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Hoppecke PU Operating & Maintenance Manual

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Operating & maintenance manual for the PU changer
IMPORTANT: Before operating the machine:
 Read the operators manual.
 Follow the safety instructions in the manual.
 Unless you have been authorised and trained, do not operate the host truck.
 No personnel to be within 1 metre distance of the machine whilst it is in
operation.
 Consider a regular thorough examination service contract to keep the
machine in optimum condition.
 The PU series may be used with any manufacturers powered pallet truck
(PPT). Therefore the operator must also be authorised and trained to use
the host powered pallet truck applicable to this PU changer.
 It is forbidden to use the machine for transporting people; they could sustain
severe or fatal injuries; and to transport any material other than industrial
truck batteries.
Page No 1 of 19
Hoppecke Batterien
GmbH & Co.KG
www.hoppecke.com
R 1.1 - 101013

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Summary of Contents for Hoppecke PU

  • Page 1: Operating & Maintenance Manual For The Pu Changer

     Consider a regular thorough examination service contract to keep the machine in optimum condition.  The PU series may be used with any manufacturers powered pallet truck (PPT). Therefore the operator must also be authorised and trained to use the host powered pallet truck applicable to this PU changer.

  • Page 2: Table Of Contents

    Table of Contents OPERATING & MAINTENANCE MANUAL FOR THE PU CHANGER ............ 1 TABLE OF CONTENTS ........................... 2 1 GENERAL ............................3 1.1 S ................3 PECIFIC USE AND CAPACITY OF THE CHANGER 2 SAFETY NOTICES FOR THE OWNER ....................4 2.1 R...

  • Page 3: General

    It is not designed to pull metal on metal. It is suitable for this task in a way described in this manual. If the PU changer is used in a way other than established in the operating instructions, the written approval of the manufacturer and, if necessary of the responsible authorities must be obtained beforehand to prevent any potential dangers.

  • Page 4: Safety Notices For The Owner

    A residual risk cannot be excluded even beyond the immediate danger area of the PU, therefore any persons standing within the area of the PU must pay particular attention to the task of battery changing in order to be able to react fast in case of an incident.

  • Page 5: Maintenance & Repair

    2.4 Maintenance & Repair 2.4.1 Risk of electric shock Warning: Before carrying out any maintenance or repair disconnect the battery from the host powered pallet truck.  A short circuit will result in an electric arc which can cause serious burns. ...

  • Page 6: Installation

    1 x top bar 1 x bottom bar 2 x M12 x 75mm bolts There are three clamps supplied with the PU. Space them out as evenly as possible over the full length of the PPT forks (this will vary according to the manufacturer).

  • Page 7: Operation

    4 Operation TO SWITCH THE MACHINE ‘ON’, THERE IS EITHER A KEY-SWITCH OR A CODE SWITCH. SEE BELOW FOR FUNCTIONALITY. 4.1 Pre start procedure NOTE: When not in use the carriage should be in the fully back (reverse) condition, i.e. The carriage is underneath the control panel of the machine.
  • Page 8 3. Enable the electronic code switch: Fig 3. Electronic code switch. The code switch is situated on the left hand side of the control panel (see Fig 5). Refer to (fig 1) image on the right for setting up instructions. The driver must log on using a 6 digit code.

  • Page 9: To Pull A Battery Off A Charging Rack Or Industrial Truck

    4.2 To pull a battery off a charging rack or industrial truck 1. Ensure the pre start procedure (3.1) is complete and before starting the operation, ensure the battery is free of electrical/ mechanical plugs, interlocks or connections before trying to remove it.

  • Page 10: To Push A Battery Off The Machine Onto A Charging Rack Or Industrial Truck

    4.3 To push a battery off the machine onto a charging rack or industrial truck 1. Move the machine using the host tiller controls and align it with the rack/ industrial truck. Then, by using the raise/ lower function on the host truck align the machine rollers and charging rollers to equal height.

  • Page 11: Maintenance

    5 Maintenance The PU changer is not designed for continual use. It is designed for a 35% duty cycle, based on duty cycle information received over time across a number of applications. In view of this a certain level of maintenance is required to maintain functionality, operating safety and maximum life expectancy: ...
  • Page 12 Drive chains: Visually check chains are clear of any debris and that Typical life is 15,000hrs there is approximately 6-12 mm of slack in the bottom Every 100hrs wipe chain with chain. If it is more than this inform the supervisor/ proprietary chain lubricant very manager.

  • Page 13: Chain Adjustment

    5.2 Chain adjustment NOTE: This is to be carried out by a trained service engineer. The left and right drive bottom chains need some slack to work correctly. This should be approximately 12-18mm. If this needs adjusting it can be achieved by using the chain adjuster and locking screws positioned on the left and right side of the carriage ends.

  • Page 14: Checking-Adjusting Unloading Valve

    5.3 Checking-adjusting unloading valve The pressure relief valve, (1.) is part of the hydraulic power pack unit and is situated under the control panel. The pressure relief valve is located on top of the 3-way solenoid valve (see photo fig 7). Remove the plastic cover and turn the valve clockwise to increase the unloading pressure and anticlockwise to decrease the unloading pressure.

  • Page 15: Spare Part List

    6 Spare Part List This list is proposed under following consideration:  Delivery time of spare parts.  Estimation which parts could fail.  Most economic way to reduce time on site. In most cases it is e.g. more rational to take a new power supply than trying to dissemble it into its parts and change the components.

  • Page 16: Electronic Schematic

    7 Electronic Schematic Fig 8. Schematic with Key-Switch Page No 16 of 19 R 1.1 - 101013...
  • Page 17 Fig 9. Schematic with electronic code switch Page No 17 of 19 R 1.1 - 101013...

  • Page 18: Hydraulic Schematic

    8 Hydraulic Schematic Fig 10. Hydraulic Schematic Page No 18 of 19 R 1.1 - 101013...

  • Page 19: Environmental Safety & Disposal

    9 Environmental safety & disposal Environmentally harmful substances are used in servicing and cleaning all types of technical equipment. Please do not simply release them into the environment but act responsibly:  Clean and lubricate the machine only in specially designated areas which are equipped to contain harmful chemicals and oils.

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