EPT33
Electric Pallet Truck
Maintenance & Use Instruction
Warning! Please read this manual carefully
before using this device.
Warning! Do not enable this function when all
components are not fully installed with this device.
CONTENT
1.The General Introduction............................................................................................. 1
2.Proper usage ..................................................................................................................... 2
3.Introduction of the product ......................................................................................... 3
3.1 Model overview................................................................................................................. 3
3.2 Model parameters .......................................................................................................... 3
4.Operating principle ........................................................................................................ 6
5.Operating principle ........................................................................................................ 7
5.1 Running system................................................................................................................. 7
5.2 Steering system ................................................................................................................. 7
5.3 Brake structure and brake schematic diagram. ................................................... 7
5.4 Operating System ............................................................................................................. 9
5.5 Electric System .................................................................................................................. 9
5.6 Hydraulic principle .......................................................................................................... 9
6.Electrical schematic diagram ................................................................................... 10
7.Hydraulic Scheme ........................................................................................................ 11
8.Operating Instruction ................................................................................................. 12
8.1 Operation ........................................................................................................................... 12
8.2 Emergency reverse function ...................................................................................... 12
8.3 The use of the horn and the reversing horn ........................................................ 12
8.4 Battery capacity display .............................................................................................. 13
8.5 Handling stacking operation ...................................................................................... 13
9.Safety operation and matters needing attention .............................................. 14
9.1 Repair and Maintenance .............................................................................................. 14
9.2 Routine Maintenance .................................................................................................... 15
9.3 Professional Maintenance Manual ........................................................................... 15
9.4 Battery maintenance, charging and maintenance. ............................................ 17
10.Safety Caution ............................................................................................................. 21
10.1 General rule ................................................................................................................... 21
10.2 Storage and transportation...................................................................................... 21
10.3 Check before using ...................................................................................................... 22
10.4 Safety operation regulation ..................................................................................... 22
11.Service Manual ........................................................................................................... 26
11.1 Troubleshooting ........................................................................................................... 26
11.2 Preparation before repair ........................................................................................ 26
11.3 Check the amount of hydraulic oil ........................................................................ 27
11.4 Complete repair, the preparation before using ............................................... 27
1
1.The General Introduction
EPT33 is a Electric pallet truck. It adopts the advanced structure such as ring rod lifting
system and DC controller, at same time it is equipped with high quality motor, traction
battery and pump station motor. It has the characteristics of superior performance,
convenient operation, flexible steering, reliable braking, good dynamic performance, less
noise, less pollution and beautiful appearance.
This series truck is suitable for working on the smooth ground in warehouse, if not, please
don’t use it.
The service environment：
a. The altitude does not exceed 1200 meters;
b. temperature not over +40℃，not under+5℃；
c. when environment temperature at +40℃,the relative humidity can’t over 50%，At
low temperature，allow big relative humidity;
d. ground need hard and flat;
e. It is forbidden to use this car in corrosive environment such as flammable and
explosive or acid base.
2
2.Proper usage
Please using the Electric pallet truck accord to this specification.
This is a tramp type electric pallet truck with autonomous control, lifting and lowering
is controlled by the handle button.
Improper use can cause personal injury or machine damage. Operators or operating
companies need to ensure proper using,
The Truck needs to be used on a firm, flat, intact surface and suitable surface, The truck
is designed for indoor use at room temperature from+5°C to +40°C
Use under light load without using permanent barriers or pits, It is forbidden to operate
on the slopes. During Operation. The goods must be placed approximately at the center of
the truck’s load center
Lifting or Carrying people is strictly prohibited ,If carried goods .The goods must fall on
the lifting point 。
It is prohibited to use this truck on lifting or loading ramps。
The rated capacity is marked on the capacity label or nameplate. And the operator must pay
attention to the warming signs and safety instructions
Operating lighting must be at lest 50LUX.
Modification
Any modification that may affect the truck rated capacity, stability, or safety operations must
be approved in advance by the Truck’s original manufacturer or Its authorized Manufacturer
or its successor. This includes the effects of changes such as Braking, steering , Visibility, and
the addition of removable accessories.
After the manufacturer or its successor approves the modification or change, The capacity
name plate, Label, identification marks, operation and maintenance manual must be changed
accordingly
Truck damage caused by not following Instruction will lose its
warranty.
3
3.Introduction of the product
3.1 Model Overview
This specification is for EPT33 series 1.5T type Full electric pallet truck（follow as truck）.
3.2 Model parameters
4
Model
EPT33
EPT44
Drive type
Battery
Operation type
Pedestrian
Load Capacity
Q (lbs)
3300
4400
Load Centre
c (in)
23.6
Distance between fork backrest and front wheel
x (in)
37.2
Wheel Base
y (in)
49.7
Service Weight (with battery)
Lbs
400
420
Tire material
PU
Driving wheel size
Φ×w(in)
Φ8.3×2.8
Bearing wheel size
Φ×w(in)
Φ3.2×2.4
Balance wheel size
Φ×w(in)
Φ3.9×1.6
Tread
b
11
(in)
21.1
Lifting Height
h3 (in)
7.9
The height of handle in the operation position
h
14
(in)
24.1/47
Lowered fork height
h
13
(in)
2.95
Overall Length
l
1
(in)
66.9
Body Length
l2 (in)
18.8
Overall Width
b
1
/ b
2
(in)
27
Fork Size
s/e/l (in)
2/5.9/48
Fork Width
b5 (in)
27
Ground clearance under mast
m
2
(in)
1.4
Aisle width for pallets 1000*1200 crossways
Ast (in)
72
Aisle width for pallets 1000*1200 lengthways
Ast (in)
74.1
Turing Radius
Wa (in)
56.1
Driving Speed, laden/unladen
(mph)
2.6/2.8
5
Lifting speed gradeability, laden/unladen
(mm/s)
22/25
Lowering speed gradeability, laden/unladen
(mm/s)
38/28
Maximum gradeability, laden/unladen
(%)
6/10
Brake Type
Electromagnetic
Drive Motor
(kW)
0.75
Lift Motor
(kW)
0.8
Battery, according to DIN 43531/35/36 A,B,C,no
no
Battery voltage/rate capacity
(V/Ah)
24/40
48/50
Type of drive control
DC
Noise level
(dB(A))
≤70
Steering type
Mechanical
6
4.Operating principle
With battery as power producer and controlled by electrical and hydraulic, trucks can do
some actions like walking, turning, pallet fork lift, etc.
1.Switch for lifting and lowering 2.Switch for driving 3.Emergency
reverse switch 4.Horn 5.Electricity meter
7
5.Operating principle
5.1Running system
The truck is powered by a battery, which is realized by controlling the DC motor on the drive
wheel. The speed of walking is realized by frequency conversion control motor speed, which
is controlled by the accelerator.
Gear box in the factory has been posited enough gear lubricating oil. And please change the
gear lubricating oil every 1000 hours under normal circumstances.
If you hear abnormal sound from gear box when using, please stop and check immediately. If
there are bearing failure or some problem in gear, please replace and repair them.
5.2 Steering system
The operating handle drives the rotation direction sensor which can send out the turn
signals that makes the truck turn around.
5.3 Braking system
5.3.1Braking performance depends on road conditions and vehicle load
conditions.
The brake function can be activated by the following ways：
⚫ Turn the travel switch (2) to "0" position or release the switch to make truck brake
until it stops.
⚫ With the driving switch (2) moving directly from one driving direction to the
opposite direction, the vehicle regenerates the brake until it begins to move in the
opposite direction.
⚫ The handle moves up and down to the braking area (' B ') and the vehicle brakes. If
the handle is released, the handle automatically moves to the upper braking area ('
B ') and the vehicle stops until it stops.
8
⚫ Belly switch (3) can prevent the operator will be squeezed, when vehicles are
driven towards (' Fw) encounters an obstacle, body touch belly to slow down or
start to switch vehicles (' Bw) driven a short distance, then stop. If the handle is in
the operating area and the vehicle is not moving, please consider that this is still
working.
5.3.2Working principle of braking：
The brake is composed of magnetic yoke assembly 6, excitation coil 7, spring 2, brake
disc 5, armature 1, gear sleeve 4, mounting screw 3, etc. The brake is mounted on the end
cover of the motor and the mounting screw is adjusted to the specified air gap value. The
gear sleeve is fixed on the shaft, and its outer tooth is matched with the inner tooth of the
brake disc. When working, torque is transferred, and the brake disc can move axially on the
gear sleeve.
When the brake excitation coil 7 is energized, the magnetic field generated by the coil
causes the armature 1 to attract to the yoke assembly 6, and the armature 1 is detached
(released) from the brake disc 5.At this time the motor drive shaft with brake disc 5 normal
start and operation. When coil 7 is cut off, the magnetic flux disappears and armature 1 is
released. Spring 2 presses armature 1 and compresses the friction plate on the brake disc to
generate friction, thus achieving the braking purpose.
Braking principle diagram
9
5.4 Operating System
The main working body of a moving truck is a cargo fork, which relies on a fork to carry
the pallet or cargo for transport and short distance transportation. The expansion of the
cylinder is realized by the control of the operating handle, and the pressure oil is provided
by the pumping station.
A slow-down valve is installed in the circuit of the lifting cylinder to slow down the
speed of the fork when it is falling to achieve a safe lowering effect.
5.5 Electric System
The electrical system includes walking and operation control. The truck use DC
electric control assembly.
The meter has a battery indicator. When the battery power is too low, the electric meter
will cut off the starting control line of the oil pump motor. The moving truck can only walk
without lifting the fork, and the prompt should be charged immediately. The motor of oil
pump is the dc motor for 5 minutes, so the pump motor is not suitable for long running. That
is, the lifting movement should have time interval, can not continuously carry on, otherwise
would make the motor heating, even burn.
Special note: when the truck is used for a long time, the starter of the oil pump motor
may fail, and it can't be broken after being sucked or closed. The latter is not throw control
handle, the oil pump motor is kept in the rotation, should immediately stop at this moment,
to cut off the power supply (unplug battery plug-in), make the oil pump motor stop running,
and promptly replace the starter.
5.6 Hydraulic principle
The oil pump motor drives the gear pump to provide hydraulic power, lifting oil cylinder is
responsible of fork’s lifting and lowering, The control of the lift oil road is controlled by the
buttons on the operating handle, The lifting action is controlled by a single action oil circuit
on the valve block. This model of the hydraulic system pressure can only be adjusted on the
valve block, has been debugging good, before they go out after they leave the our company
after-sales personnel or professional maintenance personnel are strictly forbidden to adjust
themselves, so as to avoid safety accident.
10
6.Electrical Schematic Diagram
11
7.Hydraulic Scheme
12
8.Operating Instruction
Before operation, please be familiar with the function of each switch/button on the
instrument panel.
8.1 Operation
1).Insert the key into the key switch, turn to the right, pull the emergency stop switch up,
open the control circuit.
2).Forks rise above ground about 10 cm
3).Open the travel switch slowly, till the requested speed
4).Any fault of the truck happening during operation, need to cut off the power immediately,
and press the red emergency power switch down.
5).Avoid take a sudden turn during driving the truck.
6).The full-load climbing degree of the truck is 6%, so Using truck Full load climbing a slope,
need to know the condition of the slope, and press the travel switch as much as possible to
get a maximum grade ability.
7).When stop driving, put the fork in the bottom, press the emergency stop switch down, and
pull out the key.
8.2Emergency reverse function
If the truck loses control during driving, or produces smoke or burnt smell during use,
please press the emergency stop switch on the dashboard of the truck, and the main power
supply will be cut off. It can be opened after finding out the reason and clearing the fault. The
method of opening is: gently pull up the red button, the button will pop up, and the opening
is complete.
The button of the emergency power-off switch is made of plastic parts. Do not use excessive
force when pushing it down or pulling it up to avoid damage to the switch.
8.3 The use of the horn and the reversing horn
Press the horn button in the center of handle to notify people around.
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8.4 Battery capacity display
The stacker battery capacity indicator has electricity capacity display function.
8.5 Handling stacking operation
（1）How to carry goods
Will truck slowly drive to the front of the need to carry items, insert the pallet fork and move
forward slowly, when the goods completely inserted into the goods after parking, control
handle upgrade button, the heavy lifting to a certain height, back slowly, don't touch the
adjacent goods, when the weight zone is put out the goods, and then walk handling.
（2）How to place the goods
When moving the goods close to the area of the goods, it will slow down. When the moving
truck is in a straight line with the goods, then the moving truck will slowly move forward to
the loading area to stop. Slowly press the down button, and once the load is held, the fork
will be lowered to the hollow position. When the fork is pulled out of the weight, the back
position will be confirmed without any obstacle. Wait for the fork to leave the weight
completely before carrying on a round of handling.
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9、Safety operation and matters needing attention
The spare parts and safety device of the truck is not allowed to change without permission.
All parts supplied by the original manufacturer are subject to strict quality inspection. To
ensure the safety and reliability of the vehicle, please use the original parts. Replacement
parts, including all oils, must be collected and processed in accordance with local
environmental and health laws and regulations.
9.1 Repair and maintenance
Maintenance technician: The maintenance and service should only be performed by
special personnel trained by the manufacturer. After the technician sent by after-sales
department of the manufacturer completed maintenance and servicing work, they should
sign on the service log.
Cleaning Operation: Flammable liquid can not be used for cleaning the stacker. Before
cleaning, take safety precautions to prevent electric sparks (e.g. sparks caused by short
circuit). When operating the accumulator, connectors on it must be disconnected. Use soft
air suction or compressed air, non-conductive and anti-static brushes to clean electric and
electronic components.
Operation of Electric System: Operation on the electric system should only be performed
by specially trained personnel. Before performing any operation on the electric system,
precautions must be made to prevent electric shock. When operating the accumulator,
connectors on it must be disconnected.
Welding operation: In order to prevent damage to electrical or electronic components,
these electrical components must be removed from the vehicle before any welding
operation.
Installation: When repairing or replacing hydraulic components, electric and electronic
components, make sure to install them back to their original positions.
Wheels:Quality of the wheels has significant effect on stability and driving performance of
the truck.Modification on wheels can be performed only with the approval from the
manufacturer. When replacing wheels, ensure that the truck is levelled as delivery
state(wheels must be replaced in pairs, i.e. replace right wheel together with left one).
Lifting chain and rollers: Chain and rollers will be worn quickly without good
lubrication.Perform periodic lubrication according to following maintenance table. Shorten
15
the lubrication period under adverse operation conditions (such as in dusty and hot
environment).
Hydraulic oil pipe: The oil pipe must be changed every 6 years. When change the hydraulic
assembled parts, the oil pipe should be also changed.
9.2 Routine Maintenance
9.2.1 check the condition of each pole, cable and protective cover of the accumulator.
9.2.2 check whether the battery box is secure.
9.2.3 check whether the truck is oiled.
9.2.4 check the situation of fork, oil pipe and horn.
9.2.5 check the braking condition.
9.2.6 check the wear condition of driving wheel, load wheel and so on.
9.3 Professional Maintenance Manual
It is very important for safe operation of the truck to perform overall professional
maintenance. Failure in performing maintenance according to specified interval may cause
malfunction of the truck, and potential risk to human and equipment.
Maintenance periods listed in this manual apply to single shift a day under normal operation
conditions. If using in dusty environment, the ambient temperature varies remarkably or in
multi-shift situation, the maintenance period has to be shortened.
Maintain the truck according to following maintenance list. Maintenance periods are as
follows:
W = Every 50 work hours, but at least once a week.
A = Every 500 work hours, but at least once every three months
B = Every 1000 work hours, but at least once every six months
C = Every 2000 work hours, but at least once every 12 months
Additional operations should be performed in trial run period:
(In initial 50 – 100 working hours or after two months)
— Check the nuts on the wheels, and tighten them if necessary.
— Check the hydraulic components for leakage, and tighten them if necessary.
—Replace the hydraulic filter.
16
Time interval(Month)●
W
A
B
C
Brake
1.1
Check the air gap of the electromagnetic brake
●
Electrical
system
2.1
Check the operation switch to show the function of the device
and components
●
2.2
Check alarm system and safety device
●
2.3
Check the cable for damage and the terminal is secure
●
2.4
Check the function of the micro switch setting
●
2.5
Check controller and EPS controller
●
2.6
Cable and motor fixing
●
Power
supply
3.1
By observing the battery
●
3.2
Visual inspection of battery charging plug
●
3.3
Check if the connection of the battery cable is tight, and if
necessary, apply the electrode with grease.
●
Driving
system
4.1
Check the gearbox for abnormal noise
●
4.2
Check the running mechanism and grease, check the reset
function of the operating handle
●
4.3
Check the drive wheel and bearing wheels for wear and
damage
●
4.4
Check wheel bearings and fixing conditions
●
Whole
frame
5.1
Check if the frame is damaged
●
5.2
Check if the sign is complete
●
5.3
Check the fixing of the mast
●
Hydraulic
movement
6.1
Check the function of the hydraulic system
●
6.2
Check hoses, pipes and connections for tightness, sealing and
damage
●
6.3
Check the cylinder and piston for damage, sealing and fixing
●
6.4
Check the load chain settings and re-tension if necessary
●
6.5
Visually inspect the mast rollers and check the wear on the
roller faces
●
6.6
Check the forks and load handlers for wear and loss
●
6.7
Check the tank for oil level
●
6.8
Update hydraulic oil
●
Maintain list
17
9.4 Battery maintenance, charging and maintenance.
Any operation of the battery must be guaranteed to stop the truck and put it in a safe
position.
9.4.1 maintenance personnel.
Battery charging, maintenance and replacement must be operated by qualified professionals.
You must carefully read the manual, supply preparation and charging requirements before
preparing for the operation.
9.4.2 fire protection measures.
Smoking and open fire are strictly prohibited when operating the battery. Storage battery
and charge must be kept away from combustible materials, at least 2 meters above the
distance, the place of storage battery must be well ventilated and equipped with fire-fighting
facilities.
9.4.3 Battery type and usage note.
1) Keep the nuts on every battery cell dry and clean. Tighten every terminal and cable end,
and brush them with grease to prevent corrosion. Naked cable ends and terminal posts
should be covered with a skid-proof insulating cover.
2) Every two cells should be well-connected. Check the nuts on each pole, if loose, tighten the
nuts.
3) Keep the surfaces of accumulator clean and dry.
4) Over recharging and over discharging should be avoided, and fast charging and
insufficient recharging are also not allowed. Otherwise life span of the accumulator may be
affected.
5) Do not put conductive objects including metal tools on the accumulator, or short circuit or
even explosion may be caused.
6) Never spill any hazardous liquid or solid material on surfaces of the accumulator. When
using a densimeter or a thermometer, make sure the surface is clean and clear.
7) Recharge the discharged accumulator in time. Delayed recharging may damage the
accumulator. Do not delay recharging more than 24 hours. Recharging of the accumulator
may not work outdoors in cold weather. In this case, move it indoors to perform recharging.
8) If the accumulator will not be in use for a long time, it should be recharged and discharged
once every month and it should be fully recharged every time.
18
9) If individual cell fails, identify the cause and repair the cell immediately. Replace the cell
when it cannot be repaired.
10) The site for recharging should be well ventilated. It is prohibited to smoke or use open
fire, avoiding the risk of hydrogen explosion.
11) The weight and dimensions of the accumulator have remarkable effect on stability of the
stacker. Therefore do not modify the type of accumulator without approval from the
manufacturer.
12) Never discharge in large current, for example, performs travelling and lifting
simultaneously.
9.4.4 Disposition of batteries
Worn-out accumulators should be recycled according to local regulations, and stored in
specified zone or cast-off treatment zone. These works should be done by qualified
specialized companies.
9.4.5 Specification of the battery
The battery's non-insulated terminal must be protected by an insulating cover. When the
battery is connected and connected to the socket, the vehicle must be cut off and the switch
in the closed position. When replacing or assembling the battery, make sure the battery is
securely fixed in the battery box.
9.4.6 Storage, transportation and installation of the accumulator
The truck must be parked on the level ground steadily. To prevent short circuit, naked cable
ends and the terminal posts should be covered with insulated covers. When pulling out the
accumulator, properly arrange removed accumulator's connectors and cables without
blocking access of the accumulator.
9.4.7 Battery power indicator
Battery power display table: ten article showing represent 100% of the battery. With the
consumption of battery capacity, the glowing article shows will be from top to down.
19
The color of LED show the different states ：
Name
LED Color
Parameter value
The standard battery remaining
power
Green
70-100%
Orange
30-60%
Red blinking
0-20%
Battery discharge on 70%，red lamp will blinking “Energy storage”;
Battery discharge on80%, two lamp will blinking “run out of battery”, Must to the
accumulator.
9.4.8 Charging
The Electric truck is supplied with a special charger for recharging.
Read the instruction manual carefully before recharging.
The batteries should be recharged in well-ventilated areas. Make sure no metal objects
placed on the accumulator. Check all cables connection and connectors for obvious defects.
Observe strictly all safety instructions, e.g. replenishment of the accumulator and
preparation for recharging.
For safety working, the truck should be added protective cover before using.
Personnel should stay away from batteries as much as possible to avoid danger.
9.4.9 Removal and installation of battery
Before disassembling and installing the battery, it is required to park the truck and turn off
the power of the truck.
Battery removal and installation steps:
A: Unscrew 4 fixing screws (1).
B: Take out the front panel (2).
C: Unscrew the 2 fixing bolts and remove the two battery cables (3).
20
D: Insert or replace the battery (4) in the direction shown in the figure.
Install the battery in the reverse order, paying attention to the correct position and
wiring of the battery. Place the battery cable so that it does not cut when you put it in the
battery.
21
10.Safety Caution
10.1 General rule
10.1.1 The operator must have a forklift operation qualification which proved by the
relevant departments of the training before driving truck.。
10.1.2 The operator must read the instructions before use all of the content, after fully
understand operation method can drive Truck.
10.1.3 truck must not carry passengers.。
10.1.4 Operators should pay special attention to when homework operating environment,
including other people nearby and fixed object.
10.1.5 Without the manufacturer's approval, shall not modify, add or remove tractor parts,
lest affect performance of tractor.
10.2 Storage and transportation
10.2.1 Use container or car to transport the truck should pay attention to at the time of
shipment:
○
1 Front and rear wheels with wedge, begin to pull up the parking system, prevent
sliding in the process of transportation;
○
2 Using the lasso, not placed in the weak structure of the truck；
22
○
3 When moving the truck. Pay attention to keep the center of the moving truck in the
middle of two fork
○
4 During Transportation, Remove the Trailer and fix the tractor with a dedicated strap
for lifting according to the figure below。
10.2.2 When Truck doesn't work, should be parked in a dry ventilated cleaning warehouse,
Protect the truck from the sun and rain
And please note:
○
1 Turn off the Electrical lock and make the safety switch off, unplug the power plug
○
2 Begin to pull up the parking system, front and rear wheels with block mat;；
○
3 Such as discontinued for a long time, battery should be added once every 15 day
electricity.
10.3 Check before using
10.3.1 New car if there is any damage in transportation, please don't be put into use, and
promptly get in touch with the supplier, do proper processing.
10.3.2 New cars in the factory run parts has been filling lubricating oil.
10.3.3 Truck equipped with battery.The battery is charged before leaving factory.If leaving
the factory for a long time, may the battery is low.Before use should pay attention to
electricity meter shows that when the electricity meter display to the last two warning, must
charge at once.
10.4Safety operation regulation
10.4.1Requirement for operator: The Truck must be operated by a trained operator, He
can perform and operation demonstration on the user to move and mainpulate the cargo,
and can clearly guide the user how to operate the forklift.
10.4.2 Operator’s rights, obligations and responsibilities：Has been trained by the
operation of the vehicle, the driver must be clear of his rights and obligations; and he is
familiar with the contents of the relevant operating instructions. If the vehicle is pedestrian
type, the driver must also wear safety boots.
23
10.4.3 Prohibit unauthorized person to operate：The operator is responsible for the
vehicle,he need to prohibit unauthorized person to operate. Transport or lift person is also
forbidden.
10.4.4 Malfunctions and defects：If the vehicle has any malfunctions or defects,need to
inform administrator, If the vehicle cannot be safely operated (e.g.: wheel wear or brake
failure), then it must stop using until it is fully repaired.
10.4.5 Safe operation and environmental protection：inspection and maintenance must
be performed in accordance with the time intervals on the maintenance list.
Parts of the vehicle cannot be changed without any permission, especially safety devices. The
operating speed of the truck is not allowed to change.
All original spare parts have been verified by quality assurance department. To ensure the
safety and reliability of the operation of the truck must use only the manufacturer's spare
parts. The old parts, such as oils and fuels must be handled in accordance with the relevant
environmental protection rules.
10.4.6 Hazardous area: Hazardous area usually refers to the following range: vehicle or its
load lifting devices (e.g. fork or accessories) is dangerous for personnel when running or
lifting movements, or the ongoing regional transport loads. Typically, this range extends to
the load or truck accessories landing area.
Unauthorized personnel must be asked to leave the dangerous zone. As long as the situation
might cause some kind of damage, the driver must give a warning, if the driver asked the
person to leave but did not leave the hazardous zone, the driver must immediately stop the
vehicle.
10.4.7 High-risk environment：Working in high-risk environment, operator must have a
special design to be protected.
The vehicle was not specially designed for the high-risk environment.
24
10.4.8 Safety devices and warning signs: Safety devices, warning signs and warning notes
described in the previous operating instructions must be taken seriously enough.
10.4.9Driving in public places: the vehicle is forbidden to drive in public places expect in
specified special areas.
10.4.10Distance between truck: keep an appropriate distance, avoid the front vehicle
suddenly stop.
10.4.11headroom: When the headroom is below the cargo or mast, it is forbidden to use
the vehicle.
10.4.12Using in the elevator and loading platform maneuvering: if there is sufficient
loading capacity, won’t affect the operation of the vehicle, and being agreed by the operator
of the vehicle, then the elevator and loading platform can be used for vehicle transport.
Before entering the elevator or loading station, operator must personally identify. The goods
must be placed in front and occupy an appropriate place, to avoid touching the wall of the
elevate when the vehicle enters the elevator. When personnel and vehicles take the elevator
together, person can enter only after the vehicle has safely entered, and person must leave
before the vehicle.
10.4.13 Driving aisle and working area: The vehicle must be operated on the specified
aisle, all non-related person must leave the work area, and cargo should be stacked in
designated places.
10.4.14 Operation Management：Driving speed must be adapted to local conditions. When
through the corners, narrow passage, swing doors and closed place, speed must be slowed
down. Drivers must be able to visually an adequate braking distance between vehicle and the
front vehicle, and he must remain in control of his vehicle. Sudden stop (unless urgent
needs), rapid U-turn, chased each other in the Aisle is not allowed. Do not pry out of the body
to operate the vehicle.
10.4.15 Visibility: The driver must look attentively at the direction of driving, to ensure the
front situation is clearly visible. When the vehicle is backing off, if the carriage of goods block
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the line of sight, a second person walk in front of the vehicle to give appropriate guidance
and warnings is necessary.
10.4.16 Pass through the ramp: Only a known ramp which should be clean, non-slip, and
with the vehicle technical availability was allowed to go through. The goods on the forks
must face uphill. It is forbidden to turn back, move diagonally or park on the ramp. The
operator must slow down when going through the ramp, and prepare to brake at any time.
10.4.17 Load capability on ground: when the vehicle is in operation, make sure the load
pressure of the body weight or wheels on the ground does not exceed the load capacity of the
ground.
10.4.18 Vehicle Change: Any possible changes or modifications for rated load, stability or
safe operation of the vehicle, must obtain prior written approval from origin manufacturers
or its successor. After vehicle manufacturer check and approve the changes, nameplates,
labels and markings of Operation and Maintenance Manual must be modified as well.
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11.Service Manual
11.1 Troubleshooting
Fault
Cause
Treatment
The truck can't
move
The battery connector is not connected
Check the battery connector，connected if
necessary
Electric lock switch on “OFF” position
Electric lock switch turn to “0”position
Emergency Stop Switch not open
Open the Emergency stop switch
Battery power runs out
Check the battery charge，If it is
necessary to recharge
The vehicle being charge
Interrupt charging process
The fuse is damaged
Check the fuse
Goods can’t be
lifted up
The vehicle is not operating
Handle according to the treatment
method listed in Vehicles cannot move”
Low hydraulic oil level
Check hydraulic oil
The fuse is damaged
Check the fuse
Overloading
Pay attention to the rated capacity
The Up switch is in bad contact or
damaged
Check up switch and replace if necessary
Goods can’t be
lowered down
Dirty oil blocks control valve
Check hydraulic oil and clean control
valve,replace the oil if necessary
The solenoid valve for lowering is not
opened or is damaged
Check or replace the valve for lowering
Can’t stop when
lifting
Lifting micro switch is damaged
Cu off the power and replace lifting micro
switch
Moving in one
direction
The sensitive switch and the
connecting cable are not
well-contacted.
Check the sensitive switch in control
lever and the connecting cable.
The vehicle travels
very slow
The related cable are not
well-connected
Check the battery indicator light and
related cable
The car suddenly
started
Controller is damaged.
Change the controller
The handle which control the forward
or back is no reset.
Repair or change
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If above steps still can not solve problems, please contact after-sales service department of
the manufacturer and have the problems solved by specially trained technicians.
11.2 Preparation before repair
To prevent possible accidents during maintenance and repair work, following preparations
must be done:
— Park the device safely.
— Press the emergency stop switch and disconnect the connectors on accumulator.
11.3Check the amount of hydraulic oil
— A vehicle ready for repair or maintenance。
— Open the electrical box cover。
— Check the amount of hydraulic oil in the tank。
When checking the hydraulic oil level, the fork and mast must be lowered to the lowest
position.
11.4 Complete repair, the preparation before using
Use the device only after following operations have been completed.
— Clean the vehicle
— Check the brake.
— Check the emergency stop switch.
— Check the horn.
Several electromagnetic brake tests need perform immediately after the test
