Related Manuals for HANGCHA HS0608TP
Summary of Contents for HANGCHA HS0608TP
- Page 1 HS0608TP Mobile elevating work Mobile elevating work platform Maintenance Manual Maintenance Manual Maintenance Manual HANGCHA GROUP CO., LTD. HANGCHA GROUP CO., LTD. February, 2024...
- Page 2 The design of our product is constantly being updated and improved, so there may be some differences between the contents of this manual and the machine you are currently using. If there is any uncertainty, please contact HANGCHA GROUP CO., LTD. sales department or the agent.
-
Page 3: Table Of Contents
Contents 1 Specification ..........................5 1.1 Main performance parameters .................... 5 1.2 Power system specification ....................7 1.3 Installation instruction for hydraulic hose and pipe joint ............ 7 1.4 Installation instructions for fasteners ................. 10 2 Safety rules ..........................13 2.1Overview .......................... - Page 4 3.5 Safety measures ......................... 27 4 Maintenance .......................... 29 4.1 Overview ..........................29 4.2 Maintenance procedure A ....................33 4.3 Maintenance procedure B ....................37 4.4 Maintenance procedure C ....................42 4.5 Maintenance procedure D....................43 5 Maintenance procedures ...................... 48 5.1 Platform components ......................
-
Page 5: Specification
1 Specification 1.1 Main performance parameters The following technical data are all standard. We reserve the right to make changes and additions to the data. HS0608TP HS0608T Parameter item Unit Length 1.52 Width 0.78 Overall Height（Guardrail 1.76 dimensions unfolded） Height（Guardrail 2.13... - Page 6 Maximum slope rating Maximum wind speed Maximum Front-back ° allowable Left- right ° inclination Normal working noise ≤80...
-
Page 7: Power System Specification
1.2 Power system specification Power system specification Item Parameter Specification Normal temperature area（0℃～40℃） L-HM46 L-HV32 Cold area（-25℃～25℃） Hydraulic oil High temperature area（＞40℃） L-HM68 Special customization Extremely cold area（＜-30℃[-22℉]） required Flow 5 ml/r Gear pump Rated working pressure 21MPa Lifting relief valve pressure 21MPa Function valve... - Page 8 M42×2 260± 16Nm 240± 15Nm M45×2 1.3.2Hydraulic pipe joint torque Note: When removing or installing hydraulic pipe joints, it must be operated according to the torque specified in the table below. Hydraulic pipe joint torque - Metric Thread Steel specification ED+O Ring ED+O Ring O Ring...
- Page 9 Hydraulic pipe joint torque - British system（BSP） Thread Steel specification ED+O Ring ED+O Ring O Ring G1/8A 20 ± 1 Nm 20 ± 1 Nm G1/4A 35 ± 2 Nm 40 ± 2 Nm G3/8A 50 ± 3 Nm 75 ± 5 Nm G1/2A 75 ±...
-
Page 10: Installation Instructions For Fasteners
11/16-12 40± 3 Nm 65± 4 Nm 3/4-16 50± 3 Nm 80± 6 Nm 7/8-14 75± 5 Nm 125±10Nm 1-1/16-12 110± 8 Nm 185±15Nm 1-5/16-12 160± 10Nm 280±20Nm 1.3.3Hydraulic hose and pipe joint tightening procedure When installing hydraulic hose and pipe joint, it must be installed according to the following requirements. - Page 11 1.25 30 Nm 35 Nm 42 Nm 30 Nm 37 Nm 45 Nm 55 Nm 75 Nm 85 Nm 1.25 56 Nm 77 Nm 87 Nm 60 Nm 80 Nm 92 Nm 95 Nm 125 Nm 150 Nm 1.75 100 Nm 130 Nm 155 Nm 1.25...
- Page 12 3/4-10 1-1/8" 315Nm 445Nm 7/8-9 509Nm 715Nm Tightening torque of fasteners – American system（UNF） Opposite dimension Diameter（in） Grade 5 Grade 8 of nut（s） 1/4-28 7/16" 11.5Nm 16Nm 5/16-24 1/2" 23Nm 32Nm 3/8-24 9/16" 41Nm 58Nm 7/16-20 5/8" 65Nm 92Nm 1/2-20 3/4"...
-
Page 13: Safety Rules
If you have any questions about the use or operation of the machine, please call Hangcha Group in time for consultation. Most of the accidents involved in the operation, maintenance and repair process are caused by the failure to follow the basic safety operation procedures and precautions in the actual operation. -
Page 14: Symbol Description
2.3Accident notification In case of any malfunction of machine, please contact Hangcha Group co., Ltd. Immediately. Even if there was no personal injury or property damage in the accident, please be sure to contact us by phone and provide all necessary details. If you failure to notify the manufacturer within 48 hours after the accident, the warranty period of the product maybe invalid. -
Page 15: Electrocution Hazard
NOTICE After the accident, the operator should check the machine and its functions thoroughly. All functions should be tested first from the ground controller and then from the platform controller. Lifting height shall not exceed 3m until all damage has been repaired and all controllers can be operated correctly. -
Page 16: Tip-Over Hazard
Safe load Safe load capacity Maximum manual operation Model Person capacity (extension force platform) HS0608TP 230kg 113kg 1(indoor) 200N(indoor) Tip-over hazard ★ Do not allow personnel, equipment and materials on the platform to exceed the maximum load capacity. ★ Only when the machine is on firm, level ground can the platform be lifted or extended. - Page 17 Do not use batteries that lighter than the original equipment. The battery not only provides power, but also acts as a counterweight, which is essential for maintaining the stability of the machine. For HS0608TP , each battery pack must weigh 52kg. ★ Do not operate the machine when the front door open.
-
Page 18: Working Environment Hazard
2.6Working environment hazard Before using the machine or during its operation, inspect the workplace for possible hazards, and pay attention to environmental restrictions, including inflammable and explosive gases or dusts. Working environment hazard ★ Do not operate on surfaces, edges, or potholes that cannot support the machine. Only when the machine is on firm, level ground can the platform be lifted or extended. -
Page 19: Unsafe Operation Hazard
Beaufort mile/h Description Ground conditions scale Clam No wind, smoke vertically up. 0～0.2 0～0.5 0.3～1.5 1～3 Light breeze Smoke indicates wind direction. Bare skin feels windy. Light breeze 1.6～3.3 4～7 Leaves rustle slightly. Gentle breeze Twig began to shake. 3.4～5.4 8～12 Dust and scraps of paper kicked up. -
Page 20: Fall Hazard
★ Do not replace parts critical to machine stability with parts of different weights or specifications. ★ Do not modify or alter the aerial work platform without the prior written permission of the manufacturer. ★ Do not install additional device to hold tools or other materials on the platform or guardrail. -
Page 21: Collision Hazard
Fall hazard ★ Wear seat belts or use safety facilities in accordance with government regulations. Attach the lanyard to the anchor on the platform, and only one person can tie on each anchor. ★ Do not sit, stand or climb on the platform guard rails. Maintain a firm footing on the platform floor at all times. -
Page 22: Crushing Hazard
degree of congestion, the location of the personnel and any other factors that may cause a collision. ★ Do not operate machine in the path of any crane or moving overhead machinery unless the crane controller is locked or precautions have been taken to prevent any potential collision. -
Page 23: Damaged Machine Hazard
dangerous or where flammable and explosive gases may exist. 2.12Damaged machine hazard Comply with the operation and maintenance requirements of the parts in this manual and the maintenance manual, otherwise the machine may be damaged. Damaged machine hazard ★ Do not use damaged or faulty machines. ★... -
Page 24: Hydraulic System Hazard
hydrogen and oxygen. Any device that can cause sparks or flames (including cigarettes/smoke materials) should be kept away from the battery to prevent explosion. ★ Do not contact the battery terminals or the cable clamps with tools that may cause sparks. ★... -
Page 25: Welding And Grinding Safety
2.16Welding and grinding safety Before performing welding, grinding and polishing operations, the welder must obtain permission from the responsible department at the workplace. ★ Follow the welding manufacturer's recommendations for proper welding procedures. ★ Only after the power is turned off can connect the wire or cable for welding or grinding operations. - Page 26 NOTICE The power-off switch must be turned off after each use.
-
Page 27: Principle And System Introduction
3 Principle and system introduction 3.1 Power The power source consists of one24V lithium batteries in series to drive the 24V walking motor and oil pump motor. The walking motor and the wheel reducer are connected by splines to drive the moving motion of the machine. The gear pump and the output shaft of the motor are connected by splines to provide power to the hydraulic system. - Page 28 1. The horizontal sensor measures the angle of X-axis and Y-axis of the vehicle body. When the angle of the X axis exceeds 1.7° or the angle of the Y axis exceeds 1.7°, an alarm will be sent out, and the functions of lifting, walking and steering will be limited.
-
Page 29: Maintenance
4 Maintenance 4.1 Overview This section provides detailed operation procedures for the periodic maintenance check. ★ Maintenance inspec on must be carried out by professionally trained and qualified personnel. ★ Rou ne maintenance inspec on is the daily inspec on items during normal operation of the machine. - Page 30 Unless otherwise specified, maintenance procedures shall be performed in accordance with: ★ The machine is placed on a flat, level, solid ground. ★ The machine is in a non-working state. ★ Set the key switch of the ground controller to the OFF posi on and remove the key, so that the device cannot be started.
- Page 31 it in the corresponding space. ★ If inspection results are "unqualified", you must stop using the machine. Reinspect the machine after repair and mark it in the space marked “Qualified after repair”. Select the appropriate inspection procedure based on the type of inspection. Maintenance Inspection Report A Item Qualified Unqualified Qualified after repair...
- Page 32 D-3 Replace the gear oil of the reducer D-4 Check bushings and slides D-5 Check critical structural parts...
-
Page 33: Maintenance Procedure A
★ Check whether all labels are legible and intact, and replace the damaged and illegible labels in time. NOTICE If the label needs to be replaced, please contact Hangcha Group Co., Ltd. in time. - Page 34 A-3Check parts Daily checks on platform conditions are important for safety. Failure to detect and repair damaged, loose or missing parts in a timely manner may result in unsafe operation. Observe the whole machine to check whether any parts are damaged, improperly installed or missing.
- Page 35 ★ Check the hydraulic oil level 1、Open the right cover and visually inspect the side of the hydraulic tank. The hydraulic oil level shall be within the scale area of the level gauge of the oil tank. Model Scale line（L） HS0814TP，HS1014TP HS1214TP，HS1414TP HS0816TP，HS1016TP...
- Page 36 A-5Check the battery power Check the battery level through the LED display on the platform control handle. Handle power display Proportion Description 20-100 20-100% Battery level 20-100% 10-20 10-20% The battery level is low and must be charged immediately The battery is low, and the platform moves slowly or even stops A-6Check function The purpose of a functional check is to find out if there is a functional defect or...
-
Page 37: Maintenance Procedure B
4.3 Maintenance procedure B B-1Check the wires Maintaining the wires is essential for the normal work and safe operation of the platform. Failure to detect and replace burned, damaged, corroded or broken wires in time result in unsafe operation or even serious injury. Electrocution hazard Before checking the wires, be sure to disconnect the battery from the machine and the charger from the AC outlet. - Page 38 2、Check and verify that each rim is free of damage, distortion and weld cracking. 3、Remove the access cover and check whether the track has been tightened. 4、Use a grease gun to add butter to the grease nipple of the crawler to increase the tension of the links.
- Page 39 ★ Check lead-acid battery: 1、Wear protective clothing and safety goggles. 2、Ensure that battery cables are not corroded. 3、Ensure that battery is securely installed and cable connections are secured. 4、Remove the battery ventilation cover and check the density of each battery electrolyte with a liquid densitometer.
- Page 40 Tightening torque 9～11/N.m， Tightening torque 18～23/N.m。 2、If the terminal is not kept clean and dry, it may be continuously corroded.To prevent corrosion, apply a thin layer of Vaseline or use a terminal protector. B-4 Evaluate hydraulic oil Evaluating hydraulic oil is very important to the normal operation and prolongs the service life of the platform.
- Page 41 This procedure can only be performed when the drive motor/hydraulic motor is stopped. ★ Follow the procedure below： 1、Remove hydraulic tank air filter. 2、Check the vent. Results: The air should pass through the air filter smoothly. If the air does not pass through smoothly, the air filter must be cleaned in the following steps.
-
Page 42: Maintenance Procedure C
4.4 Maintenance procedure C C-1 Replace the air filter The hydraulic oil tank of the machine is ventilated. Impurities in the air are filtered through the air filter in the tank exhaust cap. If the air filter is faulty or damaged, it may cause impurities to enter the hydraulic oil circuit, which can cause damage to the hydraulic components. -
Page 43: Maintenance Procedure D
4.5 Maintenance procedure D D-1 Replace the return oil filter Replacing the return oil filter of the hydraulic tank is very important for the normal operation and prolongs the service life of the platform. A dirty or blocked filter may cause the platform to work improperly, and continued use may cause damage to hydraulic components. - Page 44 ground control. 5、Operate platform lifting and lowering. 6、Clean up spilled hydraulic oil around the filter. Check whether hydraulic oil spills around the filter. D-2 Replace hydraulic oil Regular replacement of hydraulic oil is very important for the normal operation of the machine and prolonging its service life. Hydraulic oil and filters with unqualified cleanliness may cause abnormal operation of the machine, and continued use may cause damage to hydraulic parts.
- Page 45 4、Disconnect and plug the oil suction pipe. 5、Disconnect and plug the oil return pipe. 6、Remove the hydraulic tank fastening bolts and remove the hydraulic tank. 7、Remove the suction filter from the tank, rinse the inside of the tank with neutral solvent, and dry the tank.
- Page 46 5、Remove the screw of refueling port and drain port, fill gear oil from the refueling port until flush with the drain port. 6、After filling the gear oil, tighten the screws refueling port and drain port. 7、Clean residual gear oil on the surface of the reducer. D-4Check bushings and sliders Maintaining the scissors boom installation bushing and moving slider is very important for the safe operation of the platform.
- Page 47 or the service life is more than 10 years. D-5 Check critical structural components Maintaining critical structural components is essential for the safe operation of the machine. The use of critical structural components that are already cracked or deformed may result in component damage and unsafe operation. Critical structural Inspection requirements for critical structural components...
-
Page 48: Maintenance Procedures
5 Maintenance procedures Maintenance procedures must be carried out by trained and qualified personnel. Replace or repair damaged parts immediately and do not operate the machine with damaged parts. Perform proper maintenance on the machine before operating it. ... - Page 49 5.1.2Platform Disassembly 1.Remove the platform control box from the platform. 2.Remove the bolts that hold the slider at the bottom of the platform at both ends of the slide. 3.Screw the bolt into the threaded hole of the slider retaining pin, then pull out the pin rod.
-
Page 50: Scissors Components
5.2 Scissors components 5.2.1Scissor Disassembly NOTICE This procedure can only be performed with the scissors boom in full retraction. Crushing hazard Keep any body parts and clothing away from moving machine parts. 1.Remove the platform from the machine. 2.Disconnect the wiring and fuel lines connected to the chassis from the scissor. 3.Secure the scissor with the lifting equipment. - Page 51 damage. High pressure hazard Remove hydraulic components slowly to reduce hydraulic oil pressure. High hydraulic pressure may penetrate the skin. If injured, seek medical attention immediately. Moving object hazard Wear safety goggles when striking the copper rod with a mallet. 1.Lift the scissor arm with lifting equipment until it can hold up the maintenance arm.
-
Page 52: Chassis Components
5.3 Chassis components 5.3.1 Removal and installation of crawler Before removing or installing the crawler, the equipment should be fixed on a suitable shelf or a jack with sufficient capacity should be placed under the frame. Unsafe operation hazard The crawler on the machine is strictly designed and selected according to the requirements of the overall performance and load stability of the machine, so its model specification, crawler width, installation center surface and diameter shall not be changed, otherwise it will lead... - Page 53 5.3.2Removal and installation of walking reducer The walking reducer is an integrated design of the reducer and the walking motor, which plays the role of driving and fixing the crawler . Before removing the walking reducer, the machine should be fixed on a suitable shelf or a jack with sufficient capacity should be placed under the chassis platform.
-
Page 54: Hydraulic System
5.4 Hydraulic system 5.4.1Remove the hydraulic pump NOTICE When installing the removed hose and pipe joints, tighten them according to the specified torque. 1. Disconnect the power and open the front door. 2. Unscrew the oil drain port at the bottom of the hydraulic tank to drain the hydraulic oil. - Page 55 5.4.3Remove hydraulic valve block Burn hazard Allow the hydraulic oil to cool to room temperature before maintaining the hydraulic system. High pressure hazard Remove hydraulic components slowly to reduce hydraulic oil pressure.High hydraulic pressure may penetrate the skin. If injured, seek medical attention immediately.
- Page 56 NOTICE Before performing this operation, ensure that the hydraulic oil in the tank is sufficient. Do not run the machine when the oil pump is empty to avoid damage to the hydraulic pump. 1. Place the maximum rated load on the platform. Ensure it is properly placed. 2.
- Page 57 When the platform descends, make sure that any body part is away from the scissor arm. 1. Lift the platform enough to support the maintenance arm. 2. Prop up the maintenance arm. 3. Lower the platform until the service arm is in contact with the scissor arms. 4.
- Page 58 5.4.7 Hydraulic schematic diagram ★ HS0608TP ★ HS0816TP，HS1016TP 液压原理图...
- Page 59 5.4.8Hydraulic troubleshooting The following table lists possible hydraulic system failure situations to help operators or maintenance personnel locate the fault. Check the fault parts according to the corresponding measures, and adjust or replace the parts according to the check results. Fault description Cause analysis Inspection measures...
-
Page 60: Electrical System
5.5Electrical system 5.5.1Electrical system When a fault occurs in the electrical system, the corresponding fault code will be displayed on the chassis panel and platform joystick screen. The following table lists the fault conditions corresponding to the fault code, which can help the operator or maintenance personnel determine the fault location. - Page 61 before power on. If it is released, consider replacing the handle or PCU. Alert only Confirm that the right turn button is released before power on. Platform Right Button ON If it is released, consider replacing the handle or PCU. Alert only Confirm that the enable button is released before power on.
- Page 62 Check the left rear motor, and replace the MC LB Fault driving motor controller normally. Check the right rear motor, and replace the MC RB Fault driving motor controller normally. Alert only Platform load close to rated weight. Platform Load is over 80% It is recommended not to increase the load.
- Page 63 5.5.3 Electrical schematic diagram...
-
Page 64: Maintenance Record Forms
6 Maintenance record forms Date Maintenance items Personnel... - Page 65 HANGCHA GROUP CO., LTD. ■Address: 666 Xiangfu Road, Hangzhou, Zhejiang, China ■Fax: 0086-571-88926789 0086-571-88132890 ■ZIP：311305 ■Web：http://www.hcforklift.com■E-mail：sales@hcforklift.com...
Need help?
Do you have a question about the HS0608TP and is the answer not in the manual?
Questions and answers