1. Delivery:
Newly purchased electric stacker, customers need to compare the characteristics and general operation of electric stacker
The basic maintenance method informs the customer in detail to avoid unnecessary hazards.
The basic structure of electric stacker can be divided into battery; computer controller; motor; electrical system; hydraulic system; mast; brake system; transmission system; and charger. The function and function of each part of the operation method need to be explained in detail to the customer , Matters needing special attention should also be particularly emphasized and notified to customers.
In order to protect the rights and interests of customers, the electric stacker will inform the customer one by one according to the content in the delivery schedule (Annex 1) when delivering the vehicle.If the confirmation is correct, please sign the customer for confirmation. .Electric stacker should pay special attention to the following items when handing over the vehicle. The customer must be informed in detail and let the customer pay special attention.
A. Power system:
The general electric stacker adopts lead storage battery as power, so the current general electric stacker adopts 48V voltage system.The battery for electric stacker needs to bear a large amount of discharge work load, so the design is different from the battery for general vehicles. The voltage is 2V, and then 24 cells are connected in series to form 48V. The 24 cells connected in series are combined in an iron battery box, and the positive and negative two are connected with a wire and connected with a connector, and the stacker circuit is connected through this connector The connector is connected to supply power to the stacker. Therefore, the battery occupies a very important part of the whole stacker. So how to maintain the battery is the most important issue. The maintenance of the battery needs to pay attention to the following items:
1. The battery will have a chemical effect during the charging process, so the moisture in the battery will be reduced, so you need to add [distilled water], and the distilled water should be added to the top of the isolation board about 15~20 cm.
2. In addition to the reduction of moisture during the battery charging process, hydrogen gas is also produced, so the charging position of the stacker must be far away from the fire source and a good location of the ventilation equipment.
3. After the battery is charged, the surface of the battery needs to be cleaned to avoid leakage of the diluted sulfuric acid generated during the charging process.
4. Generally, it is necessary to check whether the water level of the battery is normal every week. If the frequency of charging is high, the time for checking the water level of the battery needs to be shortened.
5. The battery should avoid excessive discharge and charging, so maintaining a proper charge and discharge is the only way to ensure the normal use of the battery life.
B. Motor system:
The electric stacker has a total of 3 action functions that must be driven by the motor motor, which are the walking motor; the hydraulic motor; and the steering hydraulic motor.The walking motor provides the stacker forward, backward, high, and low speed travel. The power is generally DC series motor. The hydraulic motor is connected to the hydraulic pump to provide the hydraulic power required for the operation of load rise, fall, forward tilt, and backward tilt. The DC series motor is generally used. .The steering hydraulic motor provides the full hydraulic steering power required for the steering operation of the vehicle through the connection with the hydraulic pump. Generally, a DC flyback motor is used. The DC motor is composed of the motor body including the housing, magnetic poles, and armature. Carbon brushes, commutator end caps and drive end caps. The maintenance of DC motors should pay attention to avoid overloading and overheating the motor. When the stacker is walking, it should avoid water siltation. Splashing water will cause abnormal short circuit between the armature and the carbon brush, allowing the motor to overheat and reduce the life of the motor.
C. Control system:
In order to make the DC motor operate according to the required functions, the controller configured by the electric stacker is composed of an electromagnetic contactor and a MOSFET microcomputer controller, which mainly provides the control functions of positive and reverse rotation of the walking motor, and stepless variable speed operation even if the walking is smooth. In addition, in order to protect the electromagnetic contactor, prolong the service life, control the circuit of the oil pressure and steering motor, the controller also provides its delayed cut-off function. The maintenance of the controller should focus on normal operation and use, to avoid overloading and overloading. The use of the load will overheat the MOSFET microcomputer controller and reduce the life of the controller.
D. Electrical equipment system:
The electrical components system components provide auxiliary functions of the vehicle and can be divided into 3 parts
1. Light part: including headlight, direction light and rear light group.
2. Instrument part: power/brake indicator,
Hour meter: When the power is ON, it can provide users with reference for maintenance.
Electricity Gauge: Provides the current residual battery power. When the power is insufficient, the red warning light is used to notify the user of the charging operation, and then the control circuit of the hydraulic pump motor is cut off when the user overcharges the battery without charging. The vehicle can no longer be used and has to be charged.
3. Other electrical equipment: emergency stop switch: the emergency switch is installed on the positive output circuit of the battery, which can provide the operator to cut off the power in an emergency.
Micro switch: used as seat switch, hand brake switch and hydraulic system switch.
Direction switcher: The direction switcher provides the controller the direction the vehicle wants to travel, so that the controller controls the forward or reverse rotation of the walking motor. It also provides the switch function of the horn.
Accelerator: It consists of a micro switch and a sensor, which provides a controller to control the starting of the walking motor and the stepless speed change function.
E. Charger system:
When the power indicator on the instrument panel is a red light, it means that the battery has insufficient power and must be charged immediately. The charger must confirm several key points when delivering the car:
1. Whether the AC power of the external power supply of the charger meets the specifications of the charger. The general AC power supply is three-phase 220V. If it does not meet the requirements, the customer needs to be improved.
2. The charging operation steps are as follows:
a. Lift the cover of the battery box and use the support rod to support it in a fixed position.
b. Open the battery cover of each battery, check whether the water level of the battery is in the normal position, and allow the gas generated during the charging process to escape.
c. Connect the power connector of the battery to the power connector of the charger.
d. Generally, the charger has two types: automatic charging and equal charging, which can be operated by a selection switch. The charger itself is fully automatic opening and closing. When the battery is connected to the charger, the charging machine will start automatically and set automatic charging. Mode, when charging starts, the charging switch indicator will light up. When the charging is completed, the charger will automatically stop the charging operation.
e. When the abnormal connection of the charger panel and the abnormal charging lamp are on, please notify our company department for repair immediately.
f. During the general charging process, if you want to stop charging, the most important step must pay special attention: △ first turn off the power switch of the charger, charging stops.
.△ Pull down the AC power switch of the charger, and then open the power connector of the charger and the battery.
.△ It is absolutely forbidden to pull off the power connector between the charger and the battery immediately during the charging process. The sudden reverse drawing will cause excessive reverse charging current to rush into the charger and cause damage to the charger. Sparks will be generated and the charging process will be ignited. The hydrogen gas exploded.
3. Equal charge: (EQUAL CHARGING)
When the battery is used for a period of time, the terminal voltage of the 24 connected sub-cells will be unbalanced.At this time, it can be balanced by equal charging.
Note a. Equalized charging is usually implemented once a month. If the discharge is repeated every day, it must be implemented once a week, which has extended the average distribution of power within the battery.
b. When the battery has not been used for a long time, or has been over-discharged (the specific gravity of the electrolyte is less than 1.10), it is necessary to implement equal charging.
c. It is not possible to switch the automatic/equal charging switch during recharging.
p Hazard warning: Hydrogen generated during charging is explosive, so it is strictly forbidden to smoke or fire in the charging area. It is best to make a shelf for the charger to raise it to avoid moisture on the ground and cause damage to the charger.
F. General mechanical system:
The mechanical system includes the transmission system; the differential; the power steering system; the brake system; the hand brake system; the hydraulic system; the guide mast combination and the fork frame, the frame and the overhead guard and the cab, and the operation and maintenance instructions of each part can be Refer to the operating instructions manual provided by the manufacturer.
2. How to check and maintain
A. Maintenance inspection of the battery:
1. Storage battery principle and operation:
Each sub-cell consists of anode (PbO2) and cathode (Pb) immersed in electrolyte (dilute sulfuric acid). Due to chemical action, a voltage of about 2 volts is generated between the two poles. The basic working principle is as follows:
Anode electrolyte cathode discharge anode electrolyte cathode
PbO2 + 2H2SO4 + Pb PbSO4 + 2H2O +PbSO4
Lead dioxide, dilute sulfuric acid, spongy lead, charging, lead sulfate, water, lead sulfate
2. The battery for electric stacker has the following special conditions:
a. High performance
b. Vibration and shock resistance.
c. Long life
d. Easy to maintain
3. The capacity of the storage battery: the battery used in the electric stacker is a wrapped battery, and its capacity is expressed by the following conditions:
Specific gravity of electrolyte…………………….1.28/20℃
Discharge current................................. 5 hour rate current
Discharge end voltage……………………1.70V/cell
Electrolyte temperature during discharge………………30±2℃
4. Battery management
a. Voltage drop during discharge
The reason why the terminal voltage during discharge is lower than the voltage before discharge is as follows:
? V=E-I*R V: terminal voltage
.E: voltage before discharge
I: discharge current
.R: internal impedance
The discharge reduces the specific gravity of the electrolyte, and the open circuit voltage also decreases. The internal impedance increases during discharge, and the discharge (100%) is about 2 to 3 times higher than the full discharge. Therefore, the battery voltage when the fork is raised is lower than the voltage during walking. , Because the horsepower of the lifting hydraulic motor is greater than the horsepower of the walking motor, so the discharge current during lifting is larger
b. Battery discharge rate and capacity
If the discharge current is large, the internal voltage drop increases, resulting in a sharp drop in the terminal voltage. Because the terminal voltage drops, the capacity that can be discharged is limited. The reason is that the diffusion of the electrolyte during discharge is slow and the sulfuric acid component of the electrode plate is recharged. Slow, so when the lifting operation is frequent or high-speed walking operation, the actual use time will be reduced.
c. Capacity of battery
When the discharge termination voltage is low, the discharge capacity is increased. In the capacity test, the following standards are set according to the discharge rate:
5HR………………1.7 V/cell
3贬搁………………1.65痴/肠别濒濒
1贬搁…………1.55痴/肠别濒濒
Discharging below the above voltage can not increase the discharge amount. When over-discharging, the active material will deteriorate, which will have a bad impact on the life of the battery. Therefore, the fork will rise when there is no load. If the battery voltage is 1.75V/cell(24 42V in series) is absolutely forbidden to continue to use and must be charged immediately.
d. Battery temperature and capacity
If the battery temperature is low, its capacity is significantly reduced for the following reasons.
? The electrolyte has poor diffusion, and the chemical reaction of the acting substance between the two electrodes becomes dull.
The impedance of the electrolyte increases, and the open circuit voltage also decreases.
The 5 hour rate capacity of the covered battery for electric stacker varies with the battery temperature. Therefore, the actual use time in winter is shorter than that in summer. The actual use time is shortened.
To extend the actual use time, it is best to increase the battery temperature in winter or before using it in the refrigerator, but it is more appropriate to consider the battery temperature at about 30 ℃.
e. Relationship between discharge depth and specific gravity:
The specific gravity of the battery's electrolyte is proportional to the amount of discharge, so if you know the specific gravity of the battery when it is fully charged and when it is 100% discharged, you can calculate the discharge of the battery. The specific depth measurement method knows that the depth of discharge is the most reliable, so please The specific gravity should be measured and checked regularly after use, and the battery cannot be over-discharged. During the specific gravity measurement, the electrolyte temperature can be measured at the same time. When converted to 20℃, the specific gravity should not be lower than 80% of the discharge value of about 1.16.
f. Discharge status and internal impedance:
The internal impedance gradually increases with the discharge and reaches the maximum value at the end of the discharge. This is because when the discharge is in progress, the electrode plate produces lead sulfate, which is an electrically poor conductor, and the specific gravity of the electrolyte decreases to increase the impedance. After the discharge, it must be as soon as possible. Charging, otherwise the plate will produce white lead sulfate, which seriously affects the life of the battery. The so-called white lead sulfate (Salphation) is that the plate becomes lead sulfate after discharge, if it is not charged, it will be converted into white lead sulfate, even Recharging is also difficult to restore.
g. Temperature during discharge:
During rapid discharge, the internal impedance also increases rapidly, and the temperature of the battery also rises, and the temperature at the end of the discharge rises.Similarly, the temperature at the end of the charge also rises, hoping to reduce the final temperature to below 40 ℃.
h. Charging characteristics of battery:
Charging proceeds until the voltage of each single cell reaches 2.35V~2.4V, gas occurs, and the voltage also begins to rise rapidly.The gas generation reaches the maximum in the middle of recharging, and the charging voltage remains almost constant.
Almost all the current in the mid-charging period is spent decomposing moisture into gas to increase the temperature, so the mid-term charging current should not be too large, otherwise it will cause an excessive rise in battery temperature and affect the life.
i. Charging capacity and life:
The charging capacity of the battery needs to reach 110~120% of the discharge capacity, and the relationship between the discharge capacity and the life is also the same. If the battery charge is 150% of the discharge capacity, the battery life will be shortened, which can be presumed as follows:
1200 Cycle * 120/150 = 960 Cycle
If the temperature of the battery at the end of charging is increased by 150% and the gas generation causes the electrolyte to decrease, as mentioned above, it also results in poor battery life.
In addition, if it is used in a state of insufficient charging, it will also cause a factor of shortening the battery life. Therefore, the battery temperature of the electric stacker is 10~40 ℃, and the charging of 110~120% of the discharge amount is the most appropriate method to extend the life. , The specific gravity at the end of charging is 1.28 ± 0.02 after conversion to 20℃
j. Gas generation and ventilation:
The gas that occurs during charging is a mixture of hydrogen and oxygen. Oxygen is a highly explosive gas. If the hydrogen concentration in the air exceeds 3.8%, it will explode in the event of fire.Therefore, the charging site needs to be well ventilated, and the fire cannot be close to the battery. s position.
k. Determination of specific gravity of electrolyte:
The specific gravity is measured with a specific gravity meter. The electrolyte is drawn in the outer cylinder. Read the scale above the electrolyte of the specific gravity meter in the cylinder. The specific gravity of the battery will change with temperature. If the temperature changes by 1℃, the specific gravity will change to 0.0007, so When measuring the specific gravity, the temperature must be measured at the same time, and then converted to the specific gravity of the standard temperature of 20℃ by the following formula
S20: Specific gravity after conversion at 20℃
S20 = St + 0.0007 * (t – 20) St: specific gravity measured at t℃
t: measured temperature of electrolyte
l. Supplement of distilled water:
After the cycle of charge and discharge, the electrolyte level will slowly decrease, so it is necessary to regularly check and replenish distilled water to the specified liquid level. If you forget to add distilled water and expose the electrode plate to the liquid surface, the electrode plate will be injured and must be injured. pay attention.
If the added distilled water exceeds the specified liquid level, it may overflow the battery surface during charging, causing burnout of the electrolytic cell and corrosion of the pole, so great care must be taken.
m. Determination of end of life:
If the battery reaches the end of life, the capacity will decrease. How much the capacity will decrease. The correct method is to determine the capacity test. The method and steps of the capacity test are as follows:
?Before discharging, all single cells are charged to the highest value of specific gravity and voltage, and then continue for 1 hour until fully charged.
·Discharge start time............ After charging, leave it for about 1 hour. Discharge current .................. 5 hours 1/5 of the rated capacity current (400AH/5HR is 80A constant current)
?End-of-discharge voltage…………1.7V/cell (40.8V at 24cell)
?Conversion of capacity and temperature.........The actual measured capacity is converted to a capacity of 30℃ based on the average electrolyte temperature reference chart 2 hours before the end of discharge
-20℃ -10℃ 0℃ 10℃ 20℃ 30℃ 40℃ 50℃
Example: The actual capacity measured at 20℃ is 350AH. Refer to the figure above. The capacity at 20℃ is about 95% of the capacity at 30℃, so the capacity converted to 30℃ is
350AH / 95% = 369AH
If the rated capacity of this battery is 400AH, the capacity of this battery will decline to
369AH / 400AH * 100% = 92%
5. Maintenance:
a. Points for attention in daily use:
Please pay special attention to the following precautions
? Avoid excessive discharge.
Charge in moderation and do not overcharge.
? Keep the electrolyte at the proper level.
?Explosive gas will be generated during charging, so fire gas should not be brought close.
?Do not allow the battery temperature to exceed 50°C at any time.
?Keep the battery connector and its surroundings clean and dry.
b. Daily use method:
?Select the reference cell (Pilot Cell)
Select the single cell located in or near the central part of the battery pack as the reference battery ‰ (it is recommended to select the fourth from the negative electrode), and mark it. From this, the liquid level, specific gravity, and temperature of the battery are speculated. The condition of other batteries.
·Check before operation
?Check the electrolyte surface of the “reference battery”
If the electrolyte of the "base battery" is insufficient, all batteries must be added with distilled water. When adding distilled water, be careful of the condition of the float and do not over-replenish.
?Check the voltage
If the fork is raised under no-load conditions and the voltage remains at 42V or above, it can be operated.
?Check the power plug
Only when the power plug is correctly inserted can the stacker be operated.
Points for attention during use
? Avoid raising the fork while driving the stacker.
? Driving at low speed and stacking function can make the battery have a longer service life.
?Avoid vibration and shock.
? When the speed of the fork rises and the walking speed feels down, stop using the stacker for charging, and when the walking performance is reduced, it is in a state of excessive discharge.
?Charge when the stacker is idle, which can increase the efficiency of the battery.
?Inspection and handling after use
After the stacker is in operation, please implement the following inspection and treatment:
?Cleaning and finishing
Due to weather and operating environment, the battery may be covered with rain or dust, so use a rag to clean it.
? charging
According to the actual need to charge the battery, before charging, check whether the charger connector and the electric delay connector are properly connected.
c. Regular maintenance inspection:
? Weekly inspection
Check once a week, and register the following forms
?Measure the voltage, specific gravity, and liquid temperature of the “reference battery” before and after use
? During the charging process, you should first open the lid to check whether the position of the indicator mark on the top of the float is appropriate, (the correct water level is 12mm above the top of the grid)
If the water level is too high, it will cause the electrolyte to overflow during charging, causing the acidity of the electrolyte to weaken. If the water level is not enough, the top plate will be exposed, which will reduce the life of the battery. Metal containers, and can only add certified distilled water to meet the purity requirements.
H Never use acidic water as supplemental water H
?Add distilled water to avoid pouring too much or too little distilled water into the battery.
?Check all connections and sort out worn lines or damaged insulators.
?Check the condition of each pole and whether the connecting wires are firm, and whether the battery end cover head is installed and fixed correctly.
&ARIng; It is necessary to keep the top of the battery clean and dry, because any dirt and moisture will become a conductor of electricity, and the parts with metal rust should be removed first, and then use aqueous solution or soda water or diluted ammonia to neutralize the rust And dry it, and then cover it with acid-proof liquid to protect the rusty part.
·Monthly inspection and maintenance
Check once a month, maintain and register the following forms
?Measure the voltage, specific gravity and liquid temperature of all batteries.
Check and clean the plugs of the battery and charger.
d. Environment of charging and using place
? Conditions of charging site
?Avoid rain and direct sunlight.
? is well ventilated, there is no fire, and there is no possibility of fire near the scene.
?Vibration and dust
