JOPRO Changer+ User manual

JOPRO Changer+Lift
ENGLISH

2
JOPRO Changer
Semi-automatic battery handling system
integrated with a lowlift truck.
For sideways battery change on forklift trucks.
Maximum battery weight: 2000 kg.
Please read the manual carefully before
use and keep it in a safe place for future
reference.
The information in this manual was up to
date when it was printed.
JOPRO reserves the right to make technical
changes without prior notice.
© 2018 JOPRO AB
3
Table of contents
Overview.................................................4
Controls ..................................................6
User’s Guide........................................... 8
Maintenance.........................................12
Spare Parts Mechanics ........................18
Spare Parts Electronics and Hydraulics... 20
Hydraulic Circuit Diagram..................... 22
Electric Circuit Diagram........................24
Declaration of Conformity.....................27

4
Overview
Rubber Buffers
Reduces wear when
docking against the
forklift and charger
stands.
Battery Stopper
Secures the battery
during transport.
Chain Tension Adjustment
Stretches the chain that
moves the electromagnet
transporter.
Electromagnet
Grips and holds the
battery during battery
change.
Electromagnet Rail
5
Joystick
Controls JOPRO
Changer+Lift’s move-
ments and functions.
Hydraulic Unit
Electronics Box
Spring Return Cylinder
Raises and lowers the
battery stopper.
Hydraulic Motor

6
Controls
Raises the roller bed.
7
Lowers the battery stopper.
Moves the electromagnet forward.

8
Activates the electromagnet.
Generates a strong magnetic field with
great gripping power.
If the magnet is left activated it is auto-
matically turned off after 10 minutes.
9

10
User’s Guide
Working area
Unauthorized staff are not allowed
within 1,5 meters from JOPRO
Changer+Lift when in use.
11
The electromagnet must be cen-
tered on the battery.
The rollers must be on the same level.
Mainly use the lowlifter’s height adjust-
ment. When the lowlift’s lifting range is
not enough
-use JOPRO Changer+Lift’s height
adjustment.

12
Activate the electromagnet when it
is in contact with the battery.
Electromagnet
The electromagnet generates a very strong
magnetic field.
Check that there are no loose metallic objects
within one meter from the electromagnet when it
is activated.
13
Move the battery as far in
as possible.
Check that the battery stopper
is raised so that transport to the
charger stand can be carried
out in a safe manner.

14
Maintenance
Monthly
JOPRO Changer+Lift should be
supervised regarding:
- function: check that the various
functions work correctly.
- deformations: check that there
are no visible cracks, distortions,
corrosions or other deformations.
- weldings: check that all weld-
ings are intact and have no vis-
ible cracks.
- markings: check that the marks
for maximum capacity, CE and
contact information to the manu-
facturer are intact.
- instructions: check that the
manual is always available.
When required
Chain tension
The chain in the transporter rail
should not be slacking.
Stretch the chain by tightening both
bolts equally.
15
Hydraulic oil
Check that there are no visible
leaks of hydraulic oil.
Any leakage in the system may
cause JOPRO Changer’s move-
ments to become jerky.
If necessary, refill with hydraulic oil
(ISO VG 46 quality or equivalent).

16
Lifting cylinders
Om JOPRO Changer+Lift lifts
uneven, refill the cylinders with
hydraulic oil.
Open the plugs on the two rearmost cylinders.
Fill the empty space with hydraulic oil ISO VG 32
quality or equivalent.
Refit the plugs.
Lower the roller bed to its
end postion.
17
12
Move the roller bed to the top and
then back to the bottom.
Repeat the filling procedure until the cylin-
ders lift even.
If any problems with the cylinders still oc-
cur, please contact us.

18
050-0305
050-0201
050-0202
040-0802
040-0501
010-0204
Spare Parts JOPRO Changer+Lift
Mechanics
L2
L1
19
020-0301
050-0501
020-0101
State L2together with
the order number
020-5001
State L1together with
the order number

20
070-0102
520-0301
060-0702
060-0711
Spare Parts JOPRO Changer+Lift
Electrics and Hydraulics
21
060-0208 060-0807
060-0116
060-0418
070-0201
060-0604

22
M
1
4
3
PT
AB
ab
AB
PT
P
PT
7
6
2
5
9
8
10
11
12
13a 13b14a 14b
15
16
Hydraulic Circuit Diagram
23
Pos Description Art. nr.
1 Hydraulic tank 3L 060-0401
2 Inlet Filter 3/8”, Ø 63 mm, 12 LPM 060-0420
3 Motor, 24VDC, 2.2 kW 060-0403
4 Screw Pump, 2.0 cc 060-0421
5 Check Valve 060-0422
6 Pressure Relief Valve 160-290 bar 060-0423
7 Return filter, 10 μm, (ABS ½”) 060-0424
8 Fixed Throttle Valve, flow = 7 LPM 060-0606
9 Spring Cylinder, Jopro design 060-0502
10 Serial block, aluminium 060-0425
11 Directional spool Valve, 24VDC, NG06 060-0117
12 One Way Restrictor Valve 060-0604
13 Double acting hydraulic cylinder (a+b) 060-0702
14 Double acting hydraulic cylinder (a+b) 060-0711
15 Manual valve 060-0116
16 Hydraulic motor, Orbit 241 cc WR 060-0208

24
24VDC +
-
R1
R1 TR1 K1
K1 K1
M1
20A 4A
1 2 4 3
1 4
A1 A2 10 A2
A12
5
2
3
1
4
F1 F2
S1 S2
H1
L1
Y1
1
23
1110
S3 S4
Electric Circuit Diagram
25
Pos. Description Art. No.
K1 Contactor Telemecanique 3233131 070-0501
R1 Start Relay, 24V 150A 070-0401
M1 DC motor, 24V (2,2KW 2700rpm) 060-0403
F1 Circuit Breaker 20A 070-1501
F2 Circuit Breaker 4A 070-1601
S1 Push-Button (pump) 070-2101
L1 Electromagnet 070-0101
S2+H1 Electromagnet Switch (S2) with Lamp (H1) 070-2001
D1 Diode 50V 6A 070-2801
TR1 Time Relay Proswede CRM-T FH-P 070-0901
S3 Push-Button (Roller Bed up / white) 070-2101
S4 Push-Button (Roller Bed down / grey) 070-2201
Y1 Solenoid Valve 070-2401
R2 Mini relay (E4021003) 070-2901
R3 Mini relay (E4021003) 070-2901

26 27
Alafors
........................................................
.............................................................
Anders Johansson
Jopro AB, Lunnavägen 6, SE-449 50 Alafors
.............................................................
Magnus Johansson
CEO
Declaration of conformity
Manufacturer
JOPRO AB
Lunnavägen 6
SE-449 50 Alafors
SWEDEN
Phone: [phone]
Fax: [phone]
www.jopro.se
declares that the product
Battery handling system JOPRO Changer+Lift for sideways bat-
tery change on forklift trucks
Product identification number: ..........................................................
is in compliance with the following EC Directives
2006/42/EC Machinery Directive
Person authorized to compile the technical documentation

ver. 1.8 Oct 2018
Jopro AB
Lunnavägen 6 Tel: [phone] [email protected]
SE-449 50 Alafors Fax: [phone] www.jopro.com