SBE P ES stacker Operation Manual Service manualCONTENT WARNING SAFETY INSTRUCTION OPERATE MANUAL SERVICE MANUAL BATTERY & CHARGERI. WARNING ZX WARNING ‘A MOVING VEHIVLE CAN BE DANDGEROUS ‘You or others around you can be seriously injured or even killed if you are not careful ‘or don't know how to use this truck correctly. Do not operate this truck unless you are trained and authorized. Read and obey all warning and instructions in this Manual and on the truck. Make sure the truck is in good working order. A dockboard can move or drop while you are on it, Falls form docks or dockboards can cause serious injury or even death. Make sure you are safe .II. SAFETY INSTRUCTION 1. It's the law ,you must be trained 2. Always be alert to the area around you and watch where you are driving . ‘Turn over and falls are very serious accidents, you can be crushed or even killed. Be careful that you don't pin or crush someone. 3. Be extremely careful when working around docks, dock boards and trailers. & 4. Know the capacity of your truck. The capacity plate is on the top of the power unit .It contains: L:Truck serial number 2.Capacity information (load load center and lift height ) 3.Truck weight without battery (does not include load) 4.Attachment information(if any ) ss ac = eee Tae eT ato aT a aes aa | ne TD Capacity may be reduced as lift height increases Capacity is reduced as load center increases .5. Slow down for spills or wet floors or uneven surfaces. Do not run over objects on the floor. 6. Be careful that you don't get pinned or crushed between the truck and a fixed object. 7. Do not run on road, 8. Avoid loading work on a grade. 9. An unloaded truck can tip over also. You must be just as careful using as loaded one. 10. Be careful when changing direction of travel, keep your feet clear of the truck. 1. Use your horn when you come to a cross walk or intersection. 12. It is forbidden to walk down the fork or the attachment, it is forbidden to walk up the fork or stand on the fork. Never ride on the truck or let any one else ride. 14. Itis dangerous to travel with forks at high position. Be always travel with the load or forks close to the ground. 15. Never load products that gravity center exceeding bracket height. 16, Make sure you know the load diagram, | == Et 3 HELPS it is forbidden to over load. Z Littive Weight (an)17. Be always start to travel smoothly. Quick steering will be dangerous. Avoid sudden movement of controls. 18. Before you leave your truck, lower the forks to the floor; shut the truck off with the key or disconnect the battery. Avoid parking on inclines. 19. Whenever in trouble, you must stop the stackers hang a mark of" danger “ or " trouble" and take off the key ,at the same time inform the trained service people. Do not use stacker if there's any oil or fluid leakage until it fixed. Be careful not be scratched by sharp edge or iron bar when maintain or repair truck. Only after the trouble is removed , you may use the stacker 20. Prevent exploding . Because there will bring exploding gas in the bosom of the battery, prohibit any flame nearby it absolutely. Don't let any tools close the two terminal of the battery to avoid spark or short circuit . ‘Truck can not be operated in explosive gas environments. Working temperature is between- 10 ~ 50 Humidity is less than 90%. 21. Prohibit load off center—The goods is liable to drop turning or passing rough when it departues the center . And the truck may turn over more probably. 22. Inan open area, test the braking, check it at low travel speed first, then a faster speed.23, Don't let anyone use your truck, unless they are trained or authorized, 24.Before take your truck on to a elevator, check capacity or load limit, 25, Be careful when using attachment, Thus can affect stability. 26. Be careful training while traveling. The power unit will swing wide in opposite direction. Make sure you have clearance. 27. When operating loaded truck, have the rear end of your machine pointed downhill. When operating unloaded truck have the rear end of your machine pointed upgrade. ‘Know the Hazards 28. Be careful turning while traveling forks first . The power unit will swing wide in the opposite direction . Make sure you have clearance , and watch out for people in the area . oe f 29. Powder or liquid spills can cause slippery floors . Slow down or you could lose control of steering and braking . Be careful and allow for a longer stopping distance . Don't run over objects on the floor .Operation Manual —=BEPStacker partsStacker parts. A.Power switch 1. Power disconnect (emergency stop button) Push the battery connector handle down to disconnect the battery and cut all power .. Always disconnect the battery any time the truck isn't working right . The key switch does not cut all power to the truck . Don't use the truck if it's not working right . Report the problem to your supervisor. 2. Key switch Turn the key clockwise ,. Power is ON. Turn the key counterclockwise . Power is OFF. Always turn the key off when leaving the truck . B. Control handle Horn Button Lower buttonStacker parts 1.Horn button ‘The button is located on the back of the control handle upper surface . Press down the button , and the horn sounds . 2.Reverse button The button is located on the end of the control handle . Press the button the truck will drive ahead immediately . Its function is to prevent operator form being clamped by the control handle. Caution Be careful, The reversing button cannot prevent all injuries. 3. Direction & speed knob ‘The knob is located on each side of the control handle Its function is to control operating direction and speed . Turn the knob forward gradually, and the truck will drive ahead; turn the knob backward, and the truck will drive back . The driving speed is in relation to the turning angle of the knob. The larger the turning angle , the rapidly the truck drives . However the driving speed is not in linear proportion to the turning angle. Caution After the knob is released , the direction & speed knob will reset itself and the truck will stop by brake .So do not loosen the knob when the truck is requested to continue driving . 4. Lifting button ,lowering button. The lifting button ,the lowering button is located on the front of the control handle upper surface. Press the lifting button, and the fork arms move up ; press the lowering button, the fork arms go down. C. Power meter Sufficient Charge Require UnSufficientStacker parts D. Battery Cover board on battery Check,. Charge, replace the battery or remove the charging plug, you can open the board conveniently. Caution Pay attention not to hurt your finger when close the battery cover board . Battery The battery is located between the mast and the body , one plate on each side is to clamp the battery box. To replace the battery, open the battery cover board remove side cover slide battery out Caution After replace the battery , remember to retighten the clamp plate board to prevent the battery box loosen. 10Make sure your Stacker is ready Tnspect your truck before using it If'it's not working right, or something is broken , report the problem to your supervisor . Don't use the truck . Check your truck before starting work ‘You must make sure your stuck is safe to use. 1. Walk around your truck and check it over . ~Check to make sure the battery is charged, water level is OK and vent caps are in place . Don't use an open flame to check the battery. ~Sce that all wheels are in good condition . ~Check that both forks are secure and not bent cracked or badly worn, “Inspect lft chains for damage . See that the load backrest is in place and secure ,if your truck has that option. Look under the truck for signs of hydraulic leaks . ~Iry the hom. Male sure the power disconnect works . ~Check that all controls work smoothly. 2."Test drive your truck in an uncongested area. ~Tryall the hydraulic functions . ~Check the steering. Operate the truck slowiy in both directions. Operate through the full speed range in both forward and reverse. ~Check braking distance in forward and reverse .Load size and floor conditions can affect, these distances. Know the distance it takes to stop before you start working LIf the braking distance is too Tong to stop safely don't use the truck . ‘If anything doesn't look , work or feel right ,don't use the truck .Report the problem to your supervisor, 3. Hydraulic oil checking ‘Loose the cap of hydraulic oil inside body , pull out dipstick and check it if the oil level is between the scales . Add oil when lack .12 Make sure your Stacker 4. Battery checking Inspect the battery cover board . See whether the battery fixed reliable . Check proportion of electrolyte . Refer to “battery * section. Check the terminal for loose or damage. Otherwise it will be adjust or replace .How to operate your stacker 1 Forks first When traveling forks first use both hands to operate the control handle Watch your feet if you change direction of travel. —_ 2. Power Unit First ‘When traveling power unit first stay to one side of the truck and slightly ahead of the power unit ,Use the hand closest to the truck to operate the control handle . ‘Watch your feet . ‘Stay out of the path of the truck . 3. Start and travel 3.1 Start <1>Pull up emergency stop button. <2>Tumn on switch key . Press down control handle to operation area, rotate the speed control knob in the direction you want to travel. ‘The farther you move the knob from the neutral position, the faster the truck will move.‘How to operate your stacker 2. Steering ‘You control steering by moving the control handle form side to side . For example : This picture shows the directions the truck an turn when the control handle is moved to the approximate position shown. re 3. Decrease speed Loose the rotate knob , the knob will reset to its original position and the truck's speed will decrease automatically 4. Brakeing Move the control handle all the way down or all the way up to apply the brake . When you let go of th econtrol handle it will automatically go to the upper braking position. {Brake On es Check braking before you start working . 5, To raise or lower Push the Raise /Lower buttin until the forks are at the desired height . Release the button. BO | eavetot0n Sy | erin 14How to operate your stacker 6. Two lowering speeds Push the rocker all the way for fast lowering . Push the rocker part way for a slower lowering speed. Lower button 7.Unstacking load When approaching the deposit area, slow down your truck. Elevate forks up to the position of the pallet or skid. Travel forward and put the load on the skid bed or pallet and then drop down the fork. ‘Travel backward and make the fork out of the pallet . Drop down the fork off ground 15-20cm, 8. Stacking load When approaching the deposit area ,slow down your truck . Once stop the truck right in front of the area Elevate fork to the position front of the area ‘Travel forward and travel back ward Elevate fork and travel back ward Lower fork off ground 15-20em 9. Deposit Park the truck on level ground preferably in a wide area and let the fork down the ground . Shut off switch and control the lift and drop button several times so that the inner pressure in the hydraulic tube will decrease .Take off switch . 10. Deposit the truck for a long time On the basic of the “deposit * you should do these checks and maintain additional: ~Take out plug to prevent discharge and stay to dark place. -Brush antirust oil on that part which is exposed such as piston rod and axle. -Put a cloth on vent plug. Mantle the truck with mantle, -Run the truck once a week. Lift the fork to the highest some times. -Check proportion and level of electrolyte. “Change the battery equally once a month . 1516 eprsano a aT wm ToT sor TET sane 3 + rho P1530 0001 [ss a i i 4‘ mp kvyond saana09 anoua aur ot pea ose haz ord 02 saqsupu sdusnpoy saasnphy ‘x3snpuy Aafsnpuy _qoay eoweuer fray erat evar lvcr evar coer slang STL Sutil sand SIL STAND Sra ° T T 60 ck ToT TT 5 Tr I 3 1 T I apr Tay WT [Serr ar 1s 0 a ou ps 098 ose 038 ae ads 0 (em) q0 eippeasg our f n i st Tr 1 uF a 9 TRIPE HOF PPO og 7 i U3 7 T PUNO MTT TIBET SOT TIT, AMO oar ‘008 Joov oot 008 poge nog lo9e ose| 0098 (wey yu ey uc4g FL wouoD wore wore loce ose| ove noe e pow et suet i si iarondl laos a ok [2pou £30398 ¥ Tspou eres “9-88 a8 wieerss fers sa anifesaaef-ei-sa ¥ z4Byo uo! eo! Jloads sayoe Is SqMaintenance Maintenance summarization: “The fork lift truck needs termly inspection and maintenance , make it in good working condition. Inspection and maintenance are usually ignored, you must find the problems and solve itin time, -Use the orthodoxy spare part of E-P EQUIPMENT CO., LTD -Don't use different oil when changing or adding oil. Forbid to repair the fork lift truck if you haven't been trained . “Maintenance on schedule. -After you make a maintenance ,you'd better make a record. Notice -No smoking . -You should shut off key switch and pull off the plug before service.( except some trouble shooting ). -Clean the electric part with compress air ,do not with water . -Do not place your hands, feet or any part of body into the gap between the mast and instrument . -Ifyour working condition is execrable , please make a maintenance before the schedule The weight of mastis relative heavy. Itis about 500-510kg. - The cleanliness of hydraulic oil must obey the standard of NAS-1638 class 12. 7Preventive maintenance schedule x— © — Check, revise, adjust Replsce item | ServiceRequired | Tools| (hrs) | (S0hrs) |(200krs) | (600s) (1200 hrs) Electrolyte level Eyeballing oO ° ° oO Electrolyte ‘ roportion Densimeter @- || +0) ° ° Battery quantity ° ° fe} ° oO ‘Terminal ° oO ° oO oO ‘Looseness af ing wite ° ° ° ° oO cleanness of the cf o |} 0 ° ° if there is tool the! re ° ° ° ° ° ‘The tightness of ay eo |o ° ° Far away from. fring ° ° ° ° oO Controller Daily | Weekly | Monthly Tools | (ghrs) | (SOhrs) | (200hrs) Check connector for ‘worn ‘Check contactor for Controller Check inching switch for running Cheek the connection ‘motor, battery and power unit.‘Checking | Daily | Weekly | Monthly | Trimonthly | Semiannually item Service Required | Tools | (hrs) | (SOhrs) | (200hrs) | (1200hrs) | (1200's) ‘Clean the foreign ‘body on the motor 9 % 2 Clean orreplace the ° tenet || Motor User for wom it 8, 9 2 spring isnormall | Tithe connection: | ‘correct and firm if o 9 2 ‘Brush carbon powr | der on shift plate ° ° and shit device. Transmission unit Item Service "Tools Daily Weekly Monthly i ‘Semiannually required (Bhs) (SOhrs) | (200hrs) | (600hrs) | (1200 hrs) ° ° ° ° ° ° ° ° ° ° x ° ° ° ° ° ° ° ° ° ‘Abnormal — ° ° ° ° ° Rotate handle ° ° ° ° °Wheel (drive unit, balance wheel and supporting wheel ‘required (8hrs) | (SOhrs) | (200hrs) | (600hrs) (1200 hrs) wears pa ra Gye} O ° ° O° Drive unit, | ‘balance whee! ey ing | Pghten bolt ° ° ° ° ‘wheel Whether there isrope onthe ° ° ° ° oO wheel ‘Brake system Daily Weekly | Monthly | Ttimonthly | Semiannually (Bhrs)(SOhrs) | (200hrs) | (600hrs) | (1200hrs) Check the brake state when the handle on | © ° ° ° ° Brake | vertical or level position. micro switeh Whether the micro hi ° ° ° Tighteness ° ° ° Brake drum | Wearing oO ° Clearance between ‘drum and shoes © 9 20Hydraulic system | gear for wear Checking |g ; Daily | Weekly | Monthly | Trimonthly | Semiannually item requited | Tools | (gis) | (Sohrs) | (200hrs) | (600s) | (1200hrs) | ‘Check for oil level, x oil oO fo} ° O° | ‘Hydraulic Clean suction ° reservoir strainer | Drain for foreign ° | matter | Chock for ol leaks, Hose, | jooseness, collapse, e js é Hose Reel \aeee mt & Swivel oe eee 1-2 yo0rs | Check: hydrate | Pump for oil I O° O° oO ° ce} Hydraulic | or noise Pump (Check pump drive si a a e aSDE P Service manuala | Daily | Weekly | Monthly |Trimonthly| Semiannually heating, Service required | GBhus) | GOhrs) | 200hrs) | (600hrs) | (1200 hrs) Check cain fortension damageormst =§ «3 | O | O a a ° ° ° ° ° ° ° ° ° ee hh oe Oe) SO ° ° ° ° ° ° ° ° ° ° ° exlinder | Cheek for cil leaks ° ° ° ° ° ‘Check pins and cylinder bushings for wear or ° ° ° | | Checks damage, deformationor ° ° Wear Fork | Check for stopper pins for damage or Wear ee ‘Check fork base and hook welding for ° ° efectve cracks or wear (Check cross members on outer and inner ° ° ° _masts for defective weld, cracks or damage (Check it cyinder bracket and mast for ° ° ° defective weld, cracks or damage (Check outer and inner mass for defective ‘weld, cracks or damage | . 2 2 ‘Check for defective weld, cracks or damage of ° ° ° Tift bracket | Mast & | Check roller bearings for looseness ° ° 3G, faite | Seer tlt : = Bracket | Check mast support bushing for wear oc ° damage ° (Check mast support cap bots for looseness (Goris ime e | oxi) ‘Check lit cylinder tall bolts, piston rod head ° ‘bots, Ubois, and piston head guide bots for | xisttine| ° looseness | oy) ‘Cheek roles roller pins and welded paris for ° ° ° cracks or damageAdditional Service required | Tool Emergency cut jae State ov | -@ ° ° ° Lifting and State ° ° ° ° ° Check for proper Hom operation and tight ° oO ° ° ° installation Check meters for Meters ica oO ° ° ° ° Wire damage or foo. ° ° ° ° eS acest eb ess of Satie ata ° ° ° Replace the key safe parts termly + Some parts should be checked termily to detect the damage, for improving the safety more, ‘users should replace the parts termly which is listed in the table as follows. * Ifthe parts is abnormal before the replacing time is coming, it should be replaced immediately. Key safe part’ s description ‘Term of using (year) Brake hose or tube ‘Hydraulic hose for lifting system. Lifting chain High-pressure hose, hose for hydraulic system Inner hermetic, rubber matter ‘Wiring of handel 23Table for bolt’ s tight torque Unit N+ m Grade Bolt’s diameter 46 56 66 88 6 4-5 s-7 6-8 9-12 8 w-2 12-15 14-18 22-29 10 20-25 25-31 29-39 44-58 12 35-44 44-54 49-64 16-107 4 54-69 69-88 83-98 121-162 16 88-108 108-137 127-187 189-252 8 ue-47 147-186 176-216 260-347 20 167-206 206-265 245-314 369~492 22 225~284 284-343 343-431 502-669 4 294~370 370-441 441-539 638-850 a 441~519 539-686 637-784 933~1244 ‘Note: + Use entirely 8.8 grade bolt in the important joint position. + Bolt’ s grade can be found in the head of the table, if it can, tbe found, the grade is 8.8 Table for oil used in the truck name Trademark, codename | capability (L) notice Hydraulic oil L—HM32 8 Gear oil GL5 85W/90 15 Industrial vaseline 24 Electrode of storage battery Lubrication grease ZG2# or 3# ‘Truck’ s convey, lifting, towing Convey Forklift truck is designed for material handling only. It is inapporiate for long-distance transportation. The forklift truck must be transported by ship, train or lorry. Hoist the truck Use the steel wire ropes to tie the holes in the two side of the outside mast’ s beam and the hook of the truck, Then use the lifting device to hoist the truck. Warning The steel wire and lifting device must very firm to support the truck because the truck is very heavy. When lifting the truck, don’ t take yourself below the truck, 24‘Trouble fix & parts replace (All the techical drawing under this chapter ref spare parts book) A. Trouble fix 1.unable to move Press control handle down to Working area, and press Reverser Botton P12 #11. @) v Press lifting button P12#8Jestthe voltage between the two connector of hydraulic Motor Sufficient No v v charge YES Work? NO. Check the voltage between the line connector of inching Replace inching v (forward or backward) |} switch or Check driving motor switch and contactorP6 #10 contactor y Run? YES Vv ‘Check motor parts and replace accordingly 25‘Trouble fix & parts replace 2. Unable to lift <1> Make sure power switch turned on, battery power is sufficient, emergency stop botton pulled up. ‘<2> Then check according following steps Press lifting button to see if hydraulic motor sounds normally (Chech hydraulic connector and lifting cylinder ress lifting button P12#8, test the voltage between the two connector of hydraulic Check carbon brush and motor parts and replace it accordingly Replace Check hydraulic valve hydraulic valve 26Trouble fix & parts replace 3.Unable to lower <1> Make sure power switch turned on, battery power is sufficient, emergency stop botton pulled up. <2> Then check according following steps Press lower button P12#10, orif13, test the voltagebetween the two connector of hydraulic x mv? NO __, | Check inching switch and line between hs #11 (12hole base) and lower button ‘YES | Check diode Replace button, inching switch, line accordingly YES Replace ion? Destruction? diode NO v Check electromagnet Replace P32#3,45 ‘core of hydraulic >) (inner side) or valve assy #3,8 (out side) 27‘Trouble fix & parts replace 4, Mast Vibrating during lowing: 1. Lower forks to ground and load with full capacity. 2. Release bolt #6 (P46). 3. Lift forks to top position. 4. Tighten bolt #6 (P46). 5, If still has problem after step 1-4, repeat the operation again. 6. If problem can not be solved, check and replace seal #3 (P46), 2829 5. Brake problem: Unable to brake when control handle pressed in brake zone. <2> Unable to stop the truck when control knob (P14 #19) released. <3> Unable to stop the truck when press down the emergency stop Check all connector and lines button P6 #7. . Tighten NO ¥ Check indicator light of controller, and tell trouble according to instruction book Replace controller ‘Check electronic brake assy, release the bottle #2 (P30), and replace the brake‘Trouble fix & parts replace 6. Lowering down automaticly Tighten (7) Check hydraulic Adjust safety Check electromagnet core P32#7 YES Replace seal Replace seal 30‘Trouble fix & parts replace 2. Parts replace I. Replace driving motor carbon brush 1-Tum off the power 2.Loose all necessary lines 3.Take off (Fig 1) coves 4.Loose carbon brush screw 5.Replace carbon brush 6.Revert other parts SS * Fig‘Trouble fix & parts replace Il. Replace oil pump and electromagnet core 1:Turn off power, loose the battery connect line. 2.Loose all necessary electric line and hydraulic hose 3.Loose base board screw, move the controller aside, loose connecting hydraulic hose. 4.Loose 4 bolts (Fig 3)#1 5. Pull out hydraulic units assembly 5.1 Loose (Fig 3) #8, #9, Replace #7, revert other parts 5.2 Loose (Fig 2) #7, replace #3, #8(out side) or #3, #5(inner side), revert other parts. Fig 2 Fig3 32‘Trouble fix & parts replace 33 IIL. Replace driving wheel Lift the whole truck to make driving wheel leaving ground. 2.Loose(Fig 4)#23, take off driving wheel and replace it. 3.Revert other parts.‘Trouble fix & parts replace TY. Replace load wheel 1 Lift the whole truck to make load wheel leaving ground 2.Using sepcial tool(ship with the truck) to take off spring pin(Fig 5) #2 3.Take off load wheel axle (Fig 5) #1 Replace load wheel 5 Revert other parts 34‘Trouble fix & parts replace V. Replace universal wheel 1.Lift the whole truck until 130cm apart ground 2.Loose (Fig 6)#14 3.Replace universal wheel 4,Revert other parts 35 Fig 6Trouble fix & parts replace VI. Replace seals 1. Take off (Fig 7)#8 2. Release chain, loose (Fig 9)#12, then take off chain 3. Loose (Fig 8)#4 screw, take off #5 4, Lift inner mast to be 80cm apart ground 5. Take off cylinder 6. Pull out piston (Fig 7)#7 7, Replace #1, #3 (Fig 7) 8. Revert other parts he go] 2 “oO 3. ° @ | y 36[Trouble fix & parts replace | VII. Change hydraulic oil 1. Loose(Fig 10)#13 screw, let out hydraulic oil, and resighten the screw #13. 2. Loose #10,fill in LOkg hydraulic oil, and re-tighten #10. 3, First change of hydraulic oil is after 200hours running, Request later oil change per 1000hours running. Fig 10 37‘Trouble fix & parts replace VIII. Change hydraulic oil 1. Loose(Fig 11}#33 screw, let out hydraulic oil, and re-tighten the screw #33. 2. Loose #35, fill in 10kg hydraulic oil, and re-tighten #35. 3, First change of hydraulic oil is after 200hours running. Request later oil change per 1000hours running. 38IX. Change hydraulic oil 1, Loose(Fig 12)#13 screw, let out hydraulic oil, and re-tighten the screw #13. 2, Loose #18,fill in 10kg hydraulic oil, and re-tighten #18. 3, First change of hydraulic oil is after 200hours running. Request later oil change per 1000hours running. Fig 12 39‘Trouble fix & parts replace X.Change oil of gear box : 1.Loose (Fig 13) #7 bolt, let out gear box oil 2.Loose (Fig 13) #24 bolt, add gear box oil Fig 13 40