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Noblelift CG1646 Service Maintenance Manual

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NOBLELIFT EQUIPMENT
Service & Maintenance Manual
Power Sacker
CG1646
V-CG1646-01.00
Date: 2011-2-10

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Summary of Contents for Noblelift CG1646

  • Page 1 NOBLELIFT EQUIPMENT Service & Maintenance Manual Power Sacker CG1646 V-CG1646-01.00 Date: 2011-2-10...

  • Page 2: Table Of Contents

    CONTENTS FOREWORD .............................. 3 GENERAL ............................4 1.1 INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONS ..........4 1.2 MEASUREMENT CONVERSIONS ................... 8 SPECIFICATION ..........................13 2.1 LOCATION OF COMPONENTS ....................13 SPECIFICATION SHEETS ....................16 2.2.1 Technical Features ......................16 2.2.2 Residual Capacity at different lifting height ..............16 LUBRICATION ........................

  • Page 3: Foreword

    FOREWORD Proper operation, maintenance, troubleshooting and repairs are necessary to preserve the performance of the stacker over along period of time and ensure that fault and breakdowns do not occur. The object of this service manual is to provide the information necessary especially in connection with the performance of inspections and repairs mainly in the maintenance areas.

  • Page 4: Introduction - Maintenance Safety Precautions

    1. GENERAL 1.1 INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONS Careless performing of the easy work may cause injuries. Take care to always perform work safely, at least observing the following. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment.
  • Page 5  It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system. Relieve system pressure by cycling the applicable cntrol several times with the engine(motor) stopped and ignition on, to direct any line pressure back into the reservoir.
  • Page 6  Battery should always be disconnected during replacement of electrical components.  Always use the grades of grease and oil recommended by NOBLELIFT choose the viscosity specified for the ambient temperature.  Exhaust gas is dangerous provide ventilation when working in a closed space.
  • Page 7 When changing the oil or fitter, check the drained oil and filter for any signs of excessive metal particles or other foreign materials.  Always use NOBLELIFT genuine parts for replacement. ENSURE REPLACEMENT PARTS OR COMPONENTS ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS. ...

  • Page 8: Measurement Conversions

    1.2 MEASUREMENT CONVERSIONS Length Unit mile 0.01 0.00001 0.3937 0.03281 0.01094 0.000006 0.001 39.37 3.2808 1.0936 0.00062 100000 1000 39370.7 3280.8 1093.6 0.62137 2.54 0.0254 0.000025 0.08333 0.02777 0.000015 30.48 0.3048 0.000304 0.3333 0.000189 91.44 0.9144 0.000914 0.000568 mile 160930 1609.3 1.6093 63360...
  • Page 9 Pressure Unit kgf/cm Pa=N/m lbf/in lbf/ft kgf/cm 0.98067 98066.5 98.0665 14.2233 2048.16 1.01972 100000 14.5037 2088.6 Pa=N/m 0.00001 0.001 0.001 0.00015 0.02086 0.01020 0.01 1000 0.14504 20.886 lbf/in 0.07032 0.0689 6894.76 6.89476 lbf/ft 0.00047 0.00047 47.88028 0.04788 0.00694 kgf/cm =735.56 Torr(mmHg)=0.96784atm Standard tightening torque The following charts give the standard tightening torques of bolts and nuts.
  • Page 10 INCH TABLE 4T, 5T Classification Bolt type Bolt size Torque kgf · m (lbf · ft) Torque kgf · m (lbf · ft) 0.6 ± 0.06 1.7 ± 0.2 5/16 1.2 ± 0.12 3.0 ± 0.3 2.0 ± 0.20 5.6 ± 0.5 7/16 3.2 ±...
  • Page 11 TIGHTENING TORQUE FOR HYDRAULIC PLUGS WITH O–RING O – ring Plug PF THREAD Thread Torque (kgf·m) 1.1 ± 0.1 2.6 ± 0.2 4.6 ± 0.3 8.5 ± 0.4 19 ± 1.0 33 ± 2.0 TORQUE FOR SWIVEL NUT WITH O-RING Connector O –...
  • Page 12 APPROXIMATE CONVERSIONS Conv Non–SI Conv Unit Factor Unit Factor Unit Torque × 8.9 × 0.113 newton meter (N·m) = ln·in = N·m × 0.74 × 1.36 newton meter (N·m) = lb·ft. = N·m × 0.102 × 7.22 newton meter (N·m) = kg·m = lb·ft.* Pressure (Pa = N/m...

  • Page 13: Specification

    2. SPECIFICATION 2.1 LOCATION OF COMPONENTS Control Handle Drive Wheel Start Key Switch Battery Emergency Button Caster Wheel Battery Indicator CURTIS 803 Lift Cylinder Pump Station Load Roller CONTROL HANDLE(Tiller) 1.FWD / BWD Turning Knob: Control the speed of the stacker and moving direction: forward or backward 2.Shifting Button for high speed and low speed: Snail function takes light-touch switch, when touch...

  • Page 14: Specification Sheets

    2.2 SPECIFICATION SHEETS 2.2.1 Technical Features Manufacturer`s type CG1646 Rated load Q(kg) 1600 Load centre distance c(mm) Lift height 4600 Travel speed, unladen km/h Travel speed, laden km/h Gradient performance, laden Turning radius Wa(mm) 1605 Tyre size, front 250×78 Drive motor rating Lift motor rating Sound level at driver`s ear acc.to EN 12053 B(A)
  • Page 15 Hydraulic oil Hydraulic oil must have anti-wear qualities at least. It is not advisable to mix oils of different brands or types, as the may not contain the same required additives or be of comparable viscosities. Oil and Lubrication 6.5.4 Oil and Lubricant Lubrication chart Service point Interval/Running hours...

  • Page 16: Electric System

    3 ELECTRIC SYSTEM 3.1 ELECTRIC DIAGRAM WIRING DIAGRAM...
  • Page 17 CONNECTION DIAGRAM Code NL. Drawing No. Description Qty. Battery, 280Ah FU01 Fuse, 150A Motor for pump, 3.0kw Relay for motor of pump, DC24V Lower magnet valve, DC24V Motor for traction, DC24V/1.2kw Brake, DC24V DQ-3 Main relay C100/120 DC24V DQ-13 Controller CURTIS 1243-4220 DQ-10 Diodes 1N5408 DQ-9...

  • Page 18: Cable System

    3.2CABLE SYSTEM CG1646 Controlling Circuit（TILLER Handle） Serial No Part No Description Note 30914100030 Cable of Control Circuit 30914900016 Cable of Handle European 30914800037 Cable of Electromagnetic Brake Driving Wheel 30914800038 Cable of Speed Limiting Switch 30914800039 Cable of Micro Switch...
  • Page 19 CG1646 Universal Electric Parts List...
  • Page 20 Serial Part No Description Quantity Note Asian(English) 30910100006 Charger 30910100007 Charger Asian(Chinese) 30910100001 Charger European 30910100037 Charger American 30910100041 Charger Australian 30901200004 Battery 280Ah 30909100009 Connector (Male) 95199-00 30909100010 Connector (Female) 95342-01 5010404025C0 Socket Head Screw M4×25 30906300004 Micro Switch RZ-15GW2-B3 30906300023 Cover of Micro Switch 30902700001...

  • Page 21: Drive Wheel

    Model SECOR1020241405METAL Rate voltage DC 24V Rate Power Output Torque 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 Rated output 3.0kw R.P.M 3300 rpm Rated current 200 A Rated hour 4.0 min.
  • Page 22 Initial charge  When the battery is charged for the first time, you should prepare the exclusive sulfuric acid and excluslve water of lead acids (lf no excusive water is present in local areas, distilled water can be used). Slowly pour sulphuric acid into a container containing exclusive water(or distilled water), and churn it up with an acid-resistant stick.
  • Page 23 Concentration of electrolyte Volumeratio of water to Capacity ratio of water to sulfuric acid sulfuric acid 1.100 9.80:1 5.84:1 1.200 4.33:1 2.36:1 1.270 2.80:1 1.57:1 1.280 2.75:1 1.49:1 1.400 1.90:1 1.00:1  After charging, close the vent plug , and it only can be put into use after its surface is cleaned clear. Balanced charge When in use, nonuniformity of voltage capacity, electrolyte and concentration may occur.
  • Page 24 WATER FOR LEAD ACID CELLS Index Index name Mg / l Appearance Achromatic, transparent ≤ 0.01 Residue content ≤ Manganese (Mn) content 0.00001 ≤ Ferrum(Fe) content 0.0004 ≤ 0.0005 Chlorine(Cl) content ≤ Ammonia salt content 0.0003 ≤ 0.0008 Ammonia (NH ) content ≤...
  • Page 25 DISCHARGE CURVE 5hr discharge curve 2.05 1.95 1.85 1.75 1.65 time（h） 0.5hr disvharge curve 1.95 1.85 1.75 1.65 1.55 1.45 time（min）...

  • Page 26: Charger

    3.6 CHARGER Type: DF2440 for 24V/280Ah WIRING DIAGRAM FOR CHARGER The battery generates flammable and explosive gases during charge, so excellent ventilation is required. Open the liquid refilling cap or seal cap. Do not smoke around the battery during charge. Any fire and spark is forbidden. MAIN PRODUCT SPECIFICATION Battery Output current...
  • Page 27 ELECTRICAL CHARACTERISTICS Input characteristics Item Technical specification Unit Remark Rated input voltage Input voltage range 209-231 220Vac input voltage 50—60 frequency Max input current DF2440：8 When input is on,voltage for fan,When input voltage is off,there is no Fan function output voltage for fan Output characteristics Item Technical requirements...
  • Page 28 DF2440 charger Equalizing charge Power switch BEFORE CHARGING  The charger shall be installed in a special, ventilated, dry, no dust, no corrosive gas, no interference from high electromagnetic field place. The shell of the charger should be earthed (the ground bolts are equipped at the lower part of the case).
  • Page 29  When the display indicates “Charge completion” and the indicator light is on, the battery finishes charge. The charger enters floating charge, with current of 1-3 amperes. Please check electrolyte height in the battery frequently and fill distilled water timely as required. ...
  • Page 30 or less. or loose by the output plugs. unavailable, please change a new one. ① Low power voltage. ① The power voltage may not lower than 95% of the rated voltage. If the voltage is too low, Instable charge current, not please change a new power reaching rated...

  • Page 31: Curtis Controller

    3.7 CURTIS CONTROLLER...
  • Page 32 CONNECTIONS Low Current Connections A 16-pin Molex low current connector in the controller provides the low current logic control connections: Pin 1 load sensor input [optional] Fault 1 output / pump input Pin 2 Pin 3 Fault 2 output Pin 4 main contactor driver output Pin 5 throttle: 3-wire pot high...
  • Page 33 STANDARD_PARAMETER Parameter APPLICATION RANGE DESCRIPTION PARAMETERS Software Voltage BATTERY VOLTAGE 24 (2), 36 (3), 48 (4) Nominal Battery Voltage. M1 DRIVE C/L M1 DRIVE CURRENT LIMIT 50A to Rated Maximum Mode 1 Drive current limit M2 DRIVE C/L M2 DRIVE CURRENT LIMIT 50A to Rated Maximum Mode 2 Drive current limit M3 DRIVE C/L...
  • Page 34 Defines a minimum speed (duty factor) output from CREEP SPEED CREEP SPEED LIMIT 0% to 25% the controller. The controller output will jump to this speed when a direction has been selected THROTTLE TYPE THRTL Percentage of throttle movement which represents THROTTLE DEADBAND 0 to 40 DEADBAND...
  • Page 35 Dictates controller response after the emr rev switch has been activated. When "ON", the controller EMERGENCY REVERSE EMR DIR INTR On/Off becomes active if either the throttle is returned to DIRECTION INTERLOCK neutral or the Interlock switch is cycled. When "OFF", the Interlock switch must be cycled.
  • Page 36 4.Wrong throttle type selected. EMR REV 1.Emergency reverse wire or check wire Re-apple emergency reverse WIRING fault. or cycle interlock. 1.Improper sequence of KSI,interlock,and Follow proper throttle inputs. sequence;adjust throttle if 2.Wrong HPD type selected. necessary;adjust 3.Misadjusted throttle pot. programmable if necessary. 4.Sequencing delay too short.
  • Page 37 The bookmark keys allow you to quickly go back to up to three selected items without having to navigate back through the menu structure. To set a bookmark, press one of the bookmark keys for about three seconds, until the Bookmark Set screen is displayed. To jump to a set bookmark location, quickly press the appropriate bookmark key (1, 2, or 3).

  • Page 38: Battery Indicator

    3.8 BATTERY INDICATOR Type: CURTIS 803RB2448BCJ3010 Front View Rear View TERMINAL ASSIGNMENT Pin 7 or 8 = Battery +. Single voltage models: Pin 8 to battery +; Pin 7, open. Dual voltage models: When vehicle voltage is the higher voltage of the 2 operating voltages, Pin 8 connects to battery +; Pin 7, open.
  • Page 39 HOUR METER CONTROL LINES & IMPEDANCE SPECIFICATIONS Min. Impedance Low Voltage (max.) Hight Voltage (min.) HRM+ HRM- 5.0VDC 15.0VDC 80kΩ 20 kΩ HOUR METER CONTROL LOGIC Pin 1 (HRM-) Pin 6 (HRM+) Hour Meter Status High High Open Open Open Open High Open...

  • Page 40: Replace The Electric Parts

    3.9 REPLACE THE ELECTRIC PARTS REPLACE THE BATTERY Step 1: Take away the battery cover (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.
  • Page 41 REPLACE THE PUMP STATION Dismantle the cables Remove 4pcs screws. Dismantle the pipe. Then you can dismantle the pump station and replace it. REPLACE THE BATTERY INDICATOR take away the “U” clamp, dismaantle the 8 - pins plug. Then you can dismantle the battery indicator and replace it.
  • Page 42 REPLACE THE MAIN RELAY Dismantle two screws. Dismantle the cables. Then you can dsimantle the main relay and replace 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"...
  • Page 43 REPLACE THE LOGIC BOARD FOR LIFING CL-1 When the fork’s height is more than about 800mm (12”), the max. drive speed will automatically be reduced to 50% of normal speed. This is the fuction of the Micro switch to change the speed mode Remove the screw and the plastic cover.
  • Page 44 Use a small screwdriver to insert the hole, then turn counter-clockwise the mushroom head to remove the mushroom head. Take out the emergency button, remove two bolts to remove the cable, then you can dismantle the emergency button and replace it.

  • Page 45: Tool For Repairing The Pin Of Electric Plug

    3.10 TOOL FOR REPAIRING THE PIN OF ELECTRIC PLUG Application Figure Tool for removal of pins / sleeves Tool for application of pins / sleeves Tool for release of lock Tool for application of secondary locking 2 – pole Tool for application of secondary locking 4 – pole Tool for removal of pins / sleeves...

  • Page 46: Hydraulic System

    3. HYDRAULIC SYSTEM HYDRAULIC FLOW DIAGRAM CG1646 INSPECTION OF HYDRAULIC OIL External appearance Smell Condition Countermeasure Clear and no discoloration Fine Fine Possible to use Inspect the viscosity and if fine Fine Clear but the color becames brighte Mixed with other oil it can be continuously used Color changed like milk.

  • Page 47: Operation Of Pump Station

    4.1 OPERATION OF PUMP STATION REPLACE THE PUMP STATION Put the fork of the ground and drain out the hydraulic oil. CLEANING OIL TANK AND FILTER Put the fork of the ground and drain out the hydraulic oil.  Remove out the pump station ...
  • Page 48 Plug Screw of port for adding oil is ventilate. When lower, the air will come out from the tank, it might take out little oil vapour. So, it might appear little oil stains on the plug ahter some 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.

  • Page 49: Replace The Cylinder

    HYDRAULIC PIPE For shocking, the joint of the hydraulic pipe and hydraulic pipe might be loosed and leak oil, so usually check and tighten it. 4.2 REPLACE THE CYLINDER Remove three plastic bolts Take away the Fix board  Remove the joint. ...

  • Page 50: Drive Wheel

    5. DRIVE WHEEL 5.1 THE DRIVE WHEEL Driving Wheel（MR250FR）...
  • Page 51 Serial Part No Description Quantity Note Socket Head Screw 8.8 M6 x 5010406014C0 G250402001 Wheel 501990109 Seal 140 x 180 x 12 G250402002 Braking Circle 504040034 Ø180 Locking clip 349010118 16024 C2 Bearing 505020047 Ø5 x 20 Pin G250402003 Inner Gear Z=99 G250402004 Washer G250402005...
  • Page 52 Electric Brush 10 x 20 x 26 G26040003 G250402023 Spring of Electric Brush G250402024 Split Retaining Ring Ø4 Split Retaining Ring 8.8 M4x 5010604010C0 502030023 Nut 6S M5 G250402025 Electric Brush Fixing Cap G250402026 Socket Washer Ø5 5010405018C0 Socket Head Screw 8.8 M5x 504060001 Split Retaining Ring Ø6 502030025...
  • Page 53 The oil for gear box should be changed per 8 – 12 months. 5.2 REPLACE THE DRIVE WHEEL Step 1: Dismantle the plastic cover Step 2: Dismantle the platform for standing on remove the screw and nut. Step 3: Remove 6pcs screws, take out the cover plate. Step 4: Remove 4pcs bolts, dismantle the Box body .

  • Page 54: Replace The Carbon Brush Kit

    Use four screws (8.8T or more better) to 2 pcs guide pin holes screw in four “technologic screw holes”, 10 pcs screw holes so that ejection the wheel. 4 pcs technologic screw holes 5.3 REPLACE THE CARBON BRUSH KIT 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: Replace The Brake

    5.4 REPLACE THE BRAKE Remove 3 pcs screws, dismantle the connector, then you can dismantle the brake and replace it. 5.5 ADJUST THE CLEARANCE OF THE BRAKE When the brake winding is connected with the power （ +24V） ， it has the magnetic field to suck the brake plate to start the brake.
  • Page 56 Step 3: Un-tight the corresponding three screws Keep the same clearance as showing Step 4: Adjust the above-mentioned screws anticlockwise ( adjust 2-3 circle is okay) to reduce the spring strength. Brake slide should not contain grease，and nothing is blocked inside. Connected with plug connection, should connected firmly.

  • Page 57: Control Handle

    6. CONTROL HANDLE Serial Part No Description Quantity Note 5010605010C1 Screw M5×10 D06080086 Cover 5010408012C0 Socket Head Screw M8×12 5010408020C0 Socket Head Screw M8×20 302990018 Air Spring (550N×210) 422120192 Handle Arm 506030031 Anti-vibration Pad 5010406010C0 Screw M6×10 339010038 Bushing 23/19×17×10 Axle φ17×71 301703006 Elastic Pin φ4×24...
  • Page 58 TILLER Control Handle Serial Part No Description Quantity Note G28010002 Handle Body Black G28010003 Handle Cover Black G28010004 Speed Control Button Emergency Reversing G28010005 Plate for Emergence G28010006 G28010007 Bushing for Accelerator G28010008 Horn Button White G28010009 Lowering Button White G28010010 Lifting Button White...

  • Page 59: Operation Of The Control Handle

    6.1 OPERATION OF THE CONTROL HANDLE 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: Operation Of The Air Spring And Micro Switch

    Accelerator Take out the . 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 Use a Phillps screwdriver to remove 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: Caster Wheel

    7. CASTER WHEEL Step 1: Use a crane or other tool to hoist the stacker Step 2: Remove 4pcs screw. Then you can dismantle the caster wheel and replace it. WHEEL replace: Remove the nut and bolt, then you can dismantle it and replace it. 8.

  • Page 63: Trouble Diagnostics

    9. TROUBLE DIAGNOSTICS 9.1 MAINTENANCE LIST Maintenance Time Interval Standard=● Refrigerating house=＃ 6 12 ● Inspection of any damage of bearing parts Chassis ● Inspection of all joints of bolts truck frame ● Inspection of noise and leakage of driving system ●...

  • Page 64: Trouble Shoot

    9.2 TROUBLE SHOOT...

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