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Knowledge

Knowledge Centre

Everything a buyer or a maintenance team needs — how to size a truck, how to look after it, and what to check when something goes wrong.

🔍 Selection Guide ❓ FAQ 🔧 Maintenance ⚕️ Troubleshooting
Step 1

How to Size a Truck — Five Questions

Answer these five and the shortlist writes itself.

1️⃣

How heavy is the load?

Weigh the heaviest pallet, not the average. Then check the load centre — a 1.5 t truck rated at 500 mm carries less if your load centre is 600 mm. Always size with margin.

2️⃣

How high must it lift?

Top beam height + pallet height + 100 mm clearance. Check residual capacity at full height, which is lower than the nominal rating on most trucks.

3️⃣

How wide is the aisle?

Measured between rack uprights, not between rack centres. This single number decides whether you need a stacker, a reach truck, a three-way forklift or a counterbalance truck.

4️⃣

What kind of pallet?

Closed-bottom (single-faced) pallets need support legs or a counterbalance design — a straddle stacker cannot pick them. Check whether you handle both types.

5️⃣

Where does it work?

Indoors, outdoors, cold store or hazardous area. Each changes the specification: IP rating, battery chemistry, hydraulic oil, tyres and certification.

Truck typeTypical minimum aisleBest for
Hand pallet truck1.8 mHorizontal movement, no stacking
Electric pallet truck2.0 mLong-distance horizontal transport
Straddle / leg stacker2.2 mOpen-bottom pallets, stacking to 4 m
Counterbalance stacker (legless)2.4 mClosed pallets, truck loading, no outriggers
Reach stacker / reach truck2.4–2.8 mDeep racking, stacking to 7 m
Three-way forklift1.6 mVery narrow aisle, racking to 12 m
Counterbalance forklift3.5–4.0 mTruck loading, mixed loads, general purpose
FAQ

Frequently Asked Questions

01What is the difference between a stacker and a forklift?
A stacker lifts a pallet vertically between its support legs, so the pallet must be approached from the open side and the truck cannot pick a pallet off a truck bed. A counterbalance forklift carries the load outside the front wheels, so it can pick pallets from the floor or from a trailer without outriggers — but it needs a much wider aisle. Stackers are cheaper to buy and run; forklifts are more flexible.
02How do I know what lifting height I need?
Measure to the top of the highest beam you will place a pallet on, then add the pallet height and a clearance allowance of at least 100 mm. Do not size to the rack height alone — a 6 m rack with 1.2 m pallets and a 7.2 m top beam needs a truck that lifts to about 7.3 m. Also check the residual capacity: a truck rated 1.5 t at 500 mm load centre lifts less at full height with a long load centre.
03What aisle width do I need?
As a working guide: a hand pallet truck needs about 1.8 m to turn; a powered pallet truck about 2.0 m; a reach truck 2.4–2.8 m for stacking; a counterbalance forklift 3.5–4.0 m; a three-way forklift as little as 1.6 m. Always confirm with the truck drawing — the exact figure depends on the mast, the battery compartment and the load length.
04Lithium or lead-acid battery?
For a single shift with a charging room, lead-acid is usually cheaper over five years. For two or three shifts, lithium normally pays back within two years because you avoid a spare battery set, a battery room, watering and equalising charges — and opportunity charging during breaks keeps the truck working. Lithium also performs far better below freezing.
05Can you customise the truck for my application?
Yes. Fork length, overall width, lifting height, capacity, colour and branding are all customisable, and we build special trucks for drum handling, bricks, gas cylinders, crates and other non-standard loads. Send a drawing or a photo of the load and the working area and we will come back with a proposal.
06What is the lead time?
Standard models are typically 30–45 days from deposit, depending on the model and quantity. Customised trucks and AGV projects take longer. We will confirm the exact date in the quotation and keep you updated with production photos.
07How are the trucks packed for sea freight?
Trucks are wrapped and packed in plywood or wooden cases with a moisture barrier, or shipped in steel-frame racks for multiple units. We supply the packing list, fumigation certificate where required, and loading photos. A loading plan is available if you use your own forwarder.
08What warranty do you offer?
Twelve months from the date of shipment on the truck, covering manufacturing defects. Wear parts — wheels, brushes, seals and hydraulic oil — are excluded. We supply the failed part free within the warranty period; labour is the customer’s responsibility unless agreed otherwise.
09Do you supply spare parts?
Yes. Controllers, drive wheels, load wheels, handles, hydraulic power units, motors and seals are all available. Standard parts ship within 3–7 days. We recommend keeping a small critical spares kit with your first order — we will advise what to include.
10Can you supply CE documentation?
Yes. A CE declaration of conformity and the supporting technical file are available for the models covered by our CE scope. Tell us your destination country at the enquiry stage so we confirm the applicable documentation before the order is placed.
11What training do you provide?
We provide an operation and maintenance manual in English with every truck, plus a start-up video call if required. For fleet orders we can send a technician to site for commissioning and operator training — travel and accommodation at cost.
12Can I visit the factory?
Yes, and we encourage it. We are in Taizhou, Jiangsu — about one hour from Shanghai by high-speed rail and two hours from Nanjing. We can also arrange a live video walk-through of the production line and a demonstration of the model you are considering.
Maintenance

Maintenance Schedule

A truck that is checked daily lasts twice as long as one that is only repaired. Print this and put it on the wall.

🗓️

Daily

  • Check hydraulic oil level and look for leaks under the truck
  • Test the horn, brakes and emergency stop
  • Check the battery charge level and top up if lead-acid
  • Inspect forks and the mast for cracks or deformation
  • Check wheels for damage, flat spots or foreign objects
🗓️

Weekly

  • Lubricate the mast channels, chains and pivot points
  • Check chain tension and adjust if uneven
  • Inspect hydraulic hoses and fittings for chafing
  • Clean the battery top and terminals; check for corrosion
  • Test the lifting and lowering speed through the full stroke
🗓️

Monthly

  • Check the hydraulic oil for contamination; replace if discoloured
  • Inspect the drive wheel and load wheels for wear; measure diameter
  • Test the controller for fault codes and clear the log
  • Check all fasteners on the mast and chassis for torque
  • Inspect the charger leads and plugs for heat damage
🗓️

Annually

  • Replace the hydraulic oil and filter
  • Replace hydraulic return filter element
  • Full load test at rated capacity
  • Inspect and repack wheel bearings
  • Check the mast for square and adjust the chain tension
  • Replace worn wheels and brake components
Troubleshooting

Common Faults and What to Check First

Eight problems that account for most breakdown calls — and the first three things to check in each case.

⚠The truck will not lift
Check the hydraulic oil level first — low oil is the most common cause. Then check for a blocked suction filter, a failed solenoid valve, or a relief valve set too low. If the pump is noisy and the lift is slow, air is entering the suction line.
⚠Lifting is jerky or uneven
Almost always air in the hydraulic system or a contaminated filter. Bleed the system and replace the filter. If the mast chains are unevenly tensioned the forks will also rise unevenly — check chain tension before condemning the hydraulics.
⚠The truck will not travel
Check the emergency stop, the seat switch (riding trucks) and the turtle-speed button, which is a frequent culprit because it limits travel to walking pace. Then check the battery voltage under load — a battery that reads 24 V at rest can collapse under load.
⚠Battery drains too fast
Age and temperature are the usual causes. Capacity falls sharply below 0 °C. Check for a faulty cell with a hydrometer on lead-acid, or a cell voltage imbalance on lithium. Also check the charger is actually completing its cycle rather than being disconnected early.
⚠The truck drifts or pulls to one side
Check the drive wheel for wear and the brake for dragging. On four-wheel trucks, uneven tyre pressure or a seized brake caliper will both cause drift.
⚠Forks will not lower
Check the lowering solenoid and the down valve. If the forks hold pressure with the lever released, the valve is stuck — do not force it. On trucks with a mechanical lowering valve, check the cable adjustment first.
⚠Controller shows a fault code
Record the code before clearing it. Codes typically indicate over-temperature, under-voltage, a throttle fault or a motor fault. An intermittent under-voltage code is nearly always a battery or cable problem, not a controller problem.
⚠Excessive noise from the mast
Dry or worn mast channels, or a worn chain sheave. Lubricate first; if the noise persists with the mast under load, inspect the sheaves and the chain for elongation.

Still stuck?

Send us the model, the serial number and a video of the fault. Our technicians will diagnose it over video call — usually within one working day.

Contact Technical Support →

Cannot find the answer?

Ask us directly — if we do not know, we will tell you. Technical questions are answered by the people who build the trucks.

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