Noblelift CG1646, Service Maintenance Manual

Page 1: ...NOBLELIFT EQUIPMENT Service Maintenance Manual Power Sacker CG1646 V CG1646 01 00 Date 2011 2 10 ...

Page 2: ... 3 7 CURTIS CONTROLLER 33 3 8 BATTERY INDICATOR 40 3 9 REPLACE THE ELECTRIC PARTS 42 3 10 TOOL FOR REPAIRING THE PIN OF ELECTRIC PLUG 47 3 HYDRAULIC SYSTEM 48 4 1 OPERATION OF PUMP STATION 49 4 2 REPLACE THE CYLINDER 51 5 DRIVE WHEEL 52 5 1 THE DRIVE WHEEL 52 5 2 REPLACE THE DRIVE WHEEL 52 5 3 REPLACE THE CARBON BRUSH KIT 56 5 4 REPLACE THE BRAKE 57 5 5 ADJUST THE CLEARANCE OF THE BRAKE 57 6 CONTR...

Page 3: ...must be collected and disposed of in an environment friendly way and in accordance with the directives of respective countries Such work must be carried out in areas intended for this purpose Recyclable material should be taken care of by specialized authorities Environmentally hazardous waste such as oil filters batteries and electronics will have a negative effect on the environment or health if...

Page 4: ... THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA RESPONSIBIUTY OF THE OWNER OR OPERATOR FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LlSTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION When carrying out any operation or maintenance have trained and experienced personnel carry out the work ...

Page 5: ...ly clothes When checking always release battery plug DO NOT WEAR LONG HAIR UNRESTRAINED OR LOOSE FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT During maintenance do not allow any unauthorized person to stand near the machine Flames should never be used instead of lamps Never use a naked flame to check leaks or the level of oil or electrolyte Immediately ...

Page 6: ...achine on firm flat ground Lower the fork to the min height and stop the motor Sulfuric acid in battery electrolyte is poisonous Ist is strong enough to burn skin and eat holes in clothing If you spill acid on your clothes or skin immediately jlush with large quantities or water When working on the battery wear goggles or safety glasses If splashed into the eyes flush with water and get medical at...

Page 7: ...place with new sealing parts Thoroughly clean the machine In particular be careful to clean the grease fittings and the area around the dipsticks Be careful not to let any dirt or dust into the system Use only approved nonflammable cleaning solvents When changing the oil or fitter check the drained oil and filter for any signs of excessive metal particles or other foreign materials Always use NOBL...

Page 8: ...76400 1195800 a 0 01 100 0 0001 1 1076 4 119 58 ft2 0 092903 0 000929 1 0 1111 144 000 yd2 0 83613 0 008361 9 1 1296 00 in2 6 4516 0 000645 0 006943 0 000771 1 1ha 100a 1mile2 259ha 2 59km2 Volume Unit cm3 cc m3 l in3 ft3 yd3 cm3 m l 1 0 000001 0 001 0 061024 0 000035 0 000001 m3 1000000 1 1000 61024 35 315 1 30796 l 1000 0 001 1 61 024 0 035315 0 001308 in3 16 387 0 000016 0 01638 1 0 000578 0 00...

Page 9: ...e following charts give the standard tightening torques of bolts and nuts Exceptions are given in sections of Disassembly and Assembly METER TABLE Classification 4T 5T 10T Bolt type Bolt size Torque kgf m lbf ft Torque kgf m lbf ft M4 0 2 0 02 0 4 0 04 M5 0 3 0 03 0 8 0 08 M6 0 5 0 05 1 4 0 14 M8 1 2 0 12 3 3 0 3 M10 2 3 0 23 6 5 0 7 M12 4 0 0 4 11 3 1 1 M14 6 4 0 6 17 9 1 8 M16 9 5 0 9 26 7 2 7 M...

Page 10: ... 7 1 1 8 54 1 5 41 152 2 15 2 1 1 4 74 2 7 42 208 9 20 9 1 3 4 98 8 9 88 277 8 27 8 1 1 2 128 2 12 82 360 7 36 1 The torque in above table shall not be applied to the bolts with nylon packings and nonferrous metal washers or the ones with specially designated torque and standard H Newton meter 1 N m 0 1kgf m TIGHTENING TORQUE OF SPLIT FLANGE BOLTS The following torque shall be applied to the split...

Page 11: ...THREAD Thread Torque kgf m 1 8 1 1 0 1 1 4 2 6 0 2 3 8 4 6 0 3 1 2 8 5 0 4 3 4 19 1 0 1 33 2 0 TORQUE FOR SWIVEL NUT WITH O RING Connector O ring Swivel nut hose Tube O D inch Thread in Torque kgf m 1 2 UN 13 16 16 9 5 0 95 3 4 UN 1 3 16 12 18 1 8 1 UN 1 7 16 12 21 2 1 ...

Page 12: ...0 069 bar megapascal MPa 145 psi 0 00689 MPa Pa N m2 Power r W J s kilowatt kW 1 36 PS cv 0 736 kW kilowatt kW 1 34 HP 0 746 kW kilowatt kW 0 948 Btu s 1 055 kW watt W 0 74 ft lb s 1 36 W W J s Energy J N m kilojoule kJ 0 948 Btu 1 055 kJ joule J 0 239 calorie 4 19 J J N m Velocity and Acceleration meter per sec2 m s2 3 28 ft s2 0 305 m s2 meter per sec m s 3 28 ft s 0 305 m s kilometer per hour k...

Page 13: ...oller CONTROL HANDLE Tiller 1 FWD BWD Turning Knob Control the speed of the stacker and moving direction forward or backward 2 Shifting Button for high speed and low speed Snail function takes light touch switch when touch the button once the speed becomes low Touch the button once again the speed recovers to high 3 Universal Reversing Button the emergency directional reverse button 4 RAISE Button...

Page 14: ...nt performance laden 6 Turning radius Wa mm 1605 Tyre size front 250 78 Drive motor rating kw 1 2 Lift motor rating kw 3 0 Sound level at driver s ear acc to EN 12053 B A 70 2 2 2 Residual Capacity at different lifting height Up to TOP mm ACTUAL CAPACITY Q kg 2500 1600 1000 3700 1000 600 4600 800 500 Load centre distance C mm 600 700 2 3 LUBRICATION CG1646 A 2098mm B 1950mm C 570 or 695mm D 1050mm...

Page 15: ... 1000 h 2000h 1 Wheel bearings L A 2 Mast beam L B 3 chains L C 4 Hydraulic system C O D 5 bearings L E 6 Drive gear O F L Lubrication C Check O Oil change Oil and grease specification Lubricant Specification 15 15 Application area A Grease 2 Grease 2 Grease Bearings Bushings Joint B Grease 2 Grease 2 Grease Side shift forks C Grease 2 Grease 2 Grease Chains and wires D Hydraulic Oil 40 Hydraulic ...

Page 16: ...18 3 ELECTRIC SYSTEM 3 1 ELECTRIC DIAGRAM WIRING DIAGRAM ...

Page 17: ...0 DC24V 1 9 Et DQ 13 Controller CURTIS 1243 4220 1 10 VD DQ 10 Diodes 1N5408 2 11 FU DQ 9 Fuse 10A 1 12 S DQ 48 Emergency button ZDK31 250 1 13 SY DQ 26 1 Lock LKS 101A 1 14 P DQ 27 Battery Indicator CURTIS 803 1 15 SA DQ 23 Micro switch Z 15GW2 1 16 K DQ 14 Relay ARL2F DC24V 1 17 Kr DQ 2 1 Protect module BD W135 110 1 18 HA DQ 22 Horn DC24V 1 20 B WG 5 Control handle CH 1 1 21 SH DQ 45 Magnetic s...

Page 18: ...escription Note 1 30914100030 Cable of Control Circuit 2 30914900016 Cable of Handle 3 30914800037 Cable of Electromagnetic Brake European Driving Wheel 4 30914800038 Cable of Speed Limiting Switch 5 30914800039 Cable of Micro Switch 6 L2501008 Controlling Cables Circuit Board A4 ...

Page 19: ...21 CG1646 Universal Electric Parts List ...

Page 20: ...f Micro Switch 2 8 30902700001 Controlling Board CL 0 1 9 5010504020C0 Phillips Screw M4 20 2 10 30911100026 6A Fuse 1 11 30913300001 White Polar 8 10 2 12 30906600006 Horn 125 24V 1 13 503020023 Elastic Washer Φ8 4 14 5010408016C0 Socket Head Screw M8 16 4 15 422420032 Cable Clip 2 16 5010605012CB Phillips Screw M5 12 2 17 30906100001 Power Switch New Type 1 18 30913300003 CL Plastic Cable Clip A...

Page 21: ...15N M Gear Box transmission ratio 1 32 3 4 PUMP STATION Type MS2 Q V1C F7 5 R1 PM7 MFP1F T08C F0 for Type CG1646 Item Specification Rated voltage 24V Rated output 3 0kw R P M 3300 rpm Rated current 200 A Rated hour 4 0 min Insulation class F class IP Code IP43 Displacement 3 2cc rec Max operating pressure 200bar 3 5 BATTERY The size of battery is according to English BS standard Rate Specification...

Page 22: ... of the power supply to of the battery the cathode of the power supply to of the battery Avoid reverse polarity for fear of reverse charging The voltage of the charge power supply should be higher than 1 5 times of the charged battery When all the work is properly done the cells can be charged according to parameters outlined in the list below Model Charging current A initial charge common charge ...

Page 23: ...cells when it is fully charged shut off the charge power supply keep it still for half an hour then switch on the power supply and continue to charge with the current of phase 2 When air bubbles come out convert to 1 2 of the current of phase 2 and continue to charge the cells when air bubbles are produced shut off the charge power supply keep is still for half an hour then switch on the power sup...

Page 24: ...0 180 480 Concentration 500 C g cm3 1 1 1 3 Ignition residue content 0 02 0 24 Manganese Mn content 0 00004 0 00048 Ferrum Fe content 0 004 0 048 Arsenic As content 0 00003 0 00036 Chlorine Cl content 0 0007 0 0084 Ammonia salt content N 0 0005 0 006 Copper Cu content 0 002 0 024 Deoxidized potassium permanganate content 0 0008 0 01 Content calculated by KMn04 0 0032 0 038 Don t spatter electrolyt...

Page 25: ...E 5hr discharge curve 1 6 1 65 1 7 1 75 1 8 1 85 1 9 1 95 2 2 05 2 1 0 1 2 3 4 5 6 time h voltage V 0 5hr disvharge curve 1 4 1 45 1 5 1 55 1 6 1 65 1 7 1 75 1 8 1 85 1 9 1 95 2 0 5 10 15 20 25 30 35 time min voltage V ...

Page 26: ...p Do not smoke around the battery during charge Any fire and spark is forbidden MAIN PRODUCT SPECIFICATION Type Input power Battery capacity Input voltage Output voltage Output current range DF2440 1 9KVA 270 300 220v 31 2 40A ENVIRONMENTAL CONDITION No Item Technical specification Unit Remark 1 Humidity 5 80 With package 2 Altitude 2000 m Work normally 3 Cooling Fan convection cooling Working und...

Page 27: ...fficiency 80 3 Protection characteristics No Item Technical requirements Unit Remark 3 1 Output over voltage protection 32 V 3 2 Thermal protection When the transformer temperature is higher than 125 130 the charger automatically protect stop charging 3 3 Output current limiting protection DF2440 40 A 3 4 Output short circuit protection If a short circuit load the charger will be protected and wil...

Page 28: ...m it Please check the blower is running normally or not regularly In case of failure of microcomputer controller please inform the service engineer or maintenance staff Check height of electrolyte in the battery in accordance with the manufacturer s instructions COMMON CHARGE Connect cable plug of the battery to corresponding output plug of the charger firmly Connect the battery firstly then conne...

Page 29: ... are required to observe and check voltage and specific gravity of the batteries and determine charge time manual power off and charge stop as required TROUBLESHOOTING Failures Causes Troubleshooting The indicator light for power is on the indicator light for failure is on the blower is on the charger can not start and charge and the monitor is not display The battery is not connected or the outpu...

Page 30: ...he preceding air switch Incorrect matching of air switch Small capacity of the air switch Rated current of the preceding stage air switch is more than that of the air switch of the charger The air switch must be type D dynamic type type C illumination type is unavailable Excessive overcharge for the battery Internal short circuit of single battery of the group Check each terminal voltage of every ...

Page 31: ...33 3 7 CURTIS CONTROLLER ...

Page 32: ...onnector is provided for the handheld programmer A complete 1311 programmer kit including the appropriate connecting cable can be ordered from Curtis The 4 pin connector can also be used for the Spyglass display The display is unplugged when the programmer is used High Current Connections Three tin plated solid copper bus bars are provided for high current connections to the battery B and B and th...

Page 33: ...RATE M2 DECELERATION RATE 1 2 0 1 to 10 s Defines the rate at which the vehicle decelerates to zero speed in Mode 1 when the throttle is released to neutral M3 DECEL RATE M3 DECELERATION RATE 5 9 0 1 to 10 s Defines the rate at which the vehicle decelerates to zero speed in Mode 1 when the throttle is released to neutral M4 DECEL RATE M4 DECELERATION RATE 5 9 0 1 to 10 s Defines the rate at which ...

Page 34: ...t is decreased or the if the vehicle is moving when zero throttle is requested LOAD COMP LOAD COMPENSATION 5 Off 0 Brk 1 KSI 2 KSI Brk Fwd only 3 Adjusts the controller s response to increasing motor loads at a fixed throttle request HPD HIGH PEDAL DISABLE HPD 2 Off 0 Brake 1 KSI 2 Disables controller if 25 throttle is applied before the KSI and or brake inputs SRO STATIC RETURN TO OFF SRO 2 Off 0...

Page 35: ... TMO ENABLE CAN TMO ENABLE 1 On Off Enables or disables a CAN bus communications watchdog Loss of PDO messages once started will generate ERROR frames NOTE for standard parameter 1 on 0 off TROUBLESHOOTING CHART A Status LED is built into the controller It is visible through a window in the label on top of the controller This Status LED displays fault codes when there is a problem with the control...

Page 36: ...cutoff point 2 Corroded battery terminal 3 Loose battery or controller terminal 4 2 OVERVOLTAGE 1 Battery voltage 33V When voltage falls below overvoltage cutoff point 2 Vehicle operating with charge attached 4 3 THERMAL CUTBACK 1 Temperature 85 or 25 Clears when heatsink temperature returns to within acceptable range 2 Excessive load on vehicle 3 Improper mounting of controller 4 Working limit en...

Page 37: ...on quickly press the appropriate bookmark key 1 2 or 3 Note that the bookmarks are not permanently stored in the programmer They are cleared when the programmer is unplugged The bookmark keys can be used to make parameter adjustment easier For example in adjusting the throttle deadband you might set a bookmark at the Throttle readout Monitor THROTTLE and another at the Throttle Deadband parameter ...

Page 38: ...witch pin is not energized The control inputs HRM and HRM are enabled by the keyswitch Pin 2 is connected to the vehicle s keyswitch Pins 1 6 Hour Meter Control In normal operation Pin 1 or 6 is connected and the other is left open Only one of these pins is connected when using normal hour meter function It is possible to or the hour meter between the two inputs so that it accumulates the total ti...

Page 39: ...e is connected to the battery during recharge the gage will track the battery charge level OCR Open Circuit Reset If the gage is disconnected from the battery during recharge the gage will retain the last indication It willadvance to full when reconnected only if the battery voltage is above the OCR level For standard B reset OCR 2 09 VPC VPC volts per cell TROUBLESHOOTING Problem Possible Causes ...

Page 40: ...ver No 1 Step 2 Dismantle the plugs No 2 and 3 Step 3 Use two lifting hook to hook the hole of the battery box Then you can use a crane to take away the battery and replace it REPLACE THE CONTROLLER BATTERY INDICATOR ETC Remove 6 pcs the screws Then remove the right cover and left cover ...

Page 41: ...Then you can dismantle the pump station and replace it REPLACE THE BATTERY INDICATOR take away the U clamp dismaantle the 8 pins plug Then you can dismantle the battery indicator and replace it REPLACE THE FUSE Open the cover of the fuse seat then you can dismantle the fuse and replace it ...

Page 42: ...e it OPERATION OF THE CONTROLLER When replacing the controller be carefully tto check the tightnessof the nut specially note the cathode pillar Two 1 4 quick connect terminals S1 and S2 are provided for the connections to the motor field winding Do not allowed to access anti line otherwise the mortor will be reversed ...

Page 43: ...crew and the plastic cover with a screwdriver remove the two cables on the micro switch Then you can dismantle the micro switch and replace it REPLACE THE LOCK KEY SWITCH LKS 101A Remove the nut of the key switch Dismantle the cable of the key switc Then you can dismantle the key switch and replace it REPLACE THE EMERGENCY BUTTON Turn the mushroom head of the emergency button let the hole of the m...

Page 44: ...iver to insert the hole then turn counter clockwise the mushroom head to remove the mushroom head Take out the emergency button remove two bolts to remove the cable then you can dismantle the emergency button and replace it ...

Page 45: ...Figure Application 1 Tool for removal of pins sleeves 2 Tool for application of pins sleeves 3 Tool for release of lock 4 Tool for application of secondary locking 2 pole 5 Tool for application of secondary locking 4 pole 6 Tool for removal of pins sleeves ...

Page 46: ... Possible to use Clear but the color becames brighte Fine Mixed with other oil Inspect the viscosity and if fine it can be continuously used Color changed like milk Fine Mixed with air and water Separate water or replace oil Color changed into dark brown Bad Oxidized Replace oil Clear but there are small black spots Fine Mixed with other particles Use after filtering ...

Page 47: ...plate for valve No 5 etc Clean up with compressed air and inspect if the filter is stopped or damaged If the filter is stopped or damaged replace it Remove dust or foreign material from the tank Then assemble them TROUBLE DIAGNOSTICS Symptom Abnormality and cause Countermeasure Bubble in hydraulic oil Mixed with air Check if there is any place where air can be enteted Tighten the loosened part aga...

Page 48: ...the plug ahter some tome It is not leak For the electric current of the Relay No 1 for the lifting motor is very big and work continually hourly the contact terminal of the relay is easy demaged Please check it continually The Magnet valve is a wearing parts If the forks automatically lower after lifting the magnet valve may be blocked or dameged remove it to clear or replace ...

Page 49: ...c pipe and hydraulic pipe might be loosed and leak oil so usually check and tighten it 4 2 REPLACE THE CYLINDER Remove three plastic bolts Take away the Fix board Remove the joint Remove two screw then take then you can dismantle the cylinder and replace it ...

Page 50: ...52 5 DRIVE WHEEL 5 1 THE DRIVE WHEEL Driving Wheel MR250FR ...

Page 51: ...250402009 Bearing Washer Ø30 x 42 16 349010100 Bearing 6006 1 17 504040026 Locking clip Ø55 1 18 G250402010 Cap Ø55 x 4 1 19 5010406060C0 Socket Head Screw 8 8 M6 x 3 20 349010096 Bearing 6002 2RS 1 21 G250402011 Locking clip Ø15 E 1 22 G250402012 Motor Gear Axle Z 18 1 23 G250402013 Seal Ø20 x 32 x 7 1 24 G250402014 Motor Flange 1 25 349010098 Bearing 6004 ZZCM 1 26 G250402015 Flat Key 5 x 5 x 18...

Page 52: ...Polar End 4 47 G250402029 Washer 1 48 G250402030 Flange of Brake 1 49 50101005010 Hexagonal Head Screw 8 8 4 50 G250402031 Wheel Hub 1 51 G250402032 Locking Clip Ø14 E 1 52 G250402033 Bearing Disk 1 53 G250402034 Brake Disk 1 54 G250402035 Adjusting Screw 3 55 G250402036 Electromagnetic Coil 1 56 50101005045 Hexagonal Head Screw 8 8 3 57 G250402037 Spring 4 58 G250402038 Pin 4 59 G250402039 Disc l...

Page 53: ...ic cover Step 2 Dismantle the platform for standing on remove the screw and nut Step 3 Remove 6pcs screws take out the cover plate Step 4 Remove 4pcs bolts dismantle the Box body The drive wheel appears Cut off the power before operating Dismantle the plug for the baeke and Remove 10 pcs screws temperature senso ...

Page 54: ...w holes so that ejection the wheel 4 pcs technologic screw holes 5 3 REPLACE THE CARBON BRUSH KIT Dismantle the steel shield which wrapped the motor the carbon brush appears Remove the screw which fixing the carbon brush tilt the pressure spring of the carbon brush with a screwdriver then take out the carbon brush ...

Page 55: ...CE OF THE BRAKE When the brake winding is connected with the power 24V it has the magnetic field to suck the brake plate to start the brake During the sudden circuit cut off or the climbing the slope brake stopped the motor to drive Step 1 Use multimeter 200Ω to measure Winding resistance 25Ω Step 2 Loose the three screw that fix the brake ...

Page 56: ... same clearance as showing Step 4 Adjust the above mentioned screws anticlockwise adjust 2 3 circle is okay to reduce the spring strength Brake slide should not contain grease and nothing is blocked inside Connected with plug connection should connected firmly ...

Page 57: ...20C0 Socket Head Screw M8 20 1 5 302990018 Air Spring 550N 210 1 6 422120192 Handle Arm 1 7 506030031 Anti vibration Pad 1 8 5010406010C0 Screw M6 10 2 9 339010038 Bushing 23 19 17 10 2 10 301703006 Axle φ17 71 1 11 505020005 Elastic Pin φ4 24 1 12 D01180001 Joint of Handle 1 13 5010410016C0 Screw M10 16 2 14 506030021 Dust Ring 1 18 G28010001 Control Handle Kit 1 ...

Page 58: ...e 1 6 G28010007 Bushing for Accelerator 2 7 G28010008 Horn Button 1 White 8 G28010009 Lowering Button 1 White 9 G28010010 Lifting Button 1 White 10 G28010011 Spring for Button 6 11 G28010012 Spring Bearer Plate 2 12 G28010013 Micro Switch Button 3 13 G28010014 Micro Switch Support1 1 Black 14 G28010015 Micro Switch Support 2 1 Black 15 G28010016 Accelerator 1 16 G28010017 Micro Switch Belly Button...

Page 59: ...DLE Remove 4 pcs screws which is behind the handle Push slightly the upper cover about 10mm then open it The electric parts in the handle will appear 9 cores plug which connect to the controller Check the button on the connector contacts ...

Page 60: ...e Accelerator Specially attend the Micro switch for safety Remove the Screws and Butterfly left right and the Edge Shaft 6 2 OPERATION OF THE AIR SPRING AND MICRO SWITCH Remove the pin Take out Axis of the handle bar ...

Page 61: ...e this screw then you take out the Fixed plate Remove this screw NO 4 and Global screw on the air spring Then you can dismantle the air spring and replace it Check the Micro Switch Specially attend the Micro Switch it is a safety component ...

Page 62: ...nd bolt then you can dismantle it and replace it 8 OPERATION OF THE INTERNAL MAST 8 1 DISMANTLE THE INTERNAL MAST Put the fork of the ground and drain out the hydraulic oil Step 1 Dismantle the hydraulic pipe to the pump station Step 2 Dismantle the connector of the Micro switch Z 15GW22 B which limiting the max height of the fork Step 3 use a crane or other tool to hoist the mast ...

Page 63: ...8 1 Inspection of performance 8 2 Inspection of safety and reliability of connection of all cables and if any damage 8 3 Inspection of Amperage of fuse 8 4 Inspection of safety reliability and function of switches and unlocking cam equipment 8 5 Inspection of connector replace the worn part if necessary 8 6 Inspection of function of alarm equipment Motor 9 1 Inspection of wearing state of carbon b...

Page 64: ...66 9 2 TROUBLE SHOOT ...

Page 65: ...67 ...