HANGCHA Mini Series Operation And Maintenance Manual
Electric pallet truck
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- Page 1 Mini Range CBD12-AMC1-I ELECTRIC PALLET TRUCK OPERATION AND MAINTENANCE MANUAL Original Instruction HANGCHA GROUP CO., LTD. 3/2018...
- 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 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 Attachment installation or modification to the truck ..............3 Truck introduction ........................4 2.1 General ............................ - Page 4 9.6 Truck used oil and lubrication ....................39 Relevant safety directive or standard (CE) ................40 Part Structure, Principle and Maintenance................ 42 Drive Unit ..........................42 1.1 Data sheet ..........................42 1.2 Assemble and use notice....................... 43 1.3 Fault and troubleshooting ...................... 43 1.4 Drive Motor ..........................
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Page 5: Part Operation And Maintenance
Part Operation and Maintenance Notice for use 1.1 General Truck in this manual is only for lifting and transporting loads. This truck is not designed for heavy-duty. 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: Attachment Installation Or Modification To The Truck
1.4 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 8: 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. This manual describes the A series mini electric pallet truck, suitable for use in places where work intensity is relatively low. -
Page 9: Functional Description
2.2 Functional description Truck frame – Three-point design, compact, simple and reliable structure. Driving system – Wheel drive unit, with permanent magnetic motor and high performance electromagnetic brake, compact, reliable and powerful. Electric system – 24V lithium battery, efficient work, easy to change. –... -
Page 10: Main Part Introduction
2.3 Main part introduction Item Description Item Description Tiller handle Left hydraulic cover Control lever Battery seat Key switch with key Battery Lift cylinder Load wheels Drive cover Right hydraulic cover Drive wheel... -
Page 11: Display And Control
2.4 Display and control Item Designation Function Control lever Used for steering and braking the truck. Switches the control current ON and OFF. Key switch Removing the key prevents the truck from being switched on by unauthorized personnel. Hourmeter. Display instrument Battery charge status. -
Page 12: Display Instrument
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... -
Page 13: 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. Model CBD12-AMC1-I Operator type Pedestrian Rated capacity Q (kg) 1200 Load center distance c (mm) Load distance, centre of drive axle to fork x (mm) Wheelbase y (mm) -
Page 14: Product Plates And Warning Labels Location
Y EA R OF MA NUF ACTURE X XX X HANGCHA GROUP CO.,LTD. Ad d: 88 D ong hua n Road ,L in' an Econo mic Deve lop me nt Zon e Zhej iang 3113 05, P.R. C hina Item Description Key switch “OFF”... -
Page 15: Safety Instructions
in serious condition there will be Safety Instructions accident. Only trained and authorized operator – Make sure change the “safety parts” shall be permitted to operate the truck. during the schedule maintenance. – Wipe off the oil, grease or water on the soleplate, foot pedal and control lever. - Page 16 use the truck. fork center, when goods is deviating the – fork center, turn or pass uneven road, If there occurs to fault, battery electrolyte, hydraulic oil leakage when lifting loads, you are easily to fall. Meanwhile, going up and down the slope, please possibility of turnover will increase.
- Page 17 link mechanism. the rain. 24) Before dismantle or repair the truck, lift the battery out of the truck firstly. WARNING 25) When working environment is not enough light, please add extra lighting of 18) Make the loads in front when climbing the working area.
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Page 18: 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 Only use lifting gear with sufficient capacity (for truck weight see truck nameplate ). -
Page 19: 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 20: 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 21: Battery And Charger
Battery and charger Battery The truck comes standard with a 24V/20Ah lithium battery pack, lithium battery pack weighs about 5kg. 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. -
Page 22: Safe Operation Rules For Battery Use
5.1 Safe operation rules for battery use – Please charge the battery at an ambient temperature of 0 to 40 . – Do not decompose the battery in any way! – Please prevent the battery from water or infiltration of any corrosive liquid. –... -
Page 23: Battery Charging
5.2 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 You must use the original charger provided by our company to charge the battery. Before the battery is full, try not to interrupt the charging process. - Page 24 Fuse LED2 charging status indicator LED1 power indicator...
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Page 25: 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 26: Operation
the scales. Add oil when insufficient. Operation 7.1 Check before operation In order for the safety truck operation and keep the truck in good condition, before starting the truck, you must check it carefully. Oil leak and liquid leak check Park the truck and check oil leakage. - Page 27 the body with thumb, and inspect the forward running condition; gradually press the accelerator button to the inside of the body with thumb, and inspect the reverse running condition. 10) Brake system When the truck run forward or backward, push the handle to vertical position or press to level position to check the brake condition.
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Page 28: Start Up The Truck
7.2 Start up the truck Procedure: – Carry out check before operation 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. -
Page 29: Travel
7.3 Travel Do not drive the truck unless the panels are closed and properly locked. Do not carry passengers on the truck. Procedure: – Start up the truck. – Set the control lever (2) to the travel zone (F). Travel is only released in the travel zone (F). –... - Page 30 Travelling on inclines: 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 Never park on the slope. No turn, inclines when going uphill and downhill. Slow down when going downhill and ready for braking.
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Page 31: Steering
Backward Forward Backward Forward 7.4 Steering Procedure: – Move the control lever (2) to the left or right. -
Page 32: Braking
7.5 Braking The brake pattern of the truck depends largely on the travel route conditions. The driver must take this into account when travelling. In hazardous situations set the control lever to the brake position. The truck can brake in different ways: Automatic braking Braking witch the service brake (With the control lever in zone "B1 or B2") By inversion braking (travel switch) -
Page 33: Lifting Loads
7.6 Lifting loads Procedure: – Fully insert the load handler underneath the load unit. – Press the lift button (16) until you reach the desired lift height. CAUTION The lift speed cannot be changed. Release the button (16) as soon as you reach the limit position of the load handler. -
Page 34: Depositing Loads
7.8 Depositing loads Procedure: – 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. -
Page 35: Parking The Truck Securely
7.9 Parking the truck securely Procedure: – Drive the truck to safe area or appointed area. – 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. -
Page 36: 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 37: Maintenance
Inspection and maintenance are usually ignored, you’d better find out the problems early and 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 38: 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 39 Steering Test electric steering and its components. Check tiller recuperating function. Bearing lubrication Electrical system Test warning and safety devices in accordance with operating instructions Test the displays and controls. Check the function of micro switch and sensor. Test cable and motor attachments. Check contactors and/ or relays.
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Page 40: Remove Or Installing The Drive Cover
9.3 Remove or installing the drive cover Remove the drive cover Procedure: – Parking the truck securely. – 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... -
Page 41: Remove Or Installing The Left/Right Hydraulic Cover
9.4 Remove or installing the left/right hydraulic cover Remove the left/right hydraulic cover Procedure: – Parking the truck securely. – Unscrew the left hydraulic cover (26) and the right hydraulic cover (27) of the eight screws (28). – Remove the left/right hydraulic cover. The left/right hydraulic cover is removed. -
Page 42: Replace Wheels
driving wheels from the drive unit. 9.5 Replace wheels Procedure: – Dismantle the drive unit from the truck. CAUTION Strike the edge of the driving wheels – Remove the 12 socket hexagon screws evenly and symmetrically. which is used to fix the driving wheels Do not scratch the outer surface of with a S=5mm hex wrench. -
Page 43: Truck Used Oil And Lubrication
9.6 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 44: 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 46: Part Structure, Principle And Maintenance
Part Structure, Principle and Maintenance Drive Unit 1.1 Data sheet Speed ratio of reduction gear box 24.6857 Max. wheel torque N•m Max. wheel load 1000 Rated voltage Rated power 0.65 Rated current Rated speed r/min 2900 Drive motor Working system S2=45min Insulation grade Protection grade... -
Page 47: 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 48: 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 49 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 50 – After polishing crocus cloth and cleaning commutator, motor should work under limited speed to ensure safety until the brush working surface polishes.
- Page 51 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 group Short circuit of armature coils. according to certain sequence The welding of commutator segments and armature coils is not good or short circuit.
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Page 52: 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 53: 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 54: 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 55: 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 56: 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 57: Common Fault And Troubleshooting
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. 1.5.5 Common fault and troubleshooting Fault Probable cause... -
Page 58: Hydraulic System
Hydraulic system 2.1 Hydraulic system working principle... -
Page 59: 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 60: Electric System
Electric system 3.1 Electrical schematic diagram... -
Page 61: 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 62: 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 63 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.
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Page 64: 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 9 12 10 12 12 15 14 18 22 29 20 25 25 31 29 39 44 58 35 44 44 54 49 64... - 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...
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