OPERATION AND MAINTENANCE

MANUAL
MODEL: DL25T（II）
DOCUMENT NO.: OMDL25T005

NANJING HCT MARINE EQUIPMENT CO., LTD

ATTENTIVE ITEMSⅠ

1． Parking
The deck lifter should not be parked with outrigger cylinders, to avoid the seal damage of the
cylinders. The deck lifter can be parked with airless tires directly for a long time within 2
weeks. It is strongly recommended that at least every two weeks the deck lifter should be
traveled, in order to reduce the aging of the tires.

I-1a

2． Operation
a) Supports
The outrigger cylinder can be operated by the stick or by button on the TD400 screen
“JACK UP”&”JACK DOWN”. The sticks, which are built on the panel, can be used as
remote control by releasing the screws on the panel. The cable cross inside is around 10
meters long.
 I-2a
The limit switch can give the feedback of supports’ position. “top position”, ”middle
position” or “bottom position”. Before the operation one of the outrigger positions must
be chosen with the “JACK LOWER” switch.
Position “LOW” means the bottom position – the height of the deck lifter will be
around 2120mm when it is ready to lift.
Position “HIGH” means the middle position – the height of the deck lifter will be
around 2020mm when it is ready to lift.
Position “0” means the top position – the outrigger cylinders cannot be extended.

I-2b
The instruction will be automatically blocked when the feedback of the limit switches are
received.
The status of every outrigger cylinder can be checked by press “JACK POS” on TD400
screen.
 The number on the screen in the corners is related with the outrigger cylinders’ position.

I-2c
“1” means the top position of the outrigger cylinder
“2” means the middle position of the outrigger cylinder
“3” means the bottom position of the outrigger cylinder
“0” means the position of the outrigger cylinder is between any two of the checking
positions.
For example in the pic. I-2c, the number in lower-right corner is “0”. That means the
rear-left outrigger cylinder is not at the top position or the position switch might be stuck.
In this case the travel instruction will be blocked.
The instruction will be also blocked when the deck lifer is in traveling or the frame is up.

b) Travel
The “forward” or “back” instruction will be only activated only when the “top position”
feedback of the limit switches is received.

I-2d
c) Lifting
The lifting/lowing instruction can be activated by sticks or by button on the TD400 screen
“FRAME UP”&”FRAME DOWN”. The sticks, which are built on the panel, can be used
as remote control by releasing the screws on the panel. The cable crosses inside is around
10 meters long.
The “lifting” instruction will be activated only when the
“bottom position”
 I-2e
or “middle position”

I-2f
feedback of the limit switches is received.
The “lifting” instruction will be automatically blocked when the frame is very close to the
highest position. (for safety it is controlled both by the linear transducer and/or limit
switch)

3． Alarm
Common alarm-the red LED on the control panel with buzzer will be activated if any alarm
comes.

I-3a
a) Temperature high
b) Error of the instruction input (for example: “supports down” instruction is activated when
the supports are already at the bottom position)
c) The frame is close to the highest position
 I-3b

4． Screen
All of the alarm will be also displayed on the screen TD400. The default page of the screen is
the “Alarm page”

I‐4a

Press the ESC bottom, the USER MENU will be activated.

I-4b

I-4c
First page of the “USER MENU”: display of the “temperature”. “height difference” and
“absolute height”
The window of “Displacement&Temperature” can also be activated by pressing “DISP
INFO”
 I-4d
Moving direction:
“0” – stop
“1” – lifting
“2” – lowering

Second page of the “USER MENU”: to calibrate the height nil of the linear transducer
according to the direction.

I-4e

I-4f

Third page of the “USER MENU”: to set the height, on which the double pump will be
activated according to the direction.

I-4g
5． Calibration of the linear amplifier
When the lifting is ready, please check the “HEIGHT DIFFERENCE”. If it is not “0”, the
“CALIBRATION” must be carried out.
The Calibration Menu will be found under the “USER MENU”, press “ENTER” to get into
the setting up. The “ACTUAL HEIGHT” will be indicated on the screen. Press the bottom “↓”
input this value, then enter with the confirmation.
The calibration will be successfully done.
 CONTENTS

PREFACE ...............................................................................................................................................1

CHAPTER 1: IMPORTANT SAFETY INFORMATION ...............................................................3

1. SAFETY MARK.................................................................................................................................3

1.1 SAFETY MARK AND POSITION .........................................................................................................3

1.2 MEANING OF SAFETY MARK ...........................................................................................................3

2. SAFETY PRECAUTIONS ................................................................................................................5

2.1 GENERAL SAFETY PRECAUTIONS ....................................................................................................5

2.2 SPECIAL SAFETY PRECAUTIONS.......................................................................................................5

3. OPERATION SAFETY PRECAUTION ..........................................................................................6

3.1 SAFETY ITEMS .................................................................................................................................6

3.1.1 Safety Precaution ....................................................................................................................6
3.1.2 General Hidden Risks..............................................................................................................6
3.2 OVERVIEW .......................................................................................................................................7
3.3 GET ON AND GET OFF .....................................................................................................................7
3.4 FIRE AND EXPLOSION PREVENTION .................................................................................................7
3.5 PRECAUTION FOR BURN AND OTHER INJURIES ................................................................................8
3.5.1 Coolant....................................................................................................................................8
3.5.2 Oil............................................................................................................................................8
3.5.3 Battery.....................................................................................................................................8
3.5.4 Pipeline ...................................................................................................................................9
3.5.5 Tires.........................................................................................................................................9
3.5.6 Liquid Leakage........................................................................................................................9
3.5.7 Correct Disposal for Waste .....................................................................................................9

4. ENGINE STARTING.......................................................................................................................10

4.1 SURROUNDINGS .............................................................................................................................10

4.2 CHECK THE DECK LIFTER ..............................................................................................................10
4.3 BEFORE STARTING THE ENGINE .....................................................................................................10
4.4 START THE ENGINE ........................................................................................................................10
4.5 ENGINE STARTED........................................................................................................................... 11
4.6 CHECK LIST AFTER ENGINE STARTED ............................................................................................ 11
4.7 OPERATING .................................................................................................................................... 11
4.8 SHUT OFF THE ENGINE ...................................................................................................................12
4.9 PARKING ........................................................................................................................................12

5. SAFE DRIVING ...............................................................................................................................12

5.1 SOUND ALARM (ACCORDING TO ISO6746-1)................................................................................12

5.2 GENERAL SAFETY PRECAUTION ....................................................................................................12
5.3 SAFE DRIVING ON RAMP ...............................................................................................................13
6. SAFE OPERATING .........................................................................................................................13

6.1 DEVELOP GOOD OPERATING HABITS .............................................................................................13

6.2 SURROUNDINGS .............................................................................................................................14
6.3 VENTILATION ................................................................................................................................14

7. SAFE PARKING ..............................................................................................................................14

8. SAFETY INSPECTION AND MAINTENANCE..........................................................................14

8.1 GENERAL INFORMATION ................................................................................................................14

8.2 WORKS IN BAD-VENTILATING AREA .............................................................................................15
8.3 WORKS UNDER DECK LIFTER ........................................................................................................15
8.4 WORK ON TOP OF DECK LIFTER ....................................................................................................15
8.6 DON’T DROP SUNDRIES INSIDE OF DECK LIFTER ..........................................................................15
8.7 WASH AND CLEAR .........................................................................................................................16
8.8 WELDING ......................................................................................................................................16
8.9 MAINTENANCE OF COOLING SYSTEM ............................................................................................16
8.10 MAINTENANCE OF HYDRAULIC SYSTEM .....................................................................................17
8.11 MAINTAINING OF BATTERIES .......................................................................................................17
8.12 BATTERY CHARGING ...................................................................................................................18
8.13 MAINTENANCE OF TIRES .............................................................................................................18
8.14 MAINTENANCE OF SCISSORS COMPONENTS ................................................................................18
CHAPTER 2: PRODUCT INFORMATION ..................................................................................19

1. GENERAL DESCRIPTION............................................................................................................19

1.1 APPLICABLE SCOPE .......................................................................................................................19

1.2 DIMENSION AND MAIN CHARACTERS ............................................................................................19

2. OPERATION ....................................................................................................................................19

2.1 CONTROL SYSTEM INSIDE DRIVER’S CABIN ..................................................................................19

2.2 MANEUVER OF DECK LIFTER ........................................................................................................20
2.2.1 Start the Key Switch ..............................................................................................................20
2.2.2 Speed Changing, Steering, Horn ...........................................................................................21
2.2.2.1 Speed Changing ............................................................................................................................. 21
2.2.2.2 Steering .......................................................................................................................................... 21
2.2.2.3 Horn ............................................................................................................................................... 22
2.2.3 Parking Brake .......................................................................................................................22
2.2.4 Pedals....................................................................................................................................22
2.2.5 Flameout Switch....................................................................................................................22
2.2.6 Display ..................................................................................................................................22
2.2.7 Lifting/Lowering of Table ......................................................................................................26
2.2.8 Lifting/Lowering of Chassis ..................................................................................................26
2.3 OPERATION INSTRUCTION AND ATTENTIVE ITEMS .........................................................................27
2.3.1 Parking..................................................................................................................................27
2.3.2 Operation ..............................................................................................................................27
2.3.3 Alarm.....................................................................................................................................27
2.3.3.1 Screen............................................................................................................................................. 30
2.3.3.2 Calibration of the linear amplifier .................................................................................................. 30
CHAPTER 3: MAINTENANCE......................................................................................................33

1. REGULAR MAINTENANCE......................................................................................................... 33

2. TORSION STANDARD OF SCREWS...........................................................................................33

3. TIRES ................................................................................................................................................34

3.1 ATTENTIVE ITEMS ..........................................................................................................................34

3.2 TYPE OF TIRES ...............................................................................................................................34

4. MAINTENANCE TO ENGINE ......................................................................................................34

4.1 FILTERS .........................................................................................................................................34

4.2 COOLANT ......................................................................................................................................35
4.3 DIESEL ENGINE OIL .......................................................................................................................35
4.4 FUEL OIL .......................................................................................................................................36
4.4.1 Attentive Items .......................................................................................................................36
4.4.2 Fuel Types .............................................................................................................................36

5. REGULATIONS FOR USE OF WORKING OIL.........................................................................36

5.1 HYDRAULIC OIL ............................................................................................................................36

5.2 TRANSAXLE OIL ............................................................................................................................37
5.3 LUBRICATING GREASE...................................................................................................................37
5.4 BRAKE FLUID ................................................................................................................................37

6 OIL SPECIFICATIONS AND TANK CAPACITY ........................................................................37

6.1 OIL SPECIFICATION AND TRADE MARK..........................................................................................37

6.2 TANK CAPACITY ............................................................................................................................38

7. REGULAR SPOT TEST OF SAMPLE OIL..................................................................................38

7.1 COLLECT S.O.S SAMPLE ................................................................................................................38

7.2 S.O.S ANALYSIS ............................................................................................................................39

8 MAINTENANCE PERIODS............................................................................................................39

8.1 SPARE PARTS .................................................................................................................................39

8.2 MAINTENANCE PERIODIC TABLE ...................................................................................................40
8.2.1 Items Maintained Every 10 Working Hours or Each Time Before Working ..........................40
8.2.2 Items Maintained Every 100 Working Hours or Per Week ....................................................40
8.2.3 Items Maintained Every 250 Working Hours or Per Month..................................................41
8.2.4 Items Maintained Every 500 Working Hours or Per 3 Months .............................................41
8.2.5 Items Maintained Every 1000 Working Hours or Per 6 Months ...........................................41
8.2.6 Items Maintained Every 2000 Working Hours or Per Year ...................................................41
8.2.7 Items Maintained Every 3000 Working Hours or Every 2 Years ...........................................42
8.2.8 Items Maintained When New Deck Lifter Works First 50 Hours ..........................................42
8.3 DETAILS FOR MAINTENANCE ITEMS AND PROCEDURES .................................................................42
8.3.1 Maintenance..........................................................................................................................42
8.3.1.1 Replace/Clean Main Filter.............................................................................................................. 42
8.3.1.2 Replace Safety Strainer .................................................................................................................. 43
 8.3.1.3 Clean Main Strainer ....................................................................................................................... 43
8.3.1.4 Clean/Tighten Batteries .................................................................................................................. 43
8.3.1.5 Battery Callback............................................................................................................................. 44
8.3.1.6 Clean and Replace Cover of Radiator ............................................................................................ 44
8.3.1.7 Clean Exterior of Radiator ............................................................................................................. 44
8.3.1.8 Replace Fuse .................................................................................................................................. 44
8.3.2 Items Maintained Every 10 Working Hours or Each Time Before Working ..........................44
8.3.2.1 Engine Oil ...................................................................................................................................... 45
8.3.2.2 Hydraulic Oil.................................................................................................................................. 45
8.3.2.3 Cooling System .............................................................................................................................. 45
8.3.2.4 All-round Inspection....................................................................................................................... 45
8.3.3 Items Maintained After New Deck Lifter Works First 50 Hours............................................46
8.3.3.1 Changing Oil for Differential Mechanism and Final Transmission ................................................ 46
8.3.3.2 Changing Oil for Hydraulic Oil Tank............................................................................................. 46
8.3.4 Items Maintained Every 100 Hours or per week...................................................................46
8.3.5 Items Maintained Every 250 Hours.......................................................................................47
8.3.6 Items Maintained by First 200 Working Hours .....................................................................49
8.3.7 Items Maintained Every 500 Working Hours or per 3 Months..............................................49
8.3.8 Items Maintained by First 600 Working Hours .....................................................................50
8.3.9 Items Maintained Every 1000 Working Hours or per 6 Months............................................50
8.3.10 Items Maintained When New Deck Lifter Works First 1500 Hours.....................................50
8.3.11 Items Maintained Every 2000 Working Hours or per Year ..................................................50
8.3.12 Items Maintained Every 3000 Working Hours or per 2 Years .............................................51
CHAPTER 4: MANAGEMENT ......................................................................................................52

1. MANAGEMENT OF NEW DECK LIFTER .................................................................................52

2. STORAGE OF DECK LIFTER ......................................................................................................52

2.1 UNUSED FOR ONE MONTH.............................................................................................................52

2.2 UNUSED FOR MORE THAN ONE MONTH ........................................................................................52
2.3 REUSE AFTER LONG TIME STORAGE .............................................................................................53
CHAPTER 5: TROUBLE SHOOTING ..........................................................................................54

1. ENGINE CAN NOT BE STARTED................................................................................................54

2. MULTISTAGE CYLINDER EXTENDS OUT OF TURN............................ 错误！未定义书签。

3. THE HEIGHT OF WORKING TABLE CAN NOT BE READ ON DISPLAY ..........................54

4. ABNORMAL NOISE .......................................................................................................................54

 PREFACE

Thank you for choosing HCT Deck Lifter!

In order to keep safety and offer the best service, we strongly suggest you read this manual
carefully before operating.

This manual includes safety protection, operation instruction, lubrication and maintenance, but
does not include all detailed construction, operation and technical maintenance method for
purchased components such as the engine, front axle and rear axle, etc. You can get relevant
information from enclosed manuals offered by respective origin manufacturer.

If you find any problem in our product or in this manual, please contact Nanjing HCT Marine
Equipment Co., Ltd. We will offer you the most updated information.

IMPORTANT SAFETY INFORMATION

This part lists basic safety precaution measures, and indicates the meanings of warning marks.
Please read and understand these basic safety precaution measures before starting operating,
lubricating, maintaining and repairing.

PRODUCT INFORMATION
This part offers references to new operator and review to experienced operator.
Pictures and descriptions in this part will instruct correct procedures for checking, starting,
operating and parking.
Diagrams and drawings in this manual have no proportionate relationship with actual product,
which are just used to indicate operating measure of the Deck Lifter and its component parts, and
they are not the same as actual composition precisely.
In order to understand easily, we give definitions as following:
The directions left, right, front and rear, as mentioned throughout this manual, are as seen from
the driver's seat and facing in the normal direction of travel.

MAINTENANCE
This part offers guidelines for maintenance. Items that don’t need periodic maintenance are listed
in column of “if necessary”, periodic maintenance items should refer to the detailed description
that follows.
All regular maintenance should be performed in accordance with the schedule. For example,
when you maintain items that need to be maintained every 500 working hours or per 3 months,
you should also maintain those items that need to be maintained every 250 working hours or per
month, every 50 working hours and every10 working hours or each time when operating Deck
Lifter.

1
MANAGEMENT
This part offers detailed requirements for Deck Lifter storage and reuse, which should be
followed strictly by administrative staff and operator.

2
CHAPTER 1: IMPORTANT SAFETY INFORMATION

Most accidents are caused by neglecting the basic safety regulations or maintaining methods.
Operating staff must be trained and has the capability to locate and solve problems.
Incorrect operating, lubricating, maintaining and repairing are dangerous, and it may cause
casualty.
Don’t operate until you have read and understood all relevant information in this manual.
If any tools, procedures, working or operating methods are not recommended by Nanjing HCT
Marine Equipment Co., Ltd, please make sure they are safe and will not harm the Deck Lifter or
keep it under dangerous circumstances.

1. SAFETY MARK

1.1 Safety Mark and Position

There are lots of safety marks on our Deck Lifter. In this chapter we will indicate their meanings
and dangers. Please make sure to be familiar with them.
Marks should be changed if they are damaged; if the surface of marks are vague, you can use
duster cloth to clean, but don’t use any solvent, gasoline or strong chemical medicament which
may cause those marks losing stickiness and falling off.

1.2 Meaning of Safety Mark

3
Don’t keep close to fans while motor Mind the spurt of high pressure liquid
is running.

No smoke while filling oil Be careful of scald

4
2. SAFETY PRECAUTIONS

2.1 General Safety Precautions

 Follow relevant instructions on this manual carefully

 Don’t perform any repairing or customizing work without permission from manufacture
 Keep welding works away from Deck Lifter
 When spraying painting near Deck Lifter, please cover the Deck Lifter and prevent any
paint from touching with it
 Keep Deck Lifter away from water. Don’t leave it in the rain or under a deck full of water
 Avoid causing any mechanical damage to pistons while the Deck Lifter is rising or
lowering.

2.2 Special Safety Precautions

 Maximum lifting weight is 25 ton.

 Don’t drive the Deck Lifter on slope more than 13°
 Don’t operate Deck Lifter in rough seas. The ship’s tilting angles should be less than 5°
heel and 2°trim.
 Try to keep the Deck Lifter working at same horizontal ground, otherwise, the multi-stage
cylinders might extend in disorganized sequence.
 The center of gravity of the deck should be as close as possible to the center of the Deck
Lifter. Never attempt to move a deck if its center of gravity is more than 50cm ahead or
behind the center of the Deck Lifter’s platform, or more than 30cm to the sides of the
platform.
 Don’t attempt to move the Deck Lifter while it is raising or lowering a deck. (The safety
system will normally prevent you from doing such operation automatically.)
 The Deck Lifter is only intended to lift or lower decks which are supported by guide
columns. Don’t use the Deck Lifter to lift or lower any other type of load.
 All other irrelevant personnel should keep away from the Deck Lifter and the deck.
 Don’t raise or lower the table unless the supports have been completely lowered. (The
safety system will normally prevent you from doing such operation automatically.)
 Don’t raise the supports unless the table is fully down. (The safety system will normally
prevent you from doing such operation automatically.)
 Don’t operate oil cylinders if the oil temperature is higher than 75℃(the buzzer will alarm),
which means that you can not carry out any hydraulic operations.
 Don’t drive the deck lifter unless supports are fully up. (The safety system will normally
prevent you from doing such operation automatically.)
 You will not be able to lower supports unless you put into neutral position first. (The safety
system will normally prevent you from doing such operation automatically.)

5
3. OPERATION SAFETY PRECAUTION

3.1 Safety Items

This part indicates safety precaution and hidden risks, please spend some time to be familiar to
them before operation.

3.1.1 Safety Precaution

WARNING
Incorrect external power connection may cause explosions which will lead to casualties. The
in-line storage battery should be held solely in battery box. When external power supply is
applied, please carefully connect the anode and cathode with the counterparts of starter. If there
is no cathode pole of starter available, please use the body of the motor instead.
WARNING
During operation all irrelevant personnel should keep well away from the Deck Lifter.
WARNING
Only trained & certified technician may be allowed to repair, lubricate and maintain the Deck
Lifter. All other irrelevant personnel should be kept away from the Deck Lifter.

3.1.2 General Hidden Risks

 Before maintaining or repairing, please hang a warning label on switch of the motor or
hydraulic operation levers, i.e. “Don’t Operate”.

 While maintaining or repairing, please wear safety helmet, protection glasses and relevant
article required. Don’t wear loose clothes or jewelry, which might clamp on the operation
handles or other parts of the Deck Lifter.

 Make sure all protection boards and covers fixed well on the Deck Lifter

 Make sure no fragment, greasy dirt, tools and other incidental articles on the instrument
board or escalators.

 Be familiar to the gesture signals and only receive signals from sole person.
 Don’t load maintenance liquid into any glass container.
 Be careful while using cleanser.
 Report all contents that need to be repaired.
 Person without permit should not be on the machine.

6
Maintain according to following requirement:
 Park the Deck Lifter on the horizontal ground
 Place gear shift lever in neutral position.
 Place hydraulic operating lever in Neutral position.
 Draw up the break handle
 Put the start switch to zero position, take the key away.
 Switch off the power.

3.2 Overview

 Only trained and certificated personnel can operate and maintain the Deck Lifter
 Don’t work on the Deck Lifter unless you have read and understand all instructions and
safety precaution for operation and maintenance,
 Please make clear of any grease around operating position to avoid slip.
 Before operating the Deck Lifter, please check if there is any oil leakage, water leakage, gas
leakage, distortion, looseness and abnormal sound. Otherwise, it may cause fault or serious
accidents.

3.3 Get On and Get Off

 Please only get on & off the cabin through the escalator.
 Don’t wear loose clothes, muffles and jewelry to get on Deck Lifter.
 Don’t jump onto or down from Deck Lifter
 Don’t get on or off the Deck Lifter when it is moving.
 Please face the Deck Lifter, step firmly and keep balance well when you get on or get off.
 Don’t hold any gear shift when you get on or get off the Deck Lifter.

3.4 Fire and Explosion Prevention

Fuel, most lubricants and some cooling fluid are flammable, it is very dangerous if any smoke or
fire exists nearby, and we must be careful to this.

 It is strictly prohibited for any leaked fuel oil exists on thermal surface or electric apparatus.
 You must shut off the engine when filling fuel oil. Don’t smoke when filling fuel oil or at
any fuel-filling area.
 Keep smoke and fire away from the battery because there is explosive gas nearby caused by
battery. Use battery according to the manual strictly. Don’t smoke near battery or flammable
areas.
 Flammable fluid should be put into protected containers and screwed tightly, then placed in
safe area, classified, marked and avoid using by any non-staff personnel.

7
 Combustible material such as fuel oil, lubricant and other rags on the machine should be
cleared.
 Don’t solder or flame-cut on pipes or containers containing flammable liquid.
 Please pay special attention if muffler’s gas vent locates near area containing flammable
materials.
 Don’t park Deck Lifter near fire.
 Loose or worn wires should be tighten, repaired or replaced before starting the engine.
 Inspect if any leakage of fuel oil, machine oil and hydraulic oil. Please replace the damaged
tube if leakage exists, clear out , and then operate.
 Don’t use flame when inspecting in dark place.

3.5 Precaution for Burn and Other Injuries

3.5.1 Coolant

 The coolant of engine is hot and existing pressure when Deck Lifter is working or just
finishes working. All radiators’ pipes connected with engine are full of hot water or gas,
which will lead to serious burn if touched.
 Before checking level of coolant, the engine should be shut down first, and only when the
temperature of the cover is low enough and won’t burn your hands, then open the cover of
cooling system to check the coolant level.
 If the coolant needs to be discharged, they should be fully cooled before discharging.

3.5.2 Oil

 Please pay attention not to touch hot oil to avoid of being hurt.
 The temperature of hydraulic oil is high and with pressure when Deck Lifter is working or
just finishes working.
 Before opening cover of hydraulic oil tank, the engine should be shut down, while the cover
is cooled to normal temperature , then you can open the cover slowly.( the aim is to release
pressure slowly)
 Please release all the pressure before opening cover or hydraulic oil tank, all the pipes,
joints and spare parts.

3.5.3 Battery

 The battery might release flammable smog that might cause explosion.
 Don’t smoke while checking the electrolyte of battery.
 Electrolyte is a kind of acid material, which should be avoided to touch skin and eyes.
 Please wear protecting glasses while handling battery.

8
3.5.4 Pipeline

 Don’t knock or bend high-pressure pipeline, it is prohibited to install any damaged hard tube
or hose on Deck Lifter.
 While repairing loose or damaged hard tube or hose, please pay attention to safety.
 Don’t use bare hands to check pipeline’s leakage, we suggest use a cardboard. Tighten all
joints according to regulation. Please replace them if following problems are found.
 Joint damaged or leakage
 Outer layers tear and wear or dissever.
 Outer layer partly hunches.
 The hose has been obviously wreaked or staved.
 Strengthened steel wires imbeds into outer layer.
 Mismatch of terminal joints.

 Make sure all pipe clamps and safety boards are installed correctly to avoid overheat and
abrasion caused by vibration or friction while working.

3.5.5 Tires

We uses solid rubber tires, please try best not to touch any sharp edges to avoid tire cuts during
operation, meanwhile, do not touch oil, strong acid, or any organic solvents, so as not to
accelerate the tire aging.

3.5.6 Liquid Leakage

We suggest use plank or cardboard to check leakage, because even little leakage through hole
like a needle can penetrate muscles and cause casualty. If any liquid sprays onto your skin, please
go to see doctors immediately.

3.5.7 Correct Disposal for Waste

In order to prevent pollution, please handle the waste as following:

 Use leakage proof container when discharging liquid. Don’t pour waste onto the deck or
into river or sea.
 You must follow relevant laws or regulation strictly when dealing harmful material such as
lubricant, fuel oil, coolant, solution, filters, batteries or other harmful material.
 The replaced tires should be preserved in safe area or recycled. Don’t throw away freely.

9
4. ENGINE STARTING

4.1 Surroundings

 Before starting the engine, please observe the surrounding carefully to avoid any abnormal
circumstances to influence normal working.
 Remove the barriers on the drive way.

4.2 Check the Deck Lifter

 Check if there is oil leakage, water leakage, bolt loose, abnormal sound, spare parts damage
etc.
 Check if the liquid level of coolant, fuel oil and oil inside the engine is in normal range, and
if air filter is blocked.
 Open the power switch and check if all illumination lights and signal lights are normal.
 Check whether the instruments and horn are in normal situation. Check whether the gearshift
or control buttons locate in correct position.
 Wipe off all dirt on glasses of driver cabin or lights to ensure good visibility.
 Adjust rear-view mirror to proper angle to ensure good visibility for driver.

4.3 Before Starting the Engine

 You can only start the engine in driver’s cabin; it is prohibited to start the engine by short
circuit on motor terminal or battery, which might cause damage to electric apparatus system.
 Adjust the inclining angle of the steering wheel to drive comfortably.
 Check if all illumination system works normally.
 Check if there is any other person working on the deck lifter or nearby.

4.4 Start the Engine

 Don’t start the engine or operate the gearshift if there are labels as “Don’t Operate” hang on
power switch or gear shift.
 Put the hydraulic control lever and gearshift to “Neutral” position.
 Switch the main power switch at left side of the battery and whistle to warn personnel
nearby.
 Insert the key to rotate clockwise and start the engine
 If the engine can’t be started within 5 seconds, please stop and wait another 2 minutes to
start again. If the engine can’t be started for consecutive 3 times, please stop and check
problems first, only after all problems resolved, then start the engine once again.

10
 Start the engine and operate at place with good ventilation.

4.5 Engine Started

 Keep the engine idling until the instrument shows the pressure is normal. If no pressure is
indicated 10 minutes after engine started, please shut off the engine and check problems.
Only after resolving problems, then you can restart the engine. Otherwise, it will be harmful
to the engine.
 Please let the engine idle at low speed for 5 minutes to warm up the engine.
 Observe the instrument whether the parameter is in the normal range while operating.
 Pay attention to the following items when the engine is idling for preheating.
 It needs 15 minutes for engine preheating if the temperature is above zero degree
 It needs 30 minutes for engine preheating if the temperature is lower than zero degree
 It needs more time for engine preheating if the temperature is lower than Minus 18ºC.

4.6 Check List after Engine Started

We suggest checking the following items after engine started but before operating.
 After the engine is started, please check whether there is abnormal sound followed by
abnormal vibration, if yes, please shut down the engine and report to administrative staff
immediately. You can operate only after the problem is resolved.
 Please check engine’s rotation speed while the engine is idling.
 Observe the instruments, apparatus, warning light, and ensure them work in safe range.
 Ensure all control lever work smoothly and easily.
 Operating shift gears handles, and ensure forward, neutral and reverse gear work correctly.
 Check the foot brake valve and oil control valve according to the operating manual, and
check if it is flexible for Turn Left and Turn Right at low speed.
 Ensure the backward warning apparatus working normally.
 Ensure hand brake locating at unlock position before driving.

4.7 Operating

 The operator should make sure no one would be hurt before starting operation.
 Please be seated and operate in driver’s cabin.
 Don’t take any other person when driving the Deck Lifter
 Report the problems during working.
 Keep the Deck Lifter under control, never overload.
 Know clearly about the maximum dimension of the Deck Lifter as well as its maximum
working range.

11
4.8 Shut down the Engine

 Don’t shut down the engine immediately after the Deck Lifter finishes working, otherwise it
may cause that the engine overheat and components wear and tear soon. When the Deck
Lifter parks and brakes are applied, please run the engine at idling speed for 5 minutes,
which could cool the engine down slowly.
 Turn the key to zero location and make the engine shutdown, otherwise it will cause the
battery flows backwards.

4.9 Parking

 Park the Deck Lifter on horizontal ground, if you have to park it at a ramp, please use chock
to make it stable.
 Depress the brake pedal and stop the Deck Lifter
 Place the gearshift lever in neutral position.
 Draw the hand brake and parking brake.
 It is prohibited to shut down the engine by hydraulic system.
 Shut down the engine, and take away the key.
 Shut down the main power switch.
 Fix the hooks around the Deck Lifter by the canvas belt.

5. SAFE DRIVING

5.1 Sound Alarm (According to ISO6746-1)

 Sound should be louder than 93dB at least 7 meters ahead of the Deck Lifter
 All steering lights (Direction Indicator Light, Brake Light, Danger Warning Signal Light)
should be turned on for warning the personnel when the Deck Lifter can’t work anymore or
work at low speed.
 Pay attention to each instrument and warning apparatus.

5.2 General Safety Precaution

 For yourself and others' safety, please develop good operating habit.
 Before driving, please hoot the horn. Drive only after your confirming that there is no
person or obstacle around.
 Don’t put your body outside the Deck Lifter

12
  Try not to brake urgently
 It is dangerous to shift forward & backward under driving condition and will cause the
driving system damaged, so it shall be avoided.
 Please pay attention to objects nearby and lower the speed when operating in narrow space
or changing direction.
 In order to offer comfortable operation condition for driver and give transmission
component longer life, please lower speed or brake when changing gear. It is prohibited
for emergency turning at high speed.
 It will cause serious wearing and tearing if the parking brake is used urgently when it is
traveling.

5.3 Safe Driving on Ramp

 Traveling on a ramp might cause the Deck Lifter turnover or slip to one side, please pay
special attention to it.
 The gravity center of the vehicle will move to front wheel or rear wheel when it is moving
on a ramp, so please operate carefully and never brake urgently.
 When the Deck Lifter is traveling down along ramp, please pay attention that it should not
slip.
 If the engine flameouts when the Deck Lifter is traveling on a ramp, please depress the
brake pedal immediately and use parking brake to lock position, then place the steering and
shift gear lever in Neutral position and restart the engine.
 Try to avoid parking on any ramp, and if you can not avoid, please use hand brake and put
wedge at beneath of the tire to prevent slip.

6. SAFE OPERATING

6.1 Develop Good Operating Habits

 Please keep the shift gears switch at “Neutral” position before lifting.
 The engine’s normal rotation speed is between 1200rpm and 1400rpm, we recommend
1300RPM while lifting to avoid strong impact.
 Listen to the engine’s voice carefully, shut down the engine and apply for maintenance if
there is abnormal sound. Don’t repair those spare parts which are in working status.
 The load should not be more than Deck Lifter’s rated load weight. Please evaluate the goods
weight before working to avoid overloading. We don’t have the responsibility on deck
lifter’s damage or person’s injury caused by overloading.

13
6.2 Surroundings

 Irrelevant personnel shall not enter into working area.

6.3 Ventilation

 Make sure to keep good ventilation to avoid gas poisoning if working in bad-ventilation
area or dealing with fuel oil, please clear up spare parts and paints.

7. SAFE PARKING

Pay attention to yours and others safety when parking.

 Don’t park on a ramp. If you have to park, the ramp’s tilting angle should be less than 13
degree, meanwhile please put a wedge under tires to avoid moving.

8. SAFETY INSPECTION AND MAINTENANCE

8.1 General Information

 Operator and maintenance staff must be trained and certified, and irrelevant person should
not enter into working area.
 Please perform maintenance according to maintenance process. May you have any
uncertainty, please contact us for help.
 Comply with what indicated on Warning Board strictly. There are warning boards on the
vehicle for those issue that must be paid special attention, please follow the indication
strictly.
 Before maintaining, please paste label “Don’t Operate” or other similar warning labels on
start switch and instrument board to avoid other person starting the engine or operate
maneuver levers. Otherwise, it might cause casualty.
 Don’t wear loose clothes and jewelries when operating or maintaining the Deck Lifter,
otherwise, they might hook on the maneuver lever or other spare parts.
 Make sure all protection board and cover fixed on the Deck Lifter
 Fuel oil, machine oil, Lubricants and greasy cloth are dangerous materials, which should
avoid touching any flame.
 Spare parts unloaded from the Deck Lifter should be stored in safe place and make sure not
falling down. Put guardrail around the spare parts and hang labels “No Entry” to prevent
irrelevant person come close.
 Keep the working area clean and clear, no greasy cloths or lubricants should be scattered
around to avoid fire disaster and people tumbling.

14
 Person not permitted should not stay on the Deck Lifter.
 Sundries should be laid well, such as dinner bucket and tools etc.

8.2 Works in Bad-Ventilating Area

 Waste gas released by engine may cause diseases and death, if you have to start the engine
in bad-ventilating area, please use ventilating equipment to discharge waste gas out of this
area. If you don’t have any ventilation equipment, please open the door for ventilation.

8.3 Works under Deck Lifter

 Park the Deck Lifter at stable ground first, and lower the table to the lowest position before
repairing under Deck Lifter.
 Use wedges to fix the tires.
 Don’t work under Deck Lifter if the supports are not in good working condition.

8.4 Work on Top of Deck Lifter

 When maintaining on top of Deck Lifter, please make sure the standing place is clear and
has no obstacles.
 Use protection equipments if necessary.
 The surface of tires is slippery and dangerous, and it is prohibited to stand on it.

8.5 Maintenance When Engine Runs

In order not to be hurt, don’t maintain when engine is running. If you must do so, please follow
below instructions:
 Arrange one operator seated on driver’s seat to shut down the engine any time. All workers
must keep connected with others.
 Keep away from high-temperature parts such as exhaust pipes and silencer to avoid
scalding.
 When the working point is near rotating parts, please pay great attention to avoid being hurt.
 Don’t touch any maneuver lever. If must do so, please send signals to all other worker and
warn them to stay at safe place.
 It is prohibited to touch fans with tools or any part of body. Otherwise, it will cause serious
injury.

8.6 Don’t Drop Sundries Inside of Deck Lifter

 When opening repairing window or inlet of oil tank, please be careful not to drop any
sundries to inner side of Deck Lifter, such as nuts, bolt, cotton yarn and tools. If any
sundries drop into inner side of Deck Lifter, please make sure to take them out.

15
 When maintaining, don’t take any unnecessary tools or spare parts at hand.

8.7 Wash and Clear

 When there is the dirt on windows or rearview mirror to influence sight, you can use dry
cloth or wrung out cloth to wipe and clear.
 When using compressed air to clear the filter, you must wear protection clothes and glasses.

8.8 Welding

Welding job should be only done by certified welder and carried out in place where is equipped
with appropriate apparatus. Welding will produce gases, and also might cause fire disaster and
get electric shock. Therefore, please comply with following instruction carefully:
 Cut off the terminals of battery to avoid explosion.
 Cut off electric control unit of the engine and power socket of electric liquid shift gears
controller.
 Clear paints at where need to be welded to avoid producing poison gas.
 Welding on hydraulic equipments or pipes will produce flammable gas and sparkle, which
might cause fire or explosion. So, please try not welding at areas like this.
 If the welding sparkle drops on rubber hose, electric wires or pressured pipes, the pipes
might burst suddenly, the insulation of wires might be damaged; therefore we must use a
fireproofing cover for protection.
 When welding near tires, please pay special attention to avoid damages on tires.
 Protection clothes must be wore when welding.
 Good ventilation needs to be kept for welding area.
 Take away all flammable materials, and fire extinguishers need to be equipped in working
area.

8.9 Maintenance of Cooling System

 When operation is just finished, the temperature of Oil and water is very high with pressure,
such as Hydraulic oil, oil and water in the engine or radiator. Don’t open any covers at that
time to avoid serious burns.
 Shut down the engine to avoid hot water spraying out, and let the water cool down, then
open the cover slowly to release the pressure. Put hands near front of the radiator to check
the air temperature. But make sure not to touch the radiator.
 Don’t touch the engine, silencer, exhaust pipe and cooling water tank when Deck Lifter is in
working status, which might cause burn.
 Don’t unload oil and water temperature sensors when Deck Lifter is in working status to

16
 avoid burn. There is alkaline material in cooling system, so we must avoid them touching
our skin and eyes.
 Please choose proper container to store liquid when replacing coolant, machine oil,
transaxle oil and spare parts of filters. The waste liquid should be treated according to local
environment protection rules.

8.10 Maintenance of Hydraulic System

 Before inspecting and maintaining hydraulic system, please lock oil tank and other
hydraulic equipment, cool hydraulic oil and release all pressure of hydraulic system.
 Don’t bend or hammer high-pressure pipes; don’t install wrong-bending or damaged hard
pipes or hose on Deck Lifter.
 Maintain any loose or damaged hard pipes and hose for fuel oil, lubricating oil circuit and
hydraulic system in time.
 Any leakage could cause fire disaster, please repair or replace in time.
 Engine restart after inspection and maintenance:
All control parts should be put into Neutral position first to ensure there is no load when the
pump is starting; the traveling driven pump needs to fill some way-guiding oil. Start the
engine and run idling for more than 10 minutes, and then add loads after oil temperature
rises. By this way, pump core will not be damaged because of proper oil viscosity.
 Periodic technical maintaining for hydraulic system:
 After the first 50 hours working, check all fastening parts.
 Check oil level and all fasten parts after each 10 hours’ working.
 Renew lubricants at supports of steering oil tank of front axle after each 50 hours’
working.
 Check system’s pressure (21MPa) after each 500 hours’ working.
 Renew working oil after each 500 hours’ working.

8.11 Maintaining of Batteries

Following should be complied with strictly:

 It is prohibited to take any flame close to batteries.
 Please take protection glasses and rubber gloves if you have to touch batteries.
 If the electrolytic liquid in batteries drops onto clothes or skin, please wash with a large
amount of fresh water immediately and go to see doctor at once.
 If the electrolytic liquid is drunk carelessly, please drink a large amount of water or milk,
raw eggs or vegetable oil, and go to see doctor at once or call first-aid centre for help.
 Shut down the engine first before handling anything concerned with batteries.
 Avoid metal materials touching with batteries, which might cause short circuit.
 Before installing or uninstalling batteries, please confirm positive terminal and negative
terminal first, and then tighten the nuts.
 When installing batteries, the positive terminal should be connected first. When uninstalling

17
 batteries, the negative terminal should be cut off first.
 Please use cloth to clean top of the batteries. Gasoline, solvent, organic solvent and cleanser
are prohibited to use while cleaning.
 If the electrolytic liquid has been already frozen, don’t charge for the batteries, and don’t
use other batteries to start the engine. So please melt the electrolytic liquid and check
whether there is any leakage first when you plan to charge or start the engine by other
power.
 Uninstall the batteries from Deck Lifter before charging.
 When repairing electrical system or welding on Deck Lifter, please uninstall negative
terminal of the battery to avoid short circuit.

8.12 Battery Charging

Incorrect charging way might cause explosion. So, please handle according to relevant
regulations and comply with following items:
 Charging needs to be done in good-ventilation place. Unload the cover of battery, which is
helpful for hydrogen spread and prevents explosion.
 Adjust voltage of the charger to match that of charged batteries. Incorrect setting up will
make the charger overheat and fire, even explosion.
 Connect (+) terminal of charger with (+) terminal of battery, (—) terminal of charger with
(—) terminal of battery, and fix the two terminals tightly.
 If the charging rate is lower than 1/10, then use high-speed charging and set digital lower
than batteries’ rated capacity. If the electric current is too big, it will cause leakage or
evaporation, which might cause fire disaster or explosion.

8.13 Maintenance of Tires

 Check if all connecting nuts and bolts on rims are complete, and check if the connecting
nuts’ tightening torsion can satisfy parameter suggested by manufacture.
 While checking tires, don’t lie at front or behind of tire rotating direction, please check at
side of the tire. If you want to unload one tire, please fix other tires with wedges.
 Make sure to replace tires with same specification and pattern.

8.14 Maintenance of Scissors Components

 Check if there is any significant cracking or deformation on structural components

regularly.
 Check lubrication at the connection of bearing and shaft pin regularly, please add or replace
grease with syringe if any abnormal sound.
 Check wearing situation for scissors sliding plate regularly.

18
CHAPTER 2: PRODUCT INFORMATION

1. GENERAL DESCRIPTION

1.1 Applicable Scope

The Deck Lifter is designed to lift or lower the mobile decks in Ro-Ro ships and operate easily.
The Deck Lifter works inside Ro-Ro ships and can allow easy, safe and comfortable work under
environment from -20°C to +45°C, with up to 5°roll and 2°pitch angles.

1.2 Dimension and Main Characters

Dimension (L X W X H ): 6800mm X 3000mm X 2000mm

Table stroke: 3300mm
Lifting Capability: 25 tons
Self Weight: 12.5 tons
Wheel Base: 4250mm
Wheel Tread: 1740mm
Max. Traveling Speed: 15km/hr
Diesel Engine: Dongfeng Cummins 6BTA5.9
Tires:33X12-20
Max. Turning Angle: ±55°
Working Pressure: 21MP
Batteries: 2 x DC12V
Max. Climbing Slope: 13°

2. OPERATION

2.1 Control System inside Driver’s Cabin

Below picture indicates control system inside driver’s cabin.

19
2.2 Maneuver of Deck Lifter

2.2.1 Start the Key Switch

 Open the power switch, and turn the key switch to start the engine.
 There are 3 shifts for the key: Flameout, Power Given and Engine Starting.
 Flameout: you can only insert or pull out the key when it is at this place. When the key
switch is at this place, shutdown the engine, cut off most of circuit power in cabin.
 Power Given: Turn key switch clockwise to this place, then the electronic supervision and
instruments will be switched on.
 Engine Starting: Turn key switch clockwise to this place, the engine can be started. Release
the key after the engine starting, and the key will go back to Power Given position
automatically.

20
ATTENTION:
 It is not permitted to start the engine longer than five seconds, if you have to start the engine
once again, please stop and wait extra two minutes before starting.
 If any alarming lamp (such as lower pressure alarming lamp, engine fault alarming lamp
and fuel oil adulterating water alarming lamp) lights after the engine is preheated and
started, please shut down the engine and check immediately. You can operate the Deck
Lifter only after the alarming lamp is off, otherwise, it might take harm to you.

2.2.2 Speed Changing, Steering, Horn

2.2.2.1 Speed Changing

Direction：Pushing forward maneuver lever means traveling ahead, Pulling back maneuver lever
means reversing

Speed Changing：There are two shifts for High-speed and Low-speed. Press button down is for
High-speed and press button upward is for Low-speed. The button is with rabbit/tortoise.

2.2.2.2 Steering

The steering wheel is used for controlling direction; the rotation direction of steering wheel is the
direction that the Deck Lifter will go.

Turning left- Turning the steering wheel anti-clockwise and the Deck Lifter will turn left. The
quicker you turn the steering wheel, the quicker for Deck Lifter to turn left.
Turning right- Turn the steering wheel clockwise and the Deck Lifter will turn right. The quicker
you turn the steering wheel, the quicker for Deck Lifter to turn right.

21
The position of steering wheel can be adjusted according to driver’s request. First, push the lock
lever ahead and pull the steering wheel forward or backward to comfortable place, and then
release the lock lever.

2.2.2.3 Horn

Horn switch: Press the horn switch, and the horn will sound.

2.2.3 Parking Brake

The parking brake system is controlled by mechanism. The brakes handle locates at right side of
the seat.
ATTENTION:
The oil used in brake system is the same as that of other hydraulic system, and no need to fill
other brake liquid.
Don’t brake when the Deck Lifter is traveling unless in urgent cases, otherwise it will cause
serious harm to the brake system.

Pulling up the brake handle will brake.

Releasing the brake handle will unlock the brake.

2.2.4 Pedals

Governor Pedal: the depth of your stepping on the governor pedal will decide the quantity of oil
given.
Brake Pedal: stepping on the Brake Pedal will decrease the traveling speed or stop the Deck
Lifter.

2.2.5 Flameout Switch

Electric flameout is used in our Deck Lifter. The switch is the key on instruments panel, shutoff
the key, and the engine will go flameout.

2.2.6 Display

The display lies on the control box at left side of the deck lifter, and it will indicate its working
condition by real-time. Checking the information on display regularly will help to know working
condition of the deck lifter.
Below is the information for lifting table’s absolute height and height difference and temperature
of hydraulic oil.

22
We can set the specific parameters for lifting operations through the screen.
1. Press “ESC” button to enter into the user menu and set the height difference to zero. (This is
very important, please check each time when starting the engine ), select “calibration” menu to
enter the zero calibration setting, press "↓" button to enter the next level menu and enter
prompt values, confirm and exit to complete the zero setting.

23
2. Enter into the user menu, set changing height of lifting speed, through which can adjust lifting
speed by changing pumps’ number used. We recommend setting the value of 800 as low and high
speed switching point, which means lifting at low speed before 800 and change to high speed
after 800. (for safety and to avoid the shocking during lifting with heavy loading, the lifting
speed with loading will be limited at max. 4.5m/min)
Enter into screen for setting “double pump changeover”.

24
Input changeover height and press “enter” to confirm and exit, thus we finish the setting work
successfully.
The screen could also show different types of warning information.
1. when the temperature of hydraulic oil is higher than 75℃,the screen will show as following,
and all operation on screen will be shielded.

We must press the red emergency button on the control box to lower down the lifting table for
maintenance, or wait for the oil temperature down.
2 When the table reaches near to the top, the buzzer will alarm for cautious operation, and the
screen shows:

3. When the table has arrived the top and attempt to lift more, the screen will show:

25
2.2.7 Lifting/Lowering of Table

The control Lever for table’s lifting and lowering locates at side of control box.
Pushing the lever to left will lift the table, pulling the lever to right will lower the table.

ATTENTION:
Before lifting table, please maneuver chassis control lever to support the Deck Lifter up from the
ground first.
If the four supports are not extended completely, the table can’t be lifted or lowered. If the four
supports are not drawn back completely, the Deck Lifter can’t move any more.

2.2.8 Lifting/Lowering of Chassis

The control Lever for chassis’s lifting and lowering locates at side of control box.
Pushing the lever to left will lift the chassis, pulling the lever to right will lower the chassis.

ATTENTION:

26
Only when all the supports are drawn back completely, the Deck Lifter can move after releasing
hand brake.
If the Deck Lifter does not need to work, the working table should be lowered to lowest position,
and lower the tires to ground and all the four supporting cylinders should be drawn back
completely.

2.3 Operation Instruction and Attentive Items

2.3.1 Parking

The deck lifter should not be parked with outrigger cylinders, to avoid the seal damage of the
cylinders. The deck lifter can be parked with airless tires directly for a long time within 2 weeks.
It is strongly recommended that at least every two weeks the deck lifter should be traveled, in
order to reduce the aging of the tires.

ATTENTION:
The foot print dimension of this deck lifter is 4200mm x 2200mm, which has a difference of
50mm at each side. By locating of the deck lifter should consider this 50mm compare with the
dimension 4250mm x 2250mm.

2.3.2 Operation

a) Supports
The outrigger cylinder can be operated by the stick or by button on the TD400 screen
“JACK UP”&”JACK DOWN”. The sticks, which are built on the panel, can be used as
remote control by releasing the screws on the panel. The cable cross inside is around 10
meters long.
The limit switch can give the feedback of supports’ position. “top position”, ”middle
position” or “bottom position”. Before the operation one of the outrigger positions must
be chosen with the “JACK LOWER” switch.
Position “LOW” means the bottom position – the height of the deck lifter will be
around 2120mm when it is ready to lift.
Position “HIGH” means the middle position – the height of the deck lifter will be
around 2020mm when it is ready to lift.
Position “0” means the top position – the outrigger cylinders cannot be extended.

27
 I-2b
The instruction will be automatically blocked when the feedback of the limit switches
are received.
The status of every outrigger cylinder can be checked by press “JACK POS.” on
TD400 screen.
The number on the screen in the corners is related with the outrigger cylinders’ position.

I-2c
“1” means the top position of the outrigger cylinder
“2” means the middle position of the outrigger cylinder
“3” means the bottom position of the outrigger cylinder
“0” means the position of the outrigger cylinder is between any two of the checking
positions.
For example in the pic. I-2c, the number in lower-right corner is “0”. That means the
rear-left outrigger cylinder is not at the top position or the position switch might be stuck.
In this case the travel instruction will be blocked.
The instruction will be also blocked when the deck lifer is in traveling or the frame is
up.

28
b) Travel
The “forward” or “back” instruction will be only activated only when the “top position”
feedback of the limit switches is received.

I-2d
c) Lifting
The lifting/lowing instruction can be activated by sticks or by button on the TD400
screen “FRAME UP”&”FRAME DOWN”. The sticks, which are built on the panel, can
be used as remote control by releasing the screws on the panel. The cable crosses inside
is around 10 meters long.
The “lifting” instruction will be activated only when the
“bottom position”

I-2e
or “middle position”

I-2f
feedback of the limit switches is received.
The “lifting” instruction will be automatically blocked when the frame is very close to
the highest position. (for safety it is controlled both by the linear transducer and/or limit
switch)

29
2.3.3 Alarm

Common alarm-the red LED on the control panel with buzzer will be activated if any alarm
comes.

I-3a
a) Temperature high
b) Error of the instruction input (for example: “supports down” instruction is
activated when the supports are already at the bottom position)
c) The frame is close to the highest position

I-3b

2.3.3.1 Screen

All of the alarm will be also displayed on the screen TD400. The default page of the screen
is the “Alarm page”

I‐4a

30
Press the ESC bottom, the USER MENU will be activated.

I-4b

I-4c
First page of the “USER MENU”: display of the “temperature”. “height difference” and
“absolute height”
The window of “Displacement&Temperature” can also be activated by pressing “DISP
INFO”

I-4d
Moving direction:
“0” – stop
“1” – lifting
“2” – lowering

Second page of the “USER MENU”: to calibrate the height nil of the linear transducer
according to the direction.

31
 I-4e

I-4f

Third page of the “USER MENU”: to set the height, on which the double pump will be
activated according to the direction.

I-4g

2.3.3.2 Calibration of the linear amplifier

When the lifting is ready, please check the “HEIGHT DIFFERENCE”. If it is not “0”, the
“CALIBRATION” must be carried out.
The Calibration Menu will be found under the “USER MENU”, press “ENTER” to get into the
setting up. The “ACTUAL HEIGHT” will be indicated on the screen. Press the bottom “↓” input
this value, then enter with the confirmation.
The calibration will be successfully done.

32
CHAPTER 3: MAINTENANCE

1. REGULAR MAINTENANCE

The Deck Lifter needs to be examined and repaired regularly or irregularly.

We should try to find faults and the reason why the performance decreases as early as possible.
Thus, the Deck Lifter can improve performance and give better service to you, and the life of
Deck Lifter can also be longer as well.

 Grease or oil on the Deck Lifter is hidden dangers for fire disaster. Therefore, after working
for a period about 1000 hours, please clean the oil or greasy by dry cloth.
 Clean all joints, cover and stems before maintaining.
 Check if there is any leakage carefully, if yes, please find it and repair.
 If it is suspicious of leakage, please check all liquid level.

ATTENTION:
While changing hydraulic parts or pipeline, please release air pressure by loosing the exhaust
valve on hydraulic oil tank to avoid hydraulic oil outflow. After maintaining, please make sure to
tighten the exhaust valve first, and then you can start the engine.

 Check regularly if there is any distortion, cracks or abnormal factors.

 There is starting system of 24-voltage on the Deck Lifter. Only outside power with
24-voltage can be used to start the engine, and any higher voltage will take harm to the
electrical system.

2. TORSION STANDARD OF SCREWS

While repairing the Deck Lifter, we often unload fixing parts, please pay attention following
when reinstalling:
 The bolts and nuts unloaded from the Deck Lifter should be kept well for reinstalling use in
future. If you have to change new parts, please make sure they are the same with old one on
type and dimension.
 The strength of material is marked on top of bolt by digital such as 8.8, 10.9 etc. below table
offers the standard torsion of bolts and nuts of Grade 8.8.

Thread Dimension Standard Torsion （N.m）

M6 12±4
M8 25±7

33
 M10 55±10
M12 95±15
M14 150±20
M16 220±30
M20 450±70
M24 775±100
M30 1600±200
M36 2700±400

3. TIRES

3.1 Attentive Items

 The vehicle uses solid rubber tires; please try best not to touch any sharp edges to avoid tire
cuts during operation, meanwhile, do not touch oil, strong acid, or any organic solvents, so
as not to accelerate the tire aging.

3.2 Type of Tires

 The tires type is 33X12-20, when you want to change tires, you can buy the same type
nearby.

4. MAINTENANCE TO ENGINE

If the texts referring to engine’s maintenance in this manual has different description with that on
Engine’s Maintenance Manual, please subject to the latter.

4.1 Filters

 Please check the dusts and impurity on rough strainer each time before using the Deck lifter
and clear them if necessary. The rough filter can be washed six times before scraped. While
cleaning the filter, please check if there is any crack. Replace the filter every year even it
was cleaned less than 6 times. After the rough filter has been repaired 3 times, please
change new precise filter.
 If the engine still discharges black exhaust after installing clean rough filter, please install
new precise filter.

34
ATTENTION:
Don’t use same precise filter repeatedly after cleaning. Please use new one, otherwise it will take
harm to the engine.

4.2 Coolant

The engine’s efficiency will be enhanced if we keep it working in normal temperature range.
Therefore, we must maintain cooling system in correct way. The common troubles include
overheating, supper-cooling, spot erosion, gas erosion, crack on tank head, piston lock and
radiator block etc.

The cooling liquid is made up of cooling water and anti-freezing fluid.

 The cooling water adopts distilled water or plasma water to reduce possibility and severity
of insoluble objects.
 We suggest fill 30 percent of anti-freezing fluid into cooling water. Following is different
percentage of anti-freezing liquid under different temperature.

Consistence of Anti-freezing Liquid

Temperature Secured Mixing Rate
-15°C above 30% Anti-freezing Liquid, 70% Water
-23°C above 40% Anti-freezing Liquid, 60% Water
-37°C above 50% Anti-freezing Liquid, 50% Water
-51°C above 60% Anti-freezing Liquid, 40% Water

 Don’t fill coolant to overheating engine, which will damage the engine. Please cool the
engine first before filling coolant.
 If the coolant has been polluted, and the engine is overheating or foams appear from radiator.
Please clean the cooling system.
 The cooling fluid should be discharged completely and the cooling system should be
cleaned every 1500 working hours or every year. Meanwhile, please fill new cooling fluid.
 Foam will appear by cooling system if cooling fluid is filled quicker than 20L/min.
 Start the engine after filling new cooling fluid, then open the cover of radiator until the
temperature of cooling fluid is in normal range.

4.3 Diesel Engine Oil

Details see Operation Instruction for engine.

If the Operation Instruction is not followed strictly, carbon deposit or excessive abrasion might
shorten the life of engine.

35
4.4 Fuel Oil

4.4.1 Attentive Items

 Each time after working, please fill fuel oil and expel damp air out to avoid condensation.
 Don’t fill too much fuel into the tank because fuel oil will expand under high temperature,
which might make oil overflow out.
 Don’t fill fuel before installing filter. The fuel containing impurity will accelerate the
wearing and tearing of parts in fuel system.
 The fuel must be precipitated for 72 hours before inflating in order to guarantee it is clean.
 Please leave 5 to 10 minutes before starting the engine every day or after fuel filled, which
could discharge water and precipitate out from tank.
 Air must be discharged from fuel system after filter replaced.
 Discharge water and precipitate from fuel store box every week, which will be helpful to
prevent water and precipitate from entering fuel system.
 Please only use the recommended fuel in this part.

4.4.2 Fuel Types

In order to improve engine’s performance and life, only distillating diesel oil can be used, usually
also called as diesel engine fuel, Fuel Oil or Gas Oil. The fuel should satisfy regulation of
Chinese national standard GB252-94 to light fuel for high-speed diesel engine. If the Deck Lifter
is used in other country, the No.1 and No.2 diesel oil accorded with ASTMD975 could also be
used.

Choose for diesel oil:

Solidification Point °C 10 0 -10 -20 -30 -40
Outside Temperature °C >18 8~18 -2~8 -12~-2 -27~12 -37~-27
Details see operation instruction of the engine.

5. REGULATIONS FOR USE OF WORKING OIL

Following terms abbreviations comply with regulation of SAE J754, and others comply with
SAE J183.
All oil must be clean, and the oil in hydraulic system should satisfy requirement by NAS9.

5.1 Hydraulic Oil

The Hydraulic oil used should aim at offering longest life for components in hydraulic system

36
and hydraulic transmission system. CC/SF, CD/SF, CD/SG, CD, CE/SF, CE/SG or CE.

 Oil that is suitable for high load and can prevent corrosion, foams, rusts and oxidation can
also be used after confirmed by manufacture.
 We use Mobil L-HM32 wear-resisting hydraulic oil and some additive.

5.2 Transaxle Oil

 In order to improve performance and longer life for parts of rear axle, please choose oil of
proper viscosity. We suggest using oil that can satisfy APIGL-5 regulation for differential
mechanism and transaxle.
 Our Deck Lifter use Mobil LSD85W-90 for gear compound.

5.3 Lubricating Grease

We recommend using MPGL, NLGI No.2 of this type can lubricate in condition of light loading
at high temperature of 175°C. This Grease can offer excellent mechanic stability, anti-oxidation,
anti-rust as well as excellent separation torsion. If this kind of grease is not available, other
similar multipurpose type is also acceptable.
 Our Deck Lifter uses molybdenum disulphide Lithium-based grease or No.3/No.4 of
Calcium-based grease.

5.4 Brake Fluid

We used HZY3 in braking system.

6 OIL SPECIFICATIONS AND TANK CAPACITY

6.1 Oil Specification and Trade Mark

Oil Type and Trade Mark

Name
Oil Type Trade Mark
Axle Lubricating Oil Gear Oil Mobil LSD85W-90
Hydraulic Lubricating Oil Wear-resisting Hydraulic Oil Mobil L-HM46
Brake Fluid Wear-resisting hydraulic oil Mobil L-HM46
Engine Fuel Oil Light Diesel Oil 0# Light Diesel Oil
Molybdenum two sulfide
Lubricant Lubricant
lithium based lubricating

37
 grease
Engine Oil Diesel Engine Oil 15W-40 Mobil 1300
Cooling System Cooling Fluid -30# Anti-freezing Fluid

6.2 Tank Capacity

Capacity (Approximate)
Tank or System Liter
Cooling System 25
Fuel Tank 120
Engine Oil 9
Main Drive Shaft: 14.5
Axle Lubricating Oil
Wheel Rim: 1.5+1.5
Hydraulic Oil Tank 260L
Brake Fluid Until oil cup fully filled up
Lubricant Coat evenly on where needs lubrication

7. REGULAR SPOT TEST OF SAMPLE OIL

Check condition of the Deck Lifter by periodic sample detection method (S.O.S) and decide
whether it needs to be maintained. While collecting sample, the lubricant should be tepid and
mixed evenly to ensure the sample is representative.

7.1 Collect S.O.S sample

In order to maintain Deck Lifter in good condition, we suggest adopting regular sample
collection way to check condition of Deck Lifter and confirm whether it needs to be maintained.

There is following few ways to collect S.O.S sample:

 Use sample probe and put it into oil tank.
 Use sample valve.
 Use discharged oil when replacing oil.

ATTENTION: we recommend the first and second way. You can use the third way unless the
first two ways are impractical. Don’t collect sample from oil discharged at first or final phase
because they are not mixed evenly and are unrepresentative.

38
7.2 S.O.S Analysis

S.O.S Analysis includes following 3 tests:

 Tearing and wearing analysis.
 Chemical and physical test.
 Oil condition analysis.

Tearing and wearing analysis is to measure density of metallic element in oil sample to confirm
how the tearing and wearing are. If the testing results show the density has exceeded the normal
range, which means the parts need to be replaced.

Chemical and physical test is to confirm proportion of water, fuel oil and anti-freezing fluid in
lubricating oil.

Oil condition analysis adopt infrared ray to confirm existence or not for dusts, sulphide, Oxide
and Nitrogen as well as their density, which could help to tell when to change lubricating oil
under special working condition.

In order to give correct evaluation, infrared ray analysis and wearing/tearing analysis test should
be done together.
S.O.S Periodic Table
Differential
Tank Engine Oil Hydraulic Oil Mechanism & End Gear Box Oil
Transmission Oil
Time Interval 250h 500h 500h 500h

8 MAINTENANCE PERIODS

8.1 Spare Parts

The Deck Lifter has following spare parts for maintenance.

Spare Parts
Item Specification Quantity
Maintaining when necessary
Engine air filter main strainer P777868 1

Engine air filter safety strainer P777869 1

Battery N200 2

39
 ATS Fuse 7.5A 2
ATS Fuse 15A 2
ATS Fuse 10A 5
ATS Fuse 25A 1
Maintaining every 250 working hours or every month
Engine Oil Filter LF2054 1

Fuel Oil System Rough Filter *490R30 1

Fuel Oil System Precise Filter FF2294 1

8.2 Maintenance Periodic Table

Item Measure Introduction Page

Battery Clean/Fasten
Battery Callback
Engine’s main strainer Clean/Replace
Engine’s safety strainer Replace
Radiator’s strainer Clean
Fuse Inspect/Replace

8.2.1 Items Maintained Every 10 Working Hours or Each Time Before Working

Item Measure Introduction Page

Engine lubricating oil level Inspect
Cooling system fluid level Inspect
Water and precipitate in fuel Discharge
tank
Hydraulic oil level Inspect
Instrument and lights Inspect
Windows Clean

8.2.2 Items Maintained Every 100 Working Hours or Per Week

Item Measure Page

Finish above maintaining items
Swing shelf of front axle Fill lubricant

40
Pin for steering oil tank of front Fill lubricant
axle

8.2.3 Items Maintained Every 250 Working Hours or Per Month

Item Measure Page

Finish above maintaining items
Engine oil and filter Replace
Rough filter in fuel system Clean/Replace
Precise filter in fuel system Replace
Brake system Test
Cooling Fluid in cooling system Inspect/Fill
Transmission shaft spline Lubricate

8.2.4 Items Maintained Every 500 Working Hours or Per 3 Months

Item Measure Page

Finish above maintaining items
Gas valve of crankcase Clean
Filter in hydraulic system Replace
Fuel tank cover and oil filter Clean

8.2.5 Items Maintained Every 1000 Working Hours or Per 6 Months

Item Measure Page

Finish above maintaining items
Transmission shaft Fill lubricant

8.2.6 Items Maintained Every 2000 Working Hours or Per Year

Item Measure Page

Finish above maintaining items
Working and steering hydraulic system Replace Oil
Hydraulic system filter Replace
Axle Replace Oil
Wearing of wet brake arrester Inspect

41
8.2.7 Items Maintained Every 3000 Working Hours or Every 2 Years

Item Measure Page

Finish above maintaining items
Cooling system Clean
Cooling fluid Replace

8.2.8 Items Maintained When New Deck Lifter Works First 50 Hours

Item Measure Page

Axle Replace Oil
Working hydraulic system Replace Oil
Hydraulic system filter Replace

8.3 Details for Maintenance Items and Procedures

8.3.1 Maintenance

Please read and understand relevant warning and instruction in this manual before doing any
operation and maintenance. You would better follow instructions in diesel engine maintenance
manual strictly to clean air inlet device.

ATTENTION: when repairing air filter, the engine should be shut down to avoid damage, please
repair according to instruction in diesel engine maintenance manual.

8.3.1.1 Replace/Clean Main Filter

The repairing procedures are as following:

 Discharge the cover of air filter
 Unload the main strainer.
 Clean inside of air filter cover.
 Clean and check the main strainer, refer to part of “8.3.1.3 Clean Main Strainer”.
 Install the cleaned main strainer inside of filter cover.
 Clean and install the cover, tighten bolts on the cover by hand, and don’t use any other
tools.
If the engine still discharges black smog even after installing cleaned main strainer, then install a
new one.
The main strainer needs to be replaced after cleaned 6 times, and it must be replaced once per
year even it was cleaned less than 6 times.

42
8.3.1.2 Replace Safety Strainer

ATTENTION:
The safety strainer can’t be used until totally cleaned; otherwise, the engine will be damaged.
The main strainer has to be replaced by new one after being cleaned 3 times.
If the engine still discharges black smog even after installing cleaned main strainer, then please
install a new safety strainer.
The procedure in detail is as following:
 Unload the main strainer.
 Unload fixing bolts and safety strainer.
 Cover the air inlet and clean the inside of filter’s cover.
 Check the gasket between air entrance pipe and outer cover, replace if it was damaged.
 Open air inlet and install a new safety strainer.
 Install nuts, gaskets and bolts, the torsion of nuts is 27±7N.m.
 Install main strainer and cover, tighten the bolts on the cover by hand only, and don’t use
any other tools.

8.3.1.3 Clean Main Strainer

Main strainer can be cleaned by mechanism or pressured air.

Mechanism:
Lean main strainer on soft and clean surface, and pat end of the main strainer carefully.
ATTENTION:
Don’t lean main strainer on hard object while patting.
Pressured Air:
 Use highest 500kpa pressured clean and dry air. Don’t put the nozzle to object nearer than
5cm.）
 Blow the filter clean from the inside along the drape.
 Pack the clean strainer well and put at clean and dry place.
Inspect the filter regularly by details as following:
 Inspect the filter with a lamp.
 As long as there is a little hole, scratch, crack or other damage, the filter must all be
changed.
ATTENTION: In order to find damages more easily, it is better to arrange above inspection in
darkroom.

8.3.1.4 Clean/Tighten Batteries

The battery that this machine disposes is maintenance-free battery, which locates in cover of the
engine.
Clean the anode/cathode and surface with clean cloth, and smear the anode/cathode with

43
Vaseline.
The vibration by the engine will make battery clamps loose. Therefore we need to tighten all
fixing bolts to avoid any loose connection between battery and cable.

8.3.1.5 Battery Callback

 The batteries must be reclaimed. Waste batteries can’t be thrown away at random.
 Waste batteries should be collected by following units:
 Battery supplier
 Special reclaim factory for waste battery

8.3.1.6 Clean and Replace Cover of Radiator

The maintenance window of radiator locates inside of the engine’s cover.

 Unscrew the cover of radiator and release pressure.
 Check if there is any damage, precipitate or impurity, and use clean cloth to wipe the cover
or change a new cover if necessary.
 Install the cover.

8.3.1.7 Clean Exterior of Radiator

 Clean dust and impurity on the radiator by pressured air.

8.3.1.8 Replace Fuse

The fuse box locates inside maneuver box in driver’s cabin.

Fuse: to protect electrical system from damage caused by short circuit. If the fuse is broken,
please change another one with same specification; if the new one is also broken, please check
and maintain the circuit.
ATTENTION: only same load fuse can be replaced, otherwise the circuit might be damaged. If
the fuse has to be replaced frequently, it is possible that the circuit has faults of short circuit.

8.3.2 Items Maintained Every 10 Working Hours or Each Time Before Working

Before any operation or maintenance, make sure to read and understand the warnings and
instructions in this manual.

44
8.3.2.1 Engine Oil

Check oil level and do not fill too much oil, which might make the engine damaged. Detailed
procedures are as following:
 Ensure oil level in normal range.
 Open the oil filling cover and fill if necessary.
 Clean and close the oil filling cover.

8.3.2.2 Hydraulic Oil

Check oil level, the hydraulic oil tank locates at right side of the Deck Lifter, and the level gauge
locates by its right side.
 Keep oil level at top of the level gauge on hydraulic oil tank.
 Open oil-filling cover and fill by hose.
 Clean and close the oil-filling cover.

8.3.2.3 Cooling System

Check the level of cooling fluid; the cover of radiator locates inside of the engine cover.
 Unscrew the cover of radiator slowly and release pressure.
 Ensure the cooling fluid level within 1cm under the water filling mouth. Confirm if there
exists leakage if you have to fill water everyday.
 Check seal of the cover, and change if it is damaged.
 Close the water filling mouth.

8.3.2.4 All-round Inspection

Inspect all following parts:

 Replace if any lamps or glasses are damaged.
 Check leakage of cooling system, hose faults and dust. Get rid of leakage and clean the
impurity on radiator.
 Check leakage of hydraulic system, oil tank, hoses, pipes, bolts and joints. Ensure no
leakage exists.
 Check leakage of axle differential mechanism, final drive and wet brake system.
 Check if all covers have been closed well and if there is any damage.
 Check the escalator and its cleanness.
 Check instruments and switches, replace them if damaged.
 Check rearview mirror to ensure it at proper place for sights.
 Check the cleanness of front/behind windows of driver’s cabin. Please use dry and clean
cloth to clear if necessary.
 Start the engine and check if there is any damage on instruments, instruments glasses or
switches; check all lamps and horn, then shut down the engine.

45
8.3.3 Items Maintained After New Deck Lifter Works First 50 Hours

As new Deck Lifter will produce metal scraping after running some period, if the scrapping was
not wiped off in time, it will influence work and cause damage to spare parts.

8.3.3.1 Changing Oil for Differential Mechanism and Final Transmission

Please follow below instruction for maintenance：

 Unload the oil-discharging plug on front/rear axles and discharge oil.
 Clean and install the oil-discharging plug.
 Unload oil-filling plug and fill oil until overflowing. Refer to table of “Oil Viscosity and
Tank Capacity”.
 Install oil-filling plug. Start the engine for several minutes and inspect oil level again. If
necessary, please fill oil to required level again.

8.3.3.2 Changing Oil for Hydraulic Oil Tank

Park the Deck Lifter at horizontal ground, and draw back all cylinders, brake and shut down the
engine.
 Unload oil-filling cover of hydraulic oil tank.
 Take down the plug at bottom of the oil tank and screw oil discharging pipe joint, then
discharge oil.
 Unscrew oil discharging pipe joints and install the plug.
 Replace hydraulic system filters. Refer to table “Items Maintained Every 500 Working
Hours or per 3 Months”.
 Unload oil filling strainer, clean and install once available.
 Fill oil into hydraulic oil tank. Refer to “Oil Viscosity and Tank Capacity”.
 Check gasket of oil filling cover, and replace if damaged.
 Install oil-filling cover.
 Start and run the engine for several minutes.
 Keep oil level at top of the oil gauge. Fill some if necessary.
 Shut down the engine.

8.3.4 Items Maintained Every 100 Hours or per week

Before doing any operation or maintenance, please make sure to read and understand all relevant
safety warnings and instructions in this manual.
 Inspect above items firstly.
 Fill lubricant on swing jointing pin of front axle.
 Fill lubricant on pin of steering oil tank of front axle.

46
8.3.5 Items Maintained Every 250 Hours

Before doing any operation or maintenance, please make sure to read and understand all relevant
safety warnings and instructions in this manual.
 Inspect above items firstly.
 Replace engine oil and filter as following:
 Unload oil-discharging bolts and plug in crankcase, discharge oil, clean and install
bolts and plug.
 Unload the filter with spanner.
 Clean the base of outer cover of filter and unload all old filter gaskets.
 Coat a thin layer of engine lubricant on new filter gaskets.
 Install a new filter, when the gaskets have touched base of the filter, screw half a loop
on the base.
 Unload oil-filling cover, and fill new oil into crankcase. Refer to “Oil Viscosity and
Tank Capacity”. Clean and install the cover.
 Start the engine and heat the oil, check if there is leakage, shut down the engine.
 Keep engine oil level in normal range on oil gauge.
 Clean and change filter of fuel system according to diesel engine maintenance manual for
details. Following procedure is just for your reference.

ATTENTION: Don’t fill oil before filter installed. Fuel with impurity will accelerate wearing
speed of fuel system.

Clean rough strainer:

 Unscrew bolts on filter outer shell.
 Unload the outer shell and strainer.
 Discharge the strainer from outer shell.
 Clean strainer and outer shell in clean and incombustible solvent.
 Blow the strainer dry with pressured air.
 Clean pedestal of filter outer shell.
 Check the seal gasket and replace if damaged.
 Install clean strainer.
 Install strainer and cover into inside of out shell.
 Screw the bolts on outer shell.

 Replace the precise fuel filter and maintain according to maintenance manual.
 Unload the useless filter and reject.
 Clean the pedestal of filter and take away all old seal gasket.
 Coat clean diesel oil on seal gasket of new filter.
 Install new filter by hand, and when seal gasket touches the pedestal, screw 3/4 loop
more.
 Start diesel engine system (refer to following contents)

47
 Start fuel system. If the engine can’t be started or does not run smoothly after oil filled, the
oil spray pump and high-pressured pipe must be started first after oil filled. There is a check
valve on every oil spray pump, which can’t be opened by manual pump. Please follow
below instruction to fill oil for oil spray pump and pipeline.

ATTENTION: if only one spanner is used to screw or unscrew nuts on fuel pipes, the fuel
nozzle might be twisted and get permanent damage. So please use one spanner to clamp the
nozzle and use another spanner to unscrew the nuts.
 Loose the oil spray pipe at head of engine cylinder.
 Pull the accelerograph handle to low-speed idling position.
 Start the engine until fuel oil flows out from pipes without foams, then shut down the
engine.
 Screw nuts on fuel oil pipe, the torsion is 40±7N.m, use another spanner to clamp the
nozzle to avoid damage.
 Start the engine to check leakage.

 Check brake capability of braking system. Make sure no people or obstacles around before
beginning the test.
Following test is to check if the Deck Lifter’s brake function works well or not, but not to
test the maximum brake capability. The brake force needed when engine runs at certain
speed depends on engine’s initialization, efficiency of transmission system as well as brake’s
own capability.
The engine’s rotation speed when brake carried should be compared with that in original
braking test, then to evaluate how much wearing on brake system.

Detailed procedures are as following:

 Start the engine first, then traveling brake deployed .
 When brake deployed, put gearing shift to high-speed shift.
 Increase engine’s rotation speed to high-speed idling gradually, and the Deck Lifter
should not move any more.
WARNING: if the Deck Lifter moves, please lower engine’s rotation speed at once and deploy
parking brake.
 Lower engine’s rotation speed to low-speed idling, put shift to Neutral and deploy
parking brake, then shutdown the engine.
ATTENTION: If the Deck Lifter is still moving when traveling brake deployed, please contact
service station of Nanjing HCT Marine Equipment Co., Ltd for help. If necessary, the brake
should be repaired before the Deck Lifter is used again.

 Fill cooling fluid into cooling system

ATTENTION: Don’t fill any additive unless you have read and understood all contents in
“Cooling System Regulation”.
Detailed procedures are as following:
 Unscrew the cover of radiator slowing and release the pressure.

48
  Fill cooling fluid.
 Install the cover of radiator.

8.3.6 Items Maintained by First 200 Working Hours

 Rear Axle
Check if the oil is clean, if not, please change new oil. Detailed procedures refer to “Rear Axle”
part of “8.2.8 Items Maintained When New Deck Lifter Works First 50 Hours”.
 Hydraulic System:
Check if hydraulic oil is clean, if not, please change new oil. Detailed procedures refer to
“Hydraulic System” part of “8.2.8 Items Maintained When New Deck Lifter Works First 50
Hours”.

8.3.7 Items Maintained Every 500 Working Hours or per 3 Months

 Check above items firstly.

Before doing any operation or maintenance, make sure to read and understand all warnings
and instructions in relevant chapter of this manual.
 Clean the valve of engine crankcase.
Clean according to diesel engine maintenance manual.
 Replace filter of hydraulic system as following:
 Unload oil filling cover and release pressure in oil tank.
 Unscrew fasten bolts on filter.
 Unload the cover and strainer.
 Throw away strainer.
 Check O shape gasket, and replace it if necessary.
 Install new strainer and cover, and then screw the bolts.
 Keep hydraulic oil level at top level of oil gauge, and fill some oil if necessary.
 Check seal of oil filling cover, and replace a new gasket if it is damaged, after which
install cover of oil-filling mouth.
 Start fuel oil system by following part “Start fuel oil system” in “8.2.3 Items
Maintained Every 250 Working Hours or Per Month”.
 Start the engine pump with procedures as following:
 Open exhaust valve of engine fuel oil system.
 Loose plunge of engine pump, and then press the pump plunge up and down.
 When fuel oil flows out without foams, close the pump and locks the plunge.
 Close exhaust valve.
 Start diesel engine and check if there is any leakage.
 Clean cover of fuel oil tank and oil-filling strainer.
Fuel oil tank locates at left behind of the Deck Lifter, clean with procedure as following:
 Unload the cover.
 Replace sealing gasket if it is damaged.

49
  Take out rough filtering net from oil filling mouth.
 Clean rough filtering net with clean and non-flammable solvent.
 Install rough filtering net.
 Install cover of fuel oil tank.

8.3.8 Items Maintained by First 600 Working Hours

Detailed procedures are completely same as “8.3.6 Items Maintained by First 200 Working
Hours”.

8.3.9 Items Maintained Every 1000 Working Hours or per 6 Months

Before doing any operation or maintenance, make sure to read and understand all warnings and
instructions in relevant chapter of this manual.
 Check above items firstly.
 Fill lubricant onto universal joint of transmission shaft. The accurate place for filling
lubricant is lubricating mouth of universal joint.

8.3.10 Items Maintained When New Deck Lifter Works First 1500 Hours

Detailed procedures are completely same as “8.3.6 Items Maintained by First 200 Working
Hours”.

8.3.11 Items Maintained Every 2000 Working Hours or per Year

Before doing any operation or maintenance, make sure to read and understand all warnings and
instructions in relevant chapter of this manual.
 Check above items firstly.
 Replace oil according to chapter 8.3.3.
 Check tearing and wearing of braking arrester according to following procedure:
 Unload rear axle braking arrester and check.
 Measure the depth of concave tank by sides of braking arrester and confirm arrester’s
residual life by reference to following table.

Residual life percentage of Thickness of braking Depth of concave

braking arrester arrester (mm) tank (mm)
100 6 0.75
80 5.8 0.65

50
 60 5.62 0.56
40 5.46 0.48
20 5.3 0.4
0 5.14 0.32

 Install checking screw plug.

Please contact Hai Cheung Trading Co.(HK) Ltd. if braking arrester needs to be changed.

8.3.12 Items Maintained Every 3000 Working Hours or per 2 Years

Before doing any operation or maintenance, make sure to read and understand all warnings and
instructions in relevant chapter of this manual.
 Check above items firstly.
 Replace cooling fluid and cleaning system.

ATTENTION:
Don’t change cooling fluid before reading and understanding chapter contents of “Regulation of
cooling system”.
Please change cooling fluid as soon as possible when finding impurity and foams in cooling
fluid.
Radiator’s cover locates at behind of the engine.
 Unscrew cover of radiator and release pressure.
 Open exhaust valve to let cooling fluid flow out. The exhaust valve locates in bottom of
radiator.
 Close exhaust valve and fill clean water and cleaning fluid with consistence about 6% to
8%.
 Start the engine and let it run for 1.5 hour, then shut down and discharge all cleaning fluid.
 Close exhaust valve.
 Fill cooling fluid. Refer to “Regulation of Cooling System” and “Oil Viscosity and Tank
Capacity”.
 Start and run the engine, open the cover of radiator until thermostat is opened and the fluid
level is stable.
 The cooling fluid level should be kept within 1cm under fluid filling pipe.
 Install the cover. If gasket of cover is damaged, please change a new one.
 Shut down the engine.

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CHAPTER 4: MANAGEMENT

1. MANAGEMENT OF NEW DECK LIFTER

New Deck Lifter can only be delivered after accurate inspection and run-in. It is necessary to
carry on enough running before beginning to use, please operate completely according to
instructions in this manual.
Below items should be followed when using new Deck Lifter:
 Preheating must be done before working, no matter what season it is.
 Avoid the engine from idling. Especially when the engine is not preheated.
 Avoid urgent drive, urgent turning and unnecessary urgent stop.
 Checking and maintenance should be carried out according to regulation.

2. STORAGE OF DECK LIFTER

2.1 Unused for One Month

Besides attentive matters when parking, below items should be done for Deck Lifter that has not
been used for one month:
 Operate the Deck Lifter once a week, and make it ready to use at time.

2.2 Unused for More Than One Month

Besides attentive matters when parking, below items should be done for Deck Lifter that has not
been used for more than one month:
 Check oil tank for different parts and make sure oil quantity can satisfy request by
regulation.
 The batteries should be unloaded. Even the Deck Lifter parks indoor, if it is hot or damp
place, the batteries should be stored in another dry place, and charge them every month.
 Exterior of those parts apt to get rusty, such as cylinder rod, should be coated anti-rust
grease. But before operating Deck Lifter; please make sure to wipe anti-rust grease off first.
 Cover ventilating device, air filter, and electric control box and maneuver box where damp
air might immerge with canvas cloth.
 Run the Deck Lifter each week to ensure it is ready for working.

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2.3 Reuse After Long Time Storage

 Take away anti-damp cover.

 Wipe off anti-rust grease.
 Discharge oil in engine crankcase, differential mechanism and final decelerator, and then
clear and replace new oil.
 Discharge impurity and fixed water from hydraulic oil tank and diesel oil tank.
 Fill cooling fluid according to regulation.
 Install batteries and make them connected with cables.
 Check Deck Lifter’s components before working.
 Preheat and run the engine.

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CHAPTER 5: TROUBLE SHOOTING

1. ENGINE CAN NOT BE STARTED

Please check as following sequence:

 Check battery
It is recommended that the battery should be charged once a week at least.

 Check diesel oil

Once the diesel oil is used up, the manual diesel pump must be operated before
engine started.

 Check the pressure gauge on the block

Check the pressure gauge on the block and contact us if the pressure is higher than
40 bar when the engine is starting.

2. MULTISTAGE CYLINDER EXTENDS OUT OF TURN

 Check all spports

Make sure that all the supports stand on same flat surface. All sundries under the feet
must be removed.

3. THE HEIGHT OF WORKING TABLE CAN NOT BE READ ON DISPLAY

 Check the connector of the high linear decoder.

 Check the connector between the display and CPU.
 Measure voltage of the linear decoder output, which should be changed between
0-10V if you pull the line. Please change new linear decoder if there is no
response.

4. ABNORMAL NOISE

 The temperature is too high

The working temperature should not exceed 75 degrees Celsius. Noise might be
54
produced if the temperature is too high while lifting with load from the lifting
cylinders

 The Grease should be replaced between every shaft of the construction.

Please use the grease gun and fill up more grease into the shaft, until the
degenerative grease is squeezed out of the connection gap.

 There is no action of the deck lifter when any instruction is given

Please check the emergency button on the control cabinet, if it is pushed.

If above methods do not work or you have met other troubles, please contact us
by below email, and you can also find our contact on the website.

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This manual is used for reference to customer when operating. The copyright of this
manual belongs to Nanjing HCT Marine Equipment Co., Ltd. It is prohibited to reprint
without permit. If you find any pretermission or mistakes in this manual, please contact us
by following way immediately:

Nanjing HCT Marine Equipment Co., Ltd

Address: 6 Huyue Road, Liuhe Economic Development Zone, Nanjing, Jiangsu, China
Zipcode: 211500
Consulting Telephone: +86 21 68889889-6628
Service Telephone: +86 20 84351889
Fax: +86 21 63293888
Email: Roger_song@haicheung.com; Ren_gu@haicheung.com
Website: www.haicheung.com

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