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Summary of Contents for HANGCHA CBD15-A2MC1
- Page 1 Mini Range CBD15-A2MC1 ELECTRIC PALLET TRUCK CBD15-A2MC1-F OPERATION AND MAINTENANCE MANUAL Original Instruction HANGCHA GROUP CO., LTD. 8/2017...
- Page 2 FOREWORD Thank you very much for purchasing the A series mini range electric pallet truck of Hangcha Group . A series mini range electric pallet truck is a newly developed product for warehouse logistic, it owns characteristics as advanced performance, comfort operation, safety and security, low maintenance cost, and is an ideal tool for handling goods in warehouse, supermarket and workshop.
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Page 3: Table Of Contents
Contents Part Ⅰ：Operation and Maintenance ..................1 Notice for use .......................... 1 1.1 General ............................ 1 1.2 Use as required ........................1 1.3 Approved application conditions ....................2 1.4 Cautions for the use of cold storage truck ................3 1.5 Proprietor responsibilities ......................3 1.6 Attachment installation or modification to the truck .............. - Page 4 8.2 Start running after deposit for a long time ................36 Maintenance .......................... 37 9.1 Maintenance general ......................37 9.2 Periodic maintenance schedule..................... 38 9.3 Remove or installing the hood ....................41 9.4 Remove or installing the drive wheel cover ................42 9.5 Truck used oil and lubrication ....................
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Page 5: Part Ⅰ：operation And Maintenance
Part Ⅰ：Operation and Maintenance Notice for use 1.1 General Truck in this manual is only for lifting and transporting loads. It must be used, operated and maintained 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. -
Page 6: Approved Application Conditions
1.3 Approved application conditions － Used in specified area as factory, tourist attraction and recreation place. － Operation only on secure, level surfaces with sufficient capacity. － Operation only on routes that are visible and approved by the proprietor. － Use in specified rated load. －... -
Page 7: Cautions For The Use Of Cold Storage Truck
1.4 Cautions for the use of cold storage truck － Use special oil for cold storage, maintain and replace periodically. － All cold storage trucks cannot be shut down or parked in cold storage, or it may cause damage of hydraulic system and electric system. －... -
Page 8: Attachment Installation Or Modification To The Truck
1.6 Attachment installation or modification to the truck Without authorization by the manufacturer, it is not allowed to modify the truck privately. The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after written approval by the manufacturer has been obtained. -
Page 9: Truck Introduction
Truck introduction 2.1 General A series mini range electric pallet truck described in this manual should work under 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 Electric pallet truck... -
Page 10: Functional Description
2.2 Functional description Truck body system – Beautiful and compact outline, concise and fluent line. – Adopted steel stamping and injection moulding process is sturdy and durable. – The chassis adopts 3-wheel structure, and equips with side supporting system, it is safe and reliable. - Page 11 – Built in charger, maintenance-free colloidal battery. – 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...
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Page 12: Main Part Introduction
2.3 Main part introduction Item Description Item Description Control handle 10 Load wheel Control lever 11 Fork Lift cylinder 12 Wire fixator Drive wheel cover 13 Battery charging plug（built-in plug） Caster wheel 14 Instrument Drive wheel 15 Hood Fault indicator 16 Emergency stop switch Side door (built-in battery) 17 Key switch... -
Page 13: Display And Control
2.4 Display and control... - Page 14 Item Designation Function Control lever Control the steering and brake of the truck. Normally on normal condition. Failure regularity, see Fault indicator the failure code. Green light: Fully charged. Charging light indicator Yellow lingth: Fault Red light: Charging Battery charging plug （ built-in Insert the plug into the power outlet for battery plug）...
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Page 15: Display
2.4.1 Display Instrument [14] It displays battery power. 10 LED display bars display battery discharging status. One LED means 10% battery power. As the battery power reduces, 10 LED will light up one by one from right to left. When the remaining capacity is less than 40%, need to stop charging. Fully charged Need charge Low charging status... -
Page 16: Standard Technical Data
2.5 Standard technical data The following technical data are all standard data. Our company reserves the right of alteration and extension. CBD15-A2MC1 Model CBD15-A2MC1-F Operator type Pedestrian Load capacity Q (kg) 1500 Load center c(mm) Wheelbase y(mm) 1285 Weight Service weight with battery Tyre type Φ210×70/1... -
Page 17: Product Plates And Warning Labels Location
2.6 Product plates and warning labels location Plates and labels, such 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 Item Description 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. Fault indicator Hoist label: Strap points for crane lifting. Manufacturer’s logo Charging light indicator.
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Page 19: Safety Instructions
accident. Safety Instructions Make sure change the “safety parts” – Only trained and authorized operator during the schedule maintenance. shall be permitted to operate the truck. – Wipe off the oil, grease or water on the soleplate, foot pedal and control lever. –... - Page 20 – If there occurs to fault, battery electrolyte, 13) Goods are not allowed to deviate the hydraulic oil leakage when lifting loads, fork center, when goods is deviating the going up and down the slope, please fork center, turn or pass uneven road, organize staff to repair.
- Page 21 2000m. WARNING 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...
- Page 22 for a modification or alteration to a powered industrial truck, however, that the user must do the following: – Arrange modification alteration designed, tested implemented engineer(s)； – Maintain a permanent record of the design, test(s) and implementation of the modification or alteration; –...
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Page 23: Transport
Transport The forklift truck is designed for short-distance lifting,lowering and transporting load units, not suitable for long-distance travel. If needed, the forklift truck must be transported by using lifting device or platform to place on truck or trailer. 4.1 Lifting by crane WARNING ... -
Page 24: Securing The Truck During Transport
4.2 Securing the truck during transport Correctly fix the forklift truck to avoid move when using truck or trailer. Procedure: – Park the truck securely. – Sling the tensioning belt around the truck and attach it to the fastening rings of the transporting vehicle. -
Page 25: Transport
4.3 Transport The pallet truck is designed for short-distance material handling only and is inappropriate for long-distance transportation. If needed, the truck must be transported by using lifting device or platform to place it on truck or trailer. Before operation, fix the pallet truck firmly on the transport vehicle with belt, and block the wheel to avoid relative motion during transportation. -
Page 26: Battery
Battery The truck equips with two 12V/70Ah maintenance-free colloidal batteries. When the battery temperature reaches 25℃～30℃, its service life is the longest. Lower temperature reduces battery available capacity and higher temperature shortens battery service life. Per battery weighs about 25kg. 5.1 Safe operation rules for battery use –... - Page 27 capacity, or else it would shorten the endurance of the truck and the service life of the battery as well. – The matching between batteries and the chargers: matching on the charging parameter of the battery plays a significant role on the battery performance and its service life. Users should choose the qualified charger with same charging parameter as previous one when replacing the chargers.
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Page 28: Battery Charging
5.3 Battery charging That is, during truck operation the battery discharge process, the battery over-discharge is prohibited. After the truck is running, it is timely to charge the battery. WARNING The truck comes with charger, the charger charging power supply must be single-phase power frequency AC power. -
Page 29: Additional Charge
5.3.3 Additional charge Charger structure enables to continue charging the partially charged battery in use. -
Page 30: Replacing Battery
5.4 Replacing battery Procedure: – Park the truck securely. Remove the hood (15). See “Removing the – hood”. – Remove the screws (34), and then remove the side door(8). – Remove the battery positive and negative electrode. – From the left and right sides, respectively, pull the battery (35). -
Page 31: New Truck Breaking-In
New truck breaking-in We recommended operating the truck under light load conditions for the first stage of operation to get the most from it. Especially the requirements given below should be observed while the truck is in a stage of 100 hours of operation： –... -
Page 32: Operation
the scales. Add oil when insufficient. Operation Battery check 7.1 Check before operation Check the battery cover board. See whether In order for the safety truck operation and the battery fixed reliably. keep the truck in good condition, before Check the terminal for loose or damage. starting the truck, you must check it carefully. - Page 33 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, whether wiring is regular or fastener loosens etc.
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Page 34: Start Up
7.2 Start up Procedure: – Carry out check before 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 –... -
Page 35: Travelling
7.3 Travelling Driver should walk in front of the truck and keep at the side front of the truck when travelling. One hand holds the handle, and operates travel switch with thumb. Always watch moving direction and guide the truck. Or hold the handle with both hands and push the truck go forward. CAUTION ... -
Page 36: Braking
Slow down Slowly loosen the thumb, the direction speed control button will return automatically and the truck slows down. 7.4 Braking When the thumb off the direction speed control button, pull the handle to braking range (B1 or B2) position or vertical position, the truck brakes. CAUTION ... -
Page 37: Loading
Turn off the switch to “OFF” position, press down the emergency disconnect switch, pull out – the battery plug, and take off the key. – Fold up 7.7 Loading Procedure: – Drive the truck carefully up to the loads. – Adjust fork height to make the forks are in the tray. - Page 38 – Travel backward and make the fork out of the load. – Drop down the forks to proper position.
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Page 39: Park The Truck Securely
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). -
Page 40: Deposit The Truck For Long Time
Deposit the truck for long time 8.1 Deposit for long time – Fully check the truck, especially check the wheel damage. – Check fluid oil for leakage. – Apply lubrication grease. – Check the joint face of cylinder piston rod for looseness, and if scratch on the piston rod surface. -
Page 41: Maintenance
– solve it in time. – Use authentic parts of Hangcha Group. Don’t use different oil when changing or adding oil. Don’t rave about oil and electrolyte used – at will, and carry on handling according to the local environmental protection laws and regulations. -
Page 42: Periodic Maintenance Schedule
9.2 Periodic maintenance schedule The service intervals stated are based on single shift operation under normal operating conditions. They must be reduced accordingly if the truck is to be used in conditions of extreme dust, temperature fluctuations or multiple shifts. The following servicing checklist indicates the operations to be performed and the respective intervals to be observed. - Page 43 Motor ● Clean the foreign body on the motor ● Clean or replace the bearing ● Check the carbon brush and commutater for worn, whether spring is normal ● Whether the connection is correct and firm. ● Brush carbon powder on shift plate and shift device. Transmission ●...
- Page 44 Hydraulic system ● Test hydraulic system. Check that hydraulic ports, hose and pipe lines are secure, check for ● leaks and damage. Check cylinders and piston rods for damage and leaks, and make sure ● they are secure. ● Check hydraulic oil level and top up if necessary. ●...
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Page 45: Remove Or Installing The Hood
9.3 Remove or installing the hood Remove the hood Procedure: – Park the truck securely. – 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. -
Page 46: Remove Or Installing The Drive Wheel Cover
9.4 Remove or installing the drive wheel cover Remove the drive 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 ... -
Page 47: Truck Used Oil And Lubrication
9.5 Truck used oil and lubrication Filler plug for hydraulic oil Gliding surfaces Code Designation Mark, code Remark Normally：L-HM32 Hydraulic oil Hydraulic system High and cold environment：L-HV32 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. -
Page 48: Check The Fuses
9.6 Check the fuses Procedure: ━ Maintenance work to complete preparations before the operation. ━ Remove the hood. ━ Check the fuse (38) values are correct, if necessary, replace. Designation Control circuit Specification Fuse Control the truck power 100A... -
Page 49: Relevant Safety Directive Or Standard (Ce)
Relevant safety directive or standard (CE) After CE certificated, the truck meets the following directive and standard: – 2006/42/EC machinery directive（namely Directive of the council of the laws of the member states concerning machinery ） , 2000/14/EC Noise Directive （Namely Directive of the council of the laws of the member states concerning noise radiation of outdoor equipment）;... -
Page 51: Part Ⅱ：structure, Principle And Maintenance
Part Ⅱ：Structure, Principle and Maintenance Drive Unit 1.1 Data sheet Speed ratio of reduction gear box 24.6857 N•m Max. wheel torque Max. wheel load 1000 Rated voltage Rated power 0.65 Rated current Rated speed r/min 3100 Drive motor Working system S2=45min Insulation grade Protection grade... -
Page 52: Assemble And Use Notice
1.2 Assemble and use notice – Whn assemble, scrub the oil seal on the product. Avoid product damage, no disassemble at will. – Avoid each fitting surface and exposed gear impact, thus influence installation. Normal working oil temperature is ≤70℃. –... -
Page 53: Drive Motor
1.4 Drive Motor Wiring Diagram of Motor 24VDC Black 24VDC Black Motor use notice – Keep clean and dry around the motor, and do no place other objects on or in the motor. – Do not use with overload. – Never coexist with strong magnetic object. - Page 54 cloth, when there is grease on the surface, immerse the cloth in alcohol to wipe(park). – Check if all fasteners are tight. – Brush carrier should be fastening and no loose. If turn or remove the brush carrier needed, only mark can loosen the end cap bolt. Aim at marker line to tighten screw when brush carrier reset to keep the brush in neutral position.
- Page 55 – After polishing crocus cloth and cleaning commutator, motor should work under limited speed to ensure safety until the brush working surface polishes.
- Page 56 Fault diagnosis Probable cause Fault All copper sheet blacken Pressure of the brush is not right · Short circuit of commutator segments Commutator segments blacken in · Short circuit of armature coils group according to certain sequence · The welding of commutator segments and armature coils is not good or short circuit.
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Page 57: Electromagnetic Brake
1.5 Electromagnetic brake The spring-loaded electromagnetic brake is applied in the truck which is a single disk brake with 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 2.Stator Module 3.Brake Pad... -
Page 58: Electromagnetic Brake Working Principle
1.5.1 Electromagnetic brake working principle Motor shaft (9) is connected with shaft sleeve (4) by passing through the flat key. And shaft sleeve (4) is connected with brake pad (3) by passing through the splines. When the stator (11) is block out, the force produced by the pressure spring (10) would act on the armature (8) which makes rotated the brake pad (3) driven by the motor shaft connected closely between the armature (8) and cover plate (5). -
Page 59: Electromagnetic Brake Installation
1.5.2 Electromagnetic brake installation – Put the flat key (13) into the key groove of the motor shaft (9). Press the shaft sleeve (4) to the motor shaft (9) and fasten it with the inner spring. – Install the friction disk (5) to the end face of the motor by using three mounting bolts of the friction bolts (12). -
Page 60: Maintenance
WARNING No broken wire sheath, or else the circuit might be damaged. Do not process the locating surface or the holes of the production without authorization, or else the magnet loop would be influenced. Do not over press when fitting the motor shaft. Make sure no damage on the friction surface and wipe off the burr of the mounting holes and surfaces. -
Page 61: Adjust The Air Gap Of The Brake
1.5.4 Adjust the Air Gap of the Brake Rated air gap Z grows with the friction. In order to there is sufficient braking torque, the air gap must be set before it reaches to the maximum value. The air gap can be adjusted by several times. When the thickness of brake pad becomes the minimum value(see the specification table below), the brake pad must be replaced. - Page 62 Under the general operating conditions, the first set of the air gap is usually after 1500 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.
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Page 63: Common Fault And Troubleshooting
1.5.5 Common fault and troubleshooting Fault Probable cause Corrective action Power is obstructed Connect Too low exciting voltage Check voltage and adjust. Brake does not Improper air gap Adjust air gap work Stator coil breaks Replace stator Oil dirt mixed in Clean oil dirt Install the switch to the DC circuit Switch installed to AC circuit... -
Page 64: Hydraulic System
Hydraulic system 2.1 Hydraulic system working principle... -
Page 65: Hydraulic System Fault Diagnosis And Correction
2.2 Hydraulic system fault diagnosis and correction Fault Probable cause Corrective action Low oil level Fill to the specified oil level No oil pumps Clean oil pipe and oil tank. If hydraulic oil is from the pump Blocking of strainer dirty, please change it. -
Page 66: Electric System
Electric system 3.1 Electrical schematic diagram... -
Page 67: Drive Motor Controller
3.2 Drive motor controller 3.2.1 Maintenance Controller has no user repair parts. Do not try to open, repair or alter the controller. Otherwise it may damage the controller and also invalid the guarantee. It’s suggested to keep the controller clean and dry, periodically check and get rid of diagnose historical files. -
Page 68: Diagnostics And Troubleshooting
3.2.2 Diagnostics and Troubleshooting When faults happen, try to restart by resetting the key switch after confirmed that faults are not caused by faulty wiring connection or mechanical failure. If the faults are still on, shut down the key, check for incorrect connection or corruption of the pin 35 connecter, reconnect after repaired and cleared, and then restart again. - Page 69 Troubleshooting Chart Led Codes Fault indicator status Fault Possible Cause no power or defective controller controller powered up; No faults 1）Temperature >8℃C or < -10℃. 2）Battery contact bad.. ¤ ¤ Thermal Fault 3）Work under extreme severe environment. 4）Electromagnetic brake does not release normally. 1）Throttle input wire open or shorted.
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Page 70: Attachment：table For Bolt's Tightening Torque
Attachment：Table for bolt’s tightening torque If not specified, select the tightening torque from the below table： Unit ：N· m Grade Bolt’s diameter 4～5 5～7 6～8 9～12 10～12 12～15 14～18 22～29 20～25 25～31 29～39 44～58 35～44 44～54 49～64 76～107 54～69 69～88 83～98 121～162 88～108... - Page 71 Maintenance Record Date Repair, maintenance content Serviceman...
- Page 72 HANGCHA GROUP 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...
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