I Delivery:
When the customer newly purchases the electric stacker, he shall submit the characteristics and general operation of the electric stacker
The basic maintenance method shall be informed to the customer in detail to avoid unnecessary harm
The basic structure of electric stacker can be divided into batteries; Computer controller; Motor; Electrical system; Oil pressure system; Mast; Braking system; Transmission system; And charger The function and operation method of each part shall be explained in detail to the customer, and the matters needing special attention shall also be emphasized and told to the customer for attention
In order to protect the rights and interests of customers, the electric stacker shall inform the customers in detail one by one according to the contents in the delivery schedule (Annex I). If it is confirmed to be correct, the customer shall sign for confirmation, and both parties shall hold one copy to complete the filing
The matters needing special attention during the delivery of the electric stacker are as follows. It is necessary to inform the customer in detail and let the customer pay special attention
A. Power system:
The general electric stacker uses lead-acid battery as the power. Therefore, at present, the general electric stacker adopts 48V voltage system, and the battery of the electric stacker needs to bear a large discharge workload
Therefore, the design is different from that of ordinary vehicle batteries. The unit voltage is 2V, and then 48V is formed by connecting 24 units in series The 24 single batteries in series are combined in the iron battery box, and the positive and negative two are connected with wires and connected with the connector. Through this connector, it is connected with the circuit connector of the stacker to supply the power of 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 following items shall be paid attention to in the maintenance of the battery:
1. The battery will produce chemical action during charging, so the water in the battery will be reduced, so it is necessary to supplement [distilled water], and the distilled water should be supplemented to about 15 ~ 20 cm above the isolation plate
2. In addition to the reduction of moisture, hydrogen will also be generated during battery charging, so the charging position of the stacker must be far away from the fire source and the position with good ventilation equipment
3. After the battery is charged, the battery surface shall be cleaned to avoid leakage due to the overflow of a little dilute sulfuric acid generated during charging
4. Generally, check whether the water level of the battery is normal every week. If the charging frequency is high, shorten the time to check the water level of the battery
5. The battery should avoid excessive discharge and charging. Therefore, maintaining appropriate charge and discharge is the only way to ensure the normal use of the battery life
B. Motor system:
The electric stacker has three action functions, which must be driven by motor, namely walking motor; Hydraulic motor; Steering oil pressure motor and other three parts The traveling motor provides the power for the stacker to move forward, backward, high and low speed. Generally, DC series motor is used The hydraulic motor is connected with the hydraulic pump to provide the hydraulic power required for load rise, fall, forward tilt, backward tilt and other operations. Generally, the DC series motor is used The steering oil pressure motor provides the full oil pressure steering power required for vehicle steering operation by connecting with the oil pressure pump. Generally, the DC compound motor is used DC motor is composed of motor body, including shell, magnetic pole, armature, carbon brush, commutator end cover and drive end cover For the maintenance of DC motor, attention should be paid to avoid overload and overheating of the motor as far as possible. When the stacker moves, it should avoid water deposition, because water splashes will be splashed through the water deposition, which will cause abnormal short circuit between armature and carbon brush, overheat the motor and reduce the service life of the motor
C. Control system:
In order to make the DC motor operate according to the required functions, the controller of the electric stacker is composed of electromagnetic contactor and MOSFET microcomputer controller. It mainly provides the control function of forward, reverse and stepless variable speed operation of the travel motor, even if the travel is smooth. In addition, in order to protect the electromagnetic contact, prolong the service life, and control the circuit of oil pressure and steering motor, the controller also provides its function of delayed cut-off The maintenance of the controller should focus on normal operation and use to avoid excessive load use, because excessive load use will overheat the MOSFET microcomputer controller and reduce the service life of the controller
D. Electrical equipment system:
The electrical equipment system component provides the auxiliary function of the vehicle and can be divided into three parts
1. Lighting part: including headlamp, direction lamp and rear lamp group
2. Instrument part: power supply / brake indicator light,
Hour meter: when the power supply is on, it can provide users with maintenance reference
Electricity meter: it provides the residual power of the current battery, notifies the user of charging operation with a red warning light when the power is insufficient, and then cuts off the control circuit of the hydraulic pump motor when the user does not charge and excessively discharges the battery, so that the vehicle cannot continue to use and has to be charged
3. Other electrical appliances: emergency stop switch: the emergency switch is installed on the positive output of the battery
On the road, the operator can cut off the power supply in case of emergency
Microswitch: used as seat switch, handbrake switch and oil pressure system
Close the switch
Direction switcher: the direction switcher provides the direction that the controller vehicle wants to travel, so that the controller can control the forward rotation or reverse rotation of the walking horse It also provides the switching function of horn
Accelerator: composed of micro switch and sensor, it provides the function of controller to control the starting and stepless speed change of walking motor
E. Charger system:
When the power indicator on the instrument panel is red, it indicates that the battery is low and must be charged immediately The charger shall confirm several key points when delivering the vehicle:
1. Whether the AC power of the external power supply of the charger is consistent with the specification of the charger. Generally, the AC power supply is three-phase 220V. If not, the customer must be asked to improve
2. Charging operation steps are as follows:
a. Open the battery box cover and support it in a fixed position with a support rod
b. Open the battery cover of each battery, check whether the water level of the battery is in the normal position, and make the gas generated during charging escape
c. Connect the power connector of the battery and the power connector of the charger
d. Generally, there are two kinds of chargers: automatic charging and equal charging, which can be operated by selecting the switch, and the charger itself is a fully automatic opening and closing mode. When the battery is connected with the charger, the charging opportunity will start automatically and set the automatic charging mode by itself. When the charging starts, the indicator light of the charging switch will be on When charging is completed, the charger will automatically stop charging
e. When the abnormal wiring and charging lights on the charger panel are on, please immediately notify the Department of the company for maintenance
f. During the general charging process, if you want to stop charging, the most important steps must be paid special attention: △ first turn off the power switch of the charger and stop charging
△ pull down the AC power switch of the charger, and then open the power connector between the charger and the battery
. △ it is absolutely forbidden to immediately pull the power connector between the charger and the battery during charging, because sudden pulling will cause excessive reverse charging current impulse
The charger is damaged due to being inserted into the charger And will produce sparks, ignite the hydrogen in the charging process and produce an explosion
3. Equal charging: (equal charging)
When the battery is used for a period of time, the terminal voltage of the connected 24 sub batteries will be unbalanced. At this time, it can be balanced by equal charging
Note A. equal charging is usually carried out once a month. If the discharge is repeated every day, it must be carried out once a week. The average power distribution inside the battery has been extended
b. When the battery has not been used for a long time or has been over discharged (the specific gravity of electrolyte is less than 1.10), be sure to implement equal charging
c. It is not allowed to switch the automatic / equal charging switch while recharging is in progress
P danger warning: the hydrogen produced during charging is explosive, so it is strictly prohibited to smoke or fire in the charging area It's best to make a shelf for the charger and raise it to avoid damage to the charger due to moisture on the ground
F. General mechanical system:
Mechanical system includes transmission system; differential mechanism; Power steering system; Braking system; Handbrake system; Oil pressure system; Refer to the operation instruction manual provided by the original manufacturer for the operation and maintenance instructions of guide post mast assembly, fork frame, frame, roof protection frame and cab
II How to check and maintain
A. Maintenance and inspection of battery:
1. Principle and action of storage battery:
Each sub cell is immersed in electrolyte (dilute sulfuric acid) by anode (PbO2) and cathode (PB). 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 sponge lead charging lead sulfate water lead sulfate
2. The battery for electric stacker has the following special conditions:
a. High performance
b. Resistant to vibration and impact
c. Long life
d. Easy maintenance
3. Capacity expression of storage battery: the battery used for electric stacker is a covered battery, and its capacity is expressed by the following conditions:
Specific gravity of electrolyte.............................. 1.28/20 ℃
Discharge current................................. 5-hour rate current
Discharge termination voltage................................. 1.70v/cell
Electrolyte temperature in discharge..................... 30 ± 2 ℃
4. Battery management
a. Voltage drop during discharge
The reason why the terminal voltage in discharge is lower than that before discharge is as follows:
? v = e - I * r v: terminal voltage
. e: voltage before discharge
1: Discharge current
. R: internal impedance
·Discharge reduces the specific gravity of electrolyte and the open circuit voltage
The internal impedance increases during discharge, which is about 2 ~ 3 times higher than that of complete discharge Therefore, the battery voltage when lifting the fork is lower than that during walking, because the horsepower of the lifting oil pressure motor is higher than that of the walking motor, so the discharge current is larger when lifting
b. Discharge rate and capacity of battery
When the discharge current is large, the internal voltage drop increases, resulting in a sharp drop in the terminal voltage, which limits the capacity to discharge The reason is that the slow diffusion of electrolyte in the discharge slows the supply of sulfuric acid to the electrode plate. Therefore, the actual service time will be reduced when the lifting operation is frequent or the high-speed running
c. Capacity representation of storage battery
If the discharge termination voltage is low, increase the discharge capacity. During the capacity test, set the following standards 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
Discharge below the above voltage will not increase the discharge capacity. In case of excessive discharge, the active substance will deteriorate, which will have a bad impact on the service life of the battery Therefore, raise the fork when there is no load if the battery voltage is 1.75v/cell (42V when 24 are connected in series)
It is absolutely forbidden to continue to use, and the charging operation must be carried out immediately
d. Battery temperature and capacity
If the battery temperature is low, its capacity is significantly reduced for the following reasons
The diffusion of electrolyte is poor, and the chemical reaction of the acting substance between the two electrodes becomes slow
·When the impedance of electrolyte increases, the open circuit voltage also decreases
The 5-hour rate capacity of coated battery for electric stacker varies with battery temperature Therefore, the actual use time in winter is shorter than that in summer· The lifting operation in the refrigerator is used for a long time (high current discharge operation), and the actual use time per day is shortened
To prolong the actual use time, it is better to raise the battery temperature in winter or before using in the cold storage, but it is more appropriate to consider that the battery temperature is about 30 ℃
e. Relationship between discharge depth and specific gravity:
The specific gravity of the electrolyte of the battery is directly proportional to the discharge capacity. Therefore, if the specific gravity of the battery when fully charged and 100% discharged is known, the discharge capacity of the battery can be calculated The specific gravity measurement method shows that the discharge depth is the most accurate. Therefore, please measure and check the specific gravity regularly after use to avoid excessive discharge of the battery
During the specific gravity measurement, the temperature of electrolyte can be measured at the same time. When converted into the specific gravity at 20 ℃, its value can not be less than 80%, and the discharge value is about 1.16
f. Discharge state and internal impedance:
The internal impedance increases gradually with the progress of discharge and reaches the maximum at the end of discharge This is because when the discharge is in progress, the electrode plate produces lead sulfate of poor electrical conductor, and the specific gravity of electrolyte decreases and the impedance increases
Charge the battery as soon as possible after discharge, otherwise white lead sulfate will appear on the electrode plate, which will seriously affect the service life of the battery The so-called white lead sulfate is the plate
After discharge, it turns into lead sulfate. If it is placed without charging, it will turn into white lead sulfate. Even if it is recharged, it is difficult to recover
g. Temperature at discharge:
During rapid discharge, the internal impedance also increases rapidly, and the temperature of the battery also increases with it. The temperature at the end of discharge increases. Similarly, the temperature at the end of charging also increases. It is hoped that the end temperature can be reduced to below 40 ℃
h. Charging characteristics of battery:
When the voltage of each single battery reaches 2.35v ~ 2.4V, the gas occurs and the voltage begins to rise rapidly. The gas reaches the maximum in the middle of recharging and the charging voltage remains almost constant
The current in the middle of charging is almost spent on decomposing water into gas to increase the temperature. Therefore, the medium-term charging current should not be too large, otherwise the battery temperature will rise excessively and affect the service life
i. Charging capacity and service life:
It is necessary for the charging capacity of the battery to reach 110 ~ 120% of the discharge capacity, and the relationship between the discharge capacity and the service life is the same, that is, if the charging capacity is 120% of the discharge capacity, the service life of the battery is assumed to be 120 cycles. If the charging capacity of the battery is 150% of the discharge capacity, the service life of the battery will be shortened, which can be estimated as follows:
1200 Cycle * 120/150 = 960 Cycle
If the battery temperature rises and gas occurs at the end of the charging period of 150% charging, resulting in the reduction of electrolyte, as mentioned above, it is also a bad result affecting the battery life
In addition, if it is used in the state of insufficient charging, it will also shorten the battery life Therefore ★ the battery temperature of the electric stacker is 10 ~ 40 ℃, and the charging of 110 ~ 120% of the discharge is the most appropriate way to prolong the service life. The proportion of the final charging period is 1.28 ± 0.02 after converting to 20 ℃ ★
j. Gas generation and ventilation:
The gas generated 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 case of fire and gas. Therefore, the charging place needs to be well ventilated, and fire and gas cannot be close to the location of the battery
k. Determination of specific gravity of electrolyte:
The specific gravity is measured by a hydrometer. The outer cylinder is filled with inhaled electrolyte. Read the scale above the electrolyte of the hydrometer in the cylinder. The specific gravity of the battery will change with the temperature. If the temperature changes by 1 ℃, the change of specific gravity will be 0.0007. Therefore, when measuring the specific gravity, the temperature must be measured at the same time, and then converted to the specific gravity at the standard temperature of 20 ℃ by the following formula
S20: specific gravity after conversion at 20 ℃
S20 = st + 0.0007 * (t – 20) st: measure the specific gravity at t ℃
T: measured temperature of electrolyte
l. Supplement of distilled water:
After the cycle of charge and discharge process, the electrolytic liquid level will slowly decrease. Therefore, it is necessary to regularly check and supplement distilled water to the specified liquid level If you forget to replenish distilled water and expose the plate to the liquid level, the plate will be damaged and special attention must be paid
If the added distilled water exceeds the specified liquid level, it may overflow the battery surface during charging, causing the burning of the electrolytic cell and the corrosion of the electrode, so great attention must be paid
m. Determination of end of life:
If the battery reaches the end of its life, the capacity will decrease. The correct way to determine how much the capacity will decrease is the capacity test. The methods and steps of the capacity test are as follows:
? before discharging, all single batteries are charged to the highest specific gravity and voltage, and then continue for 1 hour until they are fully charged
·Discharge start time............... About 1 hour after charging
Discharge current..................... 1 / 5 of 5-hour rated capacity
(400ah / 5hr is the constant current of 80A)
? Discharge termination voltage............... 1.7v/cell (40.8v at 24cell)
Conversion between ? capacity and temperature......... The actual measured capacity is converted to 30 ℃ capacity based on the average electrolyte temperature reference diagram 2 hours before the end of the discharge period
-20℃ -10℃ 0℃ 10℃ 20℃ 30℃ 40℃ 50℃
Example: the actual capacity measured at 20 ℃ is 350ah. Referring to the above figure, 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 the battery is 400ah, the capacity decline of the battery is
369AH / 400AH * 100% = 92%
5. Maintenance:
a. Key points for daily use:
Please pay special attention to the following precautions
? avoid excessive discharge
·Charge moderately and do not overcharge
Keep electrolyte at proper level
? Explosive gas will be generated during charging, so fire and gas cannot be approached
? do not make the battery temperature exceed 50 ℃ at any time
? keep the battery connector and its surrounding environment clean and dry
b. Daily usage:
? select the pilot cell
Select the single battery in or near the central battery pack ? Base battery ‰ (it is recommended to choose the fourth one from the negative pole) and mark it, so as to infer the condition of other batteries from the liquid level, specific gravity and temperature of the battery
·Inspection before operation
? check the electrolytic liquid level of "reference battery"
If the electrolyte of the "reference battery" is insufficient, distilled water must be added to all batteries. When adding distilled water, pay attention to the condition of the pontoon and do not replenish it excessively
? check the voltage
If the fork is raised under no-load condition and the voltage is maintained at 42V or above, it can be operated
Check the power plug
Only when the power plug is properly plugged in can the stacker be operated
Key points for attention in use
? avoid driving the stacker while raising the fork
? driving at low speed and high stacking function make the battery have a long service life
Avoid shock and shock
? when the rising speed and walking speed of the fork feel reduced, stop using the stacker and carry out charging operation. When the walking performance is reduced, it is in the state of excessive discharge
? charge when the stacker is idle, which can increase the efficiency of the battery
? Inspection and treatment after use
After the stacker is in operation, please carry out the following inspection and treatment:
Cleaning and finishing
Due to the weather and operating environment, the battery may be stained with rain or dust, so clean it with a rag
Charging
Charge the battery according to the actual needs. Before charging, check whether the charger connector and electric connector are properly connected
c. Regular maintenance and inspection:
? weekly inspection
Check once a week and register
? measure the voltage, specific gravity and liquid temperature of the "reference battery" before and after use
? during charging, open the cover first and check whether the position of the indication mark on the top of the pontoon is appropriate (the correct water level is 12mm above the top of the grid)
If the water level is too high, the electrolyte will overflow during charging, resulting in weak acidity of the electrolyte If the water level is not enough, the top plate will be exposed, which will reduce the service life of the battery. When adding water, non-metallic containers must be used, and only approved distilled water can be added to meet the required standard of purity
H never use acid water as make-up water H
ⅸ when adding distilled water, avoid injecting too much or too little distilled water into the battery
? check all connections and tidy up worn lines or damaged insulators
? check the condition of each pole and whether the connecting wires are firm, and whether the battery end cover is installed and fixed correctly
? it is necessary to keep the top of the battery clean and dry, because any dirt and moisture will become the conductor of electricity. The corroded part of metal should be removed first, and then neutralized with water solution or soda or diluted ammonia, dried, covered and rubbed with acid proof liquid to protect the corroded part
·Monthly inspection and maintenance
Check, maintain and register once a month
Measure the voltage, specific gravity and liquid temperature of all batteries
Check and clean the plugs of storage battery and charger
d. Environment of charging and use place
? conditions of charging place
? avoid rain and direct sunlight
? there is good ventilation and no fire and gas, and there is no possibility of fire and gas near the site
Vibration and dust
