Service & Maintenance Manual PS16W Electric Pallet Truck
Contents
1. nennen 46 4 3 REPLACING OF THE CONTACTOR OF 46 4 4 REPLACING OF THE LOWERING MAGNETIC VALVE 47 4 5 REPLACING OF THE PUMP 5 424 2 47 4 6 REPLACING OF THE CARBON 48 4 7 REPLACING OF THE STEERING ASSISTED PARTS AND SENSOR 49 4 8 REPLACING THE STEERING MOTOR 1 1 4 4424 50 4 9 REPLACIING OF THE 4 4 40 20202 51 DRIVE WHEEL ____ _ 51 5 1 REPLACING OF THE DRIVE WHEEL WITH POWER ASSISTED 51 5 2 REPLACING OF THE DRIVE WHEEL WITHOUT POWER ASSISTED STEERING 53 5 3 REPLACING OF THE BALANCE 4 0 54 5 4 REPLACE THE AC MOTOR SPEED SENSOR 55 5 5 REPLACE 55 5 6 REPLACING OF THE POSITION SENSOR OF2. 56 5 7 STEERING CONTROLLER eise qus auos me cierre Rao quta Duk or uUo a baa Mrd Edd rb 57 CONTROL 58 6 1 REPLACING THE CONTROL HANDLE 4 24 42 221 59 6 2 REPLACING OF THE INTERLOCK SWITCH 1 4 1 2 44 4 61 6 3 REPLACING OF THE AIR SPRING 4 4 124 424 61 6 4 INSTALLATION OF THE AIR 2 62 TROUBLE DIAGNOSTICS ___84______ _ ____ __ 63 7 1 REGULAR MAINTENANCE 63 7 2 ROUBLE SHOOTING ccena __________6 _6_6_ 4 __ 65 FOREWORD Proper operation maintenance troubleshooting and repairs are necessary to preserve the performance of the pallet truck over along period of time and ensure that fault and breakdowns do not occur The object of this service manual is to provide the information necessary especially in connection with the performance of inspections and repairs mainly in the maintenance areas 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 wo
3. NOBLELIFT EQUIPMENT Service amp Maintenance Manual PS16W Electric Pallet Truck V PS16W 01 00 Date 2013 11 28 CONTENTS GENERAL 3 1 1 INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS 3 1 2 MEASUREMENT 65 7 eer eee 11 2 1 LOCATION OF 5 11 2 2 SPECIFICATION SHEETS 12 2 SWUIIeo m 14 ELECIHICAL STSTEM aui dior gt NE 15 3 1 ELECTRICAL DIAGRAM ______4___ 15 32 DRIVE WHEEL e ee ee ee re 16 __6__ ____________ __ 16 SA BAITER _____________ 16 _________________ 20 3 6 CURTIS CONTROLLER 25 S4 BATTERY INDICA TOR ______________ ___ 36 3 8 REPLACING THE ELECTRICAL 2 24 4 38 3 9 TOOL FOR REPAIRING THE OF ELECTRICAL 44 HYDRAULIC SYSTEM tl 45 4 1 HYDRAULIC FLOW eres cece 45 4 2 INSPECTION OF HYDRAULIC OIL
4. Off On Dual Motor Enable ____ CAN Node ID 127 Other QOSMaSped 100 800 Steer Angle Max 45 ees 15 __ 0 30 __ Seconds _ _____ 0 1100 0 fF steer Potvin Vk _ 257 28 5 _ PF steer PotMax 2527 48 Vk _ vee stecrenatie _ d s 04 30 Second 8 9 steer Fatmi 0 585 55 vn Turn EN NENNEN 0 4 Off 10 Speed to RPM Capture Speed 1 Capture Speed 2 ________ BED Capture Capture Capture Emergenc Metric Units rom rom oO QIOloOoo0s5 Ojlololo 1 1 1320 a wa m CIEN 4500 _ 4500 _ 34 EMR Enable EMR Dir Interlock NENNEN EMR Time Limit EMR Speed NENNEN 1 Off On 30 Seconds EMR Speed EMR Decel Rate Interlock Braking Decel Rate HS Motor Characterization Test Enable Tests rom 120 Max Test Speed Max Test Current SlipGain 35
5. ot 30 Seconds 04 012 ao Brake Release Rate Neutral Braking Neutral _ 0 0 Brake Full Creep 25 100 Cancel Creep Release 5 Seconds Rate fo Brake Taper 200 6000 rom Speed Speed 0 1 30 Seconds Decel Restraint Restraint 1 ______ RestraintBack 0049 0 W0 _____ o 80 mm 2 CC 29 Eo o Eo o Eo o y 4 Eo o y o Eo o y Set K Settling Time Set Speed Threshold Entry Rate Exit Rollback Reduction Current i Drive Current Regen Current Limit Interlock Brake Current Limit Power Limiting PL Nominal Speed Delta Speed Drive Limiting Map Nominal ___ ______ 500 50 __ ____ _ 900 2421222 490 0 2 75 0 65 0 35 0 242 ReenlmtingMap o 1100 0 Eo oo y Plus Delta 100 0 Eo o o froo Plus 4xDelta 100 0 Eo o Plus amp xDeta 100 0 _ d 35 0 45 0 didi 5 EE 5 100 5 Throttle Type 1 Forward Offset Reverse Deadband 00 10 __
6. 400022 NENNEN ___ Forward EM AEN FewadMap ff __ NM Pp 9 22 RwesMe 48 10 _ Reverses o 9 o 0 H HPD SRO Type 1 Sequencing 5 Seconds Doe VCL Throttle Off On IP Immo Bae Pedal Off On BEN BmkType 1 Brake 5 Vk 8 _ P Brake Offset 19 BmkeFe 025 t 2 VCL Brake Off On me n Control 1 amp F 2 10 0 Holding Voltage 0 Battery Voltage Off On Emme KD __ Set EM Brake Off ge Set Speed 5 100 rom Threshold Release Delay Jo 1200 ms _ Set Speed 5000 ms Torque Preload 800 ms pa Torque Preload Off On o Im mm Torque Preload 120 Seconds ema __ m EM Brake Fault 1 20 RR Divers MainContactor 12 om fot fon 31 0219 HedmVoae Battery Voltage Off On Compensated mebkTp 00 0 2 Open Delay Jon 0 40 Weld Check Enable 00 jOf On Main DNC Check Off O
7. Chlorine Cl content 0 0005 Ammonia salt content 0 0003 IN IN Ammonia NH4 content 0008 8 Deoxidized potassium permanganate 0 content 0 0002 Solonetz meatal oxide CaO content 0 005 Resustivity 25 C Q cm 10x10 ELECTROLYTRE FOR LEAD ACID CELLS Index name Mg l Sulphuric acid H2804 content Concentration 50 C g cm Ignition residue content Manganese Mn content Ferrum Fe content 0 004 0 048 Arsenic As content 0 00003 0 00036 Chlorine Cl content WARNING Don t spatter electrolyte or water into the batteries otherwise the battery tank will be eroded and the battery will automatically discharge which will lead to low performance of battery and even shorter life If electrolyte or water are spattered into the unintentionally please discharge with the exclusively equipped plastic pipes N DISCHARGE CURVE ohr discharge curve voltage 0 1 2 3 4 5 6 time 19 0 5 disvharge curve 1 95 1 9 1 85 1 8 1 75 voltage 0 5 10 15 20 25 30 35 time 3 5 CHARGER Type DF2440 for 24V 280Ah WIRING DIAGRAM FOR CHARGER XE mite TSTS TEANSPORUER zu i med pos SE _ HIER COATH
8. No Partname _____________ Partname SSS 1 Bumng 231917400 8 Jars 2 Handle mounting bracket e 6 Emsicwaser8 58 No Patnam No Patmibe 2 Button torhom MagnethoMerforseesw _ Li Bowing canst Belly switch cover Spina rity poten sich 77 Socket hexagonal Screw MOXiD 22 Seesaw right or toggle button right 78 Socket hexagonal Screw M3K16 7 23 Tapping screw 5142206 _ 79 weers 24 00000 reser Upper part Lower part 6 1 REPLACING THE CONTROL HANDLE STEP 1 Remove 3 screws fixing the back cover of the handle with 5mm Allen wrench STEP 2 Unplug the connectors of the handle STEP 3 Remove 2 screws fixing the driving switch with 2 5mm Allen wrench STEP 4 Remove the driving switch axle 60 6 3 REPLACING OF THE AIR SPRING STEP 1 Knock the spring pin out with hammer STEP 2 Knock the handle axle out with hammer Take care of yourself in case the handle fall 61 6 4 INSTALLATION OF THE AIR SPRING STEP 3 Knock the handle axle into the hole with STEP 4 Knock the spring pin into the hole with hammer hammer When knocking the spring pin it must be directly at the hole of the handle axle 62 7 TROUBLE DIAGNOSTICS 7 1 REGULAR MAINTENANCE e Only qualified an
9. 279 29 APPROXIMATE CONVERSIONS 51 Conv Non Sl Conv 51 Unit Factor Unit Factor Unit Torque newton meter N m 8 9 In in 0 113 Nm newton meter X 0 74 X 1 36 Nm newton meter N m x 0 102 x 7 22 I b ft Pressure N m kilopascal kPa x 4 0 in X 0 249 kilopascal kPa 0 30 Hg 3 38 kPa kilopascal kPa X 0 145 6 89 kPa bar X 14 5 psi 0 069 kg cm 1422 psi X 0 070 EM newton mm X 145 04 psi 0 069 bar megapascal MPa x 145 X 0 00689 MPa Power W J s kilowatt kW 1 36 X 0 736 kW kilowatt kW 1 34 HP 0 746 kW kilowatt kW 0 948 Btu s 1 055 kW watt W x 0 74 X 1 36 W W J s Energy J kilojoule kJ 0 948 Btu X 1 055 kJ joule J 0 239 calorie 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 X 0 305 mis kilometer per hour km h 0 62 mph X 1 61 km h Horse Power Torque X 5252 R P M TQ lb ft Z 5252 B H P Temperature 32 1 8 F C Z 1 8 32 Flow Rate liter min dm min 0 264 US gal minZ3 785 Note Non SI Unit 10 4 6 0 CLC 9 86 095 069 08r 09 06 086
10. 006 09 08 OV OV 009 OV 06 00 086 096 OVC Occ 006 081 09 Or L oc BOE 08 09 ie 06 Oct 7 99 694 2 SPECIFICATIONS 2 1 LOCATION OF COMPONENTS HR Mat CONTROL HANDLE 1 Raise Lower buttons Hocker switches adjusting fork height 2 FWD BWD REV travel button Control variable speed by turning knob 3 Emergency Reverse button Emergency reverse button or commonly known as the belly button switch 4 Horn button 5 Indicator light Indicates high low speed status Green indicates high speed red indicates slow speed 6 Shift button Shift button for high speed and low speed 11 2 2 SPECIFICATION SHEETS Type sheet for industrial truck acc to VDI 2198 Distinguishing Ig We Performa nce data 5 LLI Tires Chassis mark jud lt 1 2 1 3 1 4 1 5 1 6 1 8 1 9 2 1 3 1 3 2 3 3 3 4 3 5 3 6 3 7 4 2 4 3 4 15 4 19 4 20 4 21 4 22 4 25 4 32 4 33 4 34 4 35 5 8 5 10 6 2 6 3 6 4 6 5 8 1 8 4 Manufacturer s type designation Power battery diesel petrol gas manual Operator type Load Capacity rated load Load centre distance Load distance centre of drive axle to fork Wheelbase Service weight Axle loading laden front rear Axle loading unladen front rear Tires Tire size front Tire size rear Additional wheels dimensions Wheels num
11. 150 Flash point Cleveland open cup Pour point Max Density at 15 C kg m 861 5 Copper corrosion 100 C 3h ion 590 lt 30 0 Vickers vane pump test loss of mass on vanes after 100h mg Diameter of wear spot 1200 r min 294N 30min 75 C punit __ The oil for gear box Name Extreme pressure lithium based grease 1 mm Characteristics unit Worked Penetration 0 1mm Dropping point 26 8 310 340 sti nt Wire points oil 100 C 24h ___ 10 Extreme pressure Timken OK 14 ELECTRICAL SYSTEM 3 3 1 ELECTRICAL DIAGRAM WIRING DIAGRAM SY B 1 1 FT 10A 5 FUt su B GB qp FU3 15 200A 25 E2 SH2 SH 5 1 1 23 J1 35 B YOON REMA RTH CAN 24 Belly N C CAN H GND 5 1 gi BK BU 5 8 lt LO vo gt LL 5 3 2 3 FU 02 200A 15 3 2 DRIVE WHEEL Type 26EL AC 1 3 KW Drive Motor Model HPQ1 3 4BT3 Rate voltage 16V AC R P M 3200rpm Rate output 1 3kw Rate hour 60min Rated current 76 2A Amperager rating max 110 7HZ Insulation class H Gear Box transm
12. The generated gases are explosive Store all the oils in a specified place Keep the flammable things away from the machine Do not smoke in the working site Battery should always be disconnected during replacement of electrical components Always use the grades of grease and oil recommended by NOBLELIFT choose the viscosity specified for the ambient temperature FPS EE 4 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 electical system ALWAYS turn the key switch OFF and remove the battery plug from the battery Park the machine on firm flat ground Lower the fork to the min height and stop the motor Sulfuric acid in battery electrolyte is poisonous Ist is strong enough to burn skin and eat holes in clothing If you spill acid on your clothes or skin immediately flush it with large quantities of water When working on the battery wear goggles or safety glasses If splashed into the eyes flush with water and get
13. the electric vehicle charge and the monitor is not display The indicator light for power is D Although the charger and D Check each connection bolt on the indicator light for failure battery is connected however and wiring is on the blower is on the some part of which is charger can not 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 charger can not start and 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 disconnected 2 The battery is aging becomes invalid and low voltage 3The battery is oppositely connected Failure of DC output fuser Long term heating poor contact or loose by the output plugs 1 Low power voltage 2 Small section area of lead for power input 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 24 2 Check total battery and each single voltage voltage of of the battery In case of open a
14. 1 0 0 1 D Lift PD Current Lift Pot Min 0 4095 0 4095 0 4095 0 4095 m Lower Pot Min Lower Pot Max 27 Pump to Lift 0 1 30 Seconds J em Delay PD closed 0 1 30 Seconds ae _ Lower 0 1 30 Seconds after lift Control 2 Mode Select 0 Speed Mode Express ______ MaxSpeed 3048 100 8000 rpm 0 jw o K _______ 18 5 100 AeeRae 18 01 30 Seconds BeelRae 15 01 30 Seconds BrkeRae 4141 01 30 Seconds PumpEnable sA 1 Speed me Cp mE Ke 7772 7770 b Kis o b Fits Rate 6 _ Seconds o Tk 0 fo 50 Rep FulBrkeRateHS 0130 Seconds FuBrakeRaelS 2 01 30 Seconds LewBekRae 7 15 0130 5 2122 Fine Tuning Partial Decel Seconds o fes P Hp pm High Speed 70 0 10 ____ Show Speed 30 0 110 pf Reversal Soften 20 0 10 24212 1 0413 Seconds Speed 0 1 30 Seconds BE Mode Smedimier o o Lp dmi 1 Keo o a0 5 ke 7 o 1100 2122 fry fe p
15. 22 2 Enable of on Interlock Brake Seconds Of n EN e T o pw CNNNoeIDD2 15 _____ uw 2 7 ou e Dy ID baare ape _______ PDO Timeout 200 ms Emergency 16 200 ms 1 Motor Control Test Enable 1 0 Field Weakening Control FWBase Speed Field Weakening Eo o y 4 y NENNEN Weakening Rate Min Field Current Motor Type Reset Controller 3 7 BATTERY INDICATOR Type CURTIS 803RB2448BCJ3010 CURTIS Front View Rear View TERMINAL ASSIGNMENT Pin 7 or 8 Battery Single voltage models Pin 8 to battery Pin 7 open Dual voltage models When vehicle voltage is the higher voltage of the 2 operating voltages Pin 8 connects to battery Pin 7 open When vehicle voltage is the lower of the 2 operating voltages Pin 7 connects to battery Pin 8 open The discharge indicator uses Pin 7 or 8 for its battery state of charge measurements Connection are to be made as close as possible to battery to prevent voltage drops that will cause errors in discharge indicator readings The connection is not to be switched by the vehicle s keyswitch Pin 5 Battery Connect to battery ground as close to battery as possible Pin 2 Keyswitch The ke
16. IS A SAFETY VIOLATION WARNING SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA RESPONSIBILITY 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 carry out the work When carrying out any operation or maintenance carefully read out Operation and Maintenance Manual Read all the precautions given on the decals which are fixed to the machine Be sure you fully understand the contents of the operation It is important to prepare necessary tools and parts and to keep the machine 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 position When raising a portion of the equipment ensure that adequate support is provided Moving parts can cC eut er enish hands i feel arma or 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 syste
17. 311 programmer is easy to use with self explanatory functions After plugging in the programmer wait a few seconds for it to boot up and gather information from the controller For experimenting with settings the programmer can be left plugged in while the vehicle is driven LCD Display seven lines alphanumeric Parameter Modification Key to move around through to increase and the programmer menus decrease values Bookmark Keys for jumping easily back and forth between fields 25 The bookmark keys allow you to quickly go back to up to three selected items without having to navigate back through the menu structure To set a bookmark press one of the bookmark keys for about three seconds until the Bookmark Set screen is displayed To jump to a set bookmark location quickly press the appropriate bookmark key 1 2 or 3 Note that the bookmarks are not permanently stored in the programmer They are cleared when the programmer is unplugged The bookmark keys can be used to make parameter adjustment easier For example in adjusting the throttle deadband you might set a bookmark at the Throttle readout Monitor gt THROTTLE and another at the Throttle Deadband parameter Program gt THROTTLE DB this way you can easily toggle between the readout and the parameter Connect the 1311 handheld programmer to the truck and switch on the power Program parameter shown as below __ LLLI Settings P
18. 5 Remove the fixed plate with 2 wrenches wrench and then unplug the wiring harness 52 STEP 6 Remove 8 screws fixing the wheel gear with 5mm Allen wrench and then you can remove the drive wheel mo s gt lax STEP 2 Unplug contactors fixing cables wiring harness STEP 3 Remove 4 screws fixing the drive wheel and axle with 8mm Allen wrench Then you can remove and replace it n gt nu 7 ww w i Md ig bo m 4 7 3 j LT aab y 4 d 4 53 5 3 REPLACING OF THE BALANCE WHEEL Vise the locknuts with 19mm wrench remove 4 screws fixing the flange welded part with 10mm Allen wrench 54 5 4 REPLACE THE AC MOTOR SPEED SENSOR lt SS J Patname ____ 1 6 Spring Carrier 3 Screw 8 Body magnetic Screw 5 45 9 Break anchor plate food 1 55 STEP 1 Remove 6 screws with 6mm Allen wrench and then you can remove the break ne STEP 1 remove 3 screws of position sensor with 4mm Allen wrench 56 Xb position sensor Pin 1 blue cable OV Pin 3 brown cable 5V Pin 4 green cable Signal voltage STEP 2 remove 4 screws fixing the cables to the controller with Philips screwdriver 57 STEP 3 remove 2 screws fixing the steering controller and then you can remove and check it
19. D control Off On a goes mmm Motor type 32767 High Speed ooo i w 5 mm W hs 0190 _ UeeRte 1 Seconds Speed limitation _ Mast High Max 5000 rom Do Turning Switch Max 5000 rom Arm close Standon 5000 rom Arm close Wakier 5000 rpm remm Arm open Wakier 5000 rpm Arm open Standon 5000 rom ee Speed 1600 mm _ me 26 decel rate Mast high Mode Mast low Mode Steer Angle Speed Reduction Steer Angle Max Deg Left Steer Angle Deadband Deg Left Seconds Seconds 6000 rom 180 C2 180 Steer Deadband Deg Right Steer Angle Max Deg Right Full Turn Speed Current set Max 0 7 0 Ampere Current Lower PD Min Ampere Lower follow lift PD Max Ampere Current Step1 Lower O 2 follow lift PD Min Ampere Current 0 2 follow lift PD Max Current Step2 Lower 0 2 follow lift PD Min Current Lift P Max 0 68 Current Min Ampere 0 0 N N N N NO t cm 0 0 0 1 0 0 1 0 1 0 1 0
20. EL BOARD ind me ballery Full Power 20 A 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 Battery Output current Type Input power Input voltage Output voltage capacity range ENVIRONMENTAL CONDITION 1 Humidity 5 80 With package 3 Fan convection cooling Working under full load _ ELECTRICAL CHARACTERISTICS Input characteristics 220Vac AC input voltage 1 3 50 60 Hz frequency Max input current DF2440 8 When input is on voltage for fan When input voltage is off there is no 1 5 Fan function output voltage for fan Output characteristics 21 voltage 288 S 22 Floating voltage 312 23 Maintain voltage 288 fd 24 Constantcurrent 2404 Protection characteristics No Technical requirements Output over 32 V voltage protection When the transformer temperature is higher than Thermal protection 125 130 the charger automatically protect stop charging 21 Output current b DF2440 40 A limiting protection Output short circuit If a short circuit load the charger will be protected and protection will not work Electronic reverse The charger 15 electronically protec
21. USE THIS TRUCK IF THE GUARDING IS DAMAGED OR NOT N CORRECTLY A SSEMBLED If the guarding needs to be removed unbolt the fixing screws and remove the screen carefully The screws will remain with the screen For reattaching place the screen to the right position and fix each screw correctly If you need to replace parts please call your next service partner Move the clips for the protective screen sideways and remove the screen Assembling is in the opposite direction Please make sure that the the screen is fixed correctly and that the fixing elements are not damaged 7 2 TROUBLE SHOOTING T e the truck has malfunctions follow the instructions TROUBLE CAUSE REPAIR Load Load weight too high Lift only the max capacity mentioned on ID plate Battery discharged Charge the battery Lifting stops at 1800mm Move the protective arms into the downside position Lifting stops at 1800mm Check the sensor for the protective arm Height sensor for 1800mm height defect Check the height sensor on the Lifting fuse faulty Check and eventually replace the lifting fuse Hydraulic oil level too low Check and eventually refill hydraulic oil Cil leakage Repair the hoses and or the sealing of the cylinder mast Cil leakage from air Excessive quantity of oil Reduce oil quantity breathing Battery is charging Charge the battery completely and then remove the main power plug form the electrical socket Battery
22. arging duration will be 70 hours e lf the concentration of the electrolyte is not 1 280 0 005 it should be adjusted The method is if the concentration is too high draw out some electrolyte and add some water or distilled water until the concentration equals to the prescribed value if the concentration is too low draw out some electrolyte and add some pre confected dilute sulfuric acid with a concentration of 1 400g cm until the concentration equals to the prescribed value When the concentration of electrolyte is adjusted it should be charged for 1 hour for consistency The density ratio of electrolyte is as follows Concentration of electrolyte Volumeratio of water to Capacity ratio of water to sulfuric acid sulfuric acid 1 100 9 80 1 5 84 1 After charging close vent plug and it only can be put into use after its surface is cleaned clear 17 Balanced charge When in use nonuniformity of voltage capacity electrolyte and concentration may occur Through balanced charge such nonuniformity can be eliminated and all cells in the battery can be of uniform conditions Balanced charge is essential monthly for the batteries in use or following situation Cells whose discharge voltages are usually below the final voltage 1 7V cell Cells with heavy discharge current in circumstances where the drive motor and lift motor operate synchronously with heavy load or in circumstance with steep slope Cells not timely r
23. ber front rear x driven wheels Tread front Tread rear Lowered mast height Free Lift height Lift Extended mast height Height of tiller in drive position min max Height lowered Overall length Length to face of forks Overall width Fork dimensions Distance between fork arms Ground clearance centre of wheelbase Aisle width for pallets 1000X1200 crossways Aisle width for pallets 800X1200 lengthways Turning radius Travel speed laden unladen Lift speed laden unladen Lowering speed laden unladen Max gradeability laden unladen Service brake Drive motor rating 52 60min Lift motor rating atS3 15 Battery to DIN 43 531 35 36 A B C no Battery voltage nominal capacity 5 Battery weight Energy consumption acc to VDI cycle Type of drive control sound level at driver s ear acc to 12053 SS PS 16W Bedesran ____ 1 6 Polyurethane PU 2252 x 88 Lo ___ Electromagnetic _____________ 4925 AC speed control _ _________ 2 3 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 they may not contain the same required additives or be of comparable viscosities Name Thickened hydraulic oil ISO Viscosity Grade WO 190 O Characteristics unt At 40 C 2 At 60 C me Viscosity index 2150
24. ce it STEP 1 Remove the screws fixing the cover of STEP 2 Remove the screws fixing the carbon the pump station with cross wrench brush with cross wrench 48 a If you want to install the carbon brush to the box you should vise the spring with nipper pliers 4 7 REPLACING OF THE STEERING ASSISTED PARTS AND SENSOR position sensor Pin 1 24V steering Power input Pin 2 blue cable OV Pin 5 brown cable 5V Pin 6 green cable Signal voltage STEP 2 Dismantle the connector of the position sensor at Xa on the controller and remove it 49 4 8 REPLACING THE STEERING MOTOR STEP 1 remove 4 screws fixing the steering motor with 5mm Allen wrench and remove it 4 F lt Fe 5 3 4 STEP 3 Remove the rubber screw fixing the carbon brush and then you can remove the carbon brush and replace it 4 9 REPLACIING OF THE CYLINDER STEP 1 Remove the hydraulic pipe joint with STEP 2 Remove oil return pipe joint with 12mm 19mm wrench wrench A Watch out for the hydraulic oil spilling check if the joint is dirty and clean it STEP 3 Remove 2 screws fixing the top of ti STEP 4 Remove 4 screws of the cylinder with cylinder and frame post with 10mm Allen wr 6mm Allen wrench and then you can remove it 5 DRIVE WHEEL ih Take care of yourself when lifting up the truck 51 Allen wrench STEP 4 Remove 4 screws with 5mm Allen STEP
25. ctrically closer to battery than Pin 4 Pin 4 Relay Pin 4 also connects in series with the circuit to be switched at empty HOUR METER CONTROL LINES amp IMPEDANCE SPECIFICATIONS l l Min Impedance Low Voltage max Hight Voltage min HOUR METER CONTROL LOGIC Pin 1 HRM Pin 6 HRM Hour Meter Status tiw um AMA dw Ow DISCHARGE ADJUSTMENTS The followed table lists the voltages per cell under load that correspond to an empty indication on the gauge lockout point 1 89 1 91 1 93 NOTE factory setting RESET TYPE LEVEL AFTER OR DURING RECHARGE CTR Charge Tracking Reset If the gage is connected to the battery during recharge the gage will track the battery charge level OCR Open Circuit Reset If the gage is disconnected from the battery during recharge the gage will retain the last indication It will advance to full when reconnected only if the battery voltage is above the OCR level For standard reset OCR 2 09 VPC VPC volts per cell 37 TROUBLESHOOTING Problem Possible Causes No display Terminals not connected or improper voltage Instrument voltage does not match battery voltage B connected Stays at FULL to the wrong terminal Instrument voltage does not match battery voltage or battery not Will not reset fully charged Resets w o charging battery Not connected directly to battery terminals B connected t
26. d trained personnel are allowed to do maintenance on this truck N e Before maintaining remove the load from the forks and lower the forks to the lowest position f you need to lift the truck follow chapter 4b by using designated lashing or jacking equipment Before working put safety devices for instance designated lift jacks wedges or wooden blocks under the truck to protect against accidental lowering movement or slipping e Please pay attention by maintain the tiller arm The gas pressure spring is pre loaded by compression carelessness can cause injury e Use approved and from your dealer released original spare parts Please consider that oil leakage of hydraulic fluid can cause failures and accidents e tis allowed to adjust the pressure valve only from trained service technicians If you need to change the wheels please follow the instructions above The castors must be round and they should have no abnormal abrasion Check the items emphasized maintenance checklist a maintenance checklist Interval Month 1 3 12 TO 2 Check the hydraulic joints and hose for damage andi akage 3 inspect the hydraulic oil tevel eflfnecessary 4 Refi the hydraulic 12 month or 1600 5 Check and adjust the function ofthe pressure valve 1500 0 10 ___ 6 Inspect the forks for deformation andas T Check the chassis fo
27. echarged after discharged Undercharged cells of cells not used for a long time METHODS OF BALANCED CHARGE Normally charge the cells when it is fully charged shut off the charge power supply keep it still for half an hour then switch on the power supply and continue to charge with the current of phase 2 When air bubbles come out convert to 1 2 of the current of phase 2 and continue to charge the cells when air bubbles are produced shut off the charge power supply keep is still for half an hour then switch on the power supply and continue to charge with 1 2 of the current of phase 2 until air bubbles are produced stop charging and left it still Repeat the procedure for several times until air bubbles are produced as soon as power supply is connected In balanced charge voltage of each cell as well as the electrolyte concentration should be measured and recorded Before the charge is completed the electrolyte concentration and height should be adjusted to the prescribed parameters SULFURIC ACID FOR CELLS Sulphuric acid H2S0 Ignition residue Manganese Ferrum Fe Arsenic As Chlorine Cl Nitrogenoxides calculatedby Ammonia salt NH4 Sulfur dioxide S05 Copper Deoxidized potassium permanganate 0 Transparency mm WATER FOR LEAD ACID CELLS Index name O Mg l Appearance Achromatic transparent Manganese content Ferrum Fe content 0 0004
28. en the snap and then you can remove the fuse 42 REPLACING OF THE CONTROLLER 13 5 CURTIS1232E wo 2 STEP 1 Carefully remove the connector of control STEP 2 remove 5 screws fixing the cables B cables with hands V with 5mm Allen wrench STEP 3 Remove 4 screws with 5mm Allen wrench and then you can remove the contactor and replace it STEP 4 Remove 2 screws with 6mm Allen wrench 43 3 9 TOOL FOR REPAIRING THE PIN OF ELECTRICAL 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 44 4 HYDRAULIC SYSTEM 4 1 HYDRAULIC FLOW DIAGRAM Hydraulic Cylinder mE E Control Valve 24V D C P 63 8 150bar lt Emergency Valve Qo ip T 63 8 3 2cclr CREM 3 0KwI24V lt gt Pumping Station INSPECTION OF HYDRAULIC OIL External appearance Smell Condition Countermeasure Clear and no discoloration Possible to use l l Inspect the viscosity and if fine Clear but the color becames bright Fine Mixed with other oil it can be continuously used Color changed like milk Mixed with air and water Separate water or replace oil Color changed into dark brown Repaceol Repaceol Clear but there are small blac
29. f failure of microcomputer controller please inform the service engineer or maintenance 22 Staff Check height of electrolyte in the battery in accordance with the manufacturer s instructions COMMON CHARGE Connect cable plug of the battery to corresponding output plug of the charger firmly Connect the battery firstly then connect it to the power supply and finally start it If the output plug is connected to the electric control terminal of the vehicle mistakenly the charger fails to work the indicator light for failure is on please correct it timely Connect the charger to power supply first then turn on the power air switch and the charger starts after the power is connected The indicator light for power supply is on and the charger is under self examination condition The display indicates current system version chargeable battery voltage current battery voltage maximum chargeable current and other data After the self examination process is completed the charger begins charging The display indicates voltage V charge current A charge time H shows Hour Minute and charged electric quantity AH e When the display indicates Charge completion and the indicator light is on the battery finishes charge The charger enters floating charge with current of 1 3 amperes Please check electrolyte height in the battery frequently and fill distilled water timely as required Disconnect the po
30. ging voltage of the battery please Circuit invalid low change a new one 3 Correct the connection incorrect Open the side door to check the fuser the fuser is broken please change a new one Check the copper plates if it is unavailable please change a new one D The power voltage may not lower than 95 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 must be type D type type type is dynamic illumination unavailable Check each 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 the service Please inform engineers 3 6 CURTIS CONTROLLER CURTIS 1311 HANDHELD PROGRAMMER The Curtis 1311 handheld programmer provides programming diagnostic and test capabilities for the controller The power for operating the programmer is supplied by the host controller via a 4 pin Molex connector The programmer includes 7 alphanumeric LCD display rockertype keys for navigating through the display and for modifying parameters and three keys that can be used as bookmarks The 1
31. ission ratio i 1 30 3 3 PUMP UNIT Type MR2 B V1B F4 5 PCMAV1Y TKOSC F2 Item opecification Rated voltage 24V Rated output 3 0kw R P M 3300 rpm Rated current 200 A Rated hour 4 0 min Insulation class F class IP Code IP43 Displacement 3 2cc rec Max operating pressure 200bar 3 4 BATTERY Specification Rate PS16W Rated voltage 24V Capacity 5 hours 280Ah Box size L W H mm 645X244X570 Cell size L W H mm 77 158 525 Initial charge When the battery is charged the first time you should prepare the exclusive sulfuric acid and exclusive water of lead acids no excusive water is present in local areas distilled water can be used Slowly pour sulphuric acid into a container containing exclusive water or distilled water and churn it up with an acid resistant stick Keep it still until the fluid temperature drops to 35 C then it can be poured into cells The concentration of confected electrolyte is 1 280 0 005 25 C The conversion forrnula of electrolyte is S25 S 0 0007 t 25 which 525 The concentration of electrolyte in standard temperature of 25 C 16 5 The actually measured concentration of electrolyte T Actually measured temperature When confecting electrolyte avoid pouring water into concentrated sulphuric acid for fear that sulphuric acid splashes and leads to physical injury In addition please wear protective appliance Wipe up the cells check the nuts be tight fo
32. k i Fine Mixed with other particles Use after filtering spots x dis Cylinder Fumo Cylindar Pipe 45 4 2 INSPECTION OF HYDRAULIC OIL External appearance Smell Condition Countermeasure Clear and no discoloration Fine Fine Possible to use l Inspect the viscosity and if fine Clear but the color becames brighte Fine Mixed with other oil it can 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 are small black _ l mE Fine Mixed with other particles Use after filtering spots 4 3 REPLACING OF THE CONTACTOR OF THE PUMP STEP 3 Remove 2 screws fixing the contactor with cross wrench you remove the contactor and replace it 46 4 4 REPLACING OF THE LOWERING MAGNETIC VALVE d STEP 1 Remove the nut of the lowering STEP 2 Remove the screws of the lowering magnetic valve with hand magnetic valve with cross wrench and then you can replace STEP 1 Remove the hydraulic pipe joint with 22mm wrench STEP 2 Remove the oil return pipe joint with STEP 3 Remove 2 screws of the oil tank 12mm wrench 4 fa Y 6 B it E B gt 24 4 4 e j A i 1 5 ion and then you remove it STEP 5 You can remove the filter screen to repla
33. m pressure by cycling the applicable control lowering button several times with the 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 jewelery when performing any maintenance Wear well fitting helmet safety shoes and working Clothes When drilling grinding or hammering always Wear protective goggles Always do up safety clothes properly so that they do Not catch on protruding parts of machines Do not wear oily clothes When checking always release battery plug DO NOT WEAR LONG HAIR UNRESTRAINED OR 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 buring flame to check leaks or the level of oil or electrolyte Immediately remove any oil or grease on the floor of the operator s compartment or on the handrail It is very dangerous if someone slips while on the machine Always use the recommended pure oil or grease and be sure to use clean containers Oil is a dangerous substance Never handle oil grease or oily clothes in places where there is any fire or flame As preparation for use of fire extinguishers and other fire fighting equipment Keep the battery away from fire hazards
34. medical attention immediately Battery terminals touched by metal objects can cause short circuit and burn you Keep tools away from the terminals 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 others 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 men present one operating the pallet truck and the other one performing the maintenance In such 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 Make sure 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 cleani
35. n o dee mm Main DNC Runtime 200 Volt __ PreamgeEnbe Proportional EN ERN PD Enable Off Off On HLowrEmbe PDMaCuem 0 2 Ampere PDMnCuet 0 2 ame o bw PDDirPebd 1612 m PK e PN d Deas ap p 0 ________ _ PuhVolgg 0 Holding Voltage ho A Driver 1 Checks Off On o de mmm Driver 2 Checks Off On EN MER Driver Checks Off On Driver 4 Checks Off On 200 PWMFegeny 19 99 He 4000 500 8000 rpm Speed 32 Direction Swap Two EmoderSteps _ Encoder Options Encoder Solution Fault Detection Enable Encoder Pulse Fault Detect Time Fault Stall Time LOS Upon Encoder Fault CD D m C 5 Temperature cor K SensorEmable 7 7 Sensor Offset TempsaueHo MotorTemp LOS EN qui Battery Undervoltage User FEN Reset Volts Per Cell 33 O lt lt Q Q Cell Empty Volts Per Cell Discharge Time BDI Reset _____ DulDive
36. ng 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 39 1 90 10996 0 00062 a _ 0 000025 0 08333 0 02777 0 000015 oss 0000804 12 1 058 000015 914 0 0000 36 1 0000568 1mmz0 1cm 1um 0 001mm Area Lm 11 een Pane fas 0 000001 1550 000 1 90 19 oor 1 fovea 0 1 oi 1400 x osea 1 1296007 i 456 00055 a A 0006943 1 1 100 1milez 259ha 2 59kmz Volume 1gal US 3785 41 cms 231 ins 0 83267gal US Weight ut g M j t oc b 2 2 5 0 001 0 000001 0 03527 0 0022 1000 0 001 35 273 2 20459 1000000 1000 35273 2204 59 28 3495 0 02835 0 000028 0 0625 1 tonne metric 1 1023 ton US 0 9842 ton UK Press
37. not connected Connect the battery correctly The fuse is faulty Check and eventually replace fuses Battery discharged Charge the battery Combined emergency switch is De activate the combined Stacker emergency switch by insert and pull operating the knob zone platform folded upright downside position one of the allowed positions arms and platform in one of the allowed positions arms and or platform direction damaged connections discharge indicator The stacker only disconnected or damaged connections travels very slowly Defective height sensor for reduced Check the sensor speed at 300mm height Electric system overheated Stop using and cool down the truck Defective heat sensor Check and if necessary replace the heat sensor The controller is damaged Replace the controller The stacker starts The accelerator not moves back to its Repair or replace the accelerator suddenly neutral position If the truck has malfunctions and can t be operated out of the working zone jack the truck up and go with a load handler under the truck and safe the truck securely Then move truck out of the aisle 66
38. o wrong terminal or instrument voltage does not EMPTY too soon 4 match battery voltage or terminals not directly connected to battery 3 8 REPLACING THE ELECTRICAL PARTS e 7 STEP 1 remove 4 screws from the control with 6mm Allen wrench STEP 1 Unplug the connectors of the indicator remove the screws then you can remove it STEP 2 Remove 4 screws of the panel with 5mm Allen wrench Instruction 1 Blank 2 8 positive pole input through the key switch 4 positive pole output 5 negative pole input 6 Positive pole input through the micro switch of control handle 7 positive pole input Blank STEP 1 Remove 2 cables signed B FU of the STEP 2 Unplug the connectors 1 1 1 of the emergency button with 14mm spanner emergency button with hand STEP 3 Unplug the connectors 1 1 5 of the STEP 4 Remove the panel key switch with hand STEP 7 Remove 2 screws fixing the emergency STEP 8 Remove the top cover of the emergency button with cross wrench button 40 5 description caue management no display One pin or the entire pin without voltage find out the cause denis If Opin wit One cause low voltage protection need be charged voltage second cause the indicator is broken replace the indictor no hour display Inner part of the indicator is broken 41 REPLACING OF THE CONTACTOR ET B Op
39. r deformation and cracks 8 Check mast and chain for corrosion deformation or damages replace if necessary 10 Check the gearbox for noise and leakage oo d 11 Check the wheels for deformation and damages replace if necessary J 12 Lubricate the steering bearing je 13 Inspect and lubricate the pivot points 14 Lubricate the grease nipples _ 15 Replace the guarding andlor protective screen ifitisdamaged _______ Electric system 16 Inspect the electric wiringfordamage __ 17 Check the electric connections and terminais __ 18 Test the Emergency switch function J e 19 Check the electric drive motor for noise and damages 0 012 20 Test the display _ _ Check if correct fuses are used if necessary replace 22 Test the audiowamingsignal Tl 23 2 63 24 Check the frame leakage insulation test 2 25 Check function and wear of the accelerator __ 26 Check the electrical system of the drivemotor Braking system Check brake performance if necessary replace the brake disc or adjust the air gap mE Battery 28 Check the batteyyvotage 29 Clean and grease the terminals and check for corrosion and damage 30 Check the vattery housing for damages charger _ _ el Check the start up pro
40. r reliable connection Pour configured electrolyte into grouped batteries with fluid level 15 20mm higher than protective slice Keep it still for 4 6 hours maximum duration no more than 12 hours Only when the cells temperature drops below 35 C can it be connercted to DC and charge If cell s temperature exceeds 35 it should be taken to cool it down Check the cells in the battery for reverse polarity with DC voltmeter to assure proper polarity Connect the anode of the power supply to of the battery the cathode of the power supply to of the battery Avoid reverse polarity for fear of reverse charging The voltage of the charge power supply should be higher than 1 5 times of the charged battery When all the work is properly done the cells can be charged according to parameters outlined in the list below Charging current A Phase 1 0 5 Phase 2 0 25 15 Phase 3 0 715 Phase 4 0 35 15 19 Initial charges are conducted in 2 phases in phase1 when terminal voltages of the cells rise to 2 4V the current should be converted into phase2 continue to charge until air bubbles come out from the electrolyte keep cell voltage under constant current steady for 3 hours When the concentration of confected electrolyte reaches 1 280 0 005 it should remain unchanged within hours At this moment the total quantity of electric charge should be 4 5 times the rated capacity and the ch
41. rk must be carried out in areas intended for this purpose Recyclable material should be taken care of by 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 Careless performing of the easy work may cause injuries Take care to always perform work safely 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 or others or damage to the equipment A maintenance program must be followed to ensure that the machine is safe to operate The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual These precautions are those that apply when servicing hydraulic and larger machine component parts AWARNING MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED
42. tection during charging Function Test the audio warning signal 34 Check the air gap of the electromagnetic brake 35 Test the emergency braking EN EN EN Test the reverse and Sid Test the safety belly button function ET ES EZ 42 Test the speed limitation switch lifting height gt 300mm 3 31 32 33 34 35 36 3r 3 4 41 42 General Check ifthe protective screen and oF guarding isnot damaged 45 inspect the castor adjust the height or replace it fwom out 46 Canyoutatestun b Lubricating points Lubricate the marked points according to the maintenance checklist The required grease specification is DIN 51825 standard grease gt Bearings wheels Main frame post Chain Hydraulic system Steering bearing Gear box Check and refill hydraulic oil The required hydraulic fluid type is 64 H LP 46 DIN 51524 e Viscosity is 41 4 47 e Depending on the type the amount Is 8L Waste material like oil used batteries or other must be probably disposed and recycled according to the national regulations and if necessary brought to a recycling company The oil level height shall be in the not lifted position min 7 9L to 8 1L If necessary add oil at the filling point d Checking electrical fuses Remove the main cover e Removing reattaching guarding DO NOT
43. ted against battery protection permanent revers battery connection Charger LED indicator Power LED Yellow Power off Power LED OFF a rcge Ful LED ON EB 4 Floating Charge Full LED ON RED 5 Full Charging LEDON GREEN 000000000 eatery tpm TOO O DF2440 charger Equalizing charge Power switch BEFORE CHARGING The charger shall be installed in a special ventilated dry no dust no corrosive gas no interference from high electromagnetic field place The shell of the charger should be earthed the ground bolts are equipped at the lower part of the case The charger is only available for indoors off board charger No water should be in the charger The input power supply is 1 phases 220V 5 230V 5 50Hz 110 590 50Hz The lead section shall be no less than 4 while the capacity of mains switch shall be no less than 30A You are recommended to use the dynamic mains switch Appropriate cables may be employed according to the distance between power supply and the charger which makes the voltage drop no more than 5 Applicable environmental temperature for the charger is from 10 to 40 C and the height less than 1000 meters During use the stumbling block that affects heat radiation of the charger shall be 0 6 meter away from it Please check the blower is running normally or not regularly case o
44. ure kgf cm bar kPa Ibf inz kgf cm 0 98067 98066 5 98 0665 14 2233 2048 16 bar 1 01972 100000 14 5037 2088 6 kgf cm2 735 56 Torr mmHg 0 96784atm Standard torque The following charts give the standard torque specification of bolts and nuts Exceptions are given in the sections of Disassembly and Assembly METER TABLE Classification Bolt type Bolt size Torque kgf Ibf ft 042004 5 INCH TABLE 4T 5T Classification Bolt type Bolt size Torque kgf m Ibf ft Torque kof 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 5 718 25 5 2 55 71 6 7 2 1 38 0 3 80 106 9 10 7 1 1 8 54 1 5 44 152 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 specifications in above table shall not be applied to the bolts with nylon packings and nonferrous metal washers or the ones with specifically designated torque and standard H Newton meter 1 0 1kgf m TIGHTENING TORQUE OF SPLIT FLANGE BOLTS The following torque shall be applied to the split flange bolts Diameter Flat width Torque mm mm kgf m N m 10 14 6 7 0 7 66 7 6 8 12 17 11 5 1 112 9 8 16 22 28 5
45. wer switch and disconnect the output cable plug of the charger and plug of battery and the charge is completed EQUALIZING CHARGE When the battery group has been used for some time the performance parameters of the batteries may vary differently so equilibrium constant current charge is required If equalizing charge is required press the key for Balance charge turn on the power switch then the indicator light for Balance is on The charger enters into equalizing charge status the current value reduces from the rated value to a constant current value during charge meanwhile the display indicates When the equalizing charge is completed manual turning off is required note the output current of the charger under is constant without stop manual turning off is necessary Press the key for Balance charge after turning off the charger to make it return to normal charge WARNING The equalizing charge is a manual operation Appointed personnel are required to observe and check voltage and specific gravity of the batteries and determine charge time manual power off and charge stop as required TROUBLESHOOTING The indicator light for power is The battery is not connected or Connection of the battery should on the indicator light for failure the output plug of the charger is be corrected is on the blower is on the inserted into the controller plug of charger can not start and
46. yswitch turns on and off the LED display of the battery discharge indicator Monitoring of the battery continues when Pin 2 is turned off and the display is not lit The hour meter display is unaffected by Pin 2 although it cannot accumulate more time as long as the keyswitch pin is not energized The control inputs HRM and HRM are enabled by the keyswitch Pin 2 15 connected to the vehicle s keyswitch Pins 1 amp 6 Hour Meter Control In normal operation Pin 1 or 6 is connected and the other is left open Only one of these pins is connected when using normal hour meter function It is possible to or the hour meter between the two inputs so that it accumulates the total time either system is on Hour meter 36 control logic is detailed in Table 2 Pin 6 Hour Meter HRM for use with a switched positive voltage Pin 6 connects to a high voltage as defined in Table 1 to activate the hour meter Leaving Pin 6 open or connecting it to a low voltage gives control of the hour meter to the Hour Meter input See Table 2 Pin 1 Hour Meter HRM for use with a switched ground Pin 1 connects to low voltage level as defined in Table 1 to activate the hour meter Leaving Pin 1 openor connecting it to high voltage gives control of the hour meter to the Hour Meter input Pin 3 Relay Pin 3 connects in series with the lift coil circuit or the circuit to be switched at empty For holding relay J Pin 3 must be ele
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