HELI RSH4528-Vo Operation & Maintenance Manual
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HELI RSH4528-Vo Operation & Maintenance Manual

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HELI Reach Stacker
Operation & Maintenance
Manual
Version: OMM-9001-12-001-HD-EN

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Summary of Contents for HELI RSH4528-Vo

  • Page 1 HELI Reach Stacker Operation & Maintenance Manual Version: OMM-9001-12-001-HD-EN...
  • Page 2 FORWARD This instruction manual mainly contains the contents of the relevant safety, performance, structure, operation and maintenance etc of the RSH4528-Vo, RSH4532-Vo, RSH4536-Vo container reach stacker in order that the operator can make proper use and maintenance. The operators concerned and equipment management personnel of the users in...

  • Page 3: Table Of Contents

    CONTENT I. Safety Matters Needing Attention for Operation of Container Reach Stacker II. Main Components and Technical Parameters of the Container Reach Stacker III. Startup, Moving and Operation of the Container Reach Stacker IV. About Main Parts of Container Reach Stacker and Maintenance 1.

  • Page 4: Safety Matters Needing Attention For Operation Of Container Reach Stacker

    I. Safety Matters Needing Attention for Operation of Container Reach Stacker The driver and manager of the container reach stacker must keep firmly in mind “Safety First” and operate it safely and normally according to the Users’ Operation and Maintenance Instruction for the container reach stacker. 1.
  • Page 5 (2) For chassis transport, parking braking should be conducted to fix the vehicle, with the front and rear tyres being firmly wedged in place. (3) All parts that possibly move in the course of transportation need to be fixed or held.
  • Page 6 5. Preparations Before Use (1) Do not check fuel, oil leak, oil level and electrical meters in presence of open fire, not fill fuel while the machinery is in operation. (2) No smoking at the time of fuel system being in operation and checking storage battery.
  • Page 7 before taking the job. (2) Vehicle is forbidden to use in the presence of force-6 gale and above. (3) The driver should put on protective shoes, cap, garments and gloves during operation. (4) Up/down stairs and platform to walk on should be firmly secured. (5) Check each controller and alarm and remove any trouble such as damage or defect, if any, before driving.
  • Page 8 (7) Lifting, lowering and running are forbidden when the lifted container deviates from the central line. Lateral movement and turning by spreader are allowed only at standstill of the vehicle. Prevent the container and telescopic arm from colliding with the vehicle body or other objects when turning the spreader. (8) Do the best to make the vehicle’s action smooth and avoid sudden motion at the time of startup, loading and unloading, turning, traveling, braking and parking.
  • Page 9 container with the twist lock of spreader. Forbid moving the container before the twist lock locks it. (10) The spreader override switch can only be used in case that the safety unit sensor of the spreader fails and the spreader cannot lift weight and the twist lock cannot open and close.
  • Page 10 (13) Be careful when traveling on a slope. Move forward when climbing and backward when descending on a slope of above 1/10. Do not swerve when climbing and descending on a slope to prevent overturning. No handling operation when climbing on a slope. (14) Reduce the speed, be careful in driving and pay attention to the overhead space and the distance away from surrounding people and objects when approaching a turn, slope, moving down a slope or in case of poor visibility.
  • Page 11 (18) Slow down and be doubly careful in driving at a harbor or on a provisional board pavement. (19) The driver should leave and stall the vehicle when refueling. Do not switch on the ignition when checking storage battery or oil tank level. (20) Tilt and fully lower the gantry, make the spreader touch the ground, put the handle in the neutral gear position, stall the engine and switch off power source when leaving the vehicle, moreover, apply parking brake when parking the vehicle on a...
  • Page 12 for the hydraulic and braking systems. (30) Regularly check all moving parts of the vehicle (such as frame, telescopic arm, front axle and rear axle joints, connecting parts of variable-amplitude cylinder with telescopic arm and frame, driveshaft, all sliders, moving parts of spreader, etc.) to ensure that all pin shafts stay in normal position and bolts are well connected and not worn.
  • Page 13 (2) Propose using authentic HELI parts provided by our agents and repair service when changing any part. (3) HELI will not be responsible for any breakdown due to use of non-authentic HELI parts in the period of the equipment under guaranty.
  • Page 14 (14) Sign for forbidding entry into space behind gantry (15) Fan safety sign 9. Driver’s Room This equipment has a driver’s room with one door on the left and one on the right. The door handle is fitted with a key lock for locking the door outside the room. Press down the button to open the door.

  • Page 15: Main Components And Technical Parameters Of The Container Reach Stacker

    II. Main Components and Technical Parameters of the Container Reach Stacker 1. The Container Reach Stacker Mainly Consists of Such Parts as Listed Below Part Contents Engine, air filter, water tank, intake and exhaust system, Engine installation etc. Torque converter, gearbox assembly, drive shaft, drive Main drive system axle, etc.
  • Page 16 2. Technical Parameters of the Container Reach Stacker...
  • Page 17 Main parameters of HELI reach stacker Type RSH4528-Vo RSH4532-Vo RSH4536-Vo Line1/ 45000/ 45000/ 45000/ Lifting 32000/ 36000/ line2/ 28000/ capacity 16000 19000 line 3 14000 Line1/ 1800/ 1800/ 1800/ Load 3850/ 3850/ 3850/ line2/ centre 6400 6400 6400 line 3...

  • Page 18: Startup, Moving And Operation Of The Container Reach Stacker

    III. Startup, Moving and Operation of the Container Reach Stacker 1. Running-in Period We propose at least 200-hour running-in period for a new container reach stacker. Pay attention to following matters in the running-in period: (1) Fully warm the engine each time after its startup and avoid high-speed running immediately after it is started up.
  • Page 19 Startup switch position is shown in following diagram. Engine startup steps are as follows: a) Sit on the driver’s seat; b) Switch on the main switch; c) Insert the ignition key into the ignition lock hole and turn it clockwise to gear 1 (switch-on gear) and the instrument system is wired up.
  • Page 20 b) Turn the ignition key to the position “off” to cut off the power making the engine stop running and then take out the key. 3. Startup, Running and Stoppage of Reach Stacker (1) Startup and running of reach stacker Procedures for startup and running of reach stacker are as follows: a) Press down parking brake button to free parking brake;...
  • Page 21 b) Choose a suitable gear position for acceleration and deceleration according to load and road surface conditions. CAUTION: The action must be smooth for acceleration and deceleration of the engine. WARNING: When the reach stacker moves with load, the telescopic arm maintains an angle of 35 degrees with horizon, the spreader stays in the middle position and the lower edge of container is proposed 800mm above the seat level.
  • Page 22 CAUTION: a) Gear changing is only allowed at low engine speed; b) Gear changing is not allowed at high traveling speed of the vehicle and not at the time of acceleration; c) Reverse gear can only be used at low engine speed or stalling; d) In automatic operation state with the gear changing handle in high gear position, the operator can press controller program buttons according to running conditions, thus achieving automatic switch between high and low gear...
  • Page 23 approaches 120℃ and the red area of the meter, suspend use of the vehicle, put the gear changing handle in neutral position allowing the engine to run at low speed until the temperature decreases to the normal range. If rapid drop in temperature fails, stop the vehicle to locate the reason;...
  • Page 24 arm of RSH4532 container reach stacker mainly consists of fixed arm, telescopic arm, telescopic cylinder and slider. Telescopic arm is fitted inside the fixed arm. Anti-wearing high-performance engineering plastic sliders are provided between the two arms. One end of the telescopic cylinder is fitted on the fixed arm and the other end on telescopic arm.
  • Page 25 the telescopic arm. Sliders at this limit must be changed. Frontal circular sliders cannot be less than 32mm in thickness and must be changed at this limit. The difference of each slider cannot be over 2mm in the back-front thickness and upper-lower height.
  • Page 26 valve. Reset the safety button for sudden stoppage and uplift. b) Extension of telescopic cylinder and decline of variable amplitude cylinder: safety button is triggered and integrated operational handle moves forward turning 45° to right. The angle size decides the opening of proportioning valve.
  • Page 27 (2) Operation of spreader Spreader has 8 functional actions: twist lock opening, twist lock locking, left sway, right sway, extension, withdrawal, clockwise rotation and anticlockwise rotation, which are all controlled by 8 buttons fitted on the integrated operational handle. a) Twist lock opening: controlled by No.1 button shown in the diagram b) Twist lock locking: controlled by No.2 button shown in the diagram.
  • Page 28 Spreader safety override switch: Spreader safety override switch is controlled by the key switch as shown in the diagram. When the spreader safety unit sensor fails and the actions of sway, twist lock opening and closing and rotation cannot be performed for the spreader, for the convenience of repair, spreader safety override function can be used for provisional emergency operation.
  • Page 29 b) Maintenance of moving parts Main moving parts include damping cylinder part, twist lock, rotary bearing, knuckle bearing part of sway cylinder, gear reducer, etc. It is better to check and lubricate these parts once every 100 hours. c) Maintenance of gear reducer Change the oil 50 hours after its service for the first time.
  • Page 30 9. Loading and Unloading Operation Process (1) lifting of container Steps for lifting container are as follows: a) Park the reach stacker approximately where the driver can face the container stack or at the central position of containers placed on the transport vehicle where the integrated operational handle can be perpendicular to or reach the container stack or container transport vehicle.
  • Page 31 i) Reverse the vehicle only when no traffic is found behind. CAUTION: a) Be sure to manipulate the integrated operational handle steadily and avoid transient violent operation; b) When controller alarms, forbid use of big arm and any operation of spreader.
  • Page 32 operational handle to relock, restart from step (d) by hoisting spreader and container. f) After confirming that the 4 twist locks of spreader have been fully opened, be careful to hoist the spreader allowing the twist locks to withdraw from the corner lock holes completely (spreader landing indicator dies out and twist lock opening indicator lights).

  • Page 33: About Main Parts Of Container Reach Stacker And Maintenance

    IV. About Main Parts of Container Reach Stacker and Maintenance 1. Power System Power system includes engine installation, intake system, cooling system, discharge system, etc. The engine is integrated with transmission unit and its bracket is connected with vehicle frame by buffering rubber spacer to reduce vibration. The power of engine is transmitted to main drive system through torque converter.

  • Page 34: Main Drive System

    antifreeze willfully. Supplement same type of antifreeze timely after it leaks or evaporates. d) In case of water used for coolant, it may freeze in cold weather as the vehicle is parked, so the water in radiator should be let out. After radiator works for some time, it should be dismantled and put in boiling soda solution for washing, thus removing the scale or deposit formed on the inside of radiator.
  • Page 35 be damaged and its performance undermined. If the oil level is over high, the oil foam will make gearbox over hot. Check the oil level of gearbox once every 200 hours according to methods listed below: a) Start reach stacker making the gearbox oil temperature rise to normal working temperature（80～110°）...

  • Page 36: Hydraulic System

    (2) Propeller shaft Once every 100 hours: Use manual grease gun (never high-pressure grease gun) to feed oil to universal joint through the fill plug. Overflow indicates fullness. Once every 400 hours: Check the looseness of torque of securing bolt of propeller shaft.
  • Page 37 Servo pressure WDB brake unit Service brake pressure Parking brake release pressure Steering unit Max. pressure Overload valve pressure (1) Introduction It is powered by variable plunger pump fixed on gearbox and a group of distribution valves control the telescoping of lifting arm and rotary oil channel. Another group of distribution valves control other operations of spreader (rotation, sway, 20’-40’conversion).
  • Page 38 with the excessive oil going into main valve. Main valve and combination valve are linked up in parallel, thus ensuring the speed requirement of variable amplitude and telescoping, also giving a full play to oil pump capacity and improving the performance of the whole vehicle. (3) Servo system—servo system is integrated in combination valve and oil supply is controlled by operational handle.
  • Page 39 famous brand hydraulic oil as required if need be. In addition, this reach stacker is fitted with oil-soaked disc brake unit, so 3%-6% Lubrizol additive must be added to hydraulic oil to ensure good braking effect and eliminate braking screech. WARNING: Additive will not be consumed during normal working, so it needs...
  • Page 40 Note: These must be changed after working 1000 hours. (7) Hydraulic oil cylinder Hydraulic oil cylinder is situated at right of reach stacker. Hydraulic oil in the cylinder is supplied to the hydraulic system for arm uplift and telescoping, spreader, steering and braking system. Every day: Park the vehicle on level surface, put on parking brake, lower and withdraw arm, check liquid level through relevant window and fill up with oil through fill plug if need be.

  • Page 41: Steering System

    (9) Steering system Hydraulic oil volume supplied to steering system depends on the speed of wheel movement. LS signal emitted by steering valve makes the pressure-gradient control valve of valve block constantly provide adequate oil for steering system. Buffer valve is added to steering system for improving driver’s comfort and reducing driver’s fatigue.
  • Page 42 (11) Main valve As an integrated multiport valve this valve is of a load transducer design used for variable capacity pump. It has long service life, has no leakage, is fast in opening and closing, ensures cavitation-free work, is preventive against unnecessary system loading shock, thus extending the time of components and sealing elements.

  • Page 43: Braking System

    Test of oil pressure of main valve: There are test ports for the working pressure of luffing cylinder and telescopic cylinder on the main valve. The test connections are installed on the main valve as standard test ports. Their positions are shown on the above diagram. Gauge port A2: testing large chamber pressure of luffing cylinder.
  • Page 44 of the reacher stacker. There is an independent cooling system for the oil circulation in the axle. The advantage of the braking form is that it is not necessary to make any adjustment, the braking force will not decrease and there is no abrasion. And as the friction discs and other parts are sealed in the axle, water, soil and debris can not get There are three independent oil circuits in the unit: i.e service braking oil circuit, cooling oil circuit and parking braking oil circuit.
  • Page 45 Filters: To ensure the cleanness of the system. Temperature control sensors: To monitor the function of the system. (4) Combination valve Its main functions: overflow valve for the accumulator, pressure control valve for the steering system, differential pressure valve, pressure-gradient control valve for steering oil circuit, pilot relief valve and release valve for cooling oil circuit, etc.
  • Page 46 valve and jamming of the valve element. Prevent moist and dust from entering into the main valve. All ports and their contact surface will be protected from dust to avoid scratches and impact. When installing the oil connections, attention must be paid to the cleanness and prevention of over-tightening.
  • Page 47 during each check. When the air bag is damaged, pressure oil must be drained before the dismantling the accumulators and other parts. CAUTION: Refer to attached hydraulic system schemes. Note: Make sure that the system is not under pressure before undertaking the above-mentioned adjustment.
  • Page 48 (7) Parking Brake The parking brake is a clamping mechanical system on the flange discs of the front axle. The parking brake can be used as emergency brake. But the braking gaskets will wear seriously. Therefore the braking gaskets will be changed after the brake is used as emergency brake twice.
  • Page 49 Maintenance of filter: The motor oil filter element will be changed every 400 hours or if there is an alarm. 1. Cover 2. Indicator 3. Electrical socket 4. By-pass valve 5. Filter element 6. Shell 7. O-ring 8. Drain Note: Make sure the system is not under pressure before changing the filter element.
  • Page 50 first and then return and lower the hoist arm. Change the output oil filter element of the braking system every 400 hours or when the dual indicators are in the red zone. Note: After the filter element has been changed, check the oil level again. Note: Make sure the system is not under pressure before changing the filter element.
  • Page 51 In pipe line installation, the connection marked “In”(进) on the steering gear will connect with the pipe of oil pump, the connection marked “Return”(回) will connect with oil reservoir. The connections marked “Left”(左) and “Right”(右) will be connected with the left and right chambers respectively. The flow rate allowable in the suction pipe is 1—1.5m/s, pressure oil pipe and return oil pipe 4—5m/s.
  • Page 52 the steering wheel forcefully or dismantle the steering gear to prevent damages of the steering gear parts. Check if the piston of the steering cylinder has reached its limit positions and if the system pressure is in conformity with the specified values. f) Operation maintenance: Check leakages, oil level in the reservoir and working conditions every day.
  • Page 53 (3) Trouble shooting of the steering system Fault Cause of the Fault Remedy Damage or problem with oil pump. Change Steering wheel can Split-flow valve plugged or damaged Clean or change not be turned Plastic tube or connections damaged Clean or change or pipes blocked Pressure of split-valve is too low.
  • Page 54 around the pins. There is a left and right steering knuckle on the left and right of the steering axle respectively. The wheels are pried on the hubs through wheel rims. There are oil seals inside the bearings to make lube grease stay in the wheel hubs and steering knuckles.

  • Page 55: Electric System

    7. Electrical System 7.1 A brief introduction of the electrical system The electrical system of Heli RSH4532-V0 Reach Stacker uses modular design, CAN-BUS structure and the computer control system (WIZ) specially designed for reach stackers by 3B 6 company to integrate engine, transmission, braking, hydraulics and spreader systems into a complete control system for the unified and coordinated control of the vehicle.
  • Page 56 control unit) to control the engine and connects to WIZ system by CAN-BUS. The working conditions automatically monitored and protected by the engine electrical system are: engine inlet air pressure and temperature, cooling water temperature and water level, engine oil temperature and pressure, fuel level, pressure, temperature and sediments, electronic control injection valve condition, piston cooling, crank case pressure, crank, cam and shaft speed and battery voltage, etc.
  • Page 57 hand is away from the joystick, the arm’s luff and flex functions are automatically out of service. So it has an excellent safety feature. WIZ system has following functions: a) The measurement, warning and automatic safety protection for braking oil pressure and filter, hydraulic oil temperature and filter.
  • Page 58 7.2 Parts description of electrical system WARNING: a) When taking maintenance procedures on the vehicle, disconnect red main power switch on the side of electric box. b) Before using welding apparatus, disconnect red main power switch on the side of electric box. 7.2.1 Battery Type: 6-QA-180Ah (two) Position: Battery compartment under the left body of vehicle.
  • Page 59 connection condition of the carbon brush. If necessary, change carbon brush handles with same type as the original. (2) Starting motor Routine maintenance: Check if the connection wires are ok. For every 1600 hours, carefully clean the rectifier and check the wear and connection condition of the carbon brush.
  • Page 60 connected on the battery poles. Incorrect battery connection may result in serious damage of electrical equipment. Please refer to the connection scheme of the engine system. Normally one will wear goggles in handling batteries. Battery electrolyte contains highly corrosive sulfuric acid. If your skin is in contact with the acid, wash with large amount of soapy water and then seek medical attention.
  • Page 61 Diagnosis: 1. Low battery. 2. Open circuit or poor contact. 3. Main switch is cut off. 4. Fuse out. 5. Starting switch fault. 6. Main relay fault. 7. Starter or starter coils fault. 8. No fuel (empty fuel tank or wrong fuel pipe connection). 9.
  • Page 62 21. Air blocking in cooler. 22. Engine oil level is too high. 23. Generator belt is loose. 24. Water in engine. 25. High discharge pressure. 26. “+” end cable of accelerator pedal is breaking off. Diagnosis Function: a) The diagnosis function monitors and checks various functional modules of EMS2 system.
  • Page 63 there is no fault (1.1). e) Effect on the engine The effect on the engine differs as the seriousness of the fault discovered by the diagnosis function is different: • Engine is not affected. • Engine in idle speed. • Engine torque is limited. •...
  • Page 64 Fault Codes Code VODIA Fault description Cause Response Measures Fult-free Drain out the water accumulated in the PID/SPN 97 Oil-water separator Water entering into fuel Easy to stall. oil-water separator. Alarm indicates. Check the level of cooling fluid. PID/SPN 111 Level of cooling fluid Lower cooling fluid level The control module of engine...
  • Page 65 Code VODIA Fault description Cause Response Measures Short circuit Check if the circuit of indicator is Alarm oil-water PID/SPN 97 Open circuit No response damaged and the function of indicator separator Fault of indicator and change it when needed. Check if the circuit of indicator is Short circuit of the power damaged.
  • Page 66 Code VODIA Fault description Cause Response Measures Check if the plug-in unit of sensor is correctly mounted. Short circuit of power supply Check if the line of sensors damaged. PID / SPN 94 Pressure sensor of fuel No response of sensor, open circuit Check the mounting correctness of sensor and the function of fuel pressure sensor.
  • Page 67 Code VODIA Fault description Cause Response Measures Short circuit with positive or The preheat can not be Check if the input line of relay is Pre-heat relay negative pole activated. damaged and check the function of PID45/SPN 626 Open circuit Always preheat relay.
  • Page 68 Code VODIA Fault description Cause Response Measures Short circuit with positive or The engine can’t start. When PPID3/SID EMS start –up signal Check the line of ignition switch. negative pole the ignition switch is used, 39/SPN677 outputs Starter relay Check the line from cable to key switch. The activation time is too long.
  • Page 69 Code VODIA Fault description Cause Response Measures Check the voltage from controller Short circuit of negative pole There exists the problem on Check the battery PID / SPN 158 Voltage of battery Fault of motor the start-up of engine. Check the power generator. Fault of battery and cable Check 8-pin plug-in unit.
  • Page 70 Code VODIA Fault description Cause Response Measures Check if the cable of injection pump is damaged. The engine operates at other 5 Check if the connection of injection Electric fault cylinders. Injection pump,No.4 pump is damaged. SID 4 / SPN 654 Faults of injection pump or cylinder Abnormal noise...
  • Page 71 Code VODIA Fault description Cause Response Measures Check if 8-pin plug-in unit is damaged. SID 250 / SPN Data connection fault Fault of data connection No response Check the cable of CIU and EMS is damaged. Fault of oil pressure and air inlet sensor Fault code of oil pressure and air inlet sensor Check if the cable to oil pressure and air...
  • Page 72 7.2.3 Transmission (Please refer to the original English version of “DANA Transmission Operation Manual” for details) TE27 Transmission of American DANA Company used by Heli Reach Stacker utilizes APC200 Transmission Control Unit (TCU). It has manual and automatic control modes with complete input and output measurement and automatic control, diagnosis and protection functions.
  • Page 73 ►Description of main parts: (1) Gear shifting lever The lever selects the gear of the transmission. Its output signal is input signal for APC200. APC200 supports remote control through CAN bus (2) Transmission control unit (TCU) APC200 TCU is mounted on the operation panel in operator cab. On the TCU display, there are (refer to following scheme): 4 red 7parts LED digital displays 3 LED indicators...
  • Page 74 ► There are three indication groups: most frequently used gear selection display, vehicle speed display and travel distance display. Display Code Remarks GPOS Shows present vehicle travel direction and gear used. VSPD Shows vehicle speed in km/h or MPH (parameter setting). The initial value of speed display is 0.1 km/h or 0.1 MPH.
  • Page 75 When the controller has found a fault, indicator lamp E will flash. The cause of the fault and the solution can be found according to the fault display code. (3) Manual/auto selection switch The switch sends manual/auto selection signal to APC200. If manual/auto selection switch is not used, the auto mode will be taken as normal mode by default.
  • Page 76 (6) First and second gear start selection switch: The transmission starting gear can select this input signal. This will overrule the selection standard of starting gear. It is favorable for different transmission operations requested by the operators in accordance with available operation conditions.
  • Page 77 (1) Auto-testing function APC200 has a special circuit to check if it is working normally. 6 auto-testing modes have been written in the control programs of APC200. Displaying testing and measurement and versions; Digital input testing and measurement; Analog input testing and measurement; Speed sensor testing and measurement;...
  • Page 78 The display will normally return to display window when you select a new function group by pressing “M” button. Pressing “M” or “S” button for a short time can reselect current configuration or mode. The useful configurations in all diagnosis groups will display that the testing mode is activated when power is on.
  • Page 79 a) Digital input testing mode When this mode is selected, it will show on the display: The display shows that the input is activated. Each digital part on the display shows a specific logic input. If different inputs are activated at the same time, the different digital parts can be turned on or off at the same time.
  • Page 80 b) Analog input testing mode There are 4 analog impedance inputs in APC200. They are used for individually measuring the impedance between connection sensor input and grounding B18. When this mode is selected, it will display: After the button is released, the visual signals of 4 analog inputs will be displayed.
  • Page 81 frequency of a current speed sensor is 933Hz. The right group shows the corresponding frequency of the inductive current sensor is 1330 Hz. When last channel is displayed, you may reselect speed sensor contents by pressing down S button. d) Output testing mode When this mode is selected, the display shows: The display shows activated output.
  • Page 82 If there is fault in one group of output, the corresponding digital parts will flash slowly. There will be detailed output quantities on display. The display will alternatively shows current output conditions and types of faults. e) Voltage testing mode When this mode is selected, the display shows: When the button is released, the display shows permanent voltage value measured at A01 wire.
  • Page 83 ► Fault indication When fault happens, “E” lamp begins to flash. To make sure if the fault really exists, refer to APC200 display fault code menu described in 1.3.2 section of Chapter 1. Furthermore, fault information can be collected by CAN. The detailed information for this collection is described in section 1.3.5 and section 2.2.3 of Chapter 3.
  • Page 84 automatically, the transmission is out of gear, the vehicle will stop and parking braking alarm is on. Hydraulic system: The system uses WIZ reach stacker computer control system of Italian 3B6 Company for control. ► WIZ reach stacker computer control system specifications: System description: WIZ system of 3B6 Company is a computer control system used for reach stackers.
  • Page 85 CANBUS. It is also connected with the testing and measurement sensors outside the braking and hydraulic systems and can timely, on-line and continuously monitor the working conditions of the vehicle. (2) ARM2 is a secondary controller for the control of arm’s movement. (3) ACT11CS100R is a length and angle sensor.
  • Page 86 parameters of hoisting cylinder pressure, angle and arm’s length, etc measured by the system and judge whether it is safe. (6) JOYSTICK is an integrated control lever with two shafts, 8 buttons and on safety button. It is connected with WIZ through CANBUS. LMI Home Page HTD65 display has a 6.5"...
  • Page 87 F2: Enter into checking and maintenance page. F3: Enter in password and enter into calibration procedures F5: Enter into additional information page. F9: Return to LMI home page. Information displayed on LMI home page: a) Shows proportion of actual load and max. load b) Actual load: actual load detected by the system c) Max.
  • Page 88 w) Fuel oil low indicator x) High engine water temperature indicator y) Braking oil filter z) Emergency button pushing down indicator a) Alarm reminder b) Warning reminder ► Enter into controller port conditions page (press F1 to enter) HEAD controller diagnosis page Press F1 to enter, press F9 to return to LMI home page.
  • Page 89 ► Enter into check and maintenance page (press F2 to enter) Press F7 to set password. High-grade password is able to clear 4 time-counters and container counters. Clearing function is as follows: Press F1: the first counter is cleared; Press F2: the second counter is cleared; Press F3: the third counter is cleared;...
  • Page 90 Press F6: enlarge the selected numerical value; Press F7: decrease the selected numerical value; Press F10: confirm the input numerical value; Press F5: exit and do not confirm the input value. CanView functions In this page, the system will show canbus information. Press F9 to return to former page.
  • Page 91 Press F7: enter into parameter page. See following illustration: the value of 10 items can be checked in each page. Press F1: entering 10 items of next page; Press F2: entering 10 items of former page; Press F7: go to next page; Press F6: go to former page;...

  • Page 92: Alarm List

    Press F2: clear the record of black box; Press F3: set time and date. Press f9: return to home page. CAUTION: The record of black box can be cleared only by entering high-grade password. ► The home page shows fault alarms and warning information lists: ALARM LIST CODE FAULT DESCRIPTION...
  • Page 93 CODE FAULT DESCRIPTION SUGGESTED CORRECTIVE ACTION ACT ARM CANBUS ERROR Verify the connection of the ACT. Timeout of the canbus transmission Verify the canbus connection. JOYSTICK CANBUS ERROR Verify the connection of the JOYSTICK. Timeout of the canbus transmission Verify the canbus connection. ACT ARM FAULT ERROR Verify the connection of the ACT.
  • Page 94 WARNING LIST CODE FAULT DESCRIPTION Movement slow close to the overload Movement stop by LMI alarm Movement stop by max angle switch Movement stop by spreader seated Movement stop by twist lock signal Movement slow close to max angle Movement slow close to min angle Movement slow close to max length Movement slow close to min length Movement stop by twist signal...
  • Page 95 (2) Rear combination lights include: Width/braking lamp: bulb specification: 13499, double filaments, 24V, 5W/21W; Direction indicator: bulb specification: 13498, 24V, 21W; Backing lamp: bulb specification: 13498, 24V, 21W. (3) Warning lights: electronic flashing type, has to be changed wholly if breaking down.
  • Page 96 B—Temperature adjustment control; Use temperature adjustment control knobs to choose suitable temperature (cooling or heating). CAUTION: If coolant temperature is low, the air temperature sent to the cab will not change even the temperature adjusting knob is turned to the max. CAUTION: If you want to remove fog of the glass quickly, please turn the wind speed selection to high speed and turn the wind duct to the glass.
  • Page 97 7.2.7 Description of Instruments and Operation Console (1) General description The instrument console assembly of reach stacker used by Heli includes: Left instrument console, right instrument console and operation console.With integral structure and streamline shell design, the function zones are rationally laidout so ther are easy to read and comfortable in operation.
  • Page 98 b) Right instrument console ① Right support ② Right mantle ③ Right indicator combination ④ Defrost air outlet ⑤ Radio speaker ⑥ Air conditioning outlet...
  • Page 99 c) Operation console ① Operation console support ② Operation console mantle ③ Radio ④ Triple rocker switch (A) ⑤ Triple rocker switch(B) ⑥ Integrated control lever ⑦ Overload relief key switch ⑧ Twist lock bypass key switch ⑨ Engine stop button ⑩ Sextuple rocker switch (A) ⑪ Sextuple rocker switch (B) ⑫...
  • Page 100 Sextuple rocker switch (A): Sextuple rocker switch (B): Illustration of integrated control lever functions:...
  • Page 101 7.2.8 Component and part description of electrical compartment 1. Fuse box; 2. Control power contactor; 3. Multiple fuse box; 4. Relay box 1 5. Relay box 2; 6. Flash apparatus; 7. Engine CIU controller; 8. Main controller of hydraulic system; 9. Arm controller; 10. lights; 11.
  • Page 102 (3) Multiple fuse box: 15 Circuits Fuse Box 4FU1，4FU2，4FU3 Power fuses for front, rear and top wipers of cab and washer. 4FU4 Fuse for cab overhead lamp and fan power. 4FU5 Fuse for air conditioning power. 7FU2 Fuse for outside equipment power of main controller. 7FU3 Fuse for main controller power.
  • Page 103 Relay Box 2 Parking braking relay, parking Arm controller power relay braking valve control Reverse gear relay, reverse Horn relay reminder Neutral gear relay, neutral start Main controller power relay control 2FU3 Backing lamp & buzz fuse 3FU5 Horn relay fuse 3FU16 Parking brake valve fuse 7FU1 Unloading valve fuse...
  • Page 104 ● The battery charger is not allowed to be used to start up the engine. ● When the battery is charged, disconnect the connection between battery and electrical system on the forklift.vehicle. When the engine is running or the electronic element is energized, the connectors of the electronic control elements are not allowed to be connected or disconnected.
  • Page 105 container can not be moved before the lock knob is locked. ● The descended spreader should be placed at a proper position on the container or moved to the front of container. Do not use too much force since the self weight of spreader is enough to drive thespin lock into the lock hole of the container.
  • Page 106 7.3 Basic instruction for operation 7.3.1 Running-in period For a new vehicle, we suggest the running-in period should at least be 200 hours and attention should be paid to the following matters within the running-in period: (1) Every time when the engine is started, first fuly preheat the engine and avoid its high-speed driving soon after it is started.
  • Page 107 The procedures for starting up the engine are as follows: (1) Seat on the driving chair; (2) Connect the general switch of power supply; (3) Check the change-gear shift handl to ensure it in at neutral gear (N gear); (4) Plug the ignition key into the lock hole (0 gear), turn it clockwisely to (gear 1) vehicle control and the power supply of the vehicle is connected;...
  • Page 108 (3) Choose a proper change-gear shift, release the service brake pedal and slowly step on the accelerator pedal. The reach stacker will be stopped according to the following procedures: (1) Release the accelerator pedal; (2) Slowly step on the service brake pedal; (3) When the reach stacker is close to stop, turn the handle at change-gear shift to the zero one and release the brake pedal after the vehicle is completely stopped;...
  • Page 109 about 0.8～1m higher than the chair face. The object lifted is forbidden to be ascended, descended and laterally removed. in the course of driving. The vehicle is forbidden to drive when it lifts the weight at high position. (2) Change-gear shift of reach stacker a) The Change-gear shift handle of reach stacker is located at the left side of the steering wheel column.
  • Page 110 during acceleration. c) The backing gear can only be chosen when the engine runs at lower speed or stopped. d) In case of the automatic operation state of the vehicle, when the chang-gear handle is at higher gear, the high and lower gears of vehicle can be automatically switched over according to the driving condition.
  • Page 111 b) Water temperature meter of engine: it is not allowed to reach the red zone. c) Tachometer of engine：The rotary speed can not exceed the maximum rotary speed of engine. d) Oil temperature meter of torque converter： The application scope of oil temperature of the gearbox is 80～110℃...
  • Page 112 step-on should be avoided. The emergent brake will affect the stability of the vehicle, especially when the loaded vehicle runs at high speed, the overturning of the vehicle will be very easily caused. 7.4 Routine Electrical Inspection and Maintenance Table Routine electrical inspection and maintenance table Every Every...

  • Page 113: Product Label And Oil Consumption Table

    V. Product Label and Oil Consumption Table 1. General Map of the Pressure of the Main Components 2. Oil Consumption Table The oil consumption for each system of container reach stacker is shown in the following table. Name Brand No.（Code） Recommended Brand Capacity Fuel（Diesel oil）...
  • Page 114 3. Periodic maintenance timetable This timetable is made based on the standard work time and working conditions. If the reach stacker works under the fiercer conditions, please make maintenance ahead of time（“●”means change） (1) Engine Each 200 Each 2000 1000 hours Checking content hours hours...
  • Page 115 Each 200 1000 2000 Checking content hours hours hours hours Check if the hub bolt ○ drive axle loosened. Change the gear oil ● of drive axle Pneumatic pressure ○ ○ of tyre Check the wearing ○ state of tyre Every 400 hours or when alarm...

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