Service & Maintenance Manual Power Sacker CG1646
Contents
1. n aaa 65 2 TROUBLE SHOOT eee eee ee 66 FOREWORD Proper operation maintenance troubleshooting and repairs are necessary to preserve the performance of the stacker 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 stacker 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 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 SAFET2. NOBLELIFT EQUIPMENT IE NER Service amp Maintenance Manual Power Sacker CG1646 V CG1646 01 00 Date 2011 2 10 5 FOREWORD 3 GENERAL c 4 1 1 INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS 4 12 MEASUREMENT CONVERSIONS 8 2 13 2 1 LOCATION OF CONMPONENTS 13 2 2 SPECIFICATION SHEETS Pope 16 221 Technical ull ll 16 2 2 2 Residual Capacity different lifting height 16 23 LUBRICATIOQN 16 ELECTRICSYSIEM E 18 3 1 ELECTRIC DIAGRANM eee ene 18 22 CADEESYSTEM u 20 20 DRIVE WHEEL 23 24 PUMP STATION nente eben 23 35 BATTERY 23 3 6 CHARQGER c 28 37 CURTIS CONTROLLER iris prostituta eere tero uper 33 3 8 BATTERY INDICATOR 6 meenen nnns 40 3 9 REPLACE THE ELECTRIC 42 3
3. 5 ams i e bp Lubrication C Check O Oil change MOOI gt Oil and grease specification Lubricant Specification Application area gt 15 lt 15 D HydreuicOi 40 Hydrauic O 30 Hydraulic system _ 17 3 ELECTRIC SYSTEM ELECTRIC DIAGRAM 3 1 Pra 13 PLY 12 Pil 2101 PT PS 24 PS P2 P1 A T 1 le Abd 5 1 de PUMP NOTA TRACTION MOTOR p es 114 1 18 CONNECTION DIAGRAM Brake DC24V Main relay C100 120 24 Diodes 1N5408 Fuse 10A 3 2CABLE SYSTEM CG1646 Controlling Circuit CTILLER Handle 01646 Driving Wheel 20 CG1646 Universal Electric Parts List Tiller Handle Canbus Handle 61646 21 Serial No Part No Description Quantity Note 30909100009 Connector Male 95199 00 1 30909100010 Connector Female 5342 01 C 5010404025 0 Socket Head ScrewM4x25 4 6 30906300004 Micro Switch RZ 45GW2 B3 3 f x 30906300023 Cover of Micro Switch 2 o 8 30902700001 Controlling Board CL 0 14 9 5010504020 Phillips Screw 4 20 2 30913300001 White Polar 8 10 2 503020023 Elastic Washer 8 4 cf C 5010408016C0 Socket Head Screw 16 4 0 5010605012 Phillips Screw M5 412 2 30906100001 Power Switch New Type 1 30913300003 CL Plastic Cable Clip A
4. The display signals of the Failure of microcomputer display face rolling deadlock control power and clobber 32 1 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 15 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 7 CURTIS CONTROLLER 6 4 0 25 3 Staus status Ce IRE TRO HN COHERE Gr 0 31 PS if Ed 221 9 31 7 r8 T rmarnemos in milimeters uha 33 CONNECTIONS Low Current Connections A 16 pin Molex low current connector in the controller provides the low current logic control connections 16 15 14 13112111 10 9 Pin 1 load sensor input optional Pin 2 Fault 1 output pump input Pin 3 Fault 2 output Pin 4 main contactor driver output Pin 5 throttle 3 wire pot high Pin 6 thro
5. 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 12 55 71 6 7 2 1 38 0 3 80 106 9 10 7 1 1 8 54 1 5 41 152 2 15 2 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 the bolts with nylon packings and nonferrous metal washers or the ones with specially designated torque and standard H Newton meter 1 N m 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 N m 10 14 6 7 0 7 66 7 6 8 12 17 11 5 1 112 9 8 16 22 28 5 279 29 10 TIGHTENING TORQUE FOR HYDRAULIC PLUGS WITH O RING PF THREAD Thread Torque kgf m 1 8 1 1 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 Connector O ring Swivel nut hose Tube O D inch Thread in Torque kgf m 1 2 UN 13 16 16 9 5 0 95 9 4 UN 1 3 16 12 18 1 8 1 UN 1 7 16 12 21 2 1 11 CONVERSIONS 51 Non Sl Conv 51 Factor Unit Factor Unit Torque newton meter N m 8 9 In in X 0 113
6. 2 5010406030 0 Socket Head Screw 6 30 4 30913300004 CLPlasticCableClipB 2 f o 501040601660 Socket Head Screw MOX18 4 f f 30906200003 Key Switch LKS 101A 1 ef rr 30905100028 Battery Indicator 803 1 C OP Phillips Serew420 2 _ 22 3 3 DRIVE WHEEL Type FR250 for TypeCG1646 Drive Motor Model MR250 Rate voltage DC 24V R P M 3000rpm Rate output 1 2kw Rate hour 60 min Rated current Rated Exciting current 8A Insulation class F class Electromagnetic Brake Model SECOR1020241405METAL Rate voltage DC 24V Rate Power 25W Output Torque 15N M Gear Box transmission ratio 1 32 3 4 PUMP STATION MS2 Q V1C F7 5 R1 PM7 MFP1F T08C FO for Type CG1646 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 5 BATTERY The size of battery is according to English BS standard opecification Rate CG1646 Rated voltage 24V Capacity 5 hours 280Ah Box size L W H mm 645X244X570 Cell size L W H mm 77X158x525 Initial charge When the battery is charged for the first time you should prepare the exclusive sulfuric acid and excluslve water of lead acids If no excusive water is present in local areas distilled w
7. 10 TOOL FOR REPAIRING THE PIN OF ELECTRIC PLUQG 47 3 HYDRAULIC SYSTEMN Nh 48 41 OPERATION OF PUMP STATION 22 22 1 49 42 REPLACE THE CYLINDER Mennen aaa 51 5 DRIVE WHEEL maii ___ _ 52 531 THE DRIVE WHEEL 52 5 2 REPLACE THE 52 53 REPLACE THE CARBON BRUSH KIT 2 22 56 24 REPLACE THE BRAKE n n 57 5 5 ADJUST THE CLEARANCE OF THE 57 6 Cen IUe MID B cem 59 6 1 OPERATION OF THE CONTROL HANDLE 2 22 22 61 6 2 OPERATION OF THE AIR SPRING AND MICRO SWITCH 62 A CASTER WHEEL ________________ 64 8 OPERATION OF THE INTERNAL 5 2 2 21 64 9 TROUBLE 5 65 9 1 MAINTENANCE LIST
8. Key Switch 7 3 Emergency Button 8 Caster Wheel 4 gt Battery Indicator CURTIS 803 9 Lift Cylinder 5 Pump Station 10 Load Roller CONTROL HANDLE Tiller 1 FWD BWD Turning Knob Control the speed of the stacker and moving direction forward or backward 2 Shifting Button for high speed and low speed Snail function takes light touch switch when touch the button once the speed becomes low Touch the button once again the speed recovers to high 3 Universal Reversing Button the emergency directional reverse button 4 RAISE Button 5 LOWER Button 6 Horn Button peed 13 2 2 SPECIFICATION SHEETS 2 2 1 Technical Features Toad centre distance 4 1 2 2 2 Residual Capacity at different lifting height Up to TOP mm ACTUAL CAPACITY Q kg 2500 160 1 100 3700 1000 600 4600 80 lt lt 50 DE _ Load centre distance C mm 600 1 700 1 CG1646 D 355mm TI 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 and Lubrication 6 5 4 and Lubricant Lubrication chart NO Service point Interval Running hours 500 h 1000 h 2000h 1 Wheel bearings 2 _ L fans L 4 Hydraulic system C
9. SHORTED 1 Controller failure 4 Sequencing delay too short 24 THROTTLE 1 input wire open When Throttle Wiper High FAULT 1 input returns to valid range 2 Throttle input wire shorted to or B 3 Defective throttle pot 37 1 sequence of KSl interlock and Wr Follow proper direction inputs sequence adjust throttle if 1 SR 2 Wrong SRO type selected necessary adjust 3 Interlock or direction switch circuit open programmable if necessary 4 throttle type selected MEM S S 22 EMR REV 1 reverse wire or check wire Re apple emergency reverse WIRING fault or cycle interlock 1 sequence of KSl interlock and Follow proper throttle inputs sequence adjust throttle if 2 3 HPD 2 Wrong HPD type selected necessary adjust 3 Misadjusted throttle pot programmable if necessary 4 Sequencing delay too short 24 THROTTLE 1 Defective throttle pot When Throttle Wiper Low FAULT2 2 Wrong throttle type selected input returns to valid range CONT COIL FLD 1 Main contactor coil shorted SHORT 2 Field winding shorted to or B MAIN CONT 1 Main contactor coil closed Check wiring and WELDED 2 Main contactor drive shorted contactor cycle KSI 1 Field winding connection open FIELD OPEN 2 Field winding open 1 Main contactor coil open Check wiring and cycle KSI 3 4 MISSING 2 Mai e Main c
10. a 40 sec delay time between S brake switch and main contactor drop out CONT DIAG CONTACTOR DIAGNOSTICS 1 On Off MAIN CONT INTR O contactor fault checks on the main contactor only A low side driver that can be programmed to drive a variety of E M brake options hourmeter pump or AUXILIARY DRIVER TYPE brush motor contactor This driver is short circuit 3 MAIN OPEN DLY 0 DELAY When ON enables the missing and welded 5 Types 0 5 protected Programmable time delay between throttle release AUXILIARY DRIVER TURN OFF DELAY On Off Defines whether the Emergency Reverse function is n ENABLE active or disabled to neutral no direction selected and Auxiliary Driver turn off EMERGENCY REVERSE EMR REV ENABLE EMERGENCY REVERSE CURRENT LIMIT EMR REV C L gt gt C gt gt 4 9 2 U gt m lt Maximum allowed armature current during braking 50A to Rated in emergency reverse 36 Dictates controller response after the emr rev switch has been activated When ON the controller EMERGENCY REVERSE EMR DIR INTR becomes active if either the throttle is returned to DIRECTION INTERLOCK neutral or the Interlock switch is When OFF the Interlock switch must cycled Enables disables EMR to operate for a specific EMR TIME LIMIT EMERGENCY TIME LIMIT 1 REVERSE EMR TIMEOUT 25 10 1 3 0 S Emergency reverse operates for the specifed time TIM
11. forks or load Never use the forks to lift people 1 2 MEASUREMENT CONVERSIONS Length m em m m 4 254 00254 0000026 008333 0 02777 0000015 1mm 0 1cm 1um 0 001mm Area m eas 000045 2777 00076 1 _ 1ha 100a 1milez 259ha 2 59kmz Volume 1gal US 3785 41 cms 231 ins 0 83267gal US Weight o 9 1 0001 0000 0002 1000000 1000 35273 2204 59 28 3495 0 02835 0 000028 0 0625 1 tonne metric 1 1023 ton US 0 9842 ton UK Pressure kgf cm bar kPa Ibf inz Ibf ft kgf cm 0 98067 980665 98 0665 14 2233 2048 16 1 01972 100000 14 5037 2088 6 0 00001 0 001 0 001 0 00015 0 02086 0 01020 0 14504 Ibf in 0 07032 0 0689 6894 76 6 89476 144 Ibf ft 0 00047 0 00047 47 88028 0 04788 0 00694 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 Bolt type M _ _ M 2 009 0880068 ____ 7 0548006 _ 4T 5T Classification Bolt type Bolt size Torque kgf m lbf ft Torque kgf m 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
12. 250402005 Outer Cover mu mu 349010096 Bearing 6002 2RS G250402016 Motor Rotor 250402018 Field Winding 5010408016 0 Socket Head Screw 10 9 M8x 250402019 Pole shoe 6250402020 Driving Motor Case G250402021 Electric Brush Fixing Board Electric Brush 10 x 20 x 26 35 526040003 M19 4 36 250402023 opring of Electric Brush 4 G250402024 Split Retaining Ring 24 4 sorososoraco 4 Cs somme 504060001 Split Retaining Ring 26 sums Ns _ 45 var expe ZA mere t seo o me 1 m emo 7 m 7 __ _ G250402036 Electromagnetic Coil Fa SK LT saena a ST 6250027 Sis 4 _ 8 6280402038 Pa 4 _ 9 6250402030 _ DiscikeSoew 1 E MENNE 61 504070000 Oxing4730X262 2434 1 _ 504060005 Split Washer 25 ENN NEL LL ewm Sm 3 _ er E 0 o DI cm m Remarks Those with can not be pro
13. 46 3 10 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 47 3 HYDRAULIC SYSTEM HYDRAULIC FLOW DIAGRAM Aydrauic Cylinder Contol 4 hed 2 Cylinder P EN 55 8 u To bar Emergency Valve Pump Slatian Cylinder T T 1 gt 114 310 3 2007 EN OTE V Punping Slaton Pipe wg INSPECTION OF HYDRAULIC OIL External appearance Smell Condition Countermeasure Clear and no discoloration Fine Fine Possible to use l l 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 Bad Replace oil Clear but there are small black l l Fine Mixed with other particles Use after filtering spots 48 4 1 OPERATION OF PUMP STATION REPLACE THE PUMP STATION A WARNING Put the fork of the ground and drain out the hydraulic oil CLEANING OIL TANK AND FILTER A WARNING Put the fork of the grou
14. AL MAST 8 1 DISMANTLE THE INTERNAL MAST RNING Step 1 Dismantle the hydraulic pipe to the pump station Step 2 Dismantle the connector of the Micro switch Z 15GW22 B which limiting the max height of the fork Step 3 use a crane or other tool to hoist the mast 64 9 TROUBLE DIAGNOSTICS 9 1 MAINTENANCE LIST Maintenance Time Interval Standard e 11 Chassis and 111211 pars ruck frame 2 1 Inspection of noise and leakage of driving system Inspection of oil level of driving system Replace lubrication BN Inspection of wearing and damage state Wheel part Inspection of bearings inside wheels and ensure fit with EH wheels Steering system 41 inspection of steering operation motion 5 1 Inspection of performance and adjust it Inspection of reset function of gas spring and any leakage or Braking system damage dudum 54 Inspection of brake connection and adjust it if necessary 6 1 Inspection of performance wearingandadjustit Lifting equipment Inspection by sight of any block of loading wheel Inspection of any wearing or damage of edge of forks and pallet 5 Inspection of performance Inspection of any leakage or damage of all joints CAKA 73 Inspection of any leakage or damage of hydraulic safety Hydraulic system reliability of attachment 74 Inspection of oil ca
15. D LOOSE FIT TING 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 compartment 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 clothes in places where there is any fire or flame As Pr 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 int 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 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 ba
16. EOUT VARIABLE BRAKE VARIABLE BRAKING Che mmm upon throttle position or is fixed Prevents vehicle operation in Modes 2 or 4 if the ANTI TIEDOWN ANTI TIEDOWN On Off Modes 2 or 4 are active when the brake is first released MODULEID MopuEiD s 045 CAN bus module identification address CAN bus transmit communication object This RX COB RX COB 1 0 128 defines the value of the identifier type for a PDO SYSTEM message for transmission CAN bus receive communication object This m defines the value of the identifier type for PDO SYSTEM message for reception Enables or disables a CAN bus communications RN watchdog Loss of PDO messages once started will generate ERROR frames NOTE for standard parameter 1 Ozoff TROUBLESHOOTING CHART A Status LED is built into the controller It is visible through a window in the label on top of the controller This Status LED displays fault codes when there is a problem with the controller or with the inputs to the controller During normal operation with no faults present the Status LED flashes steadily on and off If the controller detects a fault a 2 digit fault identification code is flashed continuously until the fault is corrected Programmer LED Possible Cause Fault Clearance Display NO KNOWN FAULTS CURRENT 1 Controller failure SHUNT FAULT Cycle KSI If problem HW FAIL SAFE 1 Controller failure persists replace controller M
17. ING 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 equalizing charge 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 the electric vehicle charge and the monitor is not display D Although the charger and 0 Check each connection bolt battery
18. Nm newton meter N m X 0 74 x 1 36 Nm newton meter N m x 0 102 x 7 22 Pressure N m kilopascal kPa x 4 0 in X 0 249 kPa kilopascal kPa X 0 30 Hg 3 38 kilopascal kPa X 0 145 psi X 6 89 kPa bar X 14 5 psi X 0 069 kg cm x 1422 psi 0 070 EM newton mm X 145 04 psi 0 069 bar megapascal MPa x 145 psi X 0 00689 MPa Power W J s kilowatt KW X 1 36 PS X 0 736 kW kilowatt KW X 1 34 HP X 0 746 kW kilowatt KW X 0 948 Btu s X 1 055 kW watt W X 0 74 ft lb s 1 36 W W J s Energy J kilojoule kJ X 0 948 Btu X 1 055 kJ joule 0 239 calorie 4 19 J J N m Velocity and Acceleration meter per sec m s x 3 28 ft s 0 305 mis meter per sec m s 3 28 ft s X 0 305 m s kilometer per hour km h X 0 62 mph X 1 61 km h Horse Power Torque 5252 R P M TQ Ib ft TQ Z R P M 5252 B H P Temperature 32 1 8 C Z 1 8 32 Flow Rate liter min dm min X 0 264 US gal minZ3 785 l min Note 5 Unit 12 4 2906201 CLG 9 86 096 069 08r 09 066 086 006 091 OCL 08 OV OV 009 OV 06 006 086 096 066 006 08 09 oc BOE 08 09 ie 06 Oct 7 sapaq 2 SPECIFICATION 2 1 LOCATION OF COMPONENTS 4 3 1 Control Handle 6 Drive Wheel 2 Start
19. RATE 4 ACCELERATION RATE 1 to 3 Defines rate at which vehicle decelerates to M1 DECEL 1 DECELERATION RATE zero speed in Mode 1 when the throttle is released to neutral Defines the rate at which the vehicle decelerates to M2 DECEL RATE M2 DECELERATION RATE 1 zero speed in Mode 1 when the throttle is released to neutral Defines the rate at which the vehicle decelerates to M3 DECEL RATE M3 DECELERATION RATE zero speed in Mode 1 when the throttle is released to neutral Defines the rate at which the vehicle decelerates to M4 DECEL RATE M4 DECELERATION RATE zero speed in Mode 1 when the throttle is released to neutral when direction change is made when a direction change is made when a direction change is made 2 5 5 5 5 5 5 5 5 1 1 1 1 M1 BRAKE RATE M1 BRAKING RATE 1103 M2 BRAKING RATE P 1103 BRAKING RATE 1103 4 1103 QUICK START M2 BRAKE RATE M3 BRAKE RATE THROTTLE DECEL THROTTLE DECEL 1 to 1 0 Time to reach full braking current limit in Mode 4 S S S M4 BRAKE RATE S MN when a direction change is made Defines throttle response to the rate of throttle QUICK START change Higher values will the vehicle response to fast throttle movements Sets the rate of regen current roll off as the vehicle 0 0 0 0 0 0 0 0 9 2 9 9 2 0 approaches zero speed This parameter controls the transition
20. Y 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 for the most parts those that apply when servicing hydraulic and larger machine component parts A WARNING MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLATION WARNING SINCE THE MACHINE MANUFACTURER HAS NO 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 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 y
21. ater 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 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 S s The concentration of electrolyte in standard temperature of 25 Sc 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 for 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 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 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 charge power supply should be higher than 1 5 times of the charged battery When all the work is properly done th
22. ce the truck is certificated to be reliable for Rt operator a About 100 hours after initial operation check if any loose nuts on wheels and tighten them if necessary M ES ES EN 6 12 a b About 100 hours after initial operation check if any leakage of hydraulic parts and tighten them if required 500 hours after initial operation 65 9 2 TROUBLE SHOOT Mat drive or bt Battery indicator 1 The Key xwilch S yy 7 Emergency button 9 is aff demasged plua i tet 2 INE Gamer capies are connected to the post heed of the gt 3 The plug of battery indicator loaze ar 3 The plug of changer is not tant connecledta thes xocket KS ar lt lt 1 The fuse ar 2 ar not 2 f care handle varng harness are in good 3 The plugs of the iring boerd in Replace or repair cantra hande are in good canarian abnormal 4 The Zccelerator of the corral handle i ar net control or controler Lise CURTIS 1311 PROGRAMMER la check and a1 raira Check H according ta LED CODE page 26 and 271 end clearing of Taul aX Check the STATUS LED of ihe cartradler mash connect to the CLIRTIS 1311 PROGRAMMER watch the programmer ix kor
23. e 55 2 and 2 4 for the coil af relay for motor of pump 4 Repair or replace 16 pin plug af controller lis OK or not FOR 5 Repair or replacement the relay 6 check micro ewitche SU fe OK Adjust or replace micro switche SU jor not 7 The pump motor normal or not repar or replace the pump motor 8 The hydraulic valve of the pump is JOK or not dirty pluqqed etc 3 The hydraulic oil i insufficient 9 hydraulic oil 8 Clean up the valve core 11 The lower magnet valve is damaged or the role 51 2 andz 2 is OK or nat Cannt lower others The lower magnetic valve is 1 check the Signal lines forward land backward 5 1 4 1 output NO Replace the Accelerator of the controll handle backward 24 9 1 autput 0 5 backward not forward 2 Check whether the voltage between 15 3 and 2 1 is 24V 1 Check the snail speed switch is or not 12 Check the Protect module and its plua are or not 13 The Accelerator of the control handle is or not ____ Can forward not Renair replace the cable in the handle Can lift but the drive speed is very slowly replace or repair it 67
24. e 25 A to Full Drive field current may begin increasing This parameter FLD MAP START MAP START lt gt e Current is used to adjust the vehicle s maximum full load speed Adjusts desired field current at 50 FIELD MAP 50 10 to 100 1 current Affects speed characteristic under different load conditions Adjusts the rate of current increase as a function of when throttle request is decreased or the if the KSI 2 Adjusts the braking strength applied to the motor Off O Brake 1 A vehicle is moving when zero throttle is requested 1 RESTRAINT RESTRAINT 10 LOAD COMP LOAD COMPENSATION 2 Brk Fwd motor loads at a fixed throttle request m 5 U gt lt Off 0 Brk 1 KSI Adjusts the controllers response to increasing only 3 Off 0 1 PD HIGH PEDAL DISABLE HPD 2 Off 0 Brk 1 KSI Disables controller if gt 25 throttle is applied before the KSI and or brake inputs Requires sequencing of KSI and Brake before Fwd STATIC RETURN TO OFF SRO and Rev KSI and Brake before only Fwd is only selected SRO 2 Brk amp Fwd Delay time before HPD and SRO faults are SEQUENCING DLY SEQUENCING DELAY 0 2 1003 S 2 registered after the brake input is disengaged MAIN CONTACTOR Turns on main contactor with interlock ON or with 1 On Off INTERLOCK KSI OFF MAIN CONTACTOR DROPOUT 4 Enables or disables
25. e cells can be charged according to parameters outlined in the list below of the battery Avoid reverse polarity for fear of reverse charging The voltage of the Charging current A Phase 1 0 5 15 Phase 2 0 25 15 Phase 3 0 715 Phase 4 0 35 15 Initial charges are conducted 2 phases in phase1 when terminal voltages of the cells rise to 2 44 the current should be converted into phase2 and 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 charging duration will be 70 hours If 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 24 Concentration of electrolyte Volumeratio of wate
26. e connections to the motor field winding 34 STANDARD PARAMETER Parameter APPLICATION Software PARAMETERS DESCRIPTION BATTERY VOLTAGE standard oarameter O O O O O O O O O O O O O O 101 101 fo 101 nia N a b o o o o o o m gt gt gt gt gt gt gt gt p E 9 5 5 5 2 o 2 123 20 120 120 120 Q TI rr rr rr rtr rtr rtr rr rr Q 2 36 3 48 4 Nominal Battery Voltage M1 DRIVE C L M1 DRIVE CURRENT LIMIT Maximum Mode 1 Drive current limit M2 DRIVE C L M2 DRIVE CURRENT LIMIT Maximum Mode 2 Drive current limit M3 DRIVE C L M3 DRIVE CURRENT LIMIT Maximum Mode 3 Drive current limit M4 DRIVE C L M4 DRIVE CURRENT LIMIT Maximum Mode 4 Drive current limit M1 BRAKING CURRENT LIMIT Maximum Mode 1 Braking current limit M2 BRAKING CURRENT LIMIT Maximum Mode 2 Braking current limit M3 BRAKING CURRENT LIMIT Maximum Mode 3 Braking current limit M4 BRAKING CURRENT LIMIT Maximum Mode 4 Braking current limit Time to reach full drive output from zero output in M1 ACCEL RATE 1 ACCELERATION RATE 1 to 3 Mode 1 Time to reach full drive output from zero output in M2 ACCEL RATE 2 ACCELERATION RATE 1 to 3 Mode 2 Time to reach full drive output from zero output in Mode 3 Time to reach full drive output from zero output in 4 ACCEL
27. e the three screw that fix the brake 57 Step 3 Un tight the corresponding three screws t Keep the same clearance as showing Step 4 Adjust the above mentioned screws anticlockwise adjust 2 3 circle is okay to reduce the spring strength 4 CAUTION Brake slide should not contain grease and nothing is blocked inside Connected with plug connection should connected firmly 58 6 CONTROL HANDLE 1 0 it 5 k 7 t E n uem 4 w ED Er pied 1 At n n Y P 1 71 i T 5010408012 0 Socket Head Screw 8 12 5010408020 Socket Head Screw M8x20 59 TILLER Control Handle Description Part No G28010002 Handle Body 528010003 Handle Cover G28010004 Speed Control Button G28010005 G28010006 G28010007 G28010008 G28010009 G28010010 G28010011 G28010012 G28010013 G28010014 G28010015 G28010016 G28010017 G28010018 Emergency Reversing Plate for Emergence Bushing for Accelerator Horn Button Lowering Button Lifting Button Spring for Button Spring Bearer Plate Micro Switch Button Micro Switch Support1 Micro Switch Support 2 Accelerator Micro Switch Belly Button Accelerator Support 6 1 OPERATION OF THE CONTROL HANDLE i I 18 cj E L E L ti ip dis iiu s
28. 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 30 When 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 power switch and disconnect the output cable plug of the charger and plug of battery and the charge is completed EQUALIZ
29. ery 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 8 for its battery state of charge measurements Connection 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 keyswitch 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 is 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 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 connectin
30. 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 2504 92 Ignition residue 25 WATER FOR LEAD ACID CELLS Index name me Y Manganese Mn content 0 00001 0 1 Ammonia NH content 0000 8 IN IN IN Solonetz meatal oxide CaO content 0 005 Resustivity 25 C 10x10 ELECTROLYTRE FOR LEAD ACID CELLS Index name Mg Sulphuric acid H2804 content Concentration 50 C g cm 1 1 1 3 Ignition residue content Manganese Mn content Chlorine Cl content Ammonia salt content N Copper Cu content Deoxidized potassium permanganate content Content calculated by KMnO 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 Ferrum Fe content Arsenic As content IN IN JA x even shorter If electrolyte or water are spattered into the unintentionally please discharge with exclusively equipped plastic pipes 26 DISCHARGE CURVE ohr d
31. g 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 a 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 electrically closer to battery than Pin 4 Pin 4 Relay Pin 4 also connects in series with the circuit to be switched at empty 40 HOUR METER CONTROL LINES amp IMPEDANCE SPECIFICATIONS Min Impedance Low Voltage max Hight Voltage min HOUR METER CONTROL LOGIC Pin 1 HRM Pin 6 opn tow DISCHARGE ADJUSTMENTS The followed table lists the voltages per cell under load that correspond to an empty indication on the gauge lockout point Volt Cell 168 1 73 178 1 82 184 486 1 89 191 1 93 at Empty 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 lt Open Circuit Reset If the gage is disconnected from the battery during recharge the gage retain the last indication It willadvance to full when reconnected only if t
32. harging m DF2440 40 limiting protection protection will not work battery protection permanent revers battery connection Charger LED indicator Remark Full Charging T OO C2 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 596 230V 5 50Hz 110V 5 50 2 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 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 In case of failure of microcomputer controller please inform the service engineer or maintenance staff Check height of
33. he battery voltage is above the OCR level For standard reset OCR 2 09 VPC VPC volts per cell TROUBLESHOOTING Possible Causes No display Terminals not connected or improper voltage Instrument voltage does not match battery voltage connected Stays at FULL to the wrong terminal Instrument voltage does not match battery voltage or battery Will not reset fully charged Resets w o charging battery Not connected directly to battery terminals connected to wrong terminal or instrument voltage does not EMPTY too soon match battery voltage or terminals not directly connected to battery 41 3 9 REPLACE THE ELECTRIC PARTS REPLACE THE BATTERY ai 2 otep 1 Take away the battery cover 1 T OH Step 2 Dismantle the plugs No 2 and 3 d otep 3 Use two lifting hook to hook the hole of the battery box m Teas E se Then you can use a crane to take away the battery SS 2 replace it Remove 6 pcs screws Then remove the right cover and left cover 42 REPLACE THE PUMP STATION Dismantle the cables Remove 4 screws Dismantle the pipe Then you can dismantle the pump station and replace it REPLACE THE BATTERY INDICATOR take away the U clamp dismaantle the 8 pins plug Then you can dismantle the battery indicator and replace it REPLACE THE FUSE Open the c ver of the fuse seat then yo
34. is connected however and wiring some part of which is The indicator light for power is disconnected on the indicator light for failure battery is aging becomes 2 Check total voltage of is on the blower is on the invalid and low voltage battery and each single voltage charger can not start and of the battery In case of open charge and the monitor is not circuit aging invalid low display voltage of the battery please change a new one 3The battery is connected S Correct the incorrect oppositely connection The indicator light for power is Failure of DC output fuser Open the side door to check the on the indicator light for failure fuser If the fuser is broken is on the blower is on the please change a new one charger can not start and charge and the display Instable charge current more Long term heating poor contact Check the copper plates if it is 31 less or loose by the output plugs unavailable please change a new one 1 Low power voltage Instable charge current not reaching the rated current value 2 Small section area of lead for power input D Failure of the preceding air switch 2 Incorrect matching of air Air switch of the charger does switch 8 Small capacity of the air switch not trip and the preceding stage switch trips Internal short circuit of single battery of the group Excessive overcharge for the battery
35. ischarge curve 0 2 3 4 time 0 5 disvharge curve 0 10 15 20 25 30 35 time min 3 06 CHARGER Type DF2440 for 24V 280Ah WIRING DIAGRAM FOR CHARGER Ti de mL AA 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 ENVIRONMENTAL CONDITION Humidity 595 8096 With package Altitude 2000 Work normally Fan convection cooling Working under full load 28 ELECTRICAL CHARACTERISTICS Input characteristics Technical specification Rated input voltage Input voltage range 209 231 220Vac AC input voltage 1 3 50 60 Hz frequency input current DF2440 8 When input is on voltage fan When input voltage is is no 1 5 Fan function output voltage for fan 24 Fastcharge voltage 288 do 24 Constantcurrent 0 2440 40 AP s Protection characteristics Protection characteristics 00000000000 32 V voltage protection When the transformer temperature is higher than Thermal protection 125 130 the charger automatically EE protect stop c
36. lance k N and fall i pat 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 jlush 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 o
37. nd and drain out the hydraulic oil 271 Remove out the pump station e Take away two screws No 21 Remove the suction filter No 16 amp 17 e Clearning of oil tank and filter Clean the Fix plate for valve No 5 etc Clean up with compressed air and inspect if the filter is stopped or damaged If the filter is stopped or damaged replace it e Remove dust or foreign material from the tank e Then assemble them TROUBLE DIAGNOSTICS Check if there is any place Bubble in hydraulic oil Mixed with air where air can enteted Tighten the loosened part again Replace the oil Discoloration Replace the oil 49 The Plug Screw of port for adding oil is ventilate When lower the air will come out from the tank it might take out little oil vapour So it might appear little oil stains on the plug ahter some 50 HYDRAULIC PIPE For shocking the joint of the hydraulic pipe and hydraulic pipe might be loosed and leak oil so usually check and tighten it 42 REPLACE THE CYLINDER Remove three plastic bolts Take away the Fix board Remove the joint Remove two screw then take then you can dismantle the cylinder and replace it 51 5 DRIVE WHEEL 5 1 THE DRIVE WHEEL Driving Wheel MR250FR 22 52 Serial Part No Description Quantity Note KA 5010406014 0 Socket Head Screw 8 8 M6 x 501990109 Seal 140 x 180 x 12 1 3 6
38. on from the controller For experimenting with settings the programmer can be left plugged in while the vehicle is driven 38 LCD Display seven lines alphanumeric Parameter Modification Key to increase and decrease values to move around through the programmer menus Bookmark Keys for jumping easily back and forth between fields 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 39 3 8 BATTERY INDICATOR Type CURTIS 803RB2448BCJ3010 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 batt
39. on r missing CONTACTOR 3 Wire to main contactor open 1 Battery voltage 16 8V LOW BATTERY 2 Corroded battery terminal When voltage rises above VOLTAGE undervoltage cutoff point 3 Loose battery or controller terminal Check contactor coil and field 3 1 3 3 winding cycle KSI 1 Battery voltage gt 33V When voltage falls below 4 2 OVERVOLTAGE 2 Vehicle operating with charge attached overvoltage cutoff point 1 Temperature gt 85 or 25 Clears when heatsink CUTBACK 3 Improper mounting of controller acceptable range 4 Working limit environment 1 Mode switches shorted to 4 4 ANTI TIEDOWN 2 Mode Select 1 tied down to select Release Mode Select 1 Mode 2 or Mode 4 permanently THERMAL s 2 Excessive load on vehicle temperature returns to within 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 a 7 line alphanumeric LCD display rockertype keys for navigating through the display and for modifying parameters and three keys that can be used as bookmarks The 1311 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 informati
40. ou 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 F Moving parts can cut ar crush hands i feel Bra or legs 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 cntrol 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 ringd 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 K 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 TE HAIR UNRESTRAINE
41. pacity 202001 capacity Inspection of oil capacity 2020 8 901 1 75 Replace hydreuie ol and tie 7 6 Inspection of adjustment function of pressure regulator __ g2 Inspection of safety and reliability of connection of all cables and if 84 Inspection of safety reliability and function of switches and unlocking cam equipment 85 Inspection of connector replace the worn part if necessary 56 Inspection function of alarm equipment Ee 81 of wearing state of carbon brush 9 3 Clean motor frame with vacuum cleaner inspection of wearing of commutor Inspection of density and capacity of acid voltage of battery Inspection of safety device of connection terminal applicability of Rt Battery Clean connector of battery inspection of compactness of fit Inspection of damage of battery cable replace it if necessary fel Paint grease to truck according to the time schedule of Lubrication 11 1 lubrication feeding Inspection of the fault in grounding of electrical system Integrated Inspection of driving speed and braking distance je measurement Inspection of lifting and lowering speed 1 1 Inspection of safety device and closing device fel Commissioning under load rating Demonstration After above maintenan
42. r to Capacity ratio of water to sulfuric acid sulfuric acid 1 100 9 80 1 5 84 1 e After charging close the vent plug and it only can be put into use after its surface is cleaned clear 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 recharged after discharged Undercharged cells of cells not used for along 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
43. smoothness from braking to drive mode TAPER RATE 4 lt gt cem e o 00 um amp 2 2 2 2 2 gt gt gt gt 3 IX A m rm im rm m o o o Ir FF 9 5 oS M1 MAX SPEED M1 MAX SPEED LIMIT 096 to 10096 M2 MAX SPEED M2 MAX SPEED LIMIT 100 0 to 100 M3 MAX SPEED M3 MAX SPEED LIMIT to 10096 M4 MAX SPEED M4 MAX SPEED LIMIT to 10096 Maximum Mode 4 speed SPEED CREEP SPEED LIMIT THROTTLE TYPE THROTTLE DEADBAND 1 DEADBAND THROTTLE MAX OUTPUT THROTTLE MAX POINT THROTTLE MAP THROTTLE MAP MINIMUM FIELD CURRENT LIMIT 0 to 40 7 Percentage of throttle movement which represents the neutral deadband n Percentage of throttle movement at which full Defines a minimum speed duty factor output from 0 to 25 the controller The controller output will jump to this speed when a direction has been selected 95 60 to 100 controller output duty cycle is attained 5 20 to 809 Adjusts desired PWM output at 50 throttle to vary o 10 0 0 throttle sensitivity at low speeds 5 FIELD MIN 4 1 6A to Max Field Minimum allowed current in the field winding Sets C L max vehicle speed Maximum allowed current in the field winding Min Field C L to MAXIMUM FIELD CURRENT LIMIT Limits power dissipation in low impedance field Rated windings Adjusts the minimum armature current at which th
44. t m E 1 1 ok or _ jan F BE Ti m E tt 1 z E4 E 1 1 A 11 1 gt 9 cores plug which connect to the controller Check the button on the connector contacts 61 BCCOPEETHIOE Remove the Screws and Butterfly left amp right and the Edge Shaft 6 2 OPERATION OF THE AIR SPRING AND MICRO SWITCH adi Remove the pin Take out Axis of the handle bar 62 Use a Phillps screwdriver to remove this screw then you take out the Fixed plate Remove this screw NO 4 and Global screw and replace it n WE i ndm m m Da Ft Er ras rens eM eta En 5 al y 2 5 X 2j LE ly Lu Jh n E Pun x z o ra er a Check Micro Switch WARNING ISpecially attend the Micro Switch it is a safety component 63 7 CASTER WHEEL j Step 1 Use a crane or other tool to hoist the stacker Step 2 Remove 4pcs screw Then you can dismantle the caster wheel and replace it WHEEL replace Remove the nut and bolt then you can dismantle it and replace it 8 OPERATION OF THE INTERN
45. t pr not feshi Check the signal si 1 of the cortraler z ar Ime i amp replace tash The controller Iz faut replace t The key Switch 57 check ft 1 Chack socket connector gi the cal pi the mein contactor CE Wien contector Is 2 The micre swieh and ts role 15 5 7 4 is OK ar ves hat drive litt brake ven is OK ar net 4 QE RESTER af coil of Ine brake ub wa 17 2 The rale 7 1 E lhe brake ET ig OH cr rapar noi 3 The clearance of brake ig OK ript 1 check Send ines forward end Ves wring of 7 core forthe handle T Yes Check the Accelerator 2 Check whether the votage between 15 3 Lig and 2 1 i2 Yes norma Accelerator boerd ix replace Check dere motor OF or nal VUA UNDIS iz or not 66 1 The last two lighting bars of jbattery indicator flash alternantly 2 Check whether the 5 of Dra 1 please properly charge the battery indicator input 24 voltage 4 If not 2457 replace battery indicator jand role No 4 role output 24 Cannot litt drwe 13 Check the fuse is OK or not a Replace the tuse FLI2 14 The rol
46. thers choose 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 stacker 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 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 Do not allow anyone to stand or walk under the elevated
47. ttle 0 5V pot wiper Pin 7 throttle pot low Pin 8 auxiliary driver output typically used for an electromagnetic brake Pin 9 Mode Select 2 input Pin 10 emerg reverse check output optional Pin 11 reverse input Pin 12 forward input Pin 13 emergency reverse input Pin 14 Select 1 input Pin 15 interlock input Pin 16 keyswitch input KSI The mating connector is a 16 pin Molex Mini Fit Jr connector p n 39 01 2165 using type 5556 terminals A 4 pin low power connector is provided for the Pin1 receive data 5V Be Pin2 ground B ga handheld programmer A complete 1311 programmer I kit including appropriate connecting cable can Pin3 transmit data 5V Pin4 15V supply 100mA ordered from Curtis The 4 pin connector can also be i u 43 used for Spyglass display The display is unplugged when the programmer is used High Current Connections Three tin plated solid copper bus bars are provided for high current connections to the battery and B and the motor armature M Cables are fastened to the bus bars by 8 bolts The 1243C case provides the capture nuts required for the M8 bolts The maximum bolt insertion depth below the surface of the bus bar is 1 3 cm 1 2 Bolt shafts exceeding this length may damage the controller The torque applied to the bolts should not exceed 16 3 N m 12 ft lbs Two 1 4 quick connect terminals 51 and 52 are provided for th
48. u can dismantle the fuse and replace it 43 Dismantle two screws Dismantle the cables Then you can dsimantle the main relay and replace it When replacing the controller be carefully tto check the tightnessof the nut specially note the cathode pillar Two 1 4 quick connect terminals 51 52 provided for the connections to motor field winding Do not allowed to access anti line otherwise the mortor will be reversed 44 REPLACE THE LOGIC BOARD FOR LIFING CL 1 When the fork s height is more than about 800mm 12 the max drive speed will automatically be reduced to 50 of normal speed This is the fuction of the Micro switch to change the speed mode Remove the screw and the plastic cover with a screwdriver remove the two cables on the micro switch Then you can dismantle the micro switch and replace it Remove the nut of the key switch Dismantle the cable of the key switc Then you can dismantle the key switch and replace it REPLACE THE EMERGENCY BUTTON Turn the mushroom head of the emergency button let the hole of the mandril be line with the groove of the sleeve 45 Use small screwdriver to insert the hole then turn counter clockwise the mushroom head to remove the mushroom head Take out the emergency button remove two bolts to remove the cable then you can dismantle the emergency button and replace it
49. vided alone 54 CAUTION The oil for gear box should be changed per 8 12 months 5 2 REPLACE THE DRIVE WHEEL Step 1 Dismantle the plastic cover Step 2 Dismantle the platform for standing on remove the screw and nut Step 3 Remoye 6pcs screws take out the cover plate Step 4 Remove 4pcs bolts dismantle the Box body The wheel appears 4 Cut off the power before operating Dismantle the plug for the baeke and Remove 10 pcs screws temperature senso 55 Use four scfews 8 8T or more better to 2 pcs guide pin holes screw in four technologic screw holes 10 pcs screw holes so that ejection the wheel 4 pcs technologic screw holes 5 3 REPLACE THE CARBON BRUSH KIT TES a Dismantle the steel shield which wrapped the motor the carbon brush appears Remove the screw which fixing the carbon brush tilt the pressure spring of the carbon brush with a screwdriver then take out the carbon brush 56 5 4 REPLACE THE BRAKE Remove 3 pcs screws dismantle the connector then you can dismantle the brake and replace it 5 5 ADJUST THE CLEARANCE OF THE BRAKE When the brake winding is connected with the power 24 it has the magnetic field to suck the brake plate to start the brake During the sudden circuit cut off or the climbing the slope brake stopped the motor to drive Step 1 Use multimeter 2009 to measure Winding resi Loos
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