Service Manual
Contents
1. At least one column height reading is around O zero The PLC considers the height difference is too much to block the movement Solution Open the upper cover Turn the encoder so that the reading is almost same as the actual height about 170 Then put the belt on the encoder Choose SINGLE WHEEL to lower or to raise that column to the same height of the others Choose ALL to lower down to ground Do ENCODE ALIGNMENT again 4 Height readings are OK but UP or DOWN buttons no response Reason The small antenna circle is broken The PLC considers the emergency button is pressed Solution 1 Open the control box cover 2 In sequence 1 2 3 4 press UP button to check the 10 0 on PLC If I 0 0 is ON the small antenna or the emitter of this column or of previous column is in error 3 Change part in error with a new one NOTE 1 In new version there is a small green LED on the elec Board If the green LED is not lighted there must be the error 2 In newest version there is another red LED on the elec board also If the red LED is not lighted the small emitter is in error 5 Pressing UP button on one column the motor runs a few then stop The fork does not rise up Pressing other UP button on other columns all columns can rise up normally Reason The battery on that column in error is less charged or almost used up Solution Charge the battery fully If error repeats check the connecting cables of the batteries If2. Take out the carriage totally then sit it on ground Fig 6 7 Fig 6 8 Kernel Mobile Column Lift Manual by Shanghai Kernel Auto Equip Manufacturing Corp Ltd www kernel mfg com 8 Take off the four rollers by hand Fig 6 7 9 Screw off the plastic rubber plate Fig 6 8 10 Take out the worn bearing Fig 6 9 si e Fig 6 9 Fig 6 10 11 Put a new bearing into the roller Fig 6 10 12 Screw on the plastic rubber plate 13 Put on the roller on its shaft again 14 Grease the rubber plate 15 Do the same for other three rollers 16 Lift the carriage up then put it back into the column 17 Put everything back into its position 18 Do above steps for other carriages 15
3. Kernel Mobile Column Lift Set Capacity 8200kg 18000Lbs Each Column Item No 167219B Service Manual 2012 Aug Kernel Mobile Column Lift Manual by Shanghai Kernel Auto Equip Manufacturing Corp Ltd CHAPTER 1 CHAPTER 2 CHAPTER 3 CHAPTER 4 CHAPTER 5 CHAPTER 6 www kernel mfg com INDEX PRE CHECKING eree ii ea ee sae oe PAGE 3 TROUBLE SHOOTING sees sect cease ce sos PAGE 4 ENCOEDER ALIGNMENT PAGE 5 MANUALLY LOWER DOWNsss sssss srs sparire PAGE 9 CHANGE CYUNDER seca sone resi PAGE 11 CHANGE THE BEARING OF THE ROLLER PAGE 14 Kernel Mobile Column Lift Manual by Shanghai Kernel Auto Equip Manufacturing Corp Ltd www kernel mfg com PRE CHECKING Before any trying to solve the error occurred check the following first a Check the battery voltage If it is under 21 6V battery indicator 22 is yellow or red charge the battery first b The columns shall be in pairs 1 2 3 4 Columns in odd number or be exchanged will cause error c Adding or taking away columns shall be operated only when all the lifting forks on ground in RESET status and always in pairs d Position the columns correctly Pair of columns shall be on same axle of the vehicle e Release every EMERGENCY button on each column f While turning on the power switches the control box switch of main column 1 shall be the last on
4. the vehicle is rest on the jack stand Repeat steps to other columns until the vehicle is totally rest on the stands Then lower all the columns in the way of above part A oe ra eli Kernel Mobile Column Lift Manual by Shanghai Kernel Auto Equip Manufacturing Corp Ltd www kernel mfg com SUGGESTION 1 It is important that keep the vehicle in a upright position not inclined 2 It is important to lower the vehicle one axle by another axle within height difference of 2 3 It is better to lower the vehicle one column by another within height difference of 2 4 Ifthe T connector is not there in old model the connector shall be changed first Fig 4 10a w o T connector Fig 4 10b quick connector amp T connector Kernel Mobile Column Lift Manual by Shanghai Kernel Auto Equip Manufacturing Corp Ltd www kernel mfg com 5 CHANGE CYLINDER OF THE COLUMN 1 Take off the covers on the column Fig 5 1 2 Take off the hose holder also Fig 5 2a 5 2b Fig 5 1 Fig 5 2a Loose the lower end nut on the oil pipe Fig 5 3 Loose the other end of the pipe Fig 5 4a 5 Take off the pipe Fig 5 4b Fig 5 3 6 Take off the wheel guide of the teeth cable Fig 7 5a 7 5b Kernel Mobile Column Lift Manual by Shanghai Kernel Auto Equip Manufacturing Corp Ltd www kernel mfg com 7 Pull out the moving end of teeth cable Fig 5 5a Fig 5 5b Fig 5 6 8 Screw off the bolt on the top
5. MNS lf under some situation the lifts need EMERGENCY no power battery lowering please do following steps carefully A EMPTY COLUMNS TO LOWER DOWN 1 Take off the covers of the column Fig 4 1 2 Screw off the tap on the T connector Fig 4 2a 4 2b QI Fig 4 1 Fig 4 2a 3 Put on the oil quick connector Fig 4 3 4 Connect the hose to the hand pump Fig 4 4a 4 4b 4 4c Kernel Mobile Column Lift Manual by Shanghai Kernel Auto Equip Manufacturing Corp Ltd www kernel mfg com Take off the elec coil of the valve Fig 4 5a 4 5b Lift up the carriage a little 1 8 by hand pumping Fig 4 6a 4 6b Pull back the lock tongue by hand Fig 4 7 II Fig 4 6a Fig 4 6b Fig 4 7 8 Put the magnet on the pin of the BALANCE valve right one Fig 4 8 Fig 4 8 9 The carriage will lower down slowly 10 As soon as the magnet is pulled out the carriage will stop 11 Repeat the above steps for other columns B COLUMNS WITH VEHILCE TO LOWER DOWN Because the vehicle is heavy it is better to rest the vehicle on the safety jack stands then to pull out the columns for maintenance Put the safety jack stands under the vehicle Fig 4 9a amp 4 9b Do the steps 1 9 in above part A to one column After the vehicle is rest on that jack stand pull out the magnet Do the steps 1 9 in above A again to the another column which is opposite to the first column same axle of the vehicle Pull out magnet after
6. e g The vehicle loaded shall not exceed the capacity of each column 7 5 ton If the error is still there after checking please try to solve it referring with the trouble shooting and examples in next chapter Kernel Mobile Column Lift Manual by Shanghai Kernel Auto Equip Manufacturing Corp Ltd www kernel mfg com 2 TROUBLE SHOOTING FAULT POSSIBLE CASE REMEDY Column Battery voltage is too low Charge the batteries Does not Gil level too low Add oil as necessary referring to lubricating Litt instructions Air in hydraulic pump only Select single wheel mode and press the tt possible after the tank has been UP button until the lifting column rises empty max 1 min Safety valve not properly Have valve adjusted Contact service people adjusted to check the valve Pump has insufficient yield Replace the pump Power interrupted by broken Replace the broken fuse If the error occurs fuse in control box again contact the service people Maximum height difference Set the MODE to WHEEL SINGLE Raise or more than 2 50mm lower the specified column to minimize the exceeded height difference If the error occurs again contact the service people Raise column approximately 2 and then Column from locking system lower Battery shall be charged fully first Does not The elec magnetic lowering No power for solenoid or lowering valve is Lower valve on the hydraulic unit does faulty Contact the ser
7. gain contact the Service Department ower Power switch is OFF Set power switch to ON DIOSERCSO COR 0086 Check cable and connector connector The emergency stop button Release the emergency button Set the main has not been unlocked switch to OFF and ON again to re start FAULT POSSIBLE CASE REMEDY as power switch is Tomaia No Power Main fuse blown Replace fuse Indicator Main switch OFF Set power switch ON Some error samples 1 All lifting forks are on ground but at least one reading is around 180 Press UP buttons without responds not moving Reason The zero position of that 180 reading encoder is not correct The PLC considers the height difference is too much to block the movement Solution Do the encoder alignment as described in next chapter Kernel Mobile Column Lift Manual by Shanghai Kernel Auto Equip Manufacturing Corp Ltd www kernel mfg com 2 While raising or lowering one column keeps moving but others stop Reason The teeth belt on that column is away from the encoder The height encoder data is not changing while moving Solution Open the upper cover Turn the encoder so that the reading is almost same as the actual height Then put the belt on the encoder Choose SINGLE WHEEL to lower or to raise that column to the same height of the others Choose ALL to lower down to ground Do ENCODE ALIGNMENT again 3 While the columns are on top position press DOWN button not moving Reason
8. of the carriage Fig 5 6 Lift up the carriage by a forklift Fig 5 7a 5 7b 10 While lifting pull the teeth cable by hand Fig 5 8 pm ET ar Fig 5 7a Fig 5 7b 11 Rest the carriage on the lock Fig 5 9 12 Move the cylinder backwards Fig 5 10 13 Screw off the pipe connector Fig 5 11 Fig 5 10 Kernel Mobile Column Lift Manual by Shanghai Kernel Auto Equip Manufacturing Corp Ltd www kernel mfg com 14 Screw off the extension pipe also Fig 5 12a b Fig 5 12a Fig 5 12b 15 Pull out the lower end of the cylinder Fig 5 13 Fig 5 13 Fig 5 14 16 Using the forklift to lift up the cylinder Fig 5 14 17 Put down the cylinder 18 Change it with the new cylinder 19 Back up all the steps above NOTE In re installing it is necessary to lift up the carriage a little in order to pull back the lock tongue by hand And while lowering the lock tongue is kept pulling back The teeth cable shall be carefully put through the wheel guide and the carriage Kernel Mobile Column Lift Manual by Shanghai Kernel Auto Equip Manufacturing Corp Ltd www kernel mfg com 6 CHANGE THE BEARING OF THE ROLLER 1 Open the upper cover of the column Fig 6 1 Fig 6 4 Pull out the teeth cable Fig 6 3 screw off the bolt on the top of the carriage Fig 6 4 Take away the limit bar on the top of the column Fig 6 5 Pag Lift up the carriage by a forklift Fig 6 6 DI 9 DI o
9. still exists the error change the pair of battery with new ones Kernel Mobile Column Lift Manual by Shanghai Kernel Auto Equip Manufacturing Corp Ltd www kernel mfg com 3 ENCODER ALIGNMENT The lifting height is detected by the sensor called encoder The zero point of the sensor is checked in following steps 1 Lower down all the columns to bottom 2 Press ESC button 18 to enter USER MENU LCD screen 5 3 Press DIRECT down button 8 to choose ENCODER ALIGNMENT See LCD screen 13 4 Press ENTER button 17 5 In this screen the numbers on bottom line is the zero height code of each column If anyone is not between 3 and 7 adjustment shall be done LCD screen 14 6 To adjust please open the upper cover on the column Then separate the Strip from the gear of the sensor Fig 3 1 7 Turn the gear to increase or decrease the reading on the corresponding column The best value is 5 Value between 3 and 7 is acceptable 8 Put on the strip again Check again the readings If OK put back the upper cover OPERATOR MENU DIAGNOSTICS MENU RELEASE PASSWORD LCD screen 5 Set of Unit Special Terms Operation Prompts Encoder Alignment LCD screen 13 1 Forks move onto floor 2 Readings must be 3 5 or imm 3 5 1 1 1 3 LCD screen 14 Fig 3 1 Kernel Mobile Column Lift Manual by Shanghai Kernel Auto Equip Manufacturing Corp Ltd www kernel mfg com 4 MANUALLY LOWER DOWN THE COLU
10. vice people not open SalowernavaNe Have the valve cleaned or replaced by y 9 service people Maximum height difference Set the MODE to WHEEL SINGLE Raise or more than 2 50mm lower the specified column to minimize the exceeded height difference If the error occurs again contact the service department The anti explosion valve Release the nut connecting from pipe to blocked cylinder a little to leak some oil Then raise the lift again Column oil leaks continually people Lowers by itself Leaks in the oil ine couplings in the oil line Leaks in the oil ine couplings Tighten couplings and coupling nuts Clean or replace the valve by the service Dirty or damaged non return people valve Dirty or damaged lowering or Clean or replace the valves by the service correction valve people Kernel Mobile Column Lift Manual by Shanghai Kernel Auto Equip Manufacturing Corp Ltd www kernel mfg com FAULT POSSIBLE CASE CASE POSSIBLE CASE REMEDY Column Oil level in tank too low Add oil as necessary refer to lubricating not instructions on lifting column Properly Pump drawing in air Tighten the suction filter fastening or crimp tighter The steel plug has not been replaced by the breather cap Install the breather cap Breather cap blocked Clean breather cap Height Reading Sensor zero point not correct Do encoder alignment not Zero No Fuse blown Check and replace the fuse If fault occurs A a
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