User manual
Contents
1. Check all connections for and damages Ft b 7 3 Check the cylinder for leakage and damages and if Hydraulic the accessories are safe and secure system 74 Chekteollve o rfe Replace hydraulic oil and the filter element A 76 Checkthepressueregulatrvave e Je 8 2 Check all cable connections for safety reliability and damages Check if the amperage of fuses is proper Electric RER 8 4 Check ifthe switches and release cam mechanism is system secure and functions properly 8 5 Check the connectors and replace worn parts if necessary MH 3 9 1 Check the carbon brush for wear Moisi 93 Use a vacuum to clean motor frame Check the commutator for wear 10 1 Check the density of acid liquid capacity and voltage of the accumulator Accumulator Check the safety devices on terminals and the grease 10 3 Clean the connector of accumulator and check the connection 104 Check the cable for damages replace if necessary 11 1 Grease the stacker according to time table for filling e up lubricant 12 1 Check the grounding connection of electric system e 12 2 Check the travelling speed and braking distance General Test 12 3 Check the lifting and lowering speed 12 4 Check the safety device and switch off devices2. Trial 13 1 Perform trial run under rated load o bc rcc REESE personnel after completion of above maintenance a After about initial 100 working hours check the nuts of wheels tighten them if necessary b After about initial 100 working hours check the hydraulic system connections for leakage and tighten it if necessary c After initial 500 working hours 6 4 Service Manual Lubricant oil 6 4 1 Troubleshooting 25 Fault Cause Repair measures The stacker can not move Loads can not be lifted up Loads can not be lowered down It can not stop when lifting up Moving in one direction The travels slowly stacker very The stacker starts up suddenly Connectors on accumulator are not connected Electric lock is in position 0 Emergency stop switch is not turned on The accumulator capacity is in used up he control lever is not in drive rage F fuse blown The stacker is not operating Low hydraulic oil level fuse blown he accumulator has only 20 30 of capacity The UP switch is in bad contact or damaged Dirty oil blocks control valve The solenoid valve for lowering is not opened or is damaged The UP switch is damaged The sensitive switch and the connecting cable are not well contacted The accumulator capacity is insufficient Or the electromagnetic brake is tight Or the related cables are not well contacted T
3. long time before recharging for a long time before recharging Please disconnect the wires linked to batteries if the stacker will not be used 1 23 Signalling Warning signals can be sent by the horn on the stacker 1 24 Protection shoes According to EU standard EN 345 1 S1 standard protective shoes must be worn when operating on the stacker 1 25 Truck modification Unauthorized truck modification is not permitted No modifications or alterations to a powered industrial truck which may affect for example capacity stability or safety requirements of the truck shall be made without the prior written approval of the original truck manufacturer its authorized representative or a successor thereof When the manufacturer or its successor approve a modification or alteration they shall also make and approve appropriate changes to capacity plate decals tags and operation and maintenance handbooks Only in the event that the truck manufacturer is no longer in business and there is no successor in the interest to the business the user may arrange for a modification or alteration to a powered industrial truck provided however that the user shall a arrange for the modification or alteration to be designed tested and implemented by an engineer s expert in industrial trucks and their safety b maintain a permanent record of the design test s and implementation of the modification or alteration c approve and make appropriate
4. responsible for managing the stacker in use and must prevent any unauthorized person from driving or operating the stacker It s prohibited to transfer and raise the person by the stacker 1 4 Malfunction and Defects In case malfunction or defects occurs with the stacker the driver should immediately inform the supervisor If the stacker can not be operated safely e g with worn wheels and brake malfunction always stop using it until repaired completely 1 5 Safety operation and environment protection The checking and maintenance work described in this chapter should be executed according to the time intervals in the maintenance list SIOP Never modify any parts especially safety devices of the stacker without permission Never change the operation speeds of the stacker All original spare parts from the factory are verified by Quality Assurance Department Only use spare parts from the manufacturer for the guarantee of the safety and reliability of stacker operation The replaced material such as oil or fuel should be disposed of according to environment protection regulations 1 6 Dangerous area Dangerous area generally refers to these locations in which pallet stacker or its lifting mechanism e g fork or accessories is moving lifting or lowering thus being dangerous to persons in this area or in which the stacker is handling loads Generally the scope of this area extends to locations to which the loads or accessories on
5. the stacker is lowered OF Unauthorized persons must be ordered to leave dangerous areas The driver Y should always give warning if there is any risk of human injury If the warned persons still stay in dangerous area the driver should stop the pallet stacker immediately SIOP Use of this stacker may cause crushing and shearing injuries to personnel 1 7 High risk environment Special protection measures shall be adopted in highly dangerous working environments A The stacker is not designed for use in high risk environment 1 8 Safety devices and warning signs Sufficient attention should be paid to safety devices warning signs and precautions described in above sections in this manual 1 9 Driving in public places The stacker is prohibited to drive in public places except for special areas 1 10 Space between vehicles Remember to keep a proper distance from the vehicle ahead since it may stop suddenly at any moment 1 11 Passengers Never carry or lift persons with this stacker 1 12 Headroom Never use the stacker in areas where the headroom is lower than the height of loads or mast 1 13 Operation in a lift or loading platform If the load capacity of the lift or platform is sufficient and the space is enough for stacker operation they can be used for transportation with the permission from the stacker user The stacker must be confirmed by its driver himself before entering the lift or loading platform W
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7. CY SMS 001 EN 2 A CN TE Ta Er Rr Ne Instruction Manual CY13 AN Operators should read and understand this manual and all warning Labels on power stacker before using the stacker Keep the manual for future reference Release July 2010 EG Konformit tserkl rung EC Declaration of Conformity Hiermit erkl ren wir NOBLELIFT EQUIPMENT Jingyi Road Changxing Zhejiang China We herewith declare Da die nachfolgend bezeichnete Maschine aufgrund ihrer Konzipierung und Bauart sowie in der von uns in Verkehr gebrachten Ausf hrung den einschl gigen grundlegenden Sicherheits und Gesundheitsanforderungen der EG Richtlinien entspricht that the following machine complies with the appropriate basic safety and health requirements of the EC Directive based on its design and type as brought into circulation by US Bei einer nicht mit uns abgestimmten nderung der Maschine verliert diese Erkl rung ihre G ltigkeit In case of alteration of the machine not agreed upon by us this declaration will lose its validity Bezeichnung der Maschine Elektrohubwagen Machine Description Power Stacker Maschinentyp Machine Type CY1316 CY1318 CY1330 CY 1337 1345 Einschl gige EG Richtlinien EG Maschinenrichtlinie 2006 42 Applicable EC Directives EC Machinery Directive 2006 42 EC Angewandte harmonisierte Normen insbesondere Applicable H
8. and instructions before use Most parts of the product are made from recyclable steel The recycling and disposal of cast offs resulted during using maintenance cleaning and disassembling the product has to comply with local regulations without pollution to the environment The recycling and disposal of the cast offs should only be operated by specialised personnel in the designated area The cast offs such as hydraulic oil batteries and electronic units if improperly disposed may be hazardous to the environment and human health changes in product designs and specifications without prior notice For the latest product parameters please feel free to contact us Note All parameters provided herein are as of the publication date of the Instruction Manual Due to continuous product improvement Noblelift reserves the right to make 1 Guidelines for Safe Operation 1 1 Requirements for the driver The stacker should only be operated by personnel trained in operating the stacker who can show to the user how to move and handle loads and instruct the user how to operate the stacker 1 2 The right duty and responsibility of driver Clear with his own right and duty the driver should be trained in operating the stacker and also knows the contents in this operation manual very well If the stacker in use is controlled on foot the driver should wear safety boots during operation 1 3 Unauthorized persons are prohibited to use The driver is
9. armonized Standards EN 1726 1 1999 EN1175 1 1998 Herstellerunterschrift Datum Authorized Signature Date Dec 29 2009 Angaben zum Unterzeichner Title of Signatory President Table of Contents Pn 1 1 Guidelines for Safe 2 2 6 3 Transport and Trial Run 9 EE ODORE ren are 11 5 Maintenance Recharging and Replacement of the Accumulator Maintenance and Service Manual cccccccccccccccccccccccecs 22 Schematic Diagrams of Electric and Hydraulic System 29 Introduction Welcome to use this series of power stackers This manual gives clear information on how to master safe operation of the power stackers The differences between various power stackers are described in detail in this manual During operation and maintenance please refer to the contents corresponding to the power stacker types you are using The safety instructions and important precautions are indicated with the following icons 1 STOP This icon indicates the existence of a hazard that could result in personal injury if the safety instruction is not observed 2 A This icon indicates that a failure to observe the described instruction could lead to equipment damage uu Refers to general notes
10. changes to the capacity plate s decals tags and instruction handbook d affix a permanent and readily visible label to the truck stating the manner in which the truck has been modified or altered together with the date of the modification or alteration and the name and address of the organisation that accomplished the tasks 2 Technical Manual This series of stacker CY are designed for short and medium distance heavy duty transportation on flat road surface 2 1 Specifications CY13 Rated Loading Capacity kg 1300 Load centre distance mm Lift height 1600 4500 Travel speed unladen er h Travel speed laden km h w ENTREES BA e J6 A nn gt u a Er ue cc cupo eO om 550 580 2198 Specifications of non standard stackers or stackers equipped accessories or other optional components may be different from above tables We reserve the right to update the specifications of this stacker These tables provide only specifications of standard stackers according to VDI 2 2 Technical Standards Continuous noise level should be less than 70dB A according to 1504871 standard Continuous noise level is an average value of noise measured at the driver s ear during travelling lifting and being standby Electromagnetic Compatibility EMC The manufactu
11. connected Use soft air suction or compressed air non conductive and anti static brushes to clean electric and electronic components A If you are going to use water spray or high pressure cleaner to clean the stacker all electric and electronic components must be covered carefully in advance because moisture may cause them malfunction Never use steam nozzles for cleaning Operation of Electric System Operation on the electric system should only be performed by specially trained personnel Before performing any operation on the electric system precautions must be made to prevent electric shock When operating the 22 accumulator connectors on it must be disconnected Short time duty for traction motor and lifting motor driving motor S2 60min lifting motor 53 1526 Welding Operation To prevent electric components from being damaged remove these electric components before welding Installation When repairing or replacing hydraulic components electric and electronic components make sure to install them back to their original positions Wheels Quality of the wheels has significant effect on stability and driving performance of the stacker Modification on wheels can be performed only with the approval from the manufacturer When replacing wheels ensure that the stacker is levelled as delivery state wheels must be replaced in pairs i e replace right wheel together with left one Lifting chain and r
12. erform balanced recharging to accumulator once a month in normal use 21 6 Maintenance and Service Manual Never modify any parts especially safety devices of the stacker without permission Never change the operation speeds of the stacker All spare parts provided by original manufacturer are strictly tested Only use spare parts from the manufacturer for the guarantee of the safety and reliability of stacker operation The replaced material including oil should be collected and disposed of according to local environment protection and health regulations 6 1 Safety procedures for maintenance and service Maintenance technician The maintenance and service should only be performed by special personnel trained by the manufacturer After the technician sent by after sales department of the manufacturer completed maintenance and servicing work they should sign on the service log Lifting of the stacker When the stacker needs to be raised up for repair the lifting device must be safe and reliable and must be strictly fixed to hook holes When the stacker is raised up proper measures such as using wedges and wooden blocks must be applied to prevent the stacker from sliding down or tilting over Cleaning Operation Flammable liquid can not be used for cleaning the stacker Before cleaning take safety precautions to prevent electric sparks e g sparks caused by short circuit When operating the accumulator connectors on it must be dis
13. fork when the fork is moving upward or downward preventing crushing and shearing injuries to personnel T lifting loads the driver must check if the loads are placed on the pallet completely and the weight of loads does not exceed the loading capacity Do not transport in full load status for a long time Make sure the fork reach under the loads as far as possible When operate with Up 14 or Down button the fork will move upward or downward at a fixed speed Take the following steps to load heavy objects 1 Drive the stacker right in front of the heavy object 2 Push the right handle forward to downswing the fork then adjust left handle forward or backward to place the fork to an appropriate height below the heavy ze ge 3 Push the middle handle forward to extend the fork under the heavy object ES 7 4 Pull back the right handle upswing the fork so that the heavy object won t drop then pull back the left handle to lift the fork until the object is loaded Manipulate the left handle to make the bottom of the goods higher than the stacker wheels to avoid collision between the stacker and heavy object when the fork moves back Downswing After that pull the middle handle back to move the fork back A i 5 Adjust the left handle to place goods to a lower position T so as to facilitate the stacker s normal running Take the following steps to stack heavy objec
14. g STOP Hydrogen will be precipitated in the charging process So the accumulator room should be well ventilated and the hydrogen content shall be strictly controlled to ensure safety STOP For the safety of the cooperation the stacker should be added protective cover before using 5 5 1 Balanced Recharging After using for a period voltage and concentration may vary from battery to battery Balanced recharging will eliminate the differences so that the performance of each cell becomes uniformed In following cases balanced recharging is necessary Voltage of an individual cell is frequently below 1 7V large current occurs during discharging for example when using the driving motor and lifting motor simultaneously for accumulators that are not recharged in time after discharging Over discharged accumulators and those are not in use for a long time Perform balanced recharging as follows A Recharge with a current of 0 115A B When the voltage up to 2 5V and there occur bubbles in the electrolyte continue recharging at a reduced current of 0 0515 C Recharge the accumulator to full capacity and stop recharging for half an hour and then continue recharging with further reduced current of 0 02515A for an hour D Stoprecharging again for half an hour and continue recharging with a current of 0 02515A for an hour E Repeat step D until bubbles occurs intensely and instantly when switching on the charger P
15. g the unit or lifting loads Check before daily start up Check the entire unit for defects and failure especially the wheels and lifting mechanism Check if the accumulator is firmly fixed and well connected Starting up the stacker Turn on the emergency stop switch Insert the key in electric lock and turn it clockwise to position The coulombmeter shows current battery level Check the horn Check braking function of the control lever Now the preparation before starting up is completed It has certain risks to use the stacker in rainy snowy foggy and windy weather Before use in those conditions please evaluate the security 4 3 Operation of the stacker 4 3 1 Starting up Driving and Parking Be careful during starting up and driving especially when part of your body stretches out of stacker s outlines Do not carry any other person during driving 11 Emergency Stop Pressing the emergency stop switch will stop all electric control functions Forced Braking When the control handle is released the stacker will brake automatically emergently stop The control handle will enter the upper braking range B1 automatically STOP the lever enters braking range slowly make sure to find out its causes and troubleshooting the failure If necessary replace the air spring of the handle Starting up STOP Start up the stacker only when the battery cover is closed otarting up the stac
16. he controller is damaged The button controlling backward or forward is not back to its normal position Check the connectors on accumulator connect them if necessary Turn the Electric lock in position 1 Turn on the emergency stop switch Check the capacity of accumulator recharge if necessary Turn the control lever to drive rage F Check fuse FUO1 and FU1 Do as methods in The stacker can not move table Check hydraulic oil Check fuse FUO2 and FU2 Recharge the accumulator Check UP switch and necessary replace if Check hydraulic oil and clean control valve Replace the oil if necessary Check or replace the valve for lowering Disconnect power supply and replace the UP switch Check the sensitive switch in control lever and the connecting cable Check the capacity indicator the brake and related cables Replace the controller Repair or replace it If above steps still can not solve problems please contact after sales service department of the manufacturer and have the problems solved by specially trained technicians 6 4 2 Preparation before repair 26 To prevent possible accidents during maintenance and repair work following preparations must be done Park the stacker safely Press the emergency stop switch and disconnect the connectors on accumulator STOP When the fork needs to be lifted up or the stacker needs to be raised up for re
17. hen entering the lift the loads must enter ahead And locate the stacker in a suitable position to prevent from contacting walls around If passengers take the lift together with the stacker they have to enter after the stacker enters and stops firmly and leave before the stacker 1 14 Driving passageway and working area The stacker must be driven in designated passageway Non related persons must leave the working area Loads must be stacked in designated locations 1 15 Operation Management Driving speeds must be suitable to local conditions Always drive in lower speed when passing curved passageways narrow passageways rotary doors or any obstructed places The driver should be able to measure by sight and keep enough stopping space from vehicles ahead all the time It is prohibited to make an abrupt stop unless in emergency rapid U turn and chase with each other in obstructed places Never operate the stacker with the body stretching out of it 1 16 Visibility The driver must keep his eyes on moving direction and have a clear view of the road ahead In case the loads carried block sight of the driver another person should walk in front of the stacker giving corresponding guidance and warning to the driver 1 17 Passing a ramp Only known ramps are permitted to pass And the ramps must be clean anti skid and meet specification requirements of the stacker Loads on the fork must face the upward slope Never turn around drive ob
18. ker Travelling speed is regulated with the Forward backward button Hotate the Forward backward button to driving range and adjust the control lever in required direction the stacker will move towards selected direction 12 Driving Swing the control handle rightward or leftward to drive Motorized hand and hand rider trucks employing a steering tongue control that extends beyond the confines of the truck shall steer such that with the operator facing in the direction of travel with the load end trailing clockwise movement of the steering tongue shall steer the truck clockwise When the stacker comes across an obstacle the force applied to swing the lever should be smaller than driving in normal status In such case turn the steering wheel arm carefully to break away from the obstacle by moving forward or backward Driving on a slope A Always keep loads face the downward slope when transport loads on a slope Take following safety measures against the rolling down With the control button in position 0 quickly press the handle backward The driver should release the handle as required to make the electromagnetic brake work automatically controlling the speed and direction if the driver find the stacker is rolling down In case the stacker is rolling over the operator should get away from the stacker right away Braking STOP The braking performance of the stacker depe
19. liquely or stop on a slope Pass a ramp in lower speed and get ready for braking at any time 1 18 Load capacity of the floor Check if the weight of stacker and loads or wheel pressure on the floor exceeds the load capacity of the floor 1 19 Transportation The fork should be kept lower than 300mm from the floor during non transportation driving It is better to driver in reverse direction of the fork to get good vision and mobility Driving with the fork forward may cause unpredictable mobility problems 1 20 Speed Select a suitable speed depending on floor conditions visibility and the principle of safety operation During operation it is prohibited to speed up stop and turn suddenly for that may cause roll over of the loads and the stacker 1 21 Driving on loading platform or approach bridge Before driving the stacker onto loading platform or approach bridge of a truck make sure to check load capacity of the approach bridge and if it is equipped with anti sliding devices The driver must also check load capacity of the truck and if there are devices to prevent the truck from moving 1 22 Safe Parking Pay attention to safety when parking the stacker Never park the stacker on a slope or on a ramp The fork must be lowered down to the lowest position after parking Turn off the electric lock and remove the key to prevent unauthorized operation Please disconnect the wires linked to batteries if the stacker will not be used for a
20. mediately Acid spilage must be neutralized and treated immediately 14 The weight and dimensions of the accumulator have remarkable effect on stability of the stacker Therefore do not modify the type of accumulator without approval from the manufacturer 15 Never discharge in large current for example performs travelling and lifting simultaneously 5 1 4 Disposition of worn out accumulators Worn out accumulators should be recycled according to local regulations and stored in specified zone or cast off treatment zone These works should be done by qualified specialized companies 5 2 Specification of the accumulator 18 Battery Charger Rated power V Rated capacity Ah Input AC115 230V idi poco i Output DC24V 40A 24V 270Ah 50 60Hz Rated power V Rated capacity Input AC115 230V Output DC24V 50A Ah 400Ah 50 60Hz Battery of 24V 270Ah should be used for 1316 CY1318 CY 1330 24V 400Ahshoudl be used for CY1337 CY1345 Weight and dimensions can be found on the nameplate of the accumulator Uninsulated terminal poles on the accumulator should be protected with an insulated cover When connecting the accumulator and socket make sure to stop the stacker and put the switch at position O When replace or install the accumulator make sure the accumulator is fixed securely in battery box 5 3 Storage transportation and installation of the accumulator SIOP The stacker must be parked
21. nds on floor condition The driver must be clear about this point Three braking methods are available 13 Electromagnetic brake control handle Use reverse current brake Forward backward button Brake with the sensor i e release the lever to brake Braking with the Electromagnetic Brake STOP In case of an emergency always stop the stacker only with electromagnetic brake control lever Turn up or down the control handle to braking range B1 or B2 the drive motor will be stopped mechanically When the control handle is released it will enter the upper braking range B1 automatically After the stacker is stopped the electromagnetic brake works as parking brake Braking with reverse current brake AN If the control system or driving power fails braking with reverse current is possible Turn the forward backward button in reversed direction of driving until the stacker stops Release the forward backward button Braking by the inertia When the forward backward button is released it returns to position 0 and brakes by inertia of the motor The slowing down rate depends on the position of forward backward button If the forward backward button position is set to 0 and the inertia braking unit is removed by service technician you have to use electromagnetic brake or reverse current brake to brake the stacker 4 3 2 Operation of the forks STGP Its prohibited to stand under the
22. o ate Coe Till 4 554 VD Shift 57 55 5 pup gt Lower st s j 26 29 c 24 12 AAD MT Mif AB 41 Aas M 4 24 13 8 i gt El pag P15 Pia P12 Pt 219 PT PB CURTIS 12434220 Pe PS Pe Pal Pe KM 5 Eti pig P15 Pia P13 212 Pit Pro P8 CURTIS 1243 4220 23 22 FUL Following are names of electric components Electromagnetic 1 Accumulator 17 YB 9 brake Positive pole of NA 2 B j 18 Capacity indicator accumulator accumulator motor Solenoid valve for lowering Horn ES Emersency sto button Contactor of traction Lifting button motor DEN AE en reclining button 27 SHH Modular Switches Button Button 28 Pu Modular Switches Emergenc 9 A1 A2 A3 A4 Circuit board oar switch S7 Timing shift knob shift knob 30 t Lifting limit switch Protection module 30 7 3 Schematic diagram of hydraulic system 3 0Kw 24V 3
23. ollers Chain and rollers will be worn quickly without good lubrication Perform periodic lubrication according to following maintenance table Shorten the lubrication period under adverse operation conditions such as in dusty and hot environment Hydraulic oil pipe The oil pipe must be changed every 6 years When change the hydraulic assembled parts the oil pipe should be also changed 6 2 Routine Maintenance Before every shift 6 2 1 Check the liquid level of electrolyte in the accumulator The liquid level will be higher when being recharged 6 2 2 Check every pole every cable and their covers 6 2 3 Check if the accumulator box is secured 6 2 4 Check the stacker for oil leakage 6 2 5 Check the chain rollers fork oil pipes and horn 6 2 6 Check the brake 6 2 7 Check the wear and tear of drive wheels and loading wheels 6 3 Professional Maintenance Manual It is very important for safe operation of the stacker to perform overall professional maintenance Failure in performing maintenance according to specified interval may 23 cause malfunction of the stacker and potential risk to human and equipment Maintenance periods listed in this manual apply to single shift a day under normal operation conditions If using in dusty environment the ambient temperature varies remarkably or in multi shift situation the maintenance period has to be shortened Maintain the stacker according to following maintenance list Main
24. on the level ground steadily To prevent short circuit naked cable ends and the terminal posts should be covered with insulated covers When pulling out the accumulator properly arrange removed accumulator s connectors and cables without blocking access of the accumulator When install or remove the accumulator with a crane make sure the load capacity is sufficient weight of the accumulator is marked on both the nameplates of the accumulator and the stacker The crane must pull vertically to prevent the battery box from being damaged The hooks of the crane should be safe and secure Never let the hooks fall on an individual battery Press emergency stop switch and turn the power supply switch to OFF position Remove the connectors of accumulator cables Connect the lifting device to lifting holes Lift out the accumulator from the top and move away with handling equipment 19 Perform installation in reverse order of above steps It is noticeable to put the accumulator in right position and connect the cables securely After reinstalling the accumulator always check all cable connections and connectors for obvious damage 5 4 Capacity indicator of the accumulator Capacity indicator of the accumulator The status of accumulator discharging is indicated on the indicator with 10 bar graphs each bar represents 10 percent of increment As the consumption of accumulator capacity the lighting bars will fall do
25. pairing precautions for preventing the fork or the stacker from tilting over or falling down suddenly must be taken For information on lifting of the stacker see related parts in Transportation and Trial Run above 6 4 3 Check hydraulic oil level Get the stacker ready for maintenance or repairing Open the cover of electric unit Check hydraulic oil level in oil tank Check the hydraulic oil level only after the fork and main frame are lowered to their lowest position 6 4 5 Use Preparation after maintenance or repairing Use the stacker only after following operations have been completed Clean the stacker Check the brake Check the emergency stop switch Check the horn 6 5 Storage of the stacker If the stacker will be not in use for over two months it must be stored in antifreeze and dry locations Take protection measures before storing If the storage time is over six months please consult the manufacturer on additional protection measures During storing the stacker should better be placed with the wheels off the ground for protecting the wheels and the bearings within wheels 6 5 1 Operations before storing Clean the stacker thoroughly Check the brake Check the hydraulic oil level refill if necessary Apply lubricant oil or grease to protect all parts 21 Refill grease according to detailed lubrication cycle table Recharge the accumulato
26. r again Disconnect and clean the accumulator Apply grease on terminal poles on accumulator Besides these the accumulator must be protected according to special requirements stated in accumulator instruction manual 6 5 2 Cautions during storage Every one month Recharge the accumulator A Operations related to accumulator It is very important to recharge the accumulator periodically Otherwise the accumulator will self discharge resulting complete loss of capacity and the accumulator may become worn out thoroughly 6 5 3 Trial Run Again Clean the stacker thoroughly Refill grease according to lubrication cycle table Clean the accumulator apply pole lubricant on the terminal poles and reconnect the connectors Recharge the accumulator again Check if there is moisture in gearbox oil If so replace gearbox oil Check if there is moisture in hydraulic oil If so replace hydraulic oil Start up the stacker If the switches in electric system do not contact well clean all exposed connectors with contact detergent spray and repeat this operation to remove oxide layer on these connectors A Perform several electromagnetic brake tests immediately after trial run again 28 7 Schematic Diagrams of Electric and Hydraulic System 7 1 1 Circuit diagram 1316 CY1318 CY1330 lt GN T1 Kr 8 To Mt 24V BN 7 15 up BU 2 15 ERR 41 RISE A2
27. r spill any hazardous liquid or solid material on surfaces of the accumulator When using a densimeter or a thermometer make sure the surface is clean and clear 7 Recharge the discharged accumulator in time Delayed recharging may damage the 17 accumulator Do not delay recharging more than 24 hours Recharging of the accumulator may not work outdoors in cold weather In this case move it indoors to perform recharging 8 If the accumulator will not be in use for a long time it should be recharged and discharged once every month and it should be fully recharged every time 9 During recharging or using the liquid level of electrolyte lowers because of water evaporation so pure water should be added It is not allowed to add electrolyte with a specific weight of 1 280 10 If individual cell fails identify the cause and repair the cell immediately Replace the cell when it cannot be repaired 11 The site for recharging should be well ventilated It is prohibited to smoke or use open fire avoiding the risk of hydrogen explosion 12 The electrolyte in accumulator is toxic and corrosive For this reason always wear working suit and protection glasses to protect your body from contacting the electrolyte in accumulator 13 If your clothes skin or eyes are spilled with acid liquid in accumulator flush with large amount of clean water For skin and eyes flush with large amount of clean water and also seek doctors treatment im
28. rer confirms that the stacker complies with EN12895 and other relevant standards on limits of electromagnet radiation and interference and has been tested on static discharge Never modify any part of electrical system without written permission from the manufacturer 2 3 Operation Conditions Ambient temperature 5 C 40 C Special devices have to be used under a temperature below 5 C or in very humid environment Altitude up to 2000m please specify serial number of the stacker and part number If there is quality problems with the stacker or you need to order spare parts 2 4 label QTY c 2 O U C O Z cio c LL alo CO O u 2 Slo So 9 3 Transport and Trial Run 3 1 Transport with a crane Load capacity of the crane in use must be sufficient The load weight equals the net weight of stacker plus weight of accumulator see nameplate plate on the stacker hook holes are specially designed for transport the stacker Park the stacker in a safe position Hooks of the crane must be applied at hook holes A Hooks of the crane must be applied at hook holes ensuring the stacker will not be slipped down During operation make sure the crane whose hooks must be applied at hook holes of the stacker do not contact with the stacker 3 2 Trial Run A The stacker can only use accumulator as power s
29. tenance periods are as follows W1 Every 50 work hours but at least once a week M3 Every 500 work hours but at least once every three months M6 Every 1000 work hours but at least once every six months M12 Every 2000 work hours but at least once every 12 months Additional operations should be performed in trial run period In initial 50 100 working hours or after two months Check the nuts on the wheels and tighten them if necessary Check the hydraulic components for leakage and tighten them if necessary Replace the hydraulic filter Maintenance List storage H Chassis amp 1 1 Checkallbearingpartsfordamages Mainframe 12 Check all bolt connections 21 Check the drive system for noise and leakage Driver 2 2 Checkoillevelindrivesysem 23 Replacelubicantol ss EN d Wheels ana make may et the wheels a Same o ee system Check the performance and adjust accordingly s 5 2 Check reset function of the air spring and check for system leakage and damages 53 Checkthebrakediskfonwar 24 5 4 Check the connection of brake and adjust if necessary 6 1 Check performance and wear and adjust accordingly Lifting Visually inspect the loading wheels for blockage Mechanism 6 3 Check fork tips and pallet support for wear and damages
30. ts 1 Drive the stacker loaded with heavy object right in front of the the shelf 2 Lift the heavy object to an appropriate height with the same method as above 2 Move the fork forward to an appropriate height with the same method as above 4 Push the left handle forward slowly to lower the heavy objects and load the bottom of tray onto the shelf 5 Downswing the fork and slowly move the fork out of the shelf Then lower the fork and drive the stacker away from the shelf Place the fork to the lowest position after use then park the stacker in a safe and reliable place with even ground Make sure that the stacker can be moved with manpower after being parked Pull the key out and keep it properly 15 If you need to install a back rest make sure its height width and size of opening will minimize the possibility of loads falling against the fork Back rest shall not obstruct the view and the size of its opening can not exceed 150mm Safe Parking STOP Pay attention to safety when parking the stacker Never park the stacker on a slope or on a ramp The fork must to be lowered to its lowest position after parking Lower the fork Turn electric lock from position 1 to 0 and remove the key 16 5 Maintenance Recharging and Replacement of the Accumulator 5 1 Safety procedures for lead acid accumulator operation The stacker must be parked in a safe location before any operation on the accum
31. ulator 5 1 1 Maintenance Technician Only qualified technician can perform operations on the accumulator such as recharging maintenance and replacing Before operation carefully read instruction manuals including operation manual replenishment preparation and recharging requirements 5 1 2 Fire Prevention Measures Never smoke or use open fire when perform operations on the accumulator The accumulator should be away from flammable material at least two meters when storage or recharging The location for accumulator storage should be well ventilated and equipped with fire fighting devices 5 1 3 Maintenance of the Accumulator 1 Keep the nuts on every battery cell dry and clean Tighten every terminal and cable end and brush them with grease to prevent corrosion Naked cable ends and terminal posts should be covered with a skid proof insulating cover 2 Every two cells should be well connected Check the nuts on each pole if loose tighten the nuts 3 Keep the surfaces of accumulator clean and dry After the completion of recharging clean spilled acid with cotton yarns or brush And clean with wet towel if necessary 4 Over recharging and over discharging should be avoided and fast charging and insufficient recharging are also not allowed Otherwise life span of the accumulator may be affected 5 Do not put conductive objects including metal tools on the accumulator or short circuit or even explosion may be caused 6 Neve
32. upply Changin meters To ensure the stacker work normally after delivery and transportation following operations have to be completed Make sure all labels on the stacker are complete clear and readable If not replace with new labels immediately Check if the completeness of all parts and components and check if they are in compliance with requirements f necessary install batteries without damaging the connection cable Recharge the accumulator immediately If customers want to replace the accumulator with a new one make sure that the new accumulator match with the accumulator coulombmeter or is permitted by service technician of manufacturer 3 3 Towing of stackers without driving ability When towing the stacker without driving ability release electromagnetic brake before moving Press emergency control button and turn the power supply switch to OFF position Open the cover of electric unit Release 3 screws counter clockwise on the electric motor until the brake does not impede the stacker from moving Now you can tow the stacker STOP After arriving at the destination location recover the stacker to original status 10 1 Forward Backward button 2 Slow Speed drive button 3 Emergency reverse button 4 Horn button 4 2 Starting up the stacker The driver should always make sure that no person stayed in dangerous area of the stacker before starting up and operatin
33. wn from the top Preset Warning marks will appear when remaining capacity of accumulator meets following conditions When the remaining capacity of the standard accumulator is 30 percent Warning mark will appear and you can recharge the accumulator Preset Warning mark and a flashing Stop mark will appear when remaining capacity of accumulator meets following conditions When the remaining capacity of standard accumulator is 2096 Stop mark will appear and keep lighting When the Stop mark keeps lighting lifting function of the stacker will be cut off automatically Capacity Recharging sufficient needed Low battery lifting function can only be performed after recharging the accumulator to at least 70 of If the indicator shows low battery when lifting loads for a not very long period capacity 5 5 Recharging The CY series of stackers is supplied with a special charger for recharging Read the instruction manual carefully before recharging STGP The batteries should be recharged in well ventilated areas Make sure no metal objects placed on the accumulator Check all cables connection and connectors for 20 obvious defects Observe strictly all safety instructions e g replenishment of the accumulator and preparation for rechargin
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