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Xilin CTD15R-E/N Operation Manual

Electric pallet stacker
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CTD15R-E/N
Electric Pallet Stacker
 Operation Manual
 Parts Catalogue

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Summary of Contents for Xilin CTD15R-E/N

  • Page 1 CTD15R-E/N Electric Pallet Stacker  Operation Manual  Parts Catalogue...
  • Page 2 ******************************************************* According to ISO 21262:2020 “Industrial trucks — Safety rules for application, operation and maintenance”, load capacity and lifting height of our CTD15R-E/N Electric Pallet Stacker are stipulated as follows: ——When the lifting height of CTD15R-E/N stacker is below 3300mm (including3300mm), the maximum load capacity is the rated capacity.

  • Page 3: Table Of Contents

    Contents Brief introduction ....................1 Description ......................1 1． Outline drawing ....................2 2． Brief introduction of the structure ..............4 3． Safety Norms ....................4 4． Initial operation ....................9 5． Use and operation instruction ................ 9 6. Use, maintenance and charge of the storage batteries ........12 7.

  • Page 4: Brief Introduction

    Brief introduction CTD15R-E/N electric pallet stacker is empowered by storage batteries and an AC motor. Traveling of the truck is made by gear transmission. Forks lift with/without loads by movements of the cylindered which is driven by an DC motor and hydraulic transmission. As the traveling and lifting of the stacker are electrically driven, it possesses the characteristics of energy saving, high efficiency, stable operation, easy operation, safety and reliability, low noise and no pollution, etc.

  • Page 5: 1． Outline Drawing

    1． Outline drawing 1.1 CTD15R-E/N Outline drawing...

  • Page 6: Main Technical Parameters

    1.2 Main technical parameters Manufacturer(abbreviated) Manufacturer's type CTD15R-E/N designition Drive: electric (battery Electric type, mains, ...), diesel, Operator type: hand, Standing Characteristics pedestrian, standing, Rated capacity/rated load Q(kg) 1500 c (mm) Load center distance Load distance, center of x (mm)

  • Page 7: 2． Brief Introduction Of The Structure

    2． Brief introduction of the structure (ref.to the structure diagram and the principle diagram of major parts) The stacker mainly consists of frame, mast, fork, lifting oil cylinder, operation handle, steering device, driving wheel, storage battery pack, hydraulic power unit and control system for electrical equipment, etc. 3．...
  • Page 8 Rules that must be observed： Notice Never drive the truck when you are tired or un-concentrated, with an injection of drug, or after a liquor drinking. Safety rules and regulations shall be observed during operation or maintenance of the truck. Safety of working place：...
  • Page 9 Prepare safety operation procedure: Safety operation procedure shall be formulated with consideration of practical situations before operation of the truck. Safety shall be taken into full consideration in preparation of the safety operation procedure. Operation of truck under unsafe condition is strictly forbidden: Operation under unsafe condition is forbidden, such as under conditions with uneven floor, or impeded road.
  • Page 10 Notice Keep concentration when operating truck. Caution The driving mechanism of truck is installed on the foreside. Due to this difference from common trucks, the foreside of truck swings comparatively fast when turning around. For this reason, to prevent collision with other objects nearby the foreside of truck, do drive or turn slowly. Strictly forbid harsh driving Notice Never start up, brake or turn abruptly.
  • Page 11 The faulty truck for future repair must not be parked at places impeditive for traffic. Lower down the fork arms to the lowest position and put on the warning board. Pull off the key. When protective devices suck as protective cover of mast is not mounted, it is forbidden to operate the truck.

  • Page 12: 4． Initial Operation

    3) Charge: Warning Open flame is forbidden to appear at the charge places, otherwise, explosion or fire disaster can be caused. Make a record of charge. As for the charge method, refer to the part about storage battery operation. 4． Initial operation 4.1 Initial operation：...
  • Page 13 there is no electric power in the batteries and charging should be conducted at once. It is prohibited to operate the truck without electric power as that will greatly reduce the service life of the batteries and even damage the batteries. Fig.1 5.1.3 Check if the truck brake is normal.
  • Page 14 5.2 In operation 5.2.1 Accelerator knob: The accelerator knob is used for controlling traveling direction and speed of the stacker. When it is for the traveling operation, turn the operation handle to B area indicated in the above diagram. When the handle is in A or C area, the stacker is in a power-off status, and can not travel. When the operation handle is in B area and the accelerator knob is turned in one direction, the stacker wil travel in that direction.

  • Page 15: After Operation

    stacker to the goods shelf nearby. (The tip of the fork is 300mm from the goods shelf). Press the lowering button, adjust the height of the fork to a proper position, and insert the fork slowly and as deep as possible into the pallet of the goods.

  • Page 16: Inspection Before Operation

    connected with the positive and negative ends of the charger, the DC power supply, and the charge should be conducted 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.

  • Page 17: Inspection After Operation

    Horn Horn Press down the horn button to check whether the horn sounds. Turn on the switch of electric lock to check whether the Instrument Function instrument displays normally or not. Structural part like Check that whether lifting, lowering, forward & backward truck frame Others movement and emergency reverse of the truck is normal, and if...

  • Page 18: Daily Inspection

    2) Before service maintenance matters needing attention: Notice No smoking. Arrange the self-protection work. Wipeout the effusive oil in time. Before adding lubricating oil, clean up the dirty oil or dust on the joint with brush or cloth. Except certain situation, turn off the key switch and pull off the power socket. Lower down the fork arms to the lowest point when carrying out maintenance.
  • Page 19 Density of electrolyte The specific gravity should be1.28g/ml after charged. Clean the storage battery Cover the lid, and flush with tap water. Inspect the contactor Burnish the coarse surface of contacts using sand paper. 9.6 The inspection and maintenance after 200 hours（Monthly） Besides the weekly maintenance, the following maintenance should be carried out, and when the parts must be adjusted and replaced, please contact with maintenance personnel of our company.
  • Page 20 Adjustment of the brake clearance  1 Hollow screw 2 Fitting screw 3 Spring 4 Armature 5 Motor shaft 6 Spline housing 7 Friction plate 8 Electromagnetic coil 9 Mounting cover plate 10 Mounting screw The structure of brake is shown as the figure. After a period of use, performance of the brake will decline due to the wearing and tearing of the brake plate.

  • Page 21: The Store, Transportation And Loading Of Truck

    When it is over loaded, we advise: Hydraulic oil: LHPISOVG68, in accordance with standard DIN51524T.2, the average sustained temperature is above 60℃. When it is lightly loaded with low temperature, we advise: Hydraulic oil: HLPISOVG32, in accordance with standard DIN51524T.2, the average sustained temperature is below 60℃.

  • Page 22: Replacement Of Storage Battery

    Lubricate the truck. Check the status of storage battery and electrolyte, and imbrue the non-acid lubricating grease to the binding post of storage battery. All the electrical contacts should be sprayed using appropriate contacts spray. 10.2 Transportation of truck If the truck needs to be transported for a long distance, support the side near to driver of truck with square timber to lift the driving wheels of truck from the ground.
  • Page 23 The magnet-exciting coil of the stepper motor is broken or bad Repair or replace contact at the wire end. Bad contact. Repair or replace There is a trouble at the MOSFET Repair or replace tube type circuit board. contactor poor Repair or replace The stacker can only connection or burnt out.
  • Page 24 Damaged oil pump Repair or replace Damaged lifting button Repair or replace 10) The electric lock is not unlocked Repair or replace or is damaged. 11) Seriously insufficient voltage in Recharge the cell. The internal mast is overloaded Repair or replace and deformed The external mast is overloaded Repair or replace...

  • Page 25: Common Fault Signal And Troubleshooting

    Common fault signal and troubleshooting 13.1 Indicator light fault diagnosis When operating normally without any fault, the fault indicator light will stay on. If the controller detects one or more faults, the status indicator light will continuously flash the fault code until the fault is eliminated.
  • Page 26 Troubleshooting  When the controller fails, it will handle the fault in the manner shown in the troubleshooting table to ensure system safety. D2 Fault code and troubleshooting  Fault Code Table Fault Fault Possible causes Fault description Troubleshooting code Excessive temperature: when temperature reaches...
  • Page 27 The battery voltage is greater than 31V; The current limit decreases Fault is cleared. Overvolt Plug in the charger to linearly from 100% to 0%. Restart operate the forklift; Automatically reset when the switch when there is Fault Bad wiring between the battery voltage returns to the serious overvoltage...
  • Page 28 electromagnetic Brake driver is open; When the throttle is given as electromagnetic 0, the electromagnetic brake Fault is cleared Fault brake coil is engaged. short-circuited; The operation sequence Do not respond to the throttle between accelerator and input until the accelerator key switch or interlock returns to neutral.
  • Page 29 Cutback 17V. linearly from 100% to 2) Poor wiring 0% to prevent low controller to the battery. voltage from disconnecting the internal relay. The controller resumes when the battery voltage rises to within the operating limits. 1) Battery voltage greater Current limit decreases Fault is cleared.
  • Page 30 directional switch operation. switch. Turn off the electromagnetic brake, Voltage recovery Severe Battery voltage less than slow down the vehicle and restarts the Undervoltage and turn off the relay in key switch. the controller. 1) Incorrect operation of accelerator (e.g. The key switch needs triggering of HPD faults).
  • Page 31 Disconnect the motor Rewrite the Failure of internal and main relay, parameters and Parameter Fault parameters of the electromagnetic brake then restart the key controller. holding brake. switch. 1) Motor blocking protection; Motor The limiting current 2) The configured Boost Temp is restored Current, Boost Time and...
  • Page 32 1) The parameters are set Parameter incorrectly. Does not respond to Rewrite the Change Fault 2) Controller EEPROM throttle input. parameters. failure. If the voltage exceeds 35.5V, the key switch needs to be reset to restore the voltage. Severe Battery instantaneous No response to throttle If the transient Overvoltage...
  • Page 33 resistors in the CAN BUS circuit. 3. Set the matching BUS baud rate. 1. Drive 1 drive short circuit recovery and Driver 1 On 1) Driver 1 drive shorted. restart key switch . Close drive 1 Fault 2) Driver 1 coil open circuit. 2.

  • Page 34: Lists Of Accessories, Spare Parts And Wearing Parts

    Lists of accessories, spare parts and wearing parts Name Application specification Quantity Remarks E-lock key E-lock Fuse Electric parts Fuse Electric parts 125A Seal ring Cylinder UHS45 O ring Cylinder 50X3.55 Bonded washer Cylinder inlet Dust ring Cylinder DH40 Seal ring Cylinder UHS40 Structure diagram (explosion diagram) and principle diagram...

  • Page 35: Schematic Diagram

     Schematic Diagram D2 electric schematic diagram（Lead-acid battery）...
  • Page 36 D2S electric schematic diagram（Lithium battery）...

  • Page 37: Packing List

    Packing list Packing list of CTD15R-E/N electric pallet stacker Consignee: Ex-work No.: Contract No.: Ex-work Date: Quan Net weight Dimension Name Remarks tity (kg) (L×W×H) CTD15R-E/N electric A complete set. pallet stacker Technical documents, Accessory box accessories and spare parts.
  • Page 38  Recording card of maintenance and upkeep process: Maintenance Maintenance Maintenance Items Material used Remarks time Part personnel  Customer advisement feedback: Occurrence Location of Trouble-shoo Items Faults causes Remarks time faults ting...

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