HANGCHA CBD15-A2MC1, Operation And Maintenance Manual

Page 1: ...ELECTRIC PALLET TRUCK CBD15 A2MC1 CBD15 A2MC1 F OPERATION AND MAINTENANCE MANUAL Original Instruction HANGCHA GROUP CO LTD 8 2017 Mini Range ...

Page 2: ...ck Part one of this manual is about the brief introduction and correct operation of the mini range electric pallet truck which will tell you how to operate safely and maintain preventively part two will tell you the structure working principle and maintenance of the electric pallet truck To ensure safety and exert the truck s potential all the personnel that in charge of operation maintenance and ...

Page 3: ...tes and warning labels location 13 3 Safety Instructions 15 4 Transport 19 4 1 Lifting by crane 19 4 2 Securing the truck during transport 20 4 3 Transport 21 5 Battery 22 5 1 Safe operation rules for battery use 22 5 2 Maintenance of the Battery 22 5 3 Battery charging 24 5 3 1 Power interface 24 5 3 2 Battery charging steps 24 5 3 3 Additional charge 25 5 4 Replacing battery 26 6 New truck break...

Page 4: ...mble and use notice 48 1 3 Fault and troubleshooting 48 1 4 Drive Motor 49 1 5 Electromagnetic brake 53 1 5 1 Electromagnetic brake working principle 54 1 5 2 Electromagnetic brake installation 55 1 5 3 Maintenance 56 1 5 4 Adjust the Air Gap of the Brake 57 1 5 5 Common fault and troubleshooting 59 2 Hydraulic system 60 2 1 Hydraulic system working principle 60 2 2 Hydraulic system fault diagnosi...

Page 5: ... according to the information in this manual Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property 1 2 Use as required Pick and place goods with trays Transport goods with trays Do not carry people Do not over load Do not push or pull loads Do not work together on the same goods by multiple pallet trucks ...

Page 6: ...ation 20 Altitude 2000m Negotiating inclines up to a maximum of 6 It is prohibited to travel crosswise or obliquely When going uphill with loads keep the loads in front when going downhill keep people in front WARNING It s prohibited to use this equipment in the anti explosion area Special equipment and authorisation are required if the truck is to be used in extreme conditions e g cold stores Col...

Page 7: ...ld storage remove it from the cold storage immediately and repair in buffer zone or maintenance area 1 5 Proprietor responsibilities For the purposes of the present operating instructions the proprietor is defined as any natural or legal person who either uses the industrial truck himself or on whose behalf it is used In special cases e g leasing or renting the proprietor is considered the person ...

Page 8: ...of the vehicle it also needs to make corresponding modification to vehicle nameplate decals logo and brochures In the event the truck manufacturer is no longer in business and there is no successor in the interest to the business the user may arrange for a modification or alteration to a powered industrial truck manufacturer and the user shall a Arrange for the modification or alteration to be des...

Page 9: ...r low working strength and its continuous working time should not surpass one hour Users can get relevant information as rated load from the product model Model Meaning CBD Electric pallet truck 15 Rated load capacity 100kg A Product serial number 2 The second version M Mini Range C1 Controller type F Cold storage type ...

Page 10: ...romagnetic brake to ensure travelling safety It owns slope anti slide function to ensure safety Operation steering system New ergonomics designed control handle owns acceleration reversing horn braking lifting lowering emergency reverse functions thus makes operation easier Emergency reversing button on the control handle head can prevent driver from hurt when encountering emergency in backward dr...

Page 11: ...y Electric quantity display meter and charging indicator indicates battery quantity and charging process Emergency disconnect switch The standard equipped electronic lifting limitation and soft landing system protect working motor and loads from damaging ...

Page 12: ...3 Lift cylinder 12 Wire fixator 4 Drive wheel cover 13 Battery charging plug built in plug 5 Caster wheel 14 Instrument 6 Drive wheel 15 Hood 7 Fault indicator 16 Emergency stop switch 8 Side door built in battery 17 Key switch 9 Charging light indicator with built in charger 1 2 3 4 5 6 5 7 8 9 10 11 17 16 15 14 13 12 ...

Page 13: ...9 2 4 Display and control 2 7 9 17 16 14 13 19 20 21 20 19 22 23 22 18 ...

Page 14: ...Emergency stop switch Cut the connection with the battery close all electric function and brake 17 Key switch Switches the control current ON and OFF The truck cannot be operated by unauthorized persons when the key has been removed from the switch 18 Upright traveling button Press the button the control lever in vertical state truck can run 19 Lower button Lower lifting device 20 Lift button Rais...

Page 15: ...ng status One red LED flashing means the truck start to use reserve power 30 20 of battery power When it is lower than 20 of battery power low charging status two red LED flashes and power is locked Only after the battery power recovered to 20 or above can re use the lifting function Charging light indicator 9 It displays charger running state Red light flashes it is charging Yellow light is on ch...

Page 16: ...m 400 Dimensions Lift height h3 mm 120 Fork height lowered h13 mm 80 Overall length L1 mm 1669 Overall width b1 mm 568 Fork size s e L mm 50 160 1150 Outside fork width b5 mm 560 680 Ground clearance center of wheelbase min m2 mm 30 Min right angle stacking aisle width1000 1200 across forks Ast mm 1850 1 Min ringht angle stacking aisle width 800 1200 across forks Ast mm 1900 2 Outer turning radius...

Page 17: ... as nameplate load curve plate warning labels must be legible if identification is unclear and must be replaced The figure below shows the approximate location of the various identity resides Before operating the truck please understand the meaning of the various identities ...

Page 18: ...ated capacity 25 Fault indicator 26 Hoist label Strap points for crane lifting 27 Manufacturer s logo 28 Charging light indicator Overnight charging recommend after use 29 Key switch OFF position is off ON position is on 30 Emergency stop label press this button when in emergency thus the truck power is off 31 Series tonnage label A series rated capacity is 1 5t 32 Walking upright ...

Page 19: ... parts during the schedule maintenance Wipe off the oil grease or water on the soleplate foot pedal and control lever No smoking or any spark smoke near the battery when checking Be careful of scald when checking motor and controller 7 The controller equips with energy accumulator do not touch between B and B to avoid electric injury If you need check or clean the controller connect load like cont...

Page 20: ...d wipe off greasy dirt 11 Do not overload 12 Before start press the horn and make sure no people around 13 Goods are not allowed to deviate the fork center when goods is deviating the fork center turn or pass uneven road you are easily to fall Meanwhile possibility of turnover will increase 14 Avoid sudden drive stop or turn 15 Do not drive the truck when the forks in high position 16 When handlin...

Page 21: ...should not exceed 2000m 22 After power off brake works and the truck can not be towed dragged 23 Please obey the requirement in this manual and the truck label when operation Check label identification plate replace damaged or fallen ones 24 Fire extinguisher shall be equipped at the work site Users can choose truck equipped with fire extinguisher Driver and manger should be familiar with the fire...

Page 22: ...nent record of the design test s and implementation of the modification or alteration Make appropriate changes to the capacity plate s decals tags and instruction manual Affix a permanent and readily visible label to the truck stating the manner in which the truck has been modified or altered together with the date of the modification or alteration and the name and address of the organization that...

Page 23: ...se lifting gear with sufficient capacity for truck weight see truck nameplate Do not stay under the truck when hoisting the truck When hoisting or laying down it should be stable and slow to avoid collision or accident Procedure Park the truck securely Secure the lifting slings to the strap point and prevent them from slipping Crane slings should be fastened in such a way that they do not come int...

Page 24: ...Sling the tensioning belt around the truck and attach it to the fastening rings of the transporting vehicle Use wedges to prevent the truck from moving Tighten the tensioning belt with the tensioner WARNING The truck or trailer must have fastening rings Use wedges to prevent the truck Only use tension belt or fastening belt of good nominal strength 33 ...

Page 25: ...truck firmly on the transport vehicle with belt and block the wheel to avoid relative motion during transportation How to remove a broken truck It s not allowed to tow the forklift truck on the ground directly when the truck is broken down or damaged since the brake of the truck is closed under normal circumstances Appropriate vehicles should be used to remove the broken trucks WARNING Do not tow ...

Page 26: ...ot mix the old and new batteries Do not use when under overload high humidity or heavy grade When charging do not wrongly connect the battery polarity otherwise it may damage the battery After battery scrap please return to the recycle bin unified handling may not arbitrarily discarded 5 2 Maintenance of the Battery Do not fill water for battery maintenance when it is in service Inspect the batter...

Page 27: ...at depth of discharge is around 50 It should not be more than 80 Make the battery fully charged and store it if the truck remains unused It is also suggested to charge the battery once a week when the truck is unused Battery capacity is based on environmental temperature 25 Therefore it s a normal phenomenon that the range decreases when the temperature goes down The battery capacity decreases by ...

Page 28: ...rging steps Procedure Park the truck securely Remove the charging plug 13 together with the wire fixator 12 from the hood 15 The battery charging plug 13 is inserted into the appropriate electrical outlet To charge the battery until the charging light indicator 9 green on the battery is full charged LED red on Charging mode LED green on Full charged LED yellow flash Charger fault LED yellow on Bat...

Page 29: ...25 5 3 3 Additional charge Charger structure enables to continue charging the partially charged battery in use 15 13 12 9 ...

Page 30: ...ft and right sides respectively pull the battery 35 Install the battery in the reverse order Pay attention to the battery loading position and wiring is correct WARNING Battery box is very heavy be careful to avoid damage Disposal to the waste battery should accord with local environment regulation When replacing the battery ensure that a battery of the same specification dimension and weight is f...

Page 31: ...given below should be observed while the truck is in a stage of 100 hours of operation Avoid the new battery over discharging in early period Perform specified preventive maintenance services completely Avoid sudden stop start or turn Limited load is 70 80 of the rated load Often check and fasten the fasteners of each joint part After the break in ends replace hydraulic oil ...

Page 32: ...eck Check the battery cover board See whether the battery fixed reliably Check the terminal for loose or damage Otherwise adjust or replace 7 Instrument display check Refer to instrument part 8 Lifting and lowering button Press the lifting button and check the fork lifting condition Press the lowering button check the fork lowering condition Check if the lifting system has abnormal sound 9 Forward...

Page 33: ...Press the horn button to check sound 13 Appearance Check the truck appearance for clean rust or paint spalling 14 Others Check whether there is any abnormal noise whether wiring is regular or fastener loosens etc ...

Page 34: ...re operation and make sure each function and state is normal Pull up the emergency stop switch 16 Plug the key into key switch 17 turn to ON position in clockwise The instrument displays battery capacity Truck goes into running state 17 16 OFF O N ...

Page 35: ...ctive boots When enter narrow area as lift first get fork go Keep road clean and wipe greasy dirt water or other dirty easily causes slipping Travelling on the slope When going uphill and downhill without load keep the fork to downhill direction when going uphill and downhill with load keep the fork to uphill direction WARNING No turn inclines when going uphill and downhill Never park on the slope...

Page 36: ...o the braking range slowly or nor enter braking range do check the reason and eliminate the fault Replace gas spring if necessary 7 5 Steering Hold the left and right handle of control handle with both hands and decline to some degree move the handle to left or right to release truck steering When turn to left the truck turns left When turn to right the truck turns right 7 6 Stopping Release the d...

Page 37: ...ight to make the forks are in the tray Raise the loads several centimeters to make sure if the loads are firm Travel the truck off the area Drop the load to lower position 7 8 Unloading Procedure Approach the deposit area Raise the loads to correct height Travel forward put the load on the unloading position and then stop Make sure the loads are right above drop the forks slowly until the forks ar...

Page 38: ...34 Travel backward and make the fork out of the load Drop down the forks to proper position ...

Page 39: ...5 7 9 Park the truck securely Procedure Drive the truck to safe area or appointed area Fully lower the forks Turn off the key switch 17 and remove the key Press the emergency stop switch 16 17 16 OFF O N ...

Page 40: ...atch on the piston rod surface Apply anti rust oil to piston rod or easily rusty axle Cover the whole truck At least once a month to fully charge 8 2 Start running after deposit for a long time Remove rust preventive oil on exposed parts Clean impurity and water of the hydraulic oil tank Recharge battery fit on truck and connect Carefully check before start Inspect starting travelling slowing down...

Page 41: ... at will and carry on handling according to the local environmental protection laws and regulations Draw up complete maintenance plan After you make maintenance you d better make a record Forbid to repair the forklift truck if you haven t been trained CAUTION No fire You should shut off key switch and pull off the plug before service except some trouble shooting Clean the electric part with compre...

Page 42: ...east weekly Every 250 service hours or at least every 1 5 months Every 500 service hours or at least trimonthly Every 1000 service hours or at least semiannually Every 2000 service hours or at least annually Standard maintenance interval Cold store maintenance interval in addition to standard maintenance interval Battery D W M T S Y 1 Battery quantity 2 Terminal looseness 3 Looseness of connecting...

Page 43: ...3 Change oil Brakes D W M T S Y 1 Test brakes 2 Check magnetic brake air gap Steering D W M T S Y 1 Test electric steering and its components 2 Check tiller recuperating function 3 Bearing lubrication Wheels D W M T S Y 1 Check whether the wheels fastening 2 Check wheels for wear and damage Electrical system D W M T S Y 1 Test displays and controls 2 Check the function of micro switch and sensor 3...

Page 44: ... are secure check for leaks and damage 3 Check cylinders and piston rods for damage and leaks and make sure they are secure 4 Check hydraulic oil level and top up if necessary 5 Test emergency lowering system 6 Test relief valve and adjust if necessary 7 Replace hydraulic oil 8 Clean hydraulic oil filter ...

Page 45: ...ecurely Unscrew the hood screws 36 Lift the hood 15 The wire fixator 12 and the battery charging plug 13 from the hood 15 to take off on The hood is removed Installation and removal process is reversed WARNING Remove or installing a hood carefully clip hand 12 36 15 13 12 36 15 13 ...

Page 46: ...ive wheel cover Procedure Unscrew the drive wheel cover 4 of the four screws 37 remove the drive wheel cover The drive wheel cover is removed Installation and removal process is reversed WARNING Remove or installing the drive wheel cover carefully clip hand 4 37 37 ...

Page 47: ...k A Hydraulic oil Normally L HM32 High and cold environment L HV32 Hydraulic system C Grease Automobile general 3 lithium base lubricant Nozzle and lubrication CAUTION Into the fuel tank of hydraulic oil must be filtered and the injection volume of the hydraulic oil tank does not exceed the maximum scale A C C C C C C ...

Page 48: ...cedure Maintenance work to complete preparations before the operation Remove the hood Check the fuse 38 values are correct if necessary replace No Designation Control circuit Specification 38 Fuse Control the truck power 100A 38 ...

Page 49: ... Safety of industrial trucks Electrical requirements Part 1 General requirements for battery powered trucks EN1726 1 1998 Safety standard for machinery industrial vehicle EN12053 2001 EN1175 1 1998 EN13059 2002 EN1757 2 2001 harmonized standard Main safety elements are in accordance with 2006 42 EC machinery directive as well as EN1175 1 1998 A1 2010 EN1726 1 1998 EN1757 2 2001 standard Electronic...

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Page 51: ...motor Rated voltage V 24 Rated power kW 0 65 Rated current A 38 Rated speed r min 3100 Working system S2 45min Insulation grade F Protection grade IP44 Using the environment temperature 10 40 The service life of the brush h 1200 Brake Rated voltage V 24 Rated power W 20 Rated braking torque N m 4 Rated Air Gap mm 0 15 0 30 Pre tension torque of the mounting screw Nm 2 8 ...

Page 52: ...is 2 5 2 3 space of the inner chamber 1 3 Fault and troubleshooting Fault Probable cause Corrective action Abnormal gear noise when travelling Over large gear clearance Adjust Lack grease Replenish Over large gear wear Replace Abnormal noise when turning Rotary rolling bearing damage Replace Insufficient rotary rolling bearing grease Add grease Brake ineffective or invalid Inching switch loosen or...

Page 53: ...oke turn off the power immediately for check Often check if the motor over heats Often check motor wiring contact screw for looseness sparking smoke or insulation aging Use and maintenance Stator parts and brush neutral position has been adjusted before sold so users should not dismantle or adjust at will Check if motor rotates flexibly or abrades Check if motor outlet or terminal connection is co...

Page 54: ...rder not to affect its heat dissipation Check the motor at least once half year according to the following way a Check the outer part and clean dust on the motor b Clean and replace bearing listen if there is abnormal noise during running c Check brush abrasion and replace if necessary Replacement of the Brushes Brushes must be replaced when they are seriously worn or damaged All brushes should be...

Page 55: ...51 After polishing crocus cloth and cleaning commutator motor should work under limited speed to ensure safety until the brush working surface polishes ...

Page 56: ...rush and brush box is too large The distance between brush box and commutator working surface is too long The mica between commutator segments extrudes Brush material is not good Trade mark of brush is not right Large spark Overloaded of motor Commutator is not clear Commutator is not smooth or round Mica plate or part commutator segment extrude Brush does not grind well Brush pressure is not larg...

Page 57: ...h double friction surfaces By use of the pressure spring powerful braking torque would be generated when power off The brake could be released by the electromagnetic effect 1 Mounting Bolt of the Brake 3 Brake Pad 5 Friction Disk 2 Stator Module 4 Shaft Sleeve 6 Dustproof Cover Fig 2 3 Electromagnetic brake parts 1 2 3 4 5 6 ...

Page 58: ...rque is created There will be a air gap Z between the armature and the stator at that moment When the brake needs to be relaxed the stator is applied with direct current and the magnetic field would attract the armature 8 to move towards the stator The movement of armature compresses the pressure spring 10 which cause the loosening of the brake pad 3 by that time and the brake is released 1 Mounti...

Page 59: ...g bolts of the friction bolts 12 Cover the shaft sleeve with the friction disk 3 Install the stator module 2 to the friction disk 5 with three mounting bolts of the brake 1 Note Remove the three rubber mats of the stator module which is for stable transportation Screw down the three mounting bolts 1 with a torque wrench 15 and check the air gap Z of the brake with a feeler gauge 16 Put on the dust...

Page 60: ...e more than 10 Make sure it is free from oil and dirt when installing and using the brake 1 5 3 Maintenance Avoid rusting When truck is used in a high temperature for a long time The actuation side with rust would affect the performance Do not touch the friction surface with your hand directly Make sure it is free from oil and dirt or else the maximum torque could not be achieved Generally the wor...

Page 61: ...e air gap between stator 1 and armature 2 to the rated Z by a feeler gauge Ensure air gap at all directions are same Specification Table Rated Current V Rated Power W Rated Torque Nm Rated Air Gap mm Minimum Thickness of Rotor mm Pre tension Torque of the Mounting Bolt Nm 24 20 4 0 15 0 30 6 15 0 0 03 2 8 On the condition of power disconnected through adjusting 3 mounting bolts of brake 1 and the ...

Page 62: ...500 to 2000 hours service of the brake and it is suggested to adjust the air gap every 6 months If it comes to a poor working condition such as frequent use of brake and repeated emergency stops the air gap should be set when the brake the shorten the adjustment interval for the first time ...

Page 63: ... for a while Oil dirt mixed in Clean oil dirt Large load Reduce load or replace large specification Large load change Adjust load peak or large the specification High temperature Too high exciting voltage Check voltage and adjust Clutch or motor interfere to the brake Check control circuit eliminate interference High environment temperature Set ventilation High operating frequency Adjust to proper...

Page 64: ...60 2 Hydraulic system 2 1 Hydraulic system working principle ...

Page 65: ...lace soft tube and clean the strainer Cavity caused by the high viscosity of hydraulic oil Replace new hydraulic oil whose viscosity suits pump running speed Work only when the oil temperature is normal Bubble in the hydraulic oil Check the reason for the bubble and then take measures Forks can t lift Gear pump works Oil way block or damage Repair or replace Gear pump no work Lifting inching switc...

Page 66: ...62 3 Electric system 3 1 Electrical schematic diagram ...

Page 67: ... by battery Including but not limit to the following correct training wear goggles do not wear loose clothing and jewelry Carry out maintenance according to the following cleaning procedure Never clean the controller with high pressure washer Remove battery to disconnect power Connect load like contactor coil or horn between controller B and B to discharge controller capacity Clean dirt or corrosi...

Page 68: ...rious faults Faults are listed alphabetically Note The status LED can only indicate one fault at a time If multiple faults are detected the highest priority fault code flashes until it is cleared Programmer Diagnostics The programming devices present complete diagnostic information in plain language Faults are displayed in the Faults Diagnostics menu and the status of the controller inputs outputs...

Page 69: ... open 2 Main contactor coil drive wrong 2 4 Main On Fault 1 Main contactor coil wrongly turn off 2 5 no used 3 1 Wiring Fault 1 Incorrect throttle operation 2 Throttle port or its mechanical part has fault 3 2 Brake On Fault 1 Electromagnetic brake coil open 2 Electromagnetic brake drive short 3 3 Precharge Fault 1 Controller fault 2 Low battery voltage 3 4 Brake Off Fault 1 Electromagnetic brake ...

Page 70: ...39 44 58 12 35 44 44 54 49 64 76 107 14 54 69 69 88 83 98 121 162 16 88 108 108 137 127 157 189 252 18 118 147 147 186 176 216 260 347 20 167 206 206 265 245 314 369 492 22 225 284 284 343 343 431 502 669 24 294 370 370 441 441 539 638 850 27 441 519 539 686 637 784 933 1244 Note Use entirely 8 8 grade bolt in the important joint position Bolt s grade can be found in the head of the bolt if it can...

Page 71: ...Maintenance Record Date Repair maintenance content Serviceman ...

Page 72: ... CO LTD Address For OVERSEAS USERS Address 88 Donghuan Road Lin an Economic Development Zone Zhejiang China Fax 0086 571 88926789 0086 571 88132890 ZIP 311305 Web http www hcforklift com E mail sales hcforklift com ...