HANGCHA Mini Series, Operation And Maintenance Manual

Page 1: ...ELECTRIC PALLET TRUCK CBD12 AMC1 I OPERATION AND MAINTENANCE MANUAL Original Instruction HANGCHA GROUP CO LTD 3 2018 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: ...ruck during transport 15 4 3 Transport 16 5 Battery and charger 17 5 1 Safe operation rules for battery use 18 5 2 Battery charging 19 6 New truck breaking in 21 7 Operation 22 7 1 Check before operation 22 7 2 Start up the truck 24 7 3 Travel 25 7 4 Steering 27 7 5 Braking 28 7 6 Lifting loads 29 7 7 Transporting loads 29 7 8 Depositing loads 30 7 9 Parking the truck securely 31 8 Deposit the tru...

Page 4: ...tic brake working principle 49 1 5 2 Electromagnetic brake installation 50 1 5 3 Maintenance 51 1 5 4 Adjust the Air Gap of the Brake 52 1 5 5 Common fault and troubleshooting 53 2 Hydraulic system 54 2 1 Hydraulic system working principle 54 2 2 Hydraulic system fault diagnosis and correction 55 3 Electric system 56 3 1 Electrical schematic diagram 56 3 2 Drive motor controller 57 3 2 1 Maintenan...

Page 5: ...g 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 Light to medium duty indoor truck operations without ramps 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 mult...

Page 6: ...entle slope below 4 at full load 10 at no load Small wheel version can climb gentle slope below 2 at full load 8 at no load Long time climbing is not recommended 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 Please read others safety rules in this manual it is important to your personal safety working...

Page 7: ...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 8: ... product model This manual describes the A series mini electric pallet truck suitable for use in places where work intensity is relatively low Users can get rated load and other information from the product model Model Meaning CBD Electric pallet truck 12 Rated load capacity 100kg A Product serial number M Mini Range C1 Controller type K Small wheel version I Lithium battery The description of the...

Page 9: ...ke and electromagnetic 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...

Page 10: ...escription Item Description 1 Tiller handle 7 Left hydraulic cover 2 Control lever 8 Battery seat 3 Key switch with key 9 Battery 4 Lift cylinder 10 Load wheels 5 Drive cover 11 Right hydraulic cover 6 Drive wheel 11 10 1 3 5 6 7 9 4 8 2 ...

Page 11: ...avel speed and acceleration If the control lever is set to the brake zone B1 you can press this button to override braking the truck will travel at slow speed 14 Collision safety switch Truck moves away from operator Protect the operator from extrusion damage under emergent circumstances 15 Travel switch Controls travel direction and speed 16 Lift button Raises the load device When the battery is ...

Page 12: ...8 2 4 1 Display instrument Shows the battery charge status and the truck total travel time Start normal power up Remaining battery level is displayed Total travel time MINI STD 001 90 3 7H ...

Page 13: ...umber front rear x driven wheels 1x 4 Tread front b11 mm 410 Dimensions Lift height h3 mm 115 Fork height lowered h13 mm 75 Overall length l1 mm 1580 Overall width b1 mm 560 Fork dimensions s e l mm 53 150 1150 Distance between fork arms b5 mm 560 Ground clearance center of wheelbase m2 mm 22 Turning radius min Wa mm 13301 Performance Travel speed laden unladen km h 4 4 5 Lift speed laden unladen ...

Page 14: ...s or legs 21 Nameplate The rated capacity on the nameplate is the max load capacity by the label listed equipment Any change to the forklift or other equipment may change rated capacity 22 Manufacturer s logo 23 Series tonnage label A series rated capacity is 1 2t 24 Add hydraulic oil decal 19 20 21 22 23 24 Add 88 Donghuan Road Lin an Economic Development ZoneZhejiang 311305 P R China HANGCHA GRO...

Page 15: ...ge the safety 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 8 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 l...

Page 16: ...pe off greasy dirt 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 When handling bulky loads which restrict your vision please operate the machine in reverse or...

Page 17: ... or fallen ones 21 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 extinguisher position and application method 22 Use tray when carrying small items do not place on the fork directly 23 Do wash the inner of the truck do not place the truck outdoors and exposed to the rain 24 Before disma...

Page 18: ...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 19: ...y 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 ...

Page 20: ...rmly 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 After power off bra...

Page 21: ...the temperature drop continued the corresponding reduction of mileage is a normal phenomenon Each drop of 1 temperature the battery capacity decreased by about 1 try to avoid the 10 below the use of the environment Charger Input voltage 85Vac 265Vac Input frequency 50Hz 60Hz Output voltage current 24Vdc 10A Charger and battery parameters match or not have a significant impact on battery performanc...

Page 22: ...e battery Do not place flammable materials and working equipment that may cause sparks When the vehicle is not in use it must be stored after charging the battery If not it is recommended to charge it once a week After battery scrap please return to the recycle bin unified handling may not arbitrarily discarded WARNING Do not charge the lithium battery below 0 In case of the lithium battery fault ...

Page 23: ...sert the charger power plug into a suitable power outlet Insert the charger charging plug into the battery plug The charge indicator lights up the battery is charging the battery is fully charged for about 2 hours LED 1 Red power on LED 2 Red charging LED 2 Green charged Remove the charger power plug and charging plug respectively after charging and put the battery back into the forklift CAUTION B...

Page 24: ...20 Fuse LED2 charging status indicator LED1 power indicator ...

Page 25: ...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 26: ...inkage mechanism see whether bended or crazed Whether appear interfere when move movement point wear whether severe 5 Hydraulic oil check Open the hood check if the oil level within the scales Add oil when insufficient 6 Battery check 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 Re...

Page 27: ... the handle to vertical position or press to level position to check the brake condition 11 Steering system Left or right turn the handle to make the truck run around 3 turns and then check if the steering system is normal 12 Horn 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 whethe...

Page 28: ...and make sure each function and state is normal Insert the key in the key switch 3 and turn it clockwise as far as it will go to the ON position The truck is now operational The display instrument shows the battery charge status and the truck total travel time 3 OFF O N ...

Page 29: ...mb Always watch moving direction and guide the truck Or hold the handle with both hands and push the truck go forward CAUTION Operator must wear protective boots When enter narrow area as lift first get fork go Travel according to regulated route Keep road clean and no slipping Slow travel When you apply the slow travel speed button in the travel zone F and brake zone B1 the truck travels at reduc...

Page 30: ...going downhill and ready for braking Safety collision switch Procedure Press the safety collision switch 14 The truck accelerates in the travel direction Backward and then brakes to a halt Lifting and lowering are deactivated The safety collision switch 14 prevents the operator from being jammed between the truck and other objects The safety collision switch 14 only operates when the truck is trav...

Page 31: ...27 7 4 Steering Procedure Move the control lever 2 to the left or right 14 16 17 18 2 13 B2 F B1 15 Forward Backward Forward Backward ...

Page 32: ...CAUTION If the control lever moves slowly or not automatically to the upper brake zone the cause of this fault must be rectified Replace the gas pressure spring if necessary Braking with the service brake Procedure Set the control lever 2 up or down to one of the brake zones B1 or B2 The service brakes is the regenerative brake The truck will decelerate at the maximum rate and the brake will apply...

Page 33: ...be changed Release the button 16 as soon as you reach the limit position of the load handler 7 7 Transporting loads Drive the truck with the load unit its destination Take care to accelerate and decelerate gently and travel at constant speed Adapt you travel speed to the conditions of the route and the load unit you are transporting Drive carefully up to the storage location 16 17 ...

Page 34: ...ure Press the lower button 17 Carefully lower the load handler so that the forks are clear of the load Carefully remove the forks from the load unit CAUTION Avoid depositing the load suddenly The lower speed cannot be adjusted 16 17 ...

Page 35: ...ea Lower the load handler Set the key switch 3 to the OFF position and remove the key CAUTION When you leave the truck it must be parked securely even if you only intend to leave it for a short time Do not park the truck on an incline The load handler must always be fully lowered 3 OFF O N ...

Page 36: ...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 37: ... 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 38: ... 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 Battery D W M T S Y 1 Check the battery and battery components 2 Check the battery capacity 3 Check the battery fixed situation 4 Check battery cable connections are secure 5 Clean the battery surface Ch...

Page 39: ...ystem 2 Check that hydraulic ports hose and pipe lines 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 relief valve and adjust if necessary 6 Lubricate the truck according to the lubrication schedule 7 Replace the hydraulic oil after 2000 service hours biannually Li...

Page 40: ...Unscrew the drive cover 5 of the four screws 37 Remove the drive cover The drive cover is removed Installation and removal process is reversed WARNING Remove or installing the drive cover carefully clip hand When the drive cover is removed it is dangerous and does not allow operation of the truck 28 28 5 ...

Page 41: ...e right hydraulic cover 27 of the eight screws 28 Remove the left right hydraulic cover The left right hydraulic cover is removed Installation and removal process is reversed WARNING Remove or installing the left right hydraulic cover carefully clip hand When the left right hydraulic cover is removed it is dangerous and does not allow operation of the truck 26 27 28 28 28 28 ...

Page 42: ...ay when unscrewing the bolts and remove the bolts respectively Strike the edge of the driving wheels with a rubber hammer and remove the old driving wheels from the drive unit CAUTION Strike the edge of the driving wheels evenly and symmetrically Do not scratch the outer surface of inner ring gearbox and the inner surface of the driving wheels Install new driving wheels Apply lubricating oil to th...

Page 43: ...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 44: ...2010 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 Electr...

Page 45: ...41 ...

Page 46: ...otor Rated voltage V 24 Rated power kW 0 65 Rated current A 38 Rated speed r min 2900 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 47: ...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 48: ...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 49: ...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 50: ...46 After polishing crocus cloth and cleaning commutator motor should work under limited speed to ensure safety until the brush working surface polishes ...

Page 51: ...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 52: ...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 53: ...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 54: ...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 55: ...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 56: ...ated Z by a feeler gauge Ensure air gap at all directions are same Specification Table Rated Current V Rated Power W Rated Torque N m Rated Air Gap mm Minimum Thickness of Rotor mm Pre tension Torque of the Mounting Bolt N m 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 hollow bolts 7 set the air gap between stator 11...

Page 57: ...t after rectifying Improper air gap Adjust air gap Oil dirt mixed in Clean oil dirt Slipping Unstable operation in previous use Breaking in 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 th...

Page 58: ...54 2 Hydraulic system 2 1 Hydraulic system working principle ...

Page 59: ...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 60: ...56 3 Electric system 3 1 Electrical schematic diagram ...

Page 61: ... 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 62: ...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 63: ... 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 64: ...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 65: ...Maintenance Record Date Repair maintenance content Serviceman ...

Page 66: ...HANGCHA GROUP CO LTD Address 666 Xiangfu Road Hangzhou Zhejiang China Fax 86 571 88926735 86 571 88926789 ZIP 311305 Web http www hcforklift com E mail sales hcforklift com ...