User manual
Contents
1.2. CLB1229 CLB1236 CLB1232 SCHEMATIC DIAGRAM 27 7 2 Wiring diagram 1 Bea Pp Pa a CCC manna O 32000 foe Ekke EEk A L Re AUN AE ete 4 aa fe e ER Hat D erase CONTROLLER type 124 CLB1216 CLB1229A WIRING DIAGRAM o EEE EEE z CLB1229 CLB1236 CLB1232 WIRING DIAGRAM 28 Following are names of electric components 1 GB Accumulator 14 P Capacity indicator Positive pole of 2 B 15 KM Pump station contactor accumulator Negative pole of f 3 B 16 KM7 Main contactor accumulator 4 MU Fuse 17 YD solenoid valve 5 FU FU1 FU2 Fuse 18 H Horn 6 B accelerator 19 E CURTIS 1243 controller 7 M Drive motor 20 DI D3 D4 DS Diode 8 SI Lowering button 21 SM Emergency stop button 9 S2 Lifting button 22 SY Key switch 10 S5 Horn button 23 K 24V electro discharge module 44 56 EMmelgeney reverse 24 YB electromagnetism band type switch brake 12 SA Switch 25 SH Mode switch 13 Al A2 A3 A4 Wiring board 26 SU Lifting limit switch 29 7 3 Hydraulic system CLB1216 CLB1229 CLB1232 CLB1236 2 2hw 24 CLB1229A 2 3Kw 24Y 30
3. 6 2 4 Check the stacker for oil leakage 6 2 5 Check the chain rollers fork oil pipes and horn 6 2 6 Check the brake 6 2 7 Check the wear and tear of drive wheels and loading wheels 6 3 Professional Maintenance Manual It is very important for safe operation of the stacker to perform overall professional maintenance Failure in performing maintenance according to specified interval may cause malfunction of the stacker and potential risk to human and equipment A Maintenance periods listed in this manual apply to single shift a day under normal operation conditions If using in dusty environment the ambient temperature varies remarkably or in multi shift situation the maintenance period has to be shortened Maintain the stacker according to following maintenance list Maintenance periods are as 21 follows W1 Every 50 work hours but at least once a week M3 Every 500 work hours but at least once every three months M6 Every 1000 work hours but at least once every six months M12 Every 2000 work hours but at least once every 12 months Additional operations should be performed in trial run period In initial 50 100 working hours or after two months Check the nuts on the wheels and tighten them if necessary Check the hydraulic components for leakage and tighten them if necessary Replace the hydraulic filter Maintenance List
4. Time interval of maintenance Standard W M M M Cooling 1 3 6 12 storage H Chassis amp 1 1 Check all bearing parts for damages o Main frame 1 2 Check all bolt connections o 2 1 Check the drive system for noise and leakage Driver 2 2 Check oil level in drive system 2 3 Replace lubricant oil 3 1 Check for wear and tear Wheels 3 2 Check the bearings and make sure they fit well with the wheels a Steering 4 1 Check the steering control system 5 1 Check the performance and adjust accordingly 5 2 Check reset function of the air spring and check for J Braking system leakage and damages 5 3 Check the brake disk for wear 5 4 Check the connection of brake and adjust if necessary 6 1 Check performance and wear and adjust accordingly Lifting 6 2 Visually inspect the loading wheels for blockage Mechanism 63 Check fork tips and pallet support for wear and damages 7 1 Check performance Hydraulic 7 7 2 Check all connections for leakage and damages system b 7 3 Check the cylinder for leakage and damages and ifthe accessories are safe and secure 7 4 Check the oil level 22 7 5 Replace hydraulic oil and the filter element c 7 6 Check the pressure regulator valve 8 1 Check performance 8 2 Check all cable connections for safety reliability and J damages Hyd
5. environment lt should be with special equipment for protection if workingunder the high risk environment The stacker is not designed for use in high risk environment 1 8 Safety devices and warning signs Sufficient attention should be paid to safety devices warning signs and precautions described in above sections in this manual 1 9 Driving in public places The stacker is prohibited to drive in public places except for special areas 1 10 Space between vehicles Remember to keep a proper distance from the vehicle ahead since it may stop suddenly at any moment 1 11 Passengers Never carry or lift persons with this stacker 1 12 Headroom Never use the stacker in areas where the headroom is lower than the height of loads or mast 1 13 Operation in a lift or loading platform If the load capacity of the lift or platform is sufficient and the space is enough for stacker operation they can be used for transportation with the permission from the stacker user The stacker must be confirmed by its driver himself before entering the lift or loading platform When entering the lift the loads must enter ahead And locate the stacker in a suitable position to prevent from contacting walls around If passengers take the lift together with the stacker they have to enter after the stacker enters and stops firmly and leave before the stacker 1 14 Driving passageway and working area The stacker must be driven in designated passageway No
6. hydraulic oil level in oil tank S Check the hydraulic oil level only after the fork and main frame are lowered to their lowest position 6 4 5 Use Preparation after maintenance or repairing Use the stacker only after following operations have been completed Clean the stacker Check the brake Check the emergency stop switch Check the horn 6 5 Storage of the stacker If the stacker will be not in use for over two months it must be stored in antifreeze and dry locations Take protection measures before storing If the storage time is over six months please consult the manufacturer on additional protection measures AN During storing the stacker should better be placed with the wheels off the ground for protecting the wheels and the bearings within wheels 6 5 1 Operations before storing Clean the stacker thoroughly Check the brake Check the hydraulic oil level refill if necessary Apply lubricant oil or grease to protect all parts Refill grease according to detailed lubrication cycle table Recharge the accumulator again Disconnect and clean the accumulator Apply grease on terminal poles on 25 accumulator er Besides these the accumulator must be protected according to special requirements stated in accumulator instruction manual 6 5 2 Cautions during storage Every 2 months Recharge the accumulator JAN Operations related to accumulator It is very impo
7. stop the stacker only with electromagnetic brake control lever Turn up or down the control handle to braking range B1 or B2 the drive motor will be stopped mechanically er When the control handle is released it will enter the upper braking range B1 automatically After the stacker is stopped the electromagnetic brake works as parking brake Braking with reverse current brake If the control system or driving power fails braking with reverse current is possible Turn controller in reversed direction of driving until the stacker stops Release the controller Braking by the inertia When the forward backward button is released it returns to position O and brakes by inertia of the motor er The slowing down rate depends on the position of the controller If the controller position is set to 0 and the inertia braking unit is removed by service technician you have to use electromagnetic brake or reverse current brake to brake the stacker 4 3 2 Operation of lifting and lowering loads iN Before lifting loads the driver must check if the loads are placed on the pallet completely and the weight of loads does not exceed the loading capacity Do not transport in full load status for a long time Make sure the fork reach under the loads as far as possible ee When operate with Up or Down button the fork will move upward or downward at a fixed speed 12 Lifting of the fork Press
8. switch in control Moving in one DINA connecting cable are not lever and the connecting cable direction well contacted The accumulator capacity is Check the capacity indicator the brake The stacker insufficient Or the and related cables travels very electromagnetic brake is tight slowly Or the related cables are not well contacted The controller is damaged Replace the controller The stacker The button controlling Repair or replace it starts up backward or forward is not back suddenly Ha to its normal position se If above steps still can not solve problems please contact after sales service department of the manufacturer and have the problems solved by specially trained technicians 6 4 2 Preparation before repair To prevent possible accidents during maintenance and repair work following preparations must be done Park the stacker safely Press the emergency stop switch and disconnect the connectors on accumulator 24 S When the fork needs to be lifted up or the stacker needs to be raised up for repairing precautions for preventing the fork or the stacker from tilting over or falling down suddenly must be taken For information on lifting of the stacker see related parts in Transportation and Trial Run above 6 4 3 Check hydraulic oil level Get the stacker ready for maintenance or repairing Open the cover of electric unit Check
9. the Up Switch until the fork arrives at required height Lowering of the Fork Press Down Switch until the fork is lowered to required height Safe Parking S Pay attention to safety when parking the stacker Never park the stacker on a slope or on a ramp The fork must to be lowered to its lowest position after parking Lower the fork Turn electric lock from position 1 to 0 and remove the key 13 5 Maintenance Recharging and Replacement of the Accumulator 5 1 Safety procedures for lead acid accumulator operation The stacker must be parked in a safe location before any operation on the accumulator 5 1 1 Maintenance Technician Only qualified technician can perform operations on the accumulator such as recharging maintenance and replacing Before operation carefully read instruction manuals including operation manual replenishment preparation and recharging requirements 5 1 2 Fire Prevention Measures Never smoke or use open fire when perform operations on the accumulator The accumulator should be away from flammable material at least two meters when storage or recharging The location for accumulator storage should be well ventilated and equipped with fire fighting devices 5 1 3 Maintenance of the Accumulator 1 Keep the nuts on every battery cell dry and clean Tighten every terminal and cable end and brush them with grease to prevent corrosion Naked cable ends and terminal posts should be co
10. 4 Capacity indicator of the accumulator Capacity indicator of the accumulator The status of accumulator discharging is 16 indicated on the indicator with 10 bar graphs each bar represents 10 percent of increment As the consumption of accumulator capacity the lighting bars will fall down from the top Preset Warning marks will appear when remaining capacity of accumulator meets following conditions When the remaining capacity of the standard accumulator is 30 percent Warning mark will appear and you can recharge the accumulator Preset Warning mark and a flashing Stop mark will appear when remaining capacity of accumulator meets following conditions When the remaining capacity of standard accumulator is 20 Stop mark will appear and keep lighting When the Stop mark keeps lighting lifting function of the stacker will be cut off automatically Capacity sufficient Recharging needed Low battery FF If the indicator shows low battery when lifting loads for a not very long period lifting function can only be performed after recharging the accumulator to at least 7096 of capacity 5 5 Recharging The CLE series of stackers is supplied with a special charger for recharging Read the instruction manual carefully before recharging O The batteries should be recharged in well ventilated areas Make sure no metal objects placed on the accumulator Check all cables connection and connectors for obv
11. CLB12T CLE12T SMS 001 EN Instruction Manual CLB12T CLE12T ELECTRIC STACKER AY Operators should read and understand this manual and all warning Labels on power stacker before using the stacker Keep the manual for future reference Date 2012 6 AA O AE 2 1 Guidelines for Safe Operation cee rs ia aa E a E AEE EAE RESA a 3 2 Technical Manual IBUKA e iiiki isani entia 6 Specifications niesienie tedoen n a Bka hd da haaa a All 6 2 1 1 Structure chan NAA ee ae ete eee 6 2 1 2 Technical data NANA NBA NG eth a Vea ae 6 2 2 Technical Standards iN nate tie ocala alate 7 2 3 Operation Conditions ooo cece eceseeeeseeeeceeseeeseceeseseeacseeecseeeseeesaceeeeseeeeeaeees 7 3 Transport and Trial Run ooo eee ceeeceneceseceseceseceseceseceneceseceaeceseceseceseceaeceaeeeseseaeeeaeeeaeees 8 3 1 Transport witha Crane ANNA AN detest eet teehee mik 8 3 2 Trial RUN RANA NGNNA Kanina NANG AA E RANG E A E a E 8 3 3 Towing of stackers without driving ability 1 11111111111j nasasa 8 4 Operation 42nn A eek ne ean tan We inde ea Rn ten ee Sano ea seen te hes 10 4 1 Schematic diagram of the lever oo ceceeeseneeceseeeeseeeseneeeeseeeeseeeeeeeeeeeeees 10 4 2 Starting up the Stacker oo ee eseeeeeeeeceeeeeseeeseeeeceseeeeseeeeaeeeseeneeesaceesseeeeees 10 4 3 Operation of the stacker oo eee eecceseeeseeeeseeeeeeeseecseceeaeeeeaesseeeseceeaeeetaeeeeees 10 5 1 Safety procedures for lead acid
12. Voltage of an individual cell is frequently below 1 7V large current occurs during discharging for example when using the driving motor and lifting motor simultaneously for accumulators that are not recharged in time after discharging Over discharged accumulators and those are not in use for a long time Perform balanced recharging as follows A Recharge with a current of 0 115A B When the voltage up to 2 5V and there occur bubbles in the electrolyte continue recharging at a reduced current of 0 0515A C Recharge the accumulator to full capacity and stop recharging for half an hour and then continue recharging with further reduced current of 0 02515A for an hour D Stop recharging again for half an hour and continue recharging with a current of 0 02515A for an hour 18 E Repeat step D until bubbles occurs intensely and instantly when switching on the charger Perform balanced recharging to accumulator once a month in normal use 19 6 Maintenance and Service Manual S Never modify any parts especially safety devices of the stacker without permission Never change the operation speeds of the stacker All spare parts provided by original manufacturer are strictly tested Only use spare parts from the manufacturer for the guarantee of the safety and reliability of stacker operation The replaced material including oil should be collected and disposed of according to local environment protection and health regulatio
13. accumulator operation 14 5 2 Specification of the ACCUMUMATOL 02 ee ce eeeeeceteeeeseeeceneeeeneeeaeeeeeeeeeeeaeees 16 5 3 Storage transportation and installation of the accumulator 16 5 4 Capacity indicator of the accumulator 0 2 ee eee eseeeeceneeceneeeeseeeeseeeeeeneees 16 5 5 RechargiNngi nA NA ead deed ARN NANANA Gc ne des heeds 17 6 Maintenance and Service Manual cccccccccceessceesseeescecssceceeseeeeseeceseecneaeeseaeeeseeessaees 20 6 1 Safety procedures for maintenance and service cece ceceeeteeteeeeeeees 20 6 2 Routine Maintenance Before every Shift ccc cceeeeceteeseeeeeeeteeseeseeens 21 6 3 Professional Maintenance Manual 11 1 11111111 1a 21 6 4 Service Manual anG Na BANA naa AA GB mag SA 23 6 5 Storage of the sStacker An AG eee heeds Aneel 25 7 Schematic Diagrams of Electric eee ecceseeseceeceseceseceseceseceseceseceseceseceseeeaeeeaeeeaeeeaeees 27 T t Circ it agra ikan e E A INANI LANE 27 T2 NVITING diagram ce eiaa DRA a a 28 7 3 Hydraulie systeMm rohna AA PA AA AND PI dete 30 Introduction Welcome to use this series of power stackers This manual gives clear information on how to master safe operation of the power stackers The differences between various power stackers are described in detail in this manual During operation and maintenance please refer to the contents corresponding to the power s
14. cally emergently stop The control handle will enter the upper braking range B1 automatically O If the lever enters braking range slowly make sure to find out its causes and troubleshooting the failure If necessary replace the air spring of the handle Starting up O Start up the stacker only when the battery cover is closed Starting up the stacker Travelling speed is regulated with the controller Rotate the control lever to driving range F and adjust the control lever in required direction the stacker will move towards selected direction Driving Swing the control handle rightward or leftward to drive Driving on a slope Always keep loads face the downward slope when transport loads on a slope Take following safety measures against the rolling down With the control button in position O quickly press the handle backward The driver should release the handle as required to make the electromagnetic brake work automatically controlling the speed and direction if the driver find the stacker is rolling down Braking 11 O The braking performance of the stacker depends on floor condition The driver must be clear about this point Three braking methods are available Electromagnetic brake control handle Use reverse current brake from the controller Brake with the sensor i e release the lever to brake Braking with the Electromagnetic Brake S In case of an emergency always
15. ds and instruct the user how to operate the stacker 1 2 The right duty and responsibility of driver Clear with his own right and duty the driver should be trained in operating the stacker and also knows the contents in this operation manual very well If the stacker in use is controlled on foot the driver should wear safety boots during operation 1 3 Unauthorized persons are prohibited to use The driver is responsible for managing the stacker in use and must prevent any unauthorized person from driving or operating the stacker 1 4 Malfunction and Defects In case malfunction or defects occurs with the stacker the driver should immediately inform the supervisor If the stacker can not be operated safely e g with worn wheels and brake malfunction always stop using it until repaired completely 1 5 Safety operation and environment protection The checking and maintenance work described in this chapter should be executed according to the time intervals in the maintenance list O Never modify any parts especially safety devices of the stacker without permission Never change the operation speeds of the stacker All original spare parts from the factory are verified by Quality Assurance Department Only use spare parts from the manufacturer for the guarantee of the safety and reliability of stacker operation The replaced material such as oil or fuel should be disposed of according to environment protection regulations 1 7 High risk
16. ed No modifications or alterations to a powered industrial truck which may affect for example capacity stability or safety requirements of the truck shall be made without the prior written approval of the original truck manufacturer its authorized representative or a successor thereof This includes changes affecting for example braking steering visibility and the addition of removable attachments When the manufacturer or its successor approve a modification or alteration they shall also make and approve appropriate changes to capacity plate decals tags and operation and maintenance handbooks 2 Technical Manual CLB This series of stacker are designed for short and medium distance transportation on flat road surface The maximum capacity can be 1250kg It can be also used as an order picker or an Aerial work platform Specifications 2 1 1 Structure chart F pang B lang E ANG Npa mm Ji 5 ai ae CJ 1 2 1 2 Technical data CLB1216T CLB1229T CLB1232T CLB1236T CLB1229FT A mm 1976 1946 2096 2296 1946 B mm 1889 1908 1908 1908 1908 C mm 570 685 570 685 570 685 570 685 570 685 D mm 890 890 890 890 890 E mm 335 354 354 354 354 F mm 1150 1150 1150 1150 1150 CLE1216T CLE1229T A mm 1971 1946 B mm 1831 1831 C mm 570 685 570 685 D mm 890 890 E mm 355 355 F mm 1150 1150 S non standard stacke
17. ions must be made to prevent electric shock When operating the accumulator connectors on it must be disconnected 20 Welding Operation To prevent electric components from being damaged remove these electric components before welding Installation When repairing or replacing hydraulic components electric and electronic components make sure to install them back to their original positions Wheels Quality of the wheels has significant effect on stability and driving performance of the stacker Modification on wheels can be performed only with the approval from the manufacturer When replacing wheels ensure that the stacker is levelled as delivery state wheels must be replaced in pairs i e replace right wheel together with left one Lifting chain and rollers Chain and rollers will be worn quickly without good lubrication Perform periodic lubrication according to following maintenance table Shorten the lubrication period under adverse operation conditions such as in dusty and hot environment Hydraulic Oil Pipes Replace the hydraulic oil pipes every 6 years when replace the hydraulic assembly you should also change the oil pipes of the hydraulic assembly 6 2 Routine Maintenance Before every shift 6 2 1 Check the liquid level of electrolyte in the accumulator e The liquid level will be higher when being recharged 6 2 2 Check every pole every cable and their covers 6 2 3 Check if the accumulator box is secured
18. ious defects Observe strictly all safety instructions e g replenishment of the accumulator and preparation for recharging 5 5 1 Initial recharging 17 1 Please check the electrolyte before recharging if the electrolyte is diminished we have to add the electrolyte into the battery The Electrolyte is made of concentrated sulfuric acid and distilled water the specific gravity is 1 28040 005 Under the 25 C normal temperature and then pour the electrolyte into the battery 15 20mm overtoping the protective board is ok We can recharging the battery when the temperature of the electrolyte is lower than 35 C 2 There are two stage during the initial recharging A when voltage lt 2 4V charge current 0 5 ISAUS5A 1A 5H B When the voltage upto 2 4V please half the charging current it is 0 25 I5 A Continue to recharge until the electrolyte start bubbling Proof of 100 recharged stable voltage when the density of the electrolyte upto 1 280 0 005 without obvious change within 3 hours we think the battery was 100 recharged At that time the recharging voltage of the battery is 4 5 times than the reted capacity The whole recharging process will be 70 hours 5 5 2 Balanced Recharging After using for a period voltage and concentration may vary from battery to battery Balanced recharging will eliminate the differences so that the performance of each cell becomes uniformed In following cases balanced recharging is necessary
19. n related persons must leave the working area Loads must be stacked in designated locations 1 15 Operation Management Driving speeds must be suitable to local conditions Always drive in lower speed when passing curved passageways narrow passageways rotary doors or any obstructed places The driver should be able to measure by sight and keep enough stopping space from vehicles ahead all the time It is prohibited to make an abrupt stop unless in emergency rapid U turn and chase with each other in obstructed places Never operate the stacker with the body stretching out of it 1 16 Visibility The driver must keep his eyes on moving direction and have a clear view of the road ahead In case the loads carried block sight of the driver the stacker has to be driven reversely If this is not practical another person should walk in front of the stacker giving corresponding guidance and warning to the driver 1 17 Passing a ramp Only known ramps are permitted to pass And the ramps must be clean anti skid and meet specification requirements of the stacker Loads on the fork must face the downward slope Never turn around drive obliquely or stop on a slope Pass a ramp in lower speed and get ready for braking at any time 1 18 Load capacity of the floor Check if the weight of stacker and loads or wheel pressure on the floor exceeds the load capacity of the floor 1 19 Transportation The fork should be kept lower than 300mm from the floor d
20. ns 6 1 Safety procedures for maintenance and service Maintenance technician The maintenance and service should only be performed by special personnel trained by the manufacturer After the technician sent by after sales department of the manufacturer completed maintenance and servicing work they should sign on the service log Lifting of the stacker When the stacker needs to be raised up for repair the lifting device must be safe and reliable and must be strictly fixed to hook holes When the stacker is raised up proper measures such as using wedges and wooden blocks must be applied to prevent the stacker from sliding down or tilting over Cleaning Operation Flammable liquid can not be used for cleaning the stacker Before cleaning take safety precautions to prevent electric sparks e g sparks caused by short circuit When operating the accumulator connectors on it must be disconnected Use soft air suction or compressed air non conductive and anti static brushes to clean electric and electronic components I If you are going to use water spray or high pressure cleaner to clean the stacker all electric and electronic components must be covered carefully in advance because moisture may cause them malfunction Never use steam nozzles for cleaning Operation of Electric System Operation on the electric system should only be performed by specially trained personnel Before performing any operation on the electric system precaut
21. raulic 8 3 Check if the amperage of fuses is proper 8 4 Check if the switches and release cam mechanism is J system secure and functions properly 8 5 Check the connectors and replace worn parts if necessary 8 6 Check the warning device 9 1 Check the carbon brush for wear Motor 9 2 Check safety of additional devices of motor 9 3 Use a vacuum to clean motor frame Check the commutator for wear 10 11 Check the density of acid liquid capacity and voltage of the accumulator 10 2 Check the safety devices on terminals and the grease Accumulator 7 10 3 Clean the connector of accumulator and check the connection 10 47 Check the cable for damages replace if necessary 11 1 Grease the stacker according to time table for filling up Lubricant oil lubricant 12 1 Check the grounding connection of electric system General Test 12 2 Check the travelling speed and braking distance J 12 3 Check the lifting and lowering speed 12 4 Check the safety device and switch off devices 13 1 Perform trial run under rated load Trial 13 2 The stacker is proved to be safe and reliable to personnel after completion of above maintenance a After about initial 100 working hours check the nuts of wheels tighten them if necessary b After about initial 100 working hours check the hydraulic system connections for leakage and tighten it if necessary c After initial 500
22. ric motor until the brake does not impede the stacker from moving Now you can tow the stacker S After arriving at the destination location recover the stacker to original status 4 Operation 4 4 Schematic diagram of the lever 1 Down Switch 1 2 Forward Backward 3 Horn Button F 4 Reverse Button 7 A 5 Up Switch S 1 2 3 4 2 Starting up the stacker The driver should always make sure that no person stayed in dangerous area of the stacker before starting up and operating the unit or lifting loads Check before daily start up Check the entire unit for defects and failure especially the wheels and lifting mechanism Check if the accumulator is firmly fixed and well connected Starting up the stacker Reverse and Turn on the emergency stop switch Insert the key in electric lock and turn it clockwise to position I The coulombmeter shows current battery level Check the horn Check braking function of the control lever Now the preparation before starting up is completed 4 3 Operation of the stacker 4 3 1 Starting up Driving and Parking O Be careful during starting up and driving especially when part of your body stretches out of stacker s outlines Do not carry any other person during driving Emergency Stop Pressing the emergency stop switch will stop all electric control functions 10 Forced Braking When the control handle is released the stacker will brake automati
23. rs or stackers equipped accessories or other optional components may be different from above tables We reserve the right to update the specifications of this stacker These tables provide only specifications of standard stackers Specifications of 2 2 Technical Standards Continuous noise level should be less than 70dB A according to ISO4871 standard S Continuous noise level is an average value of noise measured at the driver s ear during travelling lifting and being standby Electromagnetic Compatibility EMC The manufacturer confirms that the stacker complies with EN12895 and other relevant standards on limits of electromagnet radiation and interference and has been tested on static discharge S Never modify any part of electrical system without written permission from the manufacturer 2 3 Operation Conditions Ambient temperature 5 C 40 C S Special devices have to be used under a temperature below 5 C or in very humid environment S If there is quality problems with the truck or you need to order spare parts please specify serial number of the truck and part number 3 Transport and Trial Run 3 1 Transport with a crane JAN Load capacity of the crane in use must be sufficient The load weight equals the net weight of stacker plus weight of accumulator see nameplate plate on the stacker The hook holes are specially designed for transport the stacker FF The hook holes are specially de
24. rtant to recharge the accumulator periodically Otherwise the accumulator will self discharge resulting complete loss of capacity and the accumulator may become worn out thoroughly 6 5 3 Trial Run Again Clean the stacker thoroughly Refill grease according to lubrication cycle table Clean the accumulator apply pole lubricant on the terminal poles and reconnect the connectors Recharge the accumulator again Check if there is moisture in gearbox oil If so replace gearbox oil Check if there is moisture in hydraulic oil If so replace hydraulic oil Start up the stacker S If the switches in electric system do not contact well clean all exposed connectors with contact detergent spray and repeat this operation to remove oxide layer on these connectors Perform several electromagnetic brake tests immediately after trial run again 26 T Schematic Diagrams of Electric 7 1 Circuit diagram P12 P11 P10 P3 IPDA A a 3 82 p 4 AT 1 CLB1216 CLB1229A SCHEMATIC DIAGRAM gots E P13 P14 P13 P14 PI PLO P9 T9 PD PO FP PA PD PD YB 1 i 1 A3 13 Hi 5 A3 12 A25 ag SY ARG 44215 ng SY ANG OZ
25. signed for transport the stacker Park the stacker in a safe position Hooks of the crane must be applied at hook holes Hooks of the crane must be applied at hook holes ensuring the stacker will not be slipped down During operation make sure the crane whose hooks must be applied at hook holes of the stacker do not contact with the stacker 3 2 Trial Run AN The stacker can only use accumulator as power supply Changing to use AC power will damage the electric circuit Cables connecting accumulator should be less than six meters To ensure the stacker work normally after delivery and transportation following operations have to be completed Check if the completeness of all parts and components and check if they are in compliance with requirements lf necessary install batteries without damaging the connection cable Recharge the accumulator immediately lf customers want to replace the accumulator with a new one make sure that the new accumulator match with the accumulator coulombmeter or is permitted by service technician of manufacturer 3 3 Towing of stackers without driving ability When towing the stacker without driving ability release electromagnetic brake before moving Press emergency control button and turn the power supply switch to OFF position Open the cover of electric unit Release 3 screws counter clockwise on the elect
26. tacker types you are using The safety instructions and important precautions are indicated with the following icons L S This icon indicates the existence of a hazard that could result in personal injury if the safety instruction is not observed 2 TAN This icon indicates that a failure to observe the described instruction could lead to equipment damage 3 E Refers to general notes and instructions before use Most parts of the product are made from recyclable steel The recycling and disposal of cast offs resulted during using maintenance cleaning and disassembling the product has to comply with local regulations without pollution to the environment The recycling and disposal of the cast offs should only be operated by specialised personnel in the designated area The cast offs such as hydraulic oil batteries and electronic units if improperly disposed may be hazardous to the environment and human health S Due to continuous product improvement Noblelift reserves the right to make changes in product designs and specifications without prior notice For the latest product parameters please feel free to contact us Note All parameters provided herein are as of the publication date of the Instruction Manual 1 Guidelines for Safe Operation 1 1 Requirements for the driver The stacker should only be operated by personnel trained in operating the stacker who can show to the user how to move and handle loa
27. umulator and socket make sure to stop the stacker and put the switch at position O When replace or install the accumulator make sure the accumulator is fixed securely in battery box 5 3 Storage transportation and installation of the accumulator S The stacker must be parked on the level ground steadily To prevent short circuit naked cable ends and the terminal posts should be covered with insulated covers When pulling out the accumulator properly arrange removed accumulator s connectors and cables without blocking access of the accumulator S When install or remove the accumulator with a crane make sure the load capacity is sufficient weight of the accumulator is marked on both the nameplates of the accumulator and the stacker The crane must pull vertically to prevent the battery box from being damaged The hooks of the crane should be safe and secure Never let the hooks fall on an individual battery Press emergency stop switch and turn the power supply switch to OFF position Remove the connectors of accumulator cables Connect the lifting device to lifting holes Lift out the accumulator from the top and move away with handling equipment Perform installation in reverse order of above steps It is noticeable to put the accumulator in right position and connect the cables securely After reinstalling the accumulator always check all cable connections and connectors for obvious damage 5
28. uring non transportation driving It is better to driver in reverse direction of the fork to get good vision and mobility Driving with the fork forward may cause unpredictable mobility problems 1 20 Speed Select a suitable speed depending on floor conditions visibility and the principle of safety operation During operation it is prohibited to speed up stop and turn suddenly for that may cause roll over of the loads and the stacker 1 21 Driving on loading platform or approach bridge Before driving the stacker onto loading platform or approach bridge of a truck make sure to check load capacity of the 4 approach bridge and if it is equipped with anti sliding devices The driver must also check load capacity of the truck and if there are devices to prevent the truck from moving 1 22 Safe Parking Pay attention to safety when parking the stacker Never park the stacker on a slope or on a ramp The fork must be lowered down to the lowest position after parking Tum off the electric lock and remove the key to prevent unauthorized operation S Please disconnect the wires linked to batteries if the stacker will not be used for a long time before recharging 1 23 Signalling Warning signals can be sent by the horn on the stacker 1 24 Protection shoes According to EU standard EN 345 1 S1 standard protective shoes must be worn when operating on the stacker 1 25 Additional equipment Unauthorized truck modification is not permitt
29. use and repair the cell immediately Replace the cell when it cannot be repaired 11 The site for recharging should be well ventilated It is prohibited to smoke or use open fire avoiding the risk of hydrogen explosion 12 The electrolyte in accumulator is toxic and corrosive For this reason always wear working suit and protection glasses to protect your body from contacting the electrolyte in accumulator 13 If your clothes skin or eyes are spilled with acid liquid in accumulator flush with large amount of clean water For skin and eyes flush with large amount of clean water and also seek doctor s treatment immediately Acid spillage must be neutralized and treated immediately 14 The weight and dimensions of the accumulator have remarkable effect on stability of the stacker Therefore do not modify the type of accumulator without approval from the manufacturer 15 Never discharge in large current for example performs travelling and lifting simultaneously 5 1 4 Disposition of worn out accumulators Worn out accumulators should be recycled according to local regulations and stored in specified zone or cast off treatment zone These works should be done by qualified specialized companies 15 5 2 Specification of the accumulator Weight and dimensions can be found on the nameplate of the accumulator Uninsulated terminal poles on the accumulator should be protected with an insulated cover When connecting the acc
30. vered with a skid proof insulating cover 2 Every two cells should be well connected Check the nuts on each pole if loose tighten the nuts 3 Keep the surfaces of accumulator clean and dry After the completion of recharging clean spilled acid with cotton yarns or brush And clean with wet towel if necessary 4 Over recharging and over discharging should be avoided and fast charging and insufficient recharging are also not allowed Otherwise life span of the accumulator may be affected 5 Do not put conductive objects including metal tools on the accumulator or short circuit or even explosion may be caused 6 Never spill any hazardous liquid or solid material on surfaces of the accumulator When using a densimeter or a thermometer make sure the surface is clean and clear 14 7 Recharge the discharged accumulator in time Delayed recharging may damage the accumulator Do not delay recharging more than 24 hours Recharging of the accumulator may not work outdoors in cold weather In this case move it indoors to perform recharging 8 If the accumulator will not be in use for a long time it should be recharged and discharged once every month and it should be fully recharged every time 9 During recharging or using the liquid level of electrolyte lowers because of water evaporation so pure water should be added It is not allowed to add electrolyte with a specific weight of 1 280 10 If individual cell fails identify the ca
31. working hours 6 4 Service Manual 6 4 1 Troubleshooting Fault Cause Repair measures Connectors on accumulator are Check the connectors on accumulator not connected connect them if necessary Electric lock is in position O Turn the Electric lock in position 1 The stacker can Emergency stop switch is not Turn on the emergency stop switch not move turned on Check the capacity of accumulator The accumulator capacity is in recharge if necessary used up Turn the control lever to drive rage F Check fuse FU and FU1 23 The control lever is not in drive rage F fuse blown Loads can not be lifted up The stacker is not operating Low hydraulic oil level fuse blown The accumulator has only 20 30 of capacity The UP switch is in bad contact or damaged Do as methods in The stacker can not move table Check hydraulic oil Check fuse 2 FU Recharge the accumulator Check UP switch and necessary replace if Loads can not be lowered down Dirty oil blocks control valve The solenoid valve for lowering is not opened or is damaged Check hydraulic oil and clean control valve Replace the oil if necessary Check or replace the valve for lowering It can not stop when lifting up The UP switch is damaged The sensitive switch and the Disconnect power supply and replace the UP switch Check the sensitive
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