Proper and comprehensive inspection of electric stackers can prevent malfunctions and extend stacker lifespan. The service intervals listed in the maintenance schedule are based on 8 hours of operation per day, totaling approximately 200 hours per month. For safe operation, maintenance should be carried out according to this schedule.
Electric Stacker Maintenance Guide
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Daily Inspection
1.1 Check hydraulic oil level Lower the forks to the lowest position,
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Lifting height 2.5m: 5L
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Lifting height 3.0m: 5.5L
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Lifting height 3.3m: 5.7L
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Lifting height 3.5m: 6L
Use the recommended grade of hydraulic oil.
1.2 Check battery charge level: Refer to battery usage and maintenance instructions.
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As-Needed Check
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Clean the stacker
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Check and tighten all fasteners
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Check wheels for damage
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50-Hour (Weekly) Maintenance
| No. | Content | |
| Brake System | 1 | Switch the tiller between zones A and B; the brake should produce a clicking sound. |
| 2 | Wipe off any oil or dust from the large steering gear. | |
| 3 | Brake clearance should be 0.00787–0.0315''. | |
| Battery | 4 | Check electrolyte level; top up with purified water if low. |
| 5 | Check electrolyte specific gravity after full charge—it. It should be 10.67 lb/gal. | |
| 6 | Clean the battery with tap water after sealing the caps. | |
| Contactor | 7 | Polish the rough contact surfaces with sandpaper. |
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200-Hour (Monthly) Maintenance
In addition to weekly checks, perform the following, like stacker hydraulic system care:
If replacement or adjustment is needed, contact after-service department . (Monthly maintenance records must be retained.)
| No. | Checkpoint | Inspection Content | |
| Stacker | 1 | General Condition | Check for abnormalities |
| 2 | Horn | Sound functionality | |
| Steering System Braking System Hydraulic System Lifting System |
3 | Tiller Operation | Switch between zones A and B, listen for clicking sound |
| 4 | Brake Clearance | Should remain at 0.2–0.8 mm | |
| 5 | Tiller Flexibility | Looseness and ease of movement | |
| 6 | Chassis & Fasteners | Cracks, lubrication, looseness | |
| 7 | Linkage & Fork Assembly | Cracks, deformation, lubrication | |
| 8 | Oil Hoses | Any leaks | |
| 9 | Hydraulic Oil | Proper level | |
| 10 | Lifting Cylinder | Any leakage | |
| Electrical System | 11 | Electrolyte | Level, specific gravity, and cleanliness |
| 12 | Plug | Functionality and any signs of damage | |
| 13 | Key Switch | Functionality | |
| 14 | Contactor | Contact quality and functionality | |
| 15 | Micro Switch | Functionality | |
| 16 | Controller | Functionality | |
| 17 | Drive Motor | Wear condition of the carbon brushes and commutator | |
| 18 | Lifting Motor | Wear condition of the carbon brushes and commutator | |
| 19 | Steering Motor | Wear condition of the carbon brushes and commutator | |
| 20 | Fuses | Integrity and proper condition | |
| 21 | Wiring Harness and Connectors | Check for looseness or damage |
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600-Hour (Quarterly) Maintenance
Repeat monthly procedures. Contact after-service department for any necessary replacements or adjustments.
Contactor
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Polish uneven contacts with sandpaper
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Replace if malfunctioning
Motor
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Check carbon brushes and commutator wear
Brake
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Clean dust and dirt from brake pads; inspect wear
Troubleshooting Electric Stacker
This part will briefly introduce how to repair a pallet stacker when meeting some common errors.
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Common Faults and Troubleshooting Methods
| Fault | Cause | Solution |
| Stacker cannot move (Contactor also not working) | 1. Control circuit fuse is blown | Replace |
| 2. Power switch contact is faulty or damaged | Repair or replace | |
| 3. Main circuit fuse is blown | Replace | |
| 4. Electric lock switch contact is faulty or damaged | Repair or replace | |
| 5. Battery connection is loose or disconnected | Tighten | |
| Stacker can only move forward (or backward) | 1. Contactor contact is faulty or burned | Repair or replace |
| 2. Circuit board is faulty | Repair or replace | |
| Stacker cannot stop while driving | Contactor contact damaged, moving contact does not reset | Emergency power cut, replace the contact of the contactor |
| Fork cannot lift | 1. Overload operation | Reduce load |
| 2. Overflow valve pressure is too low | Adjust higher | |
| 3. Lifting cylinder has abnormal internal leakage | Replace seals | |
| 4. Insufficient hydraulic oil | Add filtered hydraulic oil | |
| 5. Battery voltage is insufficient | Charge battery | |
| 6. Control handle not in horizontal or vertical position, oil pump motor not powered | Incorrect operation | |
| 7. Oil pump motor damaged | Repair or replace | |
| 8. Oil pump damaged | Repair or replace | |
| 9. Lifting button switch damaged | Repair or replace | |
| 10. Electric lock not open or damaged | Repair or replace | |
| 11. Battery voltage severely insufficient | Charge battery |
