Original Instruction: Operation Manual Spare Parts Catalogue

 

CDD(H)/CTD(H)1545-1558 CDD(H)/CTD(H)2045-2058Electric CDD(H)/CTD(H)2045-20 58Electric Pallet Stacker

●Operation manual ●Spare parts catalogue

Original instruction

Ningbo Ruyi Joint Stock Co. , Ltd.  Add:656 North Taoyuan Road Ninghai,Zhejiang Ninghai,Zhejiang China China

 

EC Declaration of Conformity

 

according to the Machinery Directive 2006/42/EC For the following equipment: : Product

: Electric Stacker 

Type Designation /Trademark Manufacturers Name Manufacturers Address

:  CTD1553

:  Ningbo Ruyi Joint Stock Co., Ltd. :  656 North Taoyuan Ninghai ,Zhejiang China  

Refer to in this declaration conforms conforms with the following directive(s): directive(s):

Machinery Directive 2006/42/EC

The company named above will keep on file for review the following technical documentation :



Operating and maintenance instructions



Technical drawings



Risk assessment



Description of of measures designed designed to ensure conformity



Other technical documentation ,e.g. quality assurance measures for design and production

 

We hope our electric pallet truck will provi convenience  for your work   convenience Please read the manual carefully before operation This manual is a common manual. We reserve the right to modify technology of the electric stacker. If there is anything in the manual that is not consistent w actual stacker, the actual stacker should be considered correct and the ma only for reference.

**************************************************** *

Warning! Operator of the truck must

strictly follow IS

Specification for Industrial Vehicles” and it is p untrained people to operate the truck.

**************************************************** *

Warning!  Accordin  Acco rding g to ISO 3691 3 691 ““Safe Safe ty Speci S pecificat ficat ion of M Motor otor Industria Indu stria l Ve Vehicl hicles”, es”, Load capac ity and lifting lift ing heig ht o off ou ourr CDD Electric Pallet Stacker are stipulated as follows: 

When t

l

he h

iftiongt

s

eighit b

3f 

his (

tacke3r

st

m elow

l

30c0mm

i

including

the rated capacity. Overload is prohibited.  

When the lifting height of this stacker is over 3300mm (excluding 3300mm), the stacker’s load capacity is less

than

reference； 

the

rated

capacity.

As

for

the

load

capacity,

you

can

take

t

 

Note: When the lifting height of the forks exceeds 500mm, the stacker must travel at the lowest continual travel distance must not exceed 2m. Inconformity with the regulations may result in:  A. Danger of injury of the driver or other people B. Damage of the stacker and goods

 

Table of Contents 1．Configuration diagram……………………………………………………1 diagram……………………………………………………1 2．Main technical parameters………………………………………………4 parameters………………………………………………4 3．Use and application…………………… application………………………………………………………..7 …………………………………..7 4．Structure……………………………………………………………………….7 5．Use and operation instructions………………………………………….7 6．Maintenance and servicing………………… servicing……………………………………………..10 …………………………..10 7．Common faults and trouble shooting………………………………..11 8．Use, maintenance and charging of the battery…………………… 13 9．Lists of accessories, spare parts and vulnerable parts………….15 10. Packing and transportation……………………………………………...15 11．Warning (points for attention) attention)……………………………………… ………………………………………… … 15 12．Principle diagrams of hydraulic and electric systems…………… 16 13．Packing list…………………………… list……………………………………………………………………17 ………………………………………17

 

1. Configuration diagram 1.1 CDD1545/CDD1545H Configuration diagram  EMBED AutoCAD.Drawing.16 AutoCAD.Drawing.16

1

 

1.2 CTD1545/CTD1545H/CTD2045/CTD2045H Configuration diagram

2

 

1.3 CDD2045/CDD2045H Configuration diagram

3

 

2. Main technical parameters 2.1 CDD1545/CDD1545H Main technical parameters 1.1

Manufacturer(abbreviated)

Ningbo Ruyi

1.2

Model

1.3

Driving m mo ode   ： Electric(Storag Electric(Storage e battery),  diesel,

 

CDD15**

   

Electric(storage Electric(st orage battery)

 

Stand driving

gasoline, fuel gas   e   r   u    t   a   e    F

   t    h   g    i   e   w

  s    i   s   s   a    h    C

1.4

Driving mode （ Manual, Walking, Stand driving, seat driving ,Order picking）

1.5

Rated load

Q(kg)

1500

1.6

Load center distance

c (mm)

600

1.8

Front overhang

x (mm)

870

1.9

Tread

Y  (mm)

1357

2.1

Service weight(with storage battery)

kg

1540

2.2

Axle load, front/rear, laden

kg

1449/1591

2.3

Axle load, front/rear, unladen

kg

1243/297

3.1

Wheels (rubber, high elasticity, pneumatic tyre, polyurethane wheel)

 

polyurethane

3.2

Wheel d diimension, ffrront

 

Φ250×80

3.3

Wheel dimension, rear

 

Φ80×70

3.4

Additional w h he eel(dimension)

3.5

Wheel nu number, fr front/rear （x = driving wheel）

3.6

Tread, front

3.7

Tread, rear

4.2

Height of mast, lowered

4.4

Lift height

4.5

Max. height of m ma ast, extended

4.9

Min. Min.//Max. Max. h he eigh ghtt of ope opera rati tion on h ha and ndle le in in th the e dr driivin ving

     

Φ150×60

 

         

position

 

  n   o    i   s   n   e   m    i    D

4.15

Height, lowered

4.19

Overall length

4.20

Length to fork face

4.21

Overall wi width of of tr truck b bo ody

4.22

Fork dimension

4.25

Fork width

4.32

Wheelbase g grrou oun nd di distance

4.33 4.33

Ai Aisl sle ew wid idth th,, w wit ith hp pal alle lett 100 1000x 0x12 1200 00 cros crossw swis ise e

4.34 4.34

Ai Aisl sle e wi widt dth, h, wi with th pall pallet et 800x 800x12 1200 00 leng length thwi wise se

4.35

Turning ra radius

5.1 5.2

Traveling speed, laden/unladen Lifting speed, laden/unladen

1x+2/4

 

       

b 10 10(mm)

886

b 11 11(mm)

410/525

h 1(mm)

2087/2337/2507

h 3(mm)

4500/5300/5800

h 4(mm)

5500/5823/6333

h 14(mm)

1057/1339

h 13 13(mm)

90

l 1(mm)

1955

l 2(mm)

802

b 1(mm)

1040

S/e/l(mm) b 5(mm)

580/695

m 2(mm)

21

 

A sst t (mm)

2464

 

A sst t (mm)

2401

W  a(mm)

1629

   

 

60×170×1070

Km/h m/s

4.5/5.6 0.12/0.133

4

 

5.3

Lowering speed, laden/ unladen

m/s

5.8

Gradeability, laden/unladen

%

0.15/0.1 6/10

5.10

  a    t   a    D   e   c   n   a   m   r   o    f   r    P   e   o   r    t   o    M

Traveling brake

 

Electromagnetic brake

 

6.1

Driving motor power

kW

0.9

6.2 6.4

Lifting motor power Battery voltage/rated capacity

kW V/Ah

6.5

Battery weight

Kg

268

 

Battery dimension（LXWXH）

mm

968×206×505

8.4

Noise level at operator’s ear, according to DIN12053

dB(A)

3 24/275

70

2.2 CTD1545/CTD1545H/CTD2045/CTD2045H Main technical parameters 1.1 1.1

Manu Manufa fact ctur urer er(a (abb bbre revi viat ated ed))

1.2

Model

1.3   e   r   u    t   a 1.4   e    F

Driving mode ： Electric(Storage battery),

Driving mode （ Manual, Walking, Stand

Electric(Storage battery)

c (mm)

600

500

x (mm)

770

770

Y  (mm)

1255

1255

Service weight(with storage battery)

kg

1435

1600

Axle load, front/rear, laden

kg

1118/1817

1506/2094

Axle load, front/rear, unladen

kg

1028/407

1160/440

 

polyurethane

polyurethane

Tread

Whee Wh eels ls

     

(rubb rubber er,,

high igh

elas elastticity city,,

pneumatic tyre, polyurethane wheel) Wh Whee eell di dime mens nsio ion n, fron frontt

 

Φ250×80

Φ250×80

Wh Whee eell d diimens mensio ion n, rrea earr

 

Φ98×82

Φ98×82

Φ150×60

Φ150×60

1x+2/2

1x+2/2

b 10 10(mm)

886

886

b 11 11(mm)

1280/1680

1280/1680

h 1(mm)

2060/2310/2480

2060/2310/2480

h 3(mm)

4500/5300/5800

4500/5300/5800

h 4(mm)

5028/5796/6306

5028/5796/6306

h 14 14(mm)

1057/1339

1057/1339

h 13 13(mm)

70

70

l 1(mm)

1955

1955

l 2(mm) b 1(mm)

802 1392-1792

802 1392-1792

Addi Additi tion onal al wh whee eel( l(di dime mens nsio ion) n)

 

Wheel number, front/rear （ x = driving

 

wheel）

3.6

Tread, front

3.7

Tread, rre ear

4.9

Electric(Storage battery)

2000

1.9

  n 4. 2   o 4.2    i   s   n 4.4   e   m    i    D 4.5 4.5

CTD20**

1500

Front o ov verhang

3.5

CTD15**

Q(kg)

1.8

3.3 3   s 3.    i   s   s 3.4   a 3.4    h    C

Ningbo Ruyi

Walking

Load oad ccen ente terr di dist stan ancce

3. 3.2 2

Ningbo Ruyi

Walking

 

driving, seat driving ,Order picking ）

1. 1.6 6

3.1

 

diesel, gasoline, fuel gas

Rated load

2.3

5

 

1.5

   t 2.1    h   g    i   e 2.2    W

 

   

Heigh eightt of mast mast,, lo lowe were red d Lift height

   

Max. Max. h hei eigh ghtt of ma mast st,, e ext xten ende ded d

 

Min./Max. height of operation handle in the driving position

4.15 4.15

Heigh eight, t, lo low wer ered ed

4.19 4.19

Ove vera rall ll le leng ngtth

4.20 4.20 4.21 4.21

Le Leng ngth th to fork fork fa face ce Over Overal alll w wid idth th of truc truck k bod body y

       

 

4.22

Fork dimension

4.25

Fork width

4.32 4.32

Whee Wheelb lbas ase eg grou round nd dist distan ance ce

4.33

4.34

 Aisle

width,

S/e/l(mm)  

with

 

pallet

1000x1200

crosswise  Aisle

width,

with

pallet

800x1200

40×120×1070

40×120×1070

b 5(mm)

240-800

240-800

m 2(mm)

65

65

 A sst t (mm)

2509

2509

 A sst t (mm)

2484

2484

W  a(mm)

1629

1629

4.5/5.6

4.5/5.6

4.35 4.35

lengthwise Tur urni ning ng ra rad dius

5.1

Traveling speed, laden/unladen

Km/h

Lifting speed, laden/unladen

m/s

0.12/0.133

0.09/0.11

Lowering speed, laden/ unladen

m/s

0.15/0.1

0.12/0.09

Max. gradeability, laden/unladen

%

6/10

5/10

  a    t   a    D 5.2   e 5.3   c   n   a 5.8   m   r   o    f   r   e    P 5.10 5.10

Tra rave vellin ing g br brak ake e

Electromagnetic brake

 

Electromagnetic brake

6.1

Driving motor power

kW

0.9

0.9

6.2

L Liifting motor power

kW

3

3

Battery voltage/rated capacity

V/Ah

24/275

24/275

B Ba attery weight

Kg

268

268

Battery dimension（LXWXH）

mm

968×206×505

968×206×505

70

70

  r   o    t   o 6.4    M

6.5

 

 

8.4

Noise level at operator’s ear, according to DIN12053

dB(A)

2.3 CDD2045/CDD2045H Main technical parameters 1.1

Manufacturer(abbreviated)

1.2

Model

Ningbo Ruyi

Ningbo Ruyi

Ningbo Ruyi

Ningbo Ruyi

CDD2045

CDD2053

CDD2055

CDD2058

Electric

Electric

Electric Driving mode ： Electric(Storag Electric(Storage e battery), diesel, gasoline, fuel gas gas   e   r   u    t   a   e 1.4 4    F 1.

Electric (Storage

1. 1.3 3 (Storage battery)

(Storage battery)

(Storage battery) battery)

Driving mode （ Manual, Walking, Stand Stand driving

Stand driving

Stand driving

Stand driving

Q(kg)

2000

2000

2000

2000

c (mm)

500

500

500

500

x (mm)

870

870

870

870

Y  (mm)

1357

1357

1357

1357

driving, seat driving ,Order picking ）

1.5

Rated load

1.6

Load cce enter d diistan tance

1.8

Front o ov verhang

1.9

Tread

2.1

Service weight(with storage battery)

kg

1600

1630

1640

1655

Axle load, front/rear, laden

kg

1554/2046

1574/2056

1579/2061

1591/2064

Axle load, front/rear, unladen

kg

1279/321

1299/331

1304/336

1316/339

polyurethane

polyurethane

polyurethane

polyurethane

   t    h   g 2.2    i   e    W

2.3

  s    i   s   s 3. 1   a 3.1    h    C

     

Wheels (rubber, high elasticity, pneumatic tyre, polyurethane wheel)

3. 3.2 2

Whe heel el dimen enssio ion, n, fro front

Φ250×80

Φ250×80

Φ250×80

Φ250×80

3. 3.3 3

Whe heel el dimen enssio ion, n, re rea ar

Φ80×70

Φ80×70

Φ80×70

Φ80×70

3. 3.4 4

Ad Addi diti tio onal nal wh whee eel( l(di dimens mensio ion) n)

Φ150×60

Φ150×60

Φ150×60

Φ150×60

3. 3.5 5

Whe heel el num umb ber, fro ront nt/r /rea earr （ x = driving wheel）

1x+2/4

1x+2/4

1x+2/4

1x+2/4

6

 

3.6

Tread, front

 

b 10 10(mm)

886

886

886

886

3.7

Tread, rear

 

b 11 11(mm)

525

525

525

525

4. 4.2 2

Height of m ma ast, st, lowe were red d

h 1(mm)

2087

2337

2407

2507

4.4

Lift height

h 3(mm)

4500

5300

5500

5800

4. 4.5 5

Max. Max. he heig ight ht of mast mast,, ext exten ende ded d

h 4(mm)

5055

5823

6033

6333

h 14 14(mm)

1057/1339

1057/1339

1057/1339

1057/1339

h 13 13(mm)

90

90

90

90

l 1(mm)

1955

1955

1955

1955

l 2(mm)

802

802

802

802

b 1(mm)

1220.8-1630

1220.8-1630

1220.8-1630

1220.8-1630

S/e/l(mm)

60×170×1070

60×170×1070

60×170×1070

60×170×1070

b 5(mm)

695

695

695

695

m 2(mm)

21

21

21

21

 A st  st (mm)

2464

2464

2464

2464

 A st  st (mm)

2401

2401

2401

2401

W  a(mm)

1629

1629

1629

1629

Km/h

4.5/5.6

4.5/5.6

4.5/5.6

4.5/5.6

Lifting speed, laden/unladen

m/s

0.09/0.11

0.09/0.11

0.09/0.11

0.09/0.11

Lowering speed, laden/ unladen

m/s

0.12/0.09

0.12/0.09

0.12/0.09

0.12/0.09

Max. gradeability, laden/unladen

%

5/10

5/10

5/10

5/10

Electromagnetic

Electromagnetic

Electromagneti

Electromagnetic

brake

brake

c brake

brake

     

Min. /Max. height of operation handle in 4. 4.9 9 4.15

drivingposition Height, lowered

4.19

Overall length

 

4. 4.20 20   n   o    i   s   n 4.21 21   e 4.   m    i    D 4.22

   

Leng ngth th to for ork k face ace

 

Ov Over eral all wid width th of truc truck kb bod ody y

 

Fork dimension

4.25

Fork w wiidth

4. 4.32 32

Whee Wheelb lbas ase e gr grou ound nd dis dista tanc nce e

   

 Aisl sle width, th, with th palle lett 10 1000 00x1 x120 200 0 4.33 crosswise  Aisl sle

width idth,,

with ith

pallet 80 800x 0x12 120 00

4.34 lengthwise 4.35

Turning radius

5.1

Traveling speed, laden/unladen

  e   c 5.2   n   a   m   r 5.3   o    f   r   e    P 5.8   a    t   a    D

5.10

 

Traveling brake

6.1

Driving motor power

kW

0.9

0.9

0.9

0.9

6.2

Lifting motor power

kW

3

3

3

3

Battery voltage/rated capacity

V/Ah

24/275

24/275

24/275

24/275

Battery weight

Kg

268

268

268

268

Battery dimension（LXWXH）

mm

968×206×505

968×206×505

968×206×505

968×206×505

dB(A)

70

70

70

70

  r   o    t   o 6.4    M

6.5

Noise level at operator’s ear, according to  

8. 8.4 4 DIN12053

  Note: Parameter Parameterss relating to h3、l shall be calculated according to h3=4500mm,l=1070.

3 Use and application This electric pallet stacker adopts storage batteries as the dynamic source and a DC motor as the driving force, traveling through gear transmission. The lifting of the fork relies on the DC motor and the hydraulic transmission system. The up-and-down movement of the oil cylinders lifts the fork and the goods. As the traveling and lifting of  the truck are electrically driven, it possesses the characteristics of energy saving, high efficiency, stable operation, easy operation, safe and reliable, low noise and no pollution, etc. The stacker is applicable for goods piling and handling on hard and flat ground. Environment for application: 7

 

a.

El Elev evat atio ion n no mor more e th than an 12 1200 00m; m;

b.

Ambien Ambientt tem temper peratu ature re no hi highe gherr tha than n +40℃ +40℃C C and no lower lower than than -2 -25℃C 5℃C;;

c.

When tthe he ambi ambient ent tem temperat perature ure rea reaches ches + +40℃C, 40℃C, tthe he relative relative hu humidi midity ty sho should uld not excee exceed d 50%; 50%; at a low lower er temperature, higher relative humidity is allowed.

d.

Hard ard an and d fla latt gr grou ound nd

e.

It is prohibi prohibited ted to us use e the truc truck k in a flam flammabl mable, e, expl explosive osive o orr corr corrosive osive enviro environment nment w with ith aci acid d and alka alkali. li.

4   Structure (See also the structure diagram and the principle diagram of the major parts) The stacker mainly consists of truck frame, mast, fork, lifting oil cylinder, operation handle, steering device, driving wheel, storage battery pack, hydraulic power unit, control system for electrical equipment, etc.

5 Use and operation instruction The electric pallet stacker adopts storage batteries as the dynamic source for short distance goods handling and stacking. Correct use and operation will bring great convenience to your work but incorrect use and operation will damage the stacker or pose risk to you and your goods.

：

5.1 Before operation 5.1.1 Before operation, please check if the stacker is in normal condition: Is there any oil leakage in the hydraulic pipes? Are the supporting wheels able to operate normally? Is there any block? It is strictly prohibited to operate the faulty stackers. 5.1.2 Check if there is any electricity in the batteries with the method indicated in Fig, I. Pull the general power supply switch out to turn on the general power supply, unlock the electric lock on the handle, and check the electric energy meter on the instrument panel of the stacker. If one grid at the zero end is bright, it indicates that there is no electric power in the batteries and charging should be conducted at once. It is strictly prohibited to operate the stacker without electricity as that will greatly reduce the service life of the batteries and even damage the batteries. Turn on supply

Electric lock door

the

power Tu Turn rn off off the the power supply

There is no electric power in the batteries if this grid is bright

Fig. II

 

5.1.3 Check if the stacker brake is normal. Check the lifting, lowering, forward and backward traveling of the stacker to see if the actions are normal. Check if the emergency reverse action of the stacker is normal with the methods indicated in Fig. II: Emergency reverse switch

8

 

Division A 

RISR  Division B

HORN

DROP Division C

Fig. II

 

Turn the operation handle to division A or division C as indicated in Fig. II, and press the lifting / lowering button on the operation handle to see if the lifting and lowering of the fork is normal. Turn the operation handle to division B as indicated in Fig. II, slowly start the stacker and press the handle to the horizontal position to see if the stacker can travel or brake normally. Turn the operation handle to division B as indicated in Fig. II and press the emergency reverse switch button on top of the operation handle to see if the stacker can travel forward.  After the above check, check, if there is no failure in the stacker, it can be put into use; iiff there is som some e failure, please repair it at once. It is strictly prohibited to use faulty stackers. 5.1.4 Check CDD2045 or CDD2 CDD2045H 045H electric pa pallet llet stackers to see that whether the folding and unfolding ac actions tions of  auxiliary supporting legs are normal. As indicated in the following drawing, press the button for unfolding to see that whether the auxiliary supporting legs can be unfolded, then press the button for folding to see whether the supporting legs can be folded.

Folding button Unfoldin g button

Folding

Unfolding

5.2 In operation ： 5.2.1 Note: A side-magnetic brake is installed on the shaft end of the driving wheel motor and there is a cam and an inching switch installed on the rotary shaft of the rotary arm. Only when the rotary arm is at 30℃±20℃(as 9

 

indicated in Fig. II), the stacker can be turned on and travel. Larger or less than the angle, the stacker will be powered-off and braked. In that case, the stacker can lift goods. When lifting goods, the stacker cannot travel.  As indicated in Fig. II, when the operation operation handle is in division division A or divis division ion C, the stacker ca can n only lift or lower but not travel travel;; when the control handl handle e is in divisio division n B, the stacker stacker can trave travell but also lift and lowe r. The operation position of the handle will not be specially described in the following descriptions, i.e. the handle must be in division A or C when the stacker lifts or lowers and it must be in division B when the stacker is traveling. 5.2.2 Operation of handling and piling： Unlock the electric door lock, and drive the stacker to the goods pile nearby. (The tip of the fork is 300mm from the goods pile). Press Press the loweri lowering ng button, adjust the height of the fork to a proper position position,, and insert the fork slowly and as deep as possible into the pallet of the goods. Press the lifting button till the fork is 200-300mm from the ground. Drive the stacker to the location of the goods shelf and stop slowly. (The tip of the fork is 300mm from the goods shelf. If it is CDD 2045 or 2045H truck, the auxiliary supporting legs must be unfolded. ) Press the lifting button and the fork rises to a proper height of the goods shelf (The bottom of the pallet is about 100mm higher than the goods shelf). Move the goods slowly to the accurate position of the shelf and press the lowering button to put the goods carefully on the shelf. Take the fork away from the goods and drive the stacker slowly to make the fork out of  the goods pallet. (The tip of the fork is 300mm from the goods shelf.) Lower the fork until it is 300mm (If it is CDD2045 or 2045H stacker, the auxiliary supporting legs must be folded.) from the ground and drive the stacker away from the shelf. Attention should be paid to that there should be no obstacles around and when turning, the speed should be reduced. 5.2.3 Operation of taking goods off the goods shelves ： Unlock the electric electric door lock, and drive the stacker to the goods shelf nearby. (The tip of the fork is 300m 300mm m from the goods shelf). Press the lowering button, adjust the height of the fork to a proper position of goods frame (If it is CDD 2045 or 2045H truck, the auxiliary supporting legs must be unfolded.), and insert the fork slowly and as deep as possible into the pallet of the goods. Press the lifting button to lift the goods till the bottom of the pallet is 100mm from the goods shelf. Slowly drive the stacker and slowly move the goods out of the shelf (the tip of the fork is 300mm 300m m from the goods shelf). Press the lowering button and the fork lowers to a height of 200-300 200-300mm mm from the ground (If it is CDD2045 or 2045H stacker, the auxiliary supporting legs must be folded.). Drive the stacker away from the goods shelf until it reaches a desired position and then slowly stop it. Press the lowering button to put down the goods, make the fork completely away from the goods and move the fork slowly out of the goods pallet.

5.3 Abnormal situation handling during operation ：

5.3.1 When pressing the lifting button, the fork can rise but when releasing the lifting button, the fork is still rising. The stacker is in a situation of out of lifting control. In that case, turn off the general power supply switch to cut off  the power supply at once. Drive the stacker to a safe position to lower the fork manually and repair the circuit of  the stacker.

5.3.2 If the brake is out of function when the stacker is in operation, the operation operation must be stopped at once and repair the stacker. 5.3.3 When the stacker is moving moving backwar backward d and pushing the operator again against st a wall or other objects, press the emergency reverse button on top of the operation handle and the stacker will automatically move forward to avoid injuring the operator. 5.4 After operation：  After operation, operation, the stacker should be parke parked d in a fixed parking position and routine routine mainte maintenance nance should be conducted according to the stipulations in clause 6 and charging should be carried out.

6 Maintenance and upkeep 10

 

Note: It is prohibited for untrained personnel to maintain the stacker. 6.1 Whether the stacker can operate satisfyingly depends on the efficient maintenance. When maintenance is ignored, the stacker may pose a threat to human lives and cause stacker and property damage. Routine inspection should be conducted, when the stacker is in operation, to eliminate abnormal conditions in time. Never use a stacker with malfunction to ensure safety and to prolong the service life of the stacker. 6.2 Mai Mainten ntenanc ance: e: The mainte maintenanc nance e of the sta stacke ckerr is div divide ided d into into three three levels levels,, i.e. i.e. rou routine tine maint maintenan enance, ce, level level I maintenance and level II maintenance. Routine maintenance: Daily maintenance is to clean the surface of the stacker body and the surface of the storage battery; examine the firmness of the power supply cable and whether the elasticity of the chain is normal. Level I maintenance: Level I maintenance should be performed once every week. Besides what should be done in daily maintenance, the operation situation of all the parts should be carefully inspected to see whether the operation is normal; whether there is any loose of the fasteners; whether the elasticity of the chain is appropriate; whether the connecting pin of the chain connection is bending or twisting; whether the up and down movement of the internal and external mast is normal; is there any oil leakage at the hydraulic connection; is there any abnormal wearing and tearing in the mechanical parts; is there any abnormal temperature rise or sparks in the electric part, etc. If there is any abnormal situation, adjustment or trouble-shooting should be conducted promptly. Level II maintenance should be carried out as planned. Overall inspection should be performed for the stacker according to the following requirements. a. Maintenance for mechanical system: Once half a year. The major content is to add lubricant to the transmission gears, bearings of the drive wheel and the rotary joints. Meanwhile examine the firmness of the fixing fittings, the flexibility of the wheels, as well as whether the forks can be lifted and lowered normally. Clean the dirt and dust on the friction plate of electromagnetic arrester and adjust the clearance to the proper distance. The operation noise of  the stacker shall not exceed 70 dB after the maintenance. b. Maintenance for hydraulic system: Once every 12 months. Examine if the oil cylinder is normal, if there is any leakage externally or internally, if the hydraulic connection and the hose are reliable with no leakage. The hydraulic oil should be kept clean and generally it should be replaced every 12 months. ISO oil product standard is adopted for the hydraulic oil. When the ambient temperature is –5~ 40℃C, HL-N46 or HL-N68 should be used; when the ambient temperature is –35~ –5℃C, HV-N46 or HV-N68 should be used. The replaced waste oil should be treated according to the local rules and regulations. c. Maintenance for electric equipment: Once every three months. First examine whether the specific gravity of the electrolytic solution of the storage battery [specific gravity at 1.24 (at 25℃C) in tropical areas and 1.26 (at 25℃C) in other areas] fits and the terminals are clean. Otherwise, the specific gravity of the electrolytic solution should be adjusted as required and the terminals should be cleaned and painted with Vaseline and tightened. Examine if  the the co conn nnec ecti tion onss of th the e elec electr tric ical al de devi vice cess ar are e reli reliab able le,, the the switch swi tches es are normal normal and the ins insula ulatio tion n is ok (The (The ins insula ulatin ting g resistance between the electrical devices and the stacker body should be above 0.5MΩ). Clean the dirt, dust, and carbon fouling of motor. Meanwhile check the wearing condition of the electric brush and replace it if necessary.

6.3 Adjustment of the brake clearance:：

 

1 Hollow screw 2 Fitting screw 3 Spring 11

 

4 Armature 7 Friction plate

5 Motor shaft

6 Spline housing

8 Electromagnetic coil

9 Mounting cover plate 10 Mounting screw  After a period of use, performance of the brake will decline due to the wearing and tearing of the brake plate. Then it is necessary to adjust the clearance of the brake. As indicated in the drawing, first use the insert ruler to check the clearance between the brake plate and magnetic steel. If the clearance is over 0.5mm, adjust it. Before the adjustment, clean the dirt and dust on the friction plate. During adjustment, first loosen the tightening screw 2, then adjust the length of the adjustment screws 1 and screw down the tightening screws. After the adjustment, the clearance between brake plate and magnetic steel shall be kept between 0.2-03mm. During the adjustment, make sure that the three tightening screws are adjusted evenly so as to ensure that the clearance between brake plate and magnetic steel are distributed around equally. After the adjustment, turn on the brake with 24v DC power. Then the brake will make clear sound.

Common faults and trouble shooting

7

 

No.

Faults

Cause

Trouble shooting

1 The fuse of the control circuit is burnt out.

Replace

2 The power switch switch cont contact act is bad or The

stacker

can’t

be

Repair or replace

damaged.

starte started. d. (Th (The e con contac tacts ts do

3The 3The ffus use e of th the em maj ajor or ccir ircu cuit it is is bro broke ken. n.

not work either.)

4 The contact of the electric lock switch is bad or broken. 5 The connection of the storage batteries is loose or has fallen off.

Repl Replac ace e Repair or replace

Tighten

1 The side-magnetic brake of the drive 1

wheel does not suck and the stacker

Repair or replace

is in a braked condition. 2 The walking motor carbon brush is worn or bad contact between the steering Th The e sta tack cker er can anno nott be st star arte ted d (T (The he cont contac acto torr works.)

Repair or replace

device and the carbon-brush. 3 The magnet-exciting coil of the walking motor is broken or bad contact at

Repair or replace

the wire end. 4 Bad contact

Repair or replace

5 There is a trouble at the MOSFET tube type circuit board. 2

3 4

Repair or replace

The stacker can only move

1 Bad or broken contact.

Repair or replace

forward (or backward)

2 The There re is a tr trou oubl ble e iin n tthe he ci circ rcui uitt boa board rd..

Re Repa pair ir or repl replac ace e

The stacker stacker can not stop stop

Br Brok oken en co cont ntac act. t. Th The e

Cut off the power supply at

while traveling.

cannot be reset.

The brake does not work.

1The e re rection b o ollt of t h he e inching s w wiitch  Adjust or tighten the bolt or

mo movi ving ng co cont ntac actt

looses or is damaged.

once and replace the contact

replace the inching switch. 12

 

2The connecting wire of the side-magnet brake

is

loose

or

the

brake

is

damaged. 3 The braking plates of the side-magnet brake are worn. 1The 1Th e bea bearin ring g of the steer steering ing dev device ice is 5

Th The e ste teer erin ing g blocked.

de devi vice ce

is

damaged 2 The bearing of the steering device lacks lubricant or there is too much dust. 1The gear or bearing is bloc blocked ked because of foreign matters.

Di Diff ffic icul ultt 6

st stee eeri ring ng

of

th the e

drive wheel, noise and the motor is overloaded.

Replace the braking plates.

Replace the bearing

Clean the bearing

Clean or replace the bearing. The fixing ring has come off,

installed or the fixing ring has come

reinstall the ring. Adjust the

off.

clearance.

3 The The fron frontt w whe heel el bear bearin ing g is is dam damag aged ed..

Repl Replac ace e tthe he bear bearin ing g

1 Overload

Reduce the load

too low. 3 Internal abnormal leakage in the lifting oil cylinder

5I 5Ins nsuf uffi fici cien entt

vo volt ltag age e

of

 Adjust the pressure pressure higher

Replace the seals  Add appropriate quantity of 

4Insufficient hydraulic oil

filtered hydraulic oil th the e

st stor orag age e

battery The forks cannot be lifted

side-magnet brake.

2T 2The here re is a cl clea eara ranc nce e in th the e bear bearin ing g

2 The pressure of the overflow valve is

7

Tighten the bolt or repair the

Charge the battery

6The control handle is not horizontal or vertical, the motor of oil pump has not

Improper operation

been turned on.. 7Damaged oil pump motor

Repair or replace

8 Damaged oil pump

Repair or replace

9 Damaged lifting button

Repair or replace

10The electric lock is not unlocked or is damaged. Seri Seriou ousl sly y in insu suff ffic icie ient nt vol volta tage ge iin n th the e ce cell ll.. 1 The internal internal mast is ove overlo rloade aded d and deformed. 2 The exter external nal mast is overl overloaded oaded and 8

13

The

forks

cannot

lowered after lifted.

be

deformed.

Repair or replace Rech Rechar arge ge Repair or replace

Repair or replace

3 Frame roller is blocked.

Repair or adjust

4 Mast guiding rode is curved.

Repair or straighten

5 The oil return hole is blocked.

Clean

 

6

Th The e elec electr trom omag agne neti ticc

valv valve e

of the the

hydraulic station is out of control.

9

Redu Reduce ced d

vo volt ltag age e

sto torrage age

ba batt tter ery y

charging)

of

Shoot the trouble

1 Damage of individual battery

Repair or replace

2L Low ow leve levell of of the the elec electr trol olyt ytic ic so solu luti tion on

Ad Add d ele elect ctro roly lyti ticc sol solut utio ion n

th the e

(a (aft fter er

3F 3For orei eign gn

ma matt tter erss

in

the the

elec electr trol olyt ytic ic

solution

Replace electrolytic solution

8 Use, maintenance and charging of the batteries 8.1 Initial charge Note: The charging environment requires good ventilation and there should be no open flame, otherwise explosion may occur. 8.1.1 Initial charge should be conducted for new batteries. Before the initial charge, the surface of the batteries should be cleaned and the batteries should be examined for damage. The bolts should be tightened to ensure reliable connection. 8.1.2 Pull out the sealing cover and replace it with the open cover type liquid hole plug and open the cover. 8.1.3 When the charging equipment is able to operate normally, pour the sulfuric acid electrolyte with a density of  1.260±0.005 1.260±0.0 05 (25℃C) and a temperature of lower than 30℃C 30 ℃C into the batteries. The liquid surface should be 1525mm higher than the protective board. In order to reduce the temperature rise caused by chemical reaction of the electrolyte and let the electrolyte fully penetrate into the pores of the polar plates and the baffle plates, the batteries should be placed still for 3-4 hours but not over 8 hours. The initial charging can only be conducted when the temperature of the solution drops to below 35℃C. (When necessary, the batteries can be put into cold water for temperature reduction). After the still placement, if the surface of the electrolyte reduces, electrolyte should be added. 8.1.4 The sulfuric acid electrolyte is prepared with battery sulfuric acid complying with the state standard GB4554-8 GB4554-84 4 and distilled water. Never use industrial sulfuric acid and running water. The standard temperature and density of the electrolyte can be converted as follows: D25＝Dt＋0.0007(t －25) Where: Whe re:

D25: D25: tthe he dens density ity of the the e elec lectro trolyt lytic ic sol soluti ution on at at 25℃C 25℃C

Dt: the actual density of the electrolytic solution at a temperature of t ℃C. t: temperature of the electrolytic solution when testing the density. 8.1.5 Sweep the electrolyte on the surface of the batteries and connect the positive and the negative poles of the battery pack respectively with the positive and the negative ends of the DC power supply (charger). Turn on the power supply. First charge with 28A (the first stage current,); when the voltage reaches 28.8V (12 ×2.4V = 28.8V), change to the second stage current 14A and continue to charge. The temperature of electrolyte during the process of charging must not exceed 45℃C and when it is close to 45℃C, the charging current should be reduced by 50% or the charging should be stopped temporarily. Wait till the temperature drops to 35℃C to continue the charging. The charging time, however, should be properly prolonged. 8.1.6 Fully charged basis: When the voltage during the second stage charging reaches 31.2V (12 ×2.6V = 31.2V), the variation of the voltage is no greater than 0.005 (V); the density of the electrolyte reaches 1.280 ±0.005 (25℃C), no obvious variation in 2 hours and there are fine air bubbles appear violently, it can be deemed that the batteries are fully charged. The charged power capacity is 4-5 times of the rated capacity and the charging time is about 70 hours. 14

 

8.1.7 In order to accurately control the sulfuric acid content of the electrolyte, the electrolyte density of the batteries should be examined during the last period of charging. If there is inconsistence, adjust with distilled water or sulfuric acid with a density of 1.40. The electrolyte density and the liquid surface should be adjusted to the stipulated value within two hours in the charging state. 8.1.8 After the initial charging is completed, the surface of the batteries should be cleaned. Close the cover of the open cover type liquid hole plug and then the batteries can be used.

8.2 Use and maintenance

8. 8.2.1 2.1 In ord order er to guaran guarantee tee the servi service ce lif life e of the batte batterie ries, s, the bat batter teries ies in use shoul should d be fully fully cha charge rged. d. Insufficiently charged batteries must not be used. During the process of use, close attention should be paid to the discharge extent. Over discharge is prohibited---the voltage reduces to 1.7V per battery (when the total voltage reduces to 1.7V×12 = 20.4V ). When the density of the electrolyte reduces to 1.17, discharging should be stopped and charging should be conducted at once. The batteries should not be placed idle for a long period of time. The supplementary charging frequently conducted during the process of use is called common charge. 8.2.2 Common charge: The first stage current of common charge is 40A and that of the second stage is 20A. The charging method is the same as that of initial charge. The charged volume is 130-140 % of the discharged volume and the charging time is about 15 hours. 8.2.3 The batteries in normal use should avoid over-charge, but over-charge must be properly conducted for the batteries in the following situation, i.e. equalizing charge. a. The “lag-behind” batteries--- batteries with a voltage lower than that of the other batteries in the charging and discharging process and the batteries having been repaired for failure. (When equalizing charge is conducted, the positive and negative poles of the “lag-behind” battery should be respectively connected with th the e po posi siti tive ve and and ne nega gati tive ve ends ends of the DC powe powerr su supp pply ly,, and and the the ch char arge ge sh shou ould ld be co cond nduc ucte ted d independently.). b. Equalizing charge should be conducted for the batteries in normal use every 2-3 months. c. Equalizing charge should be conducted for the batteries that have not been used for a long period of time before use. 8.2.4 Equalizing charge： a. Charge with a 6A current b. When the charge voltage reache reachess 31.2 31.2V V (12 ×2.6V = 31. 31.2V) 2V) and air bubbles occur in the electroly electrolyte, te, the current should be reduced by 50% (3A) and continue to charge. c. When the batteries are fully charged, stop charging for 0.5 hour and charge again with a 1.5A current for one more hour. d. Stop charging for another 0.5 hour and charge with a 1.5A current for another one hour. e. Repeat according to item d till air bubbles occur violently in the batteries once the charger is switched on.

8.3 Storage 8.3.1 Batteries Batteries should be stored in a clean, dry and well-ventilated well-ventilated warehouse with a temperat temperature ure of 5-40℃C. The valid storage period is 2 years. The batteries should be kept according to the following requirements during storage period: a.

No direct direct su sunligh nlightt on the batte batteries ries a and nd at lleast east 2 2m m away from h heat eat so source urce..

b.

Avoid Avoid conta contacti cting ng with any harm harmful ful subs substan tances ces.. No metal metallic lic mat matter terss are allowe allowed d to drop into the batteries.

15

c.

The bat batter teries ies sho should uld not be pla placed ced ups upside ide do down wn and shou should ld not be hit mech mechani anical cally ly or heavi heavily ly pressed.

d.

The batteries batteries must must not be stored wi with th electr electrolyti olyticc solution. solution. When it is require required d in specia speciall situat situation ion

 

that the batteries must be stored with electrolytic solution, the batteries should be fully charged and the density and the liquid surface of the batteries should be adjusted to the stipulated values. When the storage period comes to one month, the batteries should be complementarily charged with the common charge method.

9 Lists of accessories, spare parts and vulnerable parts No.

Name

1

Key to the electric lock  

Type & specification

Unlock the electric

Quantity

Matched with the

socket

charger

3

Fuse

Electric equipment

10A

1

4

Fuse

Electric equipment

160A

1

5

Sealing ring

Oil cylinder

UHS40

1

6

O type sealing ring

Oil cylinder

50X3.55

1

7

O type sealing ring

Oil cylinder

23.6X3.55

1

8

Composite ring

Oil inlet of cylinder

D14

1

9

Dustproof ring

Oil cylinder

DH40

1

Sealing ring

Support oil cylinder

UHS35

1

Sealing ring

Support oil cylinder

UHS31.5

1

Dustproof ring

Support oil cylinder

DHS31.5

1

13

O type sealing ring

Support oil cylinder

17×2.65

1

14

O type sealing ring

Support oil cylinder

40×3.10

1

10 CDD2045

11

with auxiliary

12

supporting

Remarks

2

lock 

Charging plug and

2

legs

Use position

1 set

10. Package & transportation  The stacker is packed with a pallet. During transportation, turnover and upside-down are not allowed. Collision is not allowed when lifting and loading onto the truck. Do not damage the outward surface of the stacker when the package is unwrapped.

11  Warning (points for attention) 16

 

11.1

Read the the manua manuall carefully carefully be before fore operatio operation n so as to know know the pe perform rformances ances o off the stacker. stacker.

11 11.2 .2

It is forbidde forbidden n to pres presss and fre freque quentl ntly y switch switch the liftin lifting g and low loweri ering ng butt buttons ons whi while le the stacker stacker is traveling. Otherwise, it might damage the stacker and the goods.

11 11.3 .3

Do not not sshak hake e the the handl handle e ra rapid pidly ly or with with hi high gh freq frequen uency. cy.

11.4

It is not allow allowed ed tto o rrapid apidly ly load load heavy goods onto the forks. forks.

11.5

The sstacke tackerr should should not not be overlo overloaded. aded. When o overl verloaded oaded,, the stac stacker ker w will ill no nott be able to

11.6

operate normally. The cen center ter of gravit gravity y of the goods goods shou should ld be pla placed ced bet between ween the ttwo wo for forks, ks, othe otherwis rwise, e, the forks will be damaged and the goods will fall down in the process of operation.

11.7

Loose and unstab unstable le goo goods ds are are not a allowe llowed d to lload oad on onto to the stac stacker. ker.

11.8

Do not not pu putt the goods on th the e for forks ks for for a long period period of time time..

11.9

Turning Turning rapi rapidly dly on na narrow rrow rroad oad is fo forbid rbidden. den. In o order rder to e ensure nsure tthe he safe safety ty of the pe people ople and goods, the stacker should turn slowly in this situation.

11.10 When the stacker is not in use, the forks should be lowered to the lowest position 11.11 Never put any part of human body under heavy goods and forks. 11.12 The stacker is applicable for use on flat ground and should never be parked on slope for a long period of  time. 11.13 Over-load or over-slope operation is forbidden. Otherwise the wheel will slip, damaging the wheel and the motor. The safety of people and goods will be affected as well. 11.14 It is forbidden to repair the stacker by untrained personnel. 11.15 Operation of the stacker under the stipulated voltage 20.4V is forbidden. 11.16 It is strictly forbidden to directly connect the plug with AC power supply for charge. 11.17 When the lift height of forks exceeds 500mm, the stacker must travel at the minimum speed and the continual traveling distance must not exceed 2m.

12 Principle diagrams of hydraulic and electric systems  “Principle diagram of hydraulic system”   “Principle diagram diagram of electri electricc system” 

17

 

13 Packing list Packing List of Electric Pallet Stacker Consignee：  Ex-factory No.： Contract No.：  No.

Ex-factory date：

Name

Quantity

Electric pallet stacker

1

with straddle legs

Net weight

Dimension

(kg)

(L×W×H)

Remarks

1

A complete set. Technical documents,

2

Accessory box

1

accessories and spare parts.

Note: 1. The following documents are in the file bag: 1Operation manual of Electric Pallet Stacker

1 volume

2Packing list 3Qualification certificate

1 copy 1 copy

2． Accessories and and spare parts No.

Name

Use position

Key to electric lock

Unlock the electric lock

Charging plug and

Matched with the

socket

charger

3

Fuse

Electric equipment

10A

1

4

Fuse

Electric equipment

160A

1

5

Sealing ring

Oil cylinder

UHS40

1

6

O type sealing ring

Oil cylinder

50X3.55

1

7

O type sealing ring

Oil cylinder

23.6X3.55

1

8

Composite ring

Oil cylinder

D14

1

9

Dustproof ring

Oil cylinder

DH40

1

1 2

Type & specification

Qty

Remarks

2 1 set

With no charger for built-in type

18

 

For

10

Sealing ring

Support oil cylinder

UHS35

1

CDD204

11

Sealing ring

Support oil cylinder

UHS31.5

1

5

12

Dustproof ring

Support oil cylinder

DHS31.5

1

13

O type sealing ring

Support oil cylinder

17×2.65

1

14

O type sealing ring

Support oil cylinder

40×2.65

1

Support oil cylinder

Hydraulic Principle Diagram  Diagram  (CDD1545/CTD1545/CTD2045/CDD1545H/CTD1545H/CTD2045H)

19

 

lift oil cylinder Support oil cylinder

Pressure relay

20

 

Hydraulic Principle Diagram (CDD2045/CDD2045H)

21

 

22

 

.

23

 

24

 

25