be adjusted to the stipulated value within two hours in the
charging state.
6．1．8 After the initial charging is completed, the surface of the batteries should be cleaned. Close
the cover of the open cover type liquid hole plug and then the batteries can be used.
6．2 Use and maintenance
6．2．1 In order to guarantee the service life of the batteries, the batteries in use should be fully
charged. Insufficiently charged batteries must not be used. During the process of use, close attention
should be paid to the discharge extent. Over discharge is prohibited---the voltage reduces to 1.7V per
battery (when the total voltage reduces to 1.7V× 12 = 20.4V). When the density of the electrolytic
solution reduces to 1.17, discharging should be stopped and charging should be conducted at once. The
batteries should not be placed idle for a long period of time. The supplementary charging frequently
conducted during the process of use is called common charge.
6．2．2 Common charge: The first stage current of common charge is 30A and that of the second stage
is 15A. The charging method is the same as that of initial charge. The charged volume is
130-140 % of the discharged volume and the charging time is about 12 hours.
6．2．3 The batteries in normal use should avoid over-charge, but over-charge must be properly
conducted for the batteries in following situations, i.e. equalizing charge.
a. The “lag-behind” batteries--- batteries with a voltage lower than that of the other batteries in
the discharging process and the batteries having been repaired for failure. (When equalizing
charge is conducted, the positive and negative poles of the “lag-behind” battery should be
respectively connected with the positive and negative ends of the charger, the DC power supply,
and the charge should be conducted independently.)
b. Equalizing charge should be conducted for the batteries in normal use every 2-3 months.
c. Equalizing charge should be conducted for the batteries that have not been used for a long
period of time before use
2．4Equalizing charge：
a. Charge with a 4A current
b. When the charge voltage reaches 31.2V (12 × 2.6V = 31.2V) and air bubbles occur in the
electrolytic solution, the current should be reduced by 50% (2A) and continue to charge.
c. When the batteries are in the state of fully charged, stop for 0.5 hour and charge again
with a 1A current for one more hour.
d. Stop for another 0.5 hour and charge with a 1A current for another one hour.
e. Repeat according to item d till air bubbles occur violently in the batteries once the charger
is switched on.

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6．3 Storage
Batteries should be stored in a clean, dry and well ventilated warehouse with a temperature of 5-40℃.
The valid shelf life is 2 years. The batteries should be kept according to the following requirements during
storage:
a. No direct sunshine on the batteries and at least 2m away from heat source.
b. Avoid contacting with any harmful substances. No metallic matters are allowed to drop
into the batteries.
c. The batteries should not be placed upright down and should not be impacted mechanically
or heavily compressed.
d. The batteries must not be stored with electrolytic solution. When it is required in special
situation that the batteries must be stored with electrolytic solution, the batteries should
be fully charged and the density and the liquid surface of the electrolytic solution should be
adjusted to the stipulated values. When the storage period comes to one month, the
batteries should be complementarily charged with the common charge method.
6．4、Operation of electrolyte
⑴Density check
The suction type densimeter shall be used to check density. During operation, avoid spilling out the
electrolyte, and do wear protection appliance.
⑵Operation besides check
Consult professional personnel, especially when complementing electrolyte (dilute sulfuric acid).
⑶Electrolyte leakage
As for the electrolyte leakage resulting from storage battery tilting and damage, emergency treatment
shall be made at once (See emergency treatment item).
6．5、Operation of storage batteries during the final stage of their lifetime
⑴Operation of storage batteries during the final stage of their lifetime
Add distilled water daily during the final stage of storage batteries.
⑵Treatment of exhausted battery
As for the exhausted battery, draw out the electrolyte and decompose the battery. It can be
discussed that whether the exhausted battery shall be recycled by the battery manufacturer. The
waste electrolyte can be disposed according to relevant local regulations.
6．6、Emergency treatment
⑴The electrolyte spills on skin
wash with large amount of water
⑵The electrolyte spills into eyes
wash with large amount of water, and then seek help from specialized doctor.
⑶The electrolyte spills on clothes
take off clothes right away, wash with water, and then flush with week basic soap solution.
⑷The electrolyte leakage
In case of electrolyte leakage outside, neutralize it with lime, strong carbonic acid soda or carbonic
acid soda, and then flush with large amount of water.
6．7、Charger
If the charger you use is full automatic type. It must meet with the following 2 requirements:
a. The output voltage of charger: 24V
b. The output current of charger: 30A
If the charger you use is semi-automatic or manually adjustable, please charge the battery pack
according to the requirements of use and maintenance mentioned in the 2.

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7．Inspection before operation:
For the sake of safety operation and good situation of the electric truck, it is compulsory to check the
truck completely before operation. Contact the sales department of our company when founding
problems.
7．1 Check point and check content:
No.
Check point
Check content
Braking
system
1
Operation handle
When the operation handle is turned, with the
handle switching between area A and B, there is
a noise from the brake.
2
Brake clearance
The clearance between brakes should be kept
between 0.2mm and 0.8mm.
Steering
system
3
Operation handle
Degree of tightness and rotary flexibility.
4
Oil pipe
Leakage or not.
5
Hydraulic oil
Appropriate oil quantity.
6
Lifting oil cylinder
Whether there is any oil leakage.
Wheels
7
Pins, screws and all
the fasteners
Check all the fasteners of the truck’s wheels, i.e.
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
Confirm the display state of the battery capacity.
10
Electrolyte
The solution level and density of electrolyte.
11
Connecting line
The connecting line and socket shall be firm.
Horn
12
Horn
Press down the horn button to check whether
the horn sounds.
Instrument
13
Function
Turn on the switch of electric lock to check
whether the instrument displays normally or not.
Others
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Truck frame, etc
Damaged or not. If there is any crack.
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Function
Check that whether lifting, lowering, forward &
backward movement and emergency reverse of
the truck is normal, and if there is any abnormal
noise.
8．Inspection after operation:
After operation, the smudge on truck shall be wiped out. Besides, the following check shall be carried
out:
Keep visibility of all graphics context marks such as warning signs, nameplates and notice board. These
marks are able to instruct, caution and warn the operator to some degree.
The situation about deformation, distortion, damage or breakage
Add lubricating oil and grease if necessary.
Replace faulty components.