SERVICE & MAINTENANCE MANUAL Semi
Contents
1. 9 1 900 0 000001 0002 wm f sars 1000000 1000 35273 2204 59 28 3495 0 02835 0 000028 1 0 0625 1 tone metric 1 1023 ton US 0 9842 ton UK Pressure kgf cm2 735 56 Torr mmHg 0 96784atm Standard tightening torque The following charts give the standard tightening torques of bolts and nuts Exceptions are given in sections of Disassembly and Assembly METER TABLE Classification 00 Botsze size Torque kgf m Ibf ft Torque kgf Ibf ft 02 02 _ _ M12 20 22 2 2 INCH TABLE 4T 5T Classification Bolt type Bolt size Torque kof Ibf ft Torque kgf Ibf ft 1 4 0 6 0 06 1 7 0 2 5 16 1 2 0 12 3 0 0 3 3 8 2 0 0 20 5 6 0 5 7 16 3 2 0 32 8 9 0 9 1 2 4 7 0 47 13 4 1 3 9 16 6 8 0 68 19 0 1 9 5 8 9 3 0 93 26 1 2 6 3 4 16 0 1 60 45 1 4 5 7 8 25 5 2 55 71 6 7 2 1 38 0 3 80 106 9 10 7 1 1 8 54 1 5 41 152 2 152 1 1 4 74 2 7 42 208 9 20 9 1 3 4 98 8 9 88 277 8 27 8 1 1 2 128 2 12 82 360 7 36 1 The torque in above table shall not be applied to nylon or nonferrous bolts washer The same is valid for not standardized ones Newton meter 1 O 1kgfm TIGHTENING TORQUE OF S2. 7 33 6 2 OPERATION OF THE WHEEL 4 eme 34 f POWER PUMP 4 4 37 7 1 REMOVE THE PUMP 38 7 2 REMOVE THE CONTROL STICK de 38 7 3 REMOVE THE MAGNETIC VALVE FOR LOWERING 40 7 4 CLEAN OIL TANK AND 41 7 5 SEPARATION OF THE MOTOR OF PUMP STATION 43 8 MAINTENANCE CHECK 15 46 8 1 OIL HYDRAULIC uis n nennen nnns 46 8 2 REGULAR MAINTENANCE 0 46 8 46 8 4 HOW CHARGE STORAGE BATTERY 46 TROUBLE 47 FOREWORD Proper operation maintenance troubleshooting and repairs are necessary to preserve the performance of the pallet truck over a long period and ensure that fault and breakdowns do not occur The
3. SERVICE amp MAINTENANCE MANUAL Semi Electric Stacker m EE nanan LI CONTENT FOREWORD ee eee 3 t 4 1 1 INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS 4 1 2 MEASUREMENT 65 7 2 12 2 1 12 2 2 SPARE PARTS 13 2 9 SPECIFICATION SHEET 15 2 4 16 9 HYDHAULIG SYSTEM heen ene 17 3 1 OPERATION OF GYLINDEHB 17 nee en ee ner nes ree MEM E e PME EIU DD eer 19 5 ELECTRIC BOX 21 5 1 ELECTRIC DIAGRAM IMEEM MUNDI 21 5 2 TOOL FOR REPAIRING THE PIN OF 2 2 23 5 3 REPLACE THE ELECTRIC 24 6 STEERING SYSTEM amp WHEEL 33 6 1 CONTROL
4. 11 0 2 10 0 90 7 0 5 A 8 0 20 0 0 120 140 20 220 210 280 2x0 m 330 Minute ie Discharging min 100 DURATION OF DISCHARGING LIFE TEST CURVE ENVIRONMENTAL TEMPERATURE 25 320 300 280 010 minute 260 240 220 200 ic 110 120 0 30 60 9 150 10 210 240 270 300 330 36 390 410 440 470 os gt Duration of discharge Disch CHARGING CURVE 28 D W 2 004000 zs 2 10118111 40 REPLACE THE BATTERY STEP 1 Remove the cover dismantle the screw which fix the power cable to the battery with 10mm wrench STEP 3 Press the handle downward and you can remove the battery and replace it INSTRUCTION OF THE CHARGER WARNING The battery generates flammable and explosive gases during charge so excellent ventilation is required Open the liquid refilling cap or seal cap Do not smoke around the battery during charge Any fire and spark is forbidden MAIN PRODUCT SPECIFICATION Input power Battery capacity Input voltage DF AL18 2 12 18 400VA 220v 5 8 3kg 30 Foreword DF AL Automatic Charge is specially developed for battery charger of power pallet engine and power stacker engine offering the automatic detection and tracking of battery until the char
5. Remove out the pump station 16 Loosen the hoop J Remove the oil tank a Remove the suction filter Cleaning of oil tank and filter Wi gt Clean the Fix plate for valve etc m I9 Clean up with compressed air and LEM 14 inspect If the filter is stopped or E damaged replace it 32 Tels Remove dust or foreign material from the K t tank 8 177 41 TROUBLE DIAGNOSTICS Symptom Abnormality and cause Check if there is any place Bubble in mE Mixed with air where air can be entered hydraulic oil Tighten the loosened part again Mixed with air and water Replace the oil Discol Became inferior in quality by oxidizing or mixed Replace the oil with other particles STEP 2 Remove the screw fixing the filter net and then you can remove and replace it 42 f OF PUMP STATION lt STEP 3 Remove 2 screws on the top of motor with Philips screwdriver then press the tuber on the top cap and remove it now you can see the internal parts of motor 43 STEP 4 Remove the screw fixing the carbon brush and then remove the clip fixing it now you can remove the carbon brush r STEP 5 Remove 4 screws on the top plate with wrench and screwdriver STEP 6 Remove the stator of the motor and then you ca
6. 2 1200 0618 Olhode 2 D E 1 3 8 _ Linking Plate Bot 1 we e Press Washer 8 2 1m 8 18i 1 4 vs Bk 8 1 2 am 18 777 Cotrpn 8 EX NO Charging Plug 211 Chain 1025 1m 0 19 SSCS eal Washer 3 15 BM 0 e 140 Draw Bar for Turnin Piston Rod 2 5 140 o jp 2 5 1 1 29 Wa 8 i8 Wehr 1 24 Wah 8 14 2 3 SPECIFICATION SHEET 2 3 1 RESIDUAL CAPACITY AT DIFFERENT LIFTING HEIGHT ACTUAL CAPACITY Up to h3 mm 1500 1000 2500 1000 3000 600 Load centre distance C mm 2 3 2 TECHNICAL FEATURE i T ha 7 as Hie HI TT 35 1 bal gt li Jun RE 1 bi bu APL LL bu bs TM L3 45 Ast 1 2 Model of manufacture SPN1030 o Drive electric battery or mains diesel petrol fuel gas manual manual T Type of operation hand pedestrian standing seated order picker pedestrian 5 Load capacity rated load Q kg 1000 5 Load centre distance c mm Wheelbase y mm 1180 24 Weight including battery 1 M d Types solid rubber superelastic nylon polyurethane Nylon
7. X 1 36 W W J s Energy J Nm kiloJoule kJ 0 948 Btu 1 055 kJ Joule J 0 239 calorie x 4 19 J J N m Velocity and Acceleration meter per sec m s 3 28 ft s 0 305 mis meter per sec m s 3 28 ft s 0 305 mis kilometer per hour km h 0 62 mph X 1 61 km h Horse Power Torque 5252 R P M TQ lb ft Z 5252 Temperature 32 1 8 F Z 1 8 32 Flow Rate liter min dm min 0 264 US gal minZ3 785 Note Non SI Unit 11 4 saibeq CLC 9 86 096 006 08v OOP 096 086 006 09 061 08 OV 009 OV 06 006 086 096 OVC Occ 006 081 091 06 Bot 08 09 45 06 Oct 7 99 694 2 SPECIFICATION 2 1 OVERVIEW a es mm a j 1111111111111111110 T LI Li a 4 4 L1 4 Hydraulic system Mast system Electric box Steering system amp wheel kits Power pump unit 2 2 SPARE PARTS LIST 5 c 3 90 A UA 5 S amp S u 4 159 160 161 162 167 inner Mast 25 5 157 2 158 13 _ 49 1 1 _ 48 Seg 1 8 Sprocket Wheel 1 13 No Description Qty No Description Qty Locking Ring 8 68
8. PU Type size front 180x50 Wheels number front rear MEM Track width rear mm 4 2 Lowered mast height h4 mm 2080 44 Lift height hs mm 3000 Extended mast height h4 mm Height of handle min max h44 mm Fork height lowered h13 mm 85 Overall length mm 4 20 Length to face of forks mm 4 21 Overall width b4 mm Basic Dimensions 777 Fork dimensions s e L mm 60 160 1100 Width over forks mm gt 4 34 Aisle width for pallets 800x1200 lengthways Turning radius Wa 130 Lift speed laden unladed mm s 79 118 Lowering speed laden unladed mm s 108 95 Lift motor Lift motor rating at Sa 15 ke at S3 15 Performance Battery voltage nominal capacity Ks A ADX 2 14 2 4 LUBRICATION Hydraulic oil CAUTION Hydraulic oil must have anti wear qualities at least It is not advisable to mix oils of different brands or types as the may not contain the same required additives or be of comparable viscosities Name Thickened hydraulic oil Characteristics io 30 Viscosity index 2 7210 180 Flash point Cleveland open cup C 160 Denityat15 C 0 gm 965 Vickers vane pump test loss of mass on vanes after 100h mg 15 3 Diameter of wear spot 1200 r min 294N 30min 75 C The oil for gear box Name Extreme pressure lithium based grease 1 Characteristics unit Worked Penetration 0 1mm 310 340 Dropping point
9. new one The release valve is damaged The battery cannot be Battery is broken Replace with a new one The charging plug is loose Turn it firm charged 47
10. purpose of this service manual is to provide necessary information especially in inspections repair and maintenance WARNING The majority of this pallet truck consists of steel it can be completely recycled Waste material in conjunction with repairs maintenance cleaning or scrapping must be collected and disposed of in an environment friendly way and in accordance with the directives of respective countries Such work must be carried out in areas intended for this purpose Recyclable material should be taken care of specialized authorities Environmentally hazardous waste such as oil filters batteries and electronics will have a negative effect on the environment or health if handled incorrectly CAUTION All of the information reported herein is based on data available at the moment of printing Our products are constantly being developed and renewed we reserves the right to modify our own products at any moment without prior notice and incurring in any sanction So it is suggested to always verify possible updates 1 GENERAL 1 1 INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS Maintenance work may cause injuries Always take care to perform work safe at least observing the following It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves others or damage to the equipment A maintenance program must be followed to ensure that the mach
11. the mast with a block to keep the STEP 2 Strike out 4 elastic pin with hammer and loading roller hanging puncher remove the shaft and then you can remove the loading roller and replace it 36 7 POWER PUMP UNIT Type MD12160 Item SPN1030 Rated voltage 12V Rated output 1 6kw R P M 2950 rpm Rated current 200 A Rated hour 2 min Insulation class F class IP Code IP54 Displacement 2 0cc rec HYDRAULIC FLOW DIAGRAM Lowering valve Emergency valve Control valve Pump station INSPECTION OF HYDRAULIC OIL External appearance Smell Condition Measurement Clear and no discoloration Possible to use Inspect the viscosity and if fine Clear but the color become brighter Fine Mixed with other oil it be continuously used Color changed like milk Mixed with air and water Separate water or replace oil Color changed into dark brown Replace oil Clear but there re small black spots Mixed with other particles Use after filtering 37 7 1 REMOVE THE PUMP STATION STEP 1 Dismantle the connector of handle control cable and turn counter clockwise the joint of the hydraulic pipe with 22mm wrench to remove the pipe The oil will spill over when removing keep clean for the stacker and yourself F STEP 2 Remove 2 screws fixing the pump station at the back of the Electric box with 8mm Allen wrench and then you can remove the pump station
12. 9 uod 7 3 REMOVE THE CONTROL STICK mL E STEP 1 Remove 4 screws on cover plate of STEP 2 Turn counter clockwise the cap of control stick control stick 38 switch for lowering with 2 wrenches one is for holding STEP 7 Remove 2 screws fixing the Micro switch STEP 8 Dismantle the screw the seat of for lifting with screwdriver and then you can micro switch with 2 wrenches one is for holding remove and replace the micro switch 39 Now you can see the spring inside and replace it 7 3 REMOVE THE MAGNETIC VALVE FOR LOWERING The Magnetic valve is a wearing part If the forks automatically lower after lifting the magnetic valve may be blocked or damaged remove it to clear or replace After remove the cover you can see the valve STEP 1 Dismantle the cable of micro switch connecting with the handle New series STEP 2 Remove the cable of on the motor STEP 3 Turn counter clockwise the fixing screw with 14mm wrench STEP 4 Then you can remove the magnetic valve and replace it CAUTION The Plug Screw of port for adding oil is ventilating When lower the air will come out from the tank it might take out little oil vapor So it might appear little oil stains on the plug Wait a little and ensure that there is no oil leakage cow STEP 1 Dismantle the lid on the top of the tank pour out the ydraulic oil WARNING
13. Extreme pressure Timken OK Similar viscosity 10 C 1081 Corrosion preventive properties 52 92 48h Wire points oil 100 C 24h 510 16 3 HYDRAULIC SYSTEM 3 1 OPERATION OF CYLINDER STRUCTURE STEP 1 Remove the joint of the hydraulic pipe and replace the hydraulic pipe with 22mm wrench STEP 2 Cut off the band fixing the hydraulic pipe STEP 4 Remove the screws on the holding plate with 6mm Allen wrench then you can remove the whole cylinder 18 CAUTION For shocking the joint of the hydraulic pipe and hydraulic pipe might be loosed and leak oil so usually check and tighten it The oil will spill over when removing keep clean for the stacker and yourself Protective Grill 5 Protective e STEP 2 Remove 4 screws and washers on the lower Protective Grill with pneumatic gun 19 4 2 REMOVE THE CHAIN STEP 1 Strike out the shaft fixing the bottom of chain onto the mast Hold tight the punch and avoid striking by the hammer 7 E 12 ai zi 4 4 STEP 2 Take out the Split pin at the upper bottom of the chain STEP 3 Remove the screw fixing the whole chain with 22mm wrench and then you can remove the chain 20 5 ELECTRIC BOX 5 1 ELECTRIC DIAGRAM WIRING DIAGRAM Electric diagram SPN 10 SB U SB 5 52 7 0 9 P
14. KMp VD VD x 7 A hol o 2 p X82 X81 4 Be Ave pee Magnet valve for lowering 3 s Microswitch 4 Batteryindicator s 0092 sv Keyswitch wsom 1 s um Fu 1 VD1 VD2 WG 98V 2 Diodes 1 5408 VD3 5 M mw Pw Pe KW Reayfomoo Pump FU Fuse200A 39 oos S Powerswitch 1 Lx pose os anson Sm Relay for charger AR92 1Z DC12V pe xe Socket Meus pas pw xw Pug Mee 1 _ 21 CABLE SYSTE 7 m 5 2 TOOL FOR REPAIRING THE PIN OF ELECTRIC PLUG Application Tool for removal of pins sleeves Tool for application of pins sleeves Tool for release of lock Tool for application of secondary locking 2 pole Tool for application of secondary locking 4 pole Tool for removal of pins sleeves 23 5 3 REPLACE THE ELECTRIC PARTS i 2 p 75 22 Remove 6 screws on the cover with Philips screwdriver dismantle the Washer and then you can remove the cover REPLACE THE CHARGER SOCKET STEP 1 Hold the screw cap with 8mm wrench and remove 4 screws fixing the charger socket with Philips screwdriver STEP 2 Take it outside with your hand STEP 3 Remove 4
15. PLIT FLANGE BOLTS 9 The following torque shall be applied to the split flange bolts Diameter Flat width Torque mm mm N m 10 14 6 7 0 7 66 7 6 8 12 17 11 5 1 112 9 8 16 22 28 5 3 279 29 O ri THREAD l Thread Torque kgf m 1 8 1 4 0 1 1 4 2 6 0 2 3 8 4 6 0 3 1 2 8 5 0 4 3 4 19 1 0 1 33 2 0 TORQUE FOR SWIVEL NUT WITH O RING it O jring Tube O D inch Thread in Torque 1 2 UN 13 16 16 9 5 0 95 3 4 UN 1 3 16 12 18 1 8 1 UN 1 7 16 12 21 2 1 10 APPROXIMATE CONVERSIONS 51 Conv 5 5 Unit Factor Unit Factor Unit Torque Newton meter 8 9 In in X 0 113 Nm Newton meter N m 0 74 1 36 Nm Newton meter x 0 102 7 22 Pressure N m kiloPascal kPa x 4 0 in 0 249 kPa kiloPascal kPa 0 30 Hg 3 38 kPa kiloPascal kPa X 0 145 6 89 kPa bar 14 5 psi 0 069 kg cm 1422 psi 0 070 Newton mm X 145 04 psi 0 069 MegaPascal MPa 145 psi 0 00689 MPa Power r W J s kiloWatt kW 1 36 0 736 kW kiloWatt kW 1 34 HP 0 746 kW kiloWatt kW 0 948 Btu s X 1 055 kW Watt W x 0 74
16. ach terminal voltage of every single battery If some of the voltages are lower than their nominal voltages the internal polar plates suffers from short circuit please remove them and change new ones Please inform the service engineers 6 STEERING SYSTEM amp WHEEL KITS 6 1 CONTROL HANDLE STEP 1 Remove the Retaining ring with spring pliers on the Steering seat strike out the shaft of the air spring with a hammer and remove the Sleeve 33 STEP 2 Remove the other shaft on the top of air spring as before then you can remove the air spring Remove the straining ring and then Remove the shaft of the tiller arm on the Steering seat and then you can remove the handle 6 2 OPERATION OF THE WHEEL 6 2 1 OPERATION OF THE BIG WHEEL LEFT ily STEP 1 Support the mast with a block to keep STEP 2 Remove the screw on the cap with 6mm the big wheel hanging Allen wrench and then remove the cap bearing bolt 34 STEP 3 Remove screw of big wheel with 2 STEP 4 Strike out the shaft you can replace the wrenches wheel 6 2 2 OPERATION OF THE FOOTBREAK STEP 2 Remove the Retaining ring with spring STEP 3 Strike out the shaft and then you can pliers remove the foot plate 35 STEP 4 Remove the bolt you can see the spring and then you can remove the whole brake Allen wrench and then you can remove the cap bearing bolt and wheel as left wheel STEP 1 Support
17. d however some part of which is disconnected 2 The battery is aging becomes invalid and low voltage 3 The battery connected oppositely Failure of DC output fuser Long term heating poor contact or loosen by the output plugs 1 Low power voltage 2 Small section area of lead for power input 1 Failure of the preceding air switch 2 Incorrect matching of air switch 3 Small capacity of the air switch Internal short circuit of single battery of the group Failure of microcomputer or control power Connection of the battery should be corrected 1 Check each connection bolt and wiring 2 Check total voltage of battery and each single voltage of the battery In case of open circuit aging invalid low voltage of the battery please change a new one 3 Correct incorrect connection Open the side door to check the fuser If the fuser is broken please change a new one Check the copper plates if it is unavailable please change a new one 1 The power voltage may not lower than 9596 of the rated voltage If the voltage is too low please change a new power supply 2 The section area of input lead of power supply may not less than the stipulated section area in the manual Rated current of the preceding stage air switch is more than that of the air switch of the charger The air switch dynamic type illumination type is must be type D type C unavailable Check e
18. dity B The battery connection is reversed in pole Where the controller within the charger is in fault you are prohibited to open it without consent It must be repaired by the professionals or notified to the engineer of maintenance service INPUT TERMINAL DIAGRAM amp DEFINITION OUTPUT TERMINAL DIAGRAM amp DEFINITION 330 0 E2 0 UL1015 BLACK 168 UL1015 RED 16 1 07575 r E QQE Hh 31 IV Troubleshooting Failures Causes Troubleshooting The indicator light for power is on the indicator light for failure is on the blower is on the charger cant start and charge and the monitor is not display The indicator light for power is on the indicator light for failure is on the blower is on the start charge and the monitor is not charger cannot and display The indicator light for power is on the indicator light for failure is on the blower is on the start and chargers cannot charge and the display Instable charge current more or less Instable charge current not reaching the rated current value Air switch of the charger does not trip and the preceding stage switch trips Excessive overcharge for the battery The display signals of the display face rolling deadlock and clobber The battery 15 connected the output plug of the charger is inserted into the controller plug of the electric vehicle Although the charger and battery is connecte
19. er the fork to the min height and stop the motor Sulfuric acid in battery electrolyte is poisonous It is strong enough to burn skin and eat holes in clothing If you spill acid on your clothes or skin immediately flush with large quantities or water When working on the battery wear goggles or safety glasses If splashed into the eyes flush with water and get medical attention immediately Battery terminals touched by metal objects can cause short circuit and burn you Keep tools away from the terminals Keep sparks lighted matches and open flame away from the top of battery Battery hydrogen gas can explode When disassembling and assembling the battery make sure that the battery terminals are correctly connected If water gets into the electrical system abnormal operation or failure can result Do not use water or steam on sensors connectors and instruments in the cab Do not handle electrical equipment while wearing wet gloves or in wet places as this can cause electric shock When working with other choose a group leader and work according to his instructions Do not perform any maintenance beyond the agreed work Unless you have special instructions to the contrary maintenance should always be carried out with the motor stopped If maintenance is carried out with the motor running there must be two technicians present One operating the stacker and the other one performing the maintenance In suc
20. ging is automatically completed 1 Items for Attention The charger shall be installed in the place of well ventilation drying without heavy power corrosive gas and strong electric magnetic interference on heavy vibration The charger is only available for indoors not for vehicle No water should be in the changer Wer input is 1 phase AC50Hz 220V 5 or 60Hz 110V 5 while the case shall be solidly grounded as the case is connected with the grounding wire of input power supply line you may complete the solid grounding within the socket only The charger is suitable for use at the ambient temperature of 10 c 40 c Any person other than the professional installer shall not open the case without consent High voltage in Usage Firstly the charger shall be solidly connected to the battery without any reverse in pole Switch on power while the power indicator lamp is lighting and the monitor would indicate the current for charging automatically Where the charging is to be completed soon the current would be generally reduced Once the voltage peak value for charging reached 15 21 the indicator lamp of charging full is lighting on the charger would stop automatically and the charging is completed Where the battery indicator lamp is lighting on it generally means the following 2 conditions A The voltage of battery for charging is less than 5V meaning the battery is seriously damaged without any vali
21. h a case never touch any moving part Before making adjustment lubricating or performing any other maintenance shut off all power controls When removing parts containing O ring Gaskets or seal clean the mounting surface and replace with new sealing parts Thoroughly clean the machine In particular be careful to clean the grease fittings and the area around the dipsticks Be careful not to let any dirt or dust into the system Use only approved nonflammable cleaning solvents When changing the oil or fitter check the drained oil and filter for any signs of excessive metal particles or other foreign materials Always use NOBLELIFT genuine parts for replacement ENSURE REPLACEMENT PARTS OR COMPONENTS ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS When checking an open gear case there is a risk of dripping things in Before removing the covers to inspect such cases empty everything from your pockets Be particularly careful to remove wrenches and nuts 1 2 MEASUREMENT CONVERSIONS Length 1mmz0 1cm 1um 0 001mm Area m 6446 00085 0006943 0000711 1 100 1milez 259ha 2 59kmz Volume 0 000001 0 001 0 061024 0 000035 0 000001 1000000 1000 61024 35 315 1 30796 1 1000 0 001 1 61024 0 035315 0 001308 m m 16 387 0 000016 0 016388 1 0 000578 0 000021 28316 8 0 028317 28 317 1728 0 03704 3785 41 cms 231 1 0 832679 05 Weight ow os
22. ine is safe to operate The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual These precautions are for the most parts those that apply when servicing hydraulic and larger truck component parts WARNING MODIFICATION OF THE TRUCK WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE TRUCK IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLATION WARNING SINCE THE TRUCK MANUFACTURER HAS DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA RESPONSIBIUTY OF THE OWNER OR OPERATOR WARNING FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION When carrying out any operation or maintenance have trained and experienced personnel to carry out the work When carrying out any operation or maintenance carefully read operation and maintenance handbook Read all the precautions given on the decals which are fixed to the truck Be sure you fully understand the content of the operation It is important to prepare necessary tools and parts for maintain the truck Your safety and that of others is the first consideration when engaging in the maintenance of equipment Always be conscious of weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable positi
23. ld not be over 15 Volt when charging e Do not use the stacker when charging 46 9 TROUBLE SHOOTING Trouble Clause Fixing Methods The forks cannot be The hydraulic oil is Pour in the oil to the maximum height enough Fill in the oil Change the oil The urgent switch 15 Turn it clockwise switch on pressed down cut off the power power Charge it The voltage is too low Turn it firm The motor cannot run The connectors of electrical wire is loose Replace with a new one The contactor of DC motor is broken Without hydraulic oil The forks cannot be lifted The oil has impurities Motor is rotary The piston rod or mast is Replace with a new one deformed resulting from partial loading slanting to one side or over loading Keep the forks in the lowest The forks were kept in the position if not in use and pay The forks cannot be high position for long time more attention to lubricate the descended with piston rod bared 10 rod arise rusting Check it if damaged replace jamming of the rod with a new one The release valve of pump is not opened Sealing parts or Replace with new ones damaged Replace with new ones Some part cracked or worn into small impurities in the oil Change the oil causes the release valve to The forks descend be unable to close tight without the release Sealing parts or Replace with new ones valve worked damaged Replace with a
24. n remove the rotor of the motor and replace the part you want to 44 7 6 SEPARATION OF THE VALVE PLATE The oil will spill over when removing keep clean for the stacker and yourself 77 STEP 3 Remove the joint of hydraulic pipe loosen it with wrench and remove it with hand 45 8 MAINTENANCE CHECK LIST 8 1 OIL HYDRAULIC OIL Check oil mass once every six mouths Suggest using No 32 hydraulic oil GB11118 89 its kinematic viscosity is 32cSt when it is on 400 the total amount is about 4 0 liter 8 2 REGULAR MAINTENANCE In order to keep a good using status necessary check and maintenance everyday is suggested Focusing mainly on 1 wheels and mandrels such as wires and rags banded on the wheels and mandrels 2 whether the forks and the masts have deformation 3 whether the voltage of the battery is normal and so on After completing the work unload the loads on the forks and lower the forks to the lowest position 8 3 LUBRICATION Add grease or oil onto all moving parts frequently in order to lubricate 8 4 HOW TO CHARGE STORAGE BATTERY e Charge storage battery when its voltage is less than 10 Volt Please check the battery liquid before charging if it is not enough add some distilled water he charging environment should be ventilated and far away from the fire ef the stacker not use for long time charge it for not less than two hours every week The voltage the indicator shou
25. on When raising a portion of the equipment ensure that adequate support is provided Moving parts can e amp t ar crush hands i feel Bra or lags It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system Relieve system pressure by cycling the applicable control several times with the engine motor stopped and ignition on to direct any line pressure back into the reservoir Pressure feed lines to system components can then be disconnected with minimal fluid loss Remove all rings watches and jewelry when performing any maintenance Wear well fitting helmet safety shoes and working Clothes When drilling grinding or hammering always Wear protective goggles 3 Always do up safety clothes properly so that they do Not catch on protruding parts of machines Do not wear oily clothes When 3 checking always release battery plug DO NOT WEAR LONG HAIR UNRESTRAINED LOOSE FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT During maintenance do not allow any unauthorized person to stand near the machine Flames should never be used instead of lamps Never use a naked flame to check leaks or the level of oil or electrolyte Immediately remove any oil or grease on the floor of the operator s compa
26. rtment or on the handrail It is very dangerous if someone slips while on the machine Always use pure oil or grease and be sure to use clean containers Oil is a dangerous substance Never handle oil grease or oily e clothes in places where there is any fire or flame As d Buy preparation for use of fire extinguishers and other fire fighting equipment Keep the battery away from fire hazards The generated gases are explosive Store all the oils in a specified place Keep the flammable things away from the machine Do not smoke at the working place Battery should always be disconnected during replacement of electrical components 5 Always use the grades of grease and oil recommended by NOBLELIFT choose the viscosity specified for the ambient temperature Exhaust gas is dangerous provide ventilation when working in a closed space Avoid breathing dust that may be generated when handling components containing asbestos fibers Wear a gas mask if necessary When working on top of the machine be careful not to lose your balance and fall Hand a caution sign in the operator s compartment for example Do not start of Maintenance in progress This will prevent anyone from starting or moving the machine by mistake When welding on the machine or working on the electrical system ALWAYS turn the key switch OFF and remove the battery plug from the battery Park the machine on firm flat ground Low
27. screws fixing the cables with Philips screwdriver now you can remove the charger socket 24 REPLACE THE KEY SWITCH STEP 4 Remove 2 screws beside the button with STEP 5 Pull down the emergency button and 3mm Allen wrench remove 2 screws fixing the cable with 12mm wrench REPLACE THE BATTERY INDICATOR STEP 3 Remove 2 screws at the bottom of the indicator with Philips screwdriver and then you can remove the indicator Electric Diagram 2 connect to 5 connect to 26 REPLACE THE RELAY Dismantle two screws with Philips screwdriver dismantle the 4 cables connecting to the relay Then you can dismantle the relay and replace it REPLACE THE FUSE Open the cover of the fuse seat then you can dismantle the fuse and replace it It may be strenuous to open the cover avoid scratching your hands by the plastic edge Remove 2 screws with 14mm wrench and then you can remove and change the fuse OPERATION OF THE BATTERY The size of battery is according to English BS standard Specification Rate SPN1030 Rated voltage 12V 1 Capacity 5 hours 150Ah Overall size L W H mm 523 X 238 X 283 Battery indicator It indicates the voltage of battery When it shows the voltage is less than 10V please charge the battery soon 24A DURATION OF DISCHARGING CURVE ENVIRONMENTAL TEMPERATURE 25 C 15 0 14 0 140 2 n Lei TL m
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