HANGCHA CBD20-AC1S Operation And Maintenance Manual
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HANGCHA CBD20-AC1S Operation And Maintenance Manual

Electric pallet truck
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Hi Range
ELECTRIC PALLET TRUCK
CBD20/30-AC1S
CBD20/30-AZ3S
CBD20/30-AC1S-I
OPERATION AND MAINTENANCE MANUAL
Original Instruction
HANGCHA GROUP CO., LTD.
11/2019

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Summary of Contents for HANGCHA CBD20-AC1S

  • Page 1 Hi Range ELECTRIC PALLET TRUCK CBD20/30-AC1S CBD20/30-AZ3S CBD20/30-AC1S-I OPERATION AND MAINTENANCE MANUAL Original Instruction HANGCHA GROUP CO., LTD. 11/2019...
  • Page 2 FOREWORD Thank you very much for purchasing the A series hi range electric pallet truck of Hangcha Group . A series hi 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.

  • Page 3: Table Of Contents

    Content PART : OPERATION AND MAINTENANCE ................1 Truck Introduction........................1 1.1 General ............................ 1 1.2 Use occasion and condition ..................... 3 1.3 Main part name ........................4 1.4 Display and control ........................5 1.4.1 Display ............................. 6 1.4.2 Control ............................. 9 1.4.3 Others .............................
  • Page 4 1.3.4 Maintenance.......................... 78 1.3.5 Fault and troubleshooting ...................... 79 1.4 Drive system dismantle......................80 Hydraulic system ........................81 2.1 Hydraulic system working principle ..................82 2.2 Hydraulic unit ......................... 84 2.3 Hydraulic unit dismantle ......................87 2.4 Dismantle the lifting cylinder from the truck or replace ............88 2.5 Hydraulic system fault diagnosis and correction ..............

  • Page 5: Part : Operation And Maintenance

    DC steering. The standard configuration for mechanical steering of pedestrian type, stand-on type standard configuration for DC steering. CBD20-AC1S-I Meaning Electric pallet truck Rated load×100kg...
  • Page 6 Truck body system Beautiful and compact outline, concise and fluent line. Chassis adopts 5-wheel structure, including one central driving wheel, two lateral auxiliary wheels as stabilization and two load wheels. It can make sure stable and safe driving. Auxiliary wheel gets damping design. Safety arm guard Hang-on foldable damping pedal Driving system...

  • Page 7: Use Occasion And Condition

    1.2 Use occasion and condition 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 8: Main Part Name

    1.3 Main part name Item Description Item Description Control handle Drive wheel Instrument Rear frame Arm guard lock switch Fork Arm guard Load wheel Rear hood assembly Key switch Auxiliary wheel Emergency stop switch Pedal Battery cover...

  • Page 9: Display And Control

    1.4 Display and control...

  • Page 10: Display

    1.4.1 Display recharged. Hourmeter indicator(green LED) Instrument [2] Said when the green LED light is normally on the timer is timing, the smallest unit of time for 0.1 hours. Every time when starting the vehicle LCD screen will display the vehicle's total run time, this time is for regular maintenance on the basis of the vehicle.
  • Page 11 D13L Display characteristics: Wide voltage input range: 9V~60V; Built-in anti-reverse circuit; Beautiful appearance and unique alarm indication design; Implement time-limited vehicle speed, power, hour meter, and fault; Positive IP65 protection level, able to adapt to a variety of complex environments; Instrument graphic 2 3 1 Paramter name...
  • Page 12 Note Speed display accuracy and unit: the controller software supports speed unit switching and decimal point measuring function, D13L can realize corresponding display; When the battery level is lower than 20%, the battery icon flashes; When the hour meter is in the main interface, it is always displayed; Some models are not used, so the speed is displayed as 0;...

  • Page 13: Control

    1.4.2 Control Control handle Key switch [10] Control truck steering and braking. When turn the control handle right and left, it can realize the truck right and left turn. The max turning angle of this handle is about 175°. Turn on the key switch, and the power is on. Turn When press the handle to horizontal position off the switch, and the power is off.
  • Page 14 Low speed switch button [18] Truck travels to the handle side(or pedal). Press this button and indicator light[19] is on, it means the truck changes to low speed travel mode. When in low speed mode, the truck will travel in low speed, 40% of max. travelling speed.

  • Page 15: Others

    1.4.3 Others cover, and you can open the battery cover by pushing this handle. Rear hood assembly [5] When check battery, take out the plug, charge There install main parts as hydraulic unit, main or replace the battery, you can easily open the drive unit and electric system etc.

  • Page 16: Standard Technical Data

    1.5 Standard technical data The following technical data are all standard data. Our company reserves the right of alteration and extension. Model CBD20-AC1S CBD30-AC1S Operator type Stand-on Stand-on Load capacity Q (kg) 2000 3000 Load center c(mm) Wheelbase y(mm) 1369...
  • Page 17 Model CBD20-AZ3S CBD30-AZ3S Operator type Stand-on Stand-on Load capacity Q (kg) 2000 3000 Load center c(mm) Wheelbase y(mm) 1369 1369 Weight Service weight with battery Tyre type Tyre size/Quantity,operator side Tyre size/Quantity,load side Auxiliary wheel size/Quantity 25×50/2 25×50/2 Tread, operator side b10(mm) Tread, load side b11(mm)
  • Page 18 Model CBD20-AC1S-I CBD30-AC1S-I Operator type Stand-on Stand-on Load capacity Q (kg) 2000 3000 Load center c(mm) Wheelbase y(mm) 1369 1369 Weight Service weight with battery Tyre type Tyre size/Quantity,operator side Tyre size/Quantity,load side Auxiliary wheel size/Quantity 25×50/2 25×50/2 Tread, operator side...

  • Page 20: Product Plates And Warning Labels Location

    WARNING ELECTRIC PALLET TRUCK MODEL-TYPE SERIAL NO. RATED CAPACITY WEIGHT WITHOUT BATTERY LOAD CENTER BATTERY VOLTAGE MAX.ALLOWABLE BATTERY WEIGHT RATED DRIVE POWER MIN.ALLOWABLE BATTERY WEIGHT YEAR OF MANUFACTURE HANGCHA GROUP CO.,LTD.
  • Page 21 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. Hoist label: Fixed point when using the crane to handle equipment. Key switch is off Emergency stop label...

  • Page 22: Safety Rules

    Safety Rules battery when checking. Be careful of scald when checking motor Only trained and authorized operator shall and controller. be permitted to operate the forklift. 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 load(like contactor coil or horn) between controller B+ and B- to discharge the...
  • Page 23 poles of the battery to avoid spark or short it is not allowed to run on the street, and circuit. only for driving in specified stacking place. or body under the forks. Never stand on the fork. WARNING 10) The work ground of forklift shall be solid and smooth concrete surface or similar ones.
  • Page 24 there is no successor in the interest to the 40 , wind speed: less than 5m/s; business, may the user arrange for a air relative humidity: less than 90% 20 modification or alteration to a powered Altitude should not exceed 2000m. industrial truck, however, that the user 22) After power off, brake works and the must do the following:...

  • Page 25: 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. 3.1 Lifting by crane WARNING Only use lifting gear with sufficient capacity (for truck weight see truck nameplate ).

  • Page 26: Securing The Truck During Transport

    3.2 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 27: How To Remove A Broken Truck

    3.3 How to remove a broken truck damaged since the brake of the truck is closed under normal circumstances. Appropriate vehicles should be used to remove the broken trucks. WARNING Do not tow the broken trucks on the ground directly, or else the braking system would be damaged.

  • Page 28: Battery

    Battery time, you must open the filling cap of each single battery to keep good ventilation 4.1 Battery safety precautions environment . 4.1.1 Safety precautions for using The battery must be charged with DC. lead-acid batteries The charging process must be complete, often intermittent charge, will affect the Users need to create a file for the battery battery capacity and life.
  • Page 29 13) Battery is strictly prohibited liquid. Always Do not open the lithium battery cover check and promptly adjust the electrolyte maintenance, lithium battery failure, timely level, so that it is located between the contact with the manufacturer. lowest level and the highest level. If the The battery is not used at a loss of power.
  • Page 30 reverse charge can cause the battery department to obtain the correct technical voltage to zero, scrapped in advance. support. 12) If the battery smells, heat, discoloration, 18) Prohibit the use of this series of products deformation or use, storage, charging any by children and other people who lack anomalies, battery...
  • Page 31 fire extinguisher. inadvertent contact, take off contaminated 25) Evacuate persons in the danger area if clothing and wash the infection with plenty the battery is cracked or ignited, and of water and soap for at least 15 minutes, immediately spray with water or soak a do not rub the ointment.
  • Page 32 Check the status of battery voltage, temperature pressure difference displayed on the BMS display before charging and discharging to ensure that all values are within the normal range. Regularly check the battery box with no If there is a lot of dust, metal scraps or water, found that water must be other debris on the battery cover and pole, immediately dry.

  • Page 33: Dimension/Service Weight

    4.3 Dimension/Service Weight CBD20-AC1 CBD30-AC1 CBD20/30-AC1S Item CBD20-AZ3 CBD30-AZ3 CBD20/30-AZ3S Length L Width W Height H Allowable lightest Allowable heaviest WARNING Battery weight and dimensions have considerable influence on operational safety of the truck. When installing or replacing battery, be sure that battery in the fixed position.

  • Page 34: Charging The Battery

    4.4 Battery charging 4.4.1 Lead-acid battery charging Drive the truck to appointed charging place, park the truck and render if safe. Open the battery cover 14 . Remove the battery plug from the truck socket 38 . Open the fill cap of each battery cell. Connect the charging plug (39) to battery plug (38).
  • Page 35 4.4.2 Lithium battery charging Model-type: SPC-24100 Input: AC186 260V/50-60Hz/20A Output: DC29.2/100A Safety precautions before charging: Please choose to charge in a relatively safe environment (such as to avoid liquid, fire and other environment). The necessary extinguisher (yellow sand and powder fire extinguisher) should be equipped around the charger so that emergency extinguishing can be carried out under extreme conditions.
  • Page 36 Charging steps Park the vehicle safely in the designated charging area as required, close the switch and unplug the key. Insert the charger power plug into a suitable power outlet. Start the charging process. Turn on the charger power switch. Unplug the charging plug after charging is complete, turn off the charger power switch, and unplug the charger plug.
  • Page 37 It often be charged deficient or has Daily charging not been used for a long time; ·The storage battery that has been made first After taking out the storage battery charging and used in normal condition, then group for checking cleaning charged again, it is named daily charging.
  • Page 38 appears, please stop replenishing. Inspect electrolyte The storage battery without a dobber It is proper to pour the electrolyte 15-20mm above the electrode plate. The storage battery with a dobber According to the dobber of the ventilation cover, read the level position of the electrolyte.
  • Page 39 Use thermometer to measure the temperature for electrolyte. Put the straw of densimeter into electrolyte uprightly, extrude rubber tube with hand and the electrolyte will be sucked into the glasses tube and then the floater of the densimeter will float. Conversion of the specific gravity Numerate reading...
  • Page 40 temperature seasons, that will hurt charger, if necessary can pause charge. you should adjust the charge current, charge voltage, charge time and etc. manually. And you should measure the specific gravity of electrolyte on time to assure the battery can be charge at best state.

  • Page 41: Replacing The Battery

    4.5 Replacing the battery Battery replacing steps Park the truck and render it safe. Open the battery cover 14 . Remove the battery plug(38) from truck socket, and place the battery plug and cable into the battery tank(37), ensure that it does not scratch cable when removing the battery.
  • Page 42 4.6 SPC Series Intelligent Charger User Manual 1 Introduction SPC series intelligent charger can automatically implement multistage charging: constant current charging, constant voltage charging and floating charging, etc. It also has the following functions: intelligent MCU control charging, short circuit protection, over temperature protection, battery voltage, output overvoltage protection, input under-voltage protection, the battery reverse connect protection, regular shutdown protection, charging status and SOC display.
  • Page 43 5.2 Fault red light flash Charger protection Please check whether the charger output is short circuit, over temperature and over voltage protection. After confirmation, power off and recharging. 6 Storage condition Temperature -40 Humidity 5 Keep away from inflammable, explosive and corrosive chemicals. Avoid strong vibration and impact.

  • Page 44: 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 Avoid the new battery over discharging in early period.

  • Page 45: Operation

    Operation 6.1 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 Check the truck for hydraulic oil, gear oil or electrolyte leak.
  • Page 46 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. 11) Steering system Left or right turn the handle to make the truck run around 3 turns, and then check if the...

  • Page 47: Start Up

    6.2 Start up Procedure: Plug into the plug. Pull up the emergency disconnect switch 13 . Turn on the key switch 12 . If you need to stand on the pedal to operate for the stand-on type truck, you need open the pedal(7) and arm guard(4).

  • Page 48: Travelling

    6.3 Travelling Pedestrian-type 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 operate travel switch with thumb. Always watch moving direction and guide truck. Or hold the handle with both hands and push the truck go forward. CAUTION Operator must wear protective boots.
  • Page 49 Stand-on type Stand-on type truck have three operation ways 1 Pedestrian operation fold arm guard and pedal Operation way is as pedestrian-type truck. When adopt this way, truck will travel at low speed. 2 Stand-on operation, but fold the arm guard. When adopt this way, truck will travel at medium speed.
  • Page 50 Slow down Slowly loosen the thumb, the direction speed control button will return automatically and the truck slows down. Stand-on type Start up the truck Open the pedal Step on the pedal Swivel the control handle to driving range (F). Adjust the direction speed control button (19) to the desired direction Control truck speed by direction speed control button (19).

  • Page 51: Braking

    6.4 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 When release the control handle, the handle swivel into the braking range slowly or nor enter braking range, do check the reason and eliminate the fault.

  • Page 52: Unloading

    Travel the truck off the area. Drop the load to lower position. 6.8 Unloading Procedure: Approach the deposit area. Raise the loads to correct height. Travel forward, put the load on the unloading position and then stop. Make sure the loads are right above, drop the forks slowly until the forks are out of the load. Travel backward and make the fork out of the load.

  • Page 53: Parking

    6.8 Parking After daily work, park the truck according to the following steps. Drive the truck to safe area or appointed area. Fully lower the forks. Turn off the key switch(12), and remove the key. Press the emergency disconnect switch(13). Fold pedal(7) and arm guard(4).

  • Page 54: Deposit The Truck For Long Time

    Deposit the truck for long time 7.1 Deposit for long time If stop use the truck for long time(over one month), park the truck according to the following ways, Park the truck in ventilated, dry and no direct sunlight room. Avoid large temperature difference, humidity, dust and corrosive gas.

  • Page 55: Maintenance

    The forklift truck needs inspection and maintenance periodically, to make it in good working condition. solve it in time. Use authentic parts of Hangcha Group. will, and carry on handling according to the local environmental protection laws and regulations. Draw up complete maintenance plan.

  • Page 56: Periodic Maintenance Schedule

    8.2 Periodic maintenance schedule D= work every 8 hours(or per day) W= work every 40 hours(or per week) M= work every166 hours(or per month) T= work every 500 hours(or 3 months) S= work every 1000hours(or 6 months) Check, revise, adjust ×...
  • Page 57 Motor Service Service required Tool item Clean the foreign body on the motor Clean or replace the bearing Check carbon brush commutator worn, whether or× or× spring is normal Whether the connection is correct and firm. Brush carbon powder commutator segment groove and commutator surface.
  • Page 58 Brake system Service Service required Tool item Check for brake condition when the control handle on horizontal position and vertical position. Check inching switch looseness or damage. Check the installation for fastening. Check the surface abrasion for equality. Check if the clearance is proper and adjust, if necessary.
  • Page 59 Lifting assembly Service Service required Tool item Check link mechanism for tension, damage or rust Check if there is abrasion between shaft and bearing of front and rear fork. Check if there is deformation or fracture on the upper and down connecting rod.

  • Page 60: Truck Used Oil And Lubrication

    8.3 Truck used oil and lubrication Hydraulic oil filer Gear oil add plug Gear oil drain plug Lubrication part Grease nipples Code Designation Mark, code Remark Normally L- HM32 Hydraulic oil Hydraulic system High and cold environment L- HV32 Gear oil GL-5 85W/90 Reduction box Automobile general 3 # lithium base...
  • Page 61 Replace gear oil Park the truck at level ground. Wipe off oil add and drain plug. Unscrew oil add plug 46 . Place an appropriate container under oil drain plug(47), unscrew oil drain plug(47), and drain the oil to the container. After oil in the reduction box drains, re-tighten the drain plug 47 .
  • Page 62 Replace hydraulic oil Park the truck at level ground. Wipe off oil add and drain plug. Unscrew oil add plug 48 Place an appropriate container under oil drain plug(49), unscrew oil drain plug(49), and drain the oil to the container. After oil in the reduction box drains, re-tighten the drain plug 49 Add appointed gear oil...

  • Page 63: Replace The Key Safe Parts Periodically

    8.4 Replace the key safe parts periodically Users should replace the parts periodically according to the following table. If the part is abnormal before the replacing time, it should be replaced immediately. Term of using (year) Hydraulic hose for lifting system High-pressure hose, hose for hydraulic system Inner sealing element, rubber matter of the...

  • Page 64: Removing The Hood

    8.6 Removing the hood Procedure: Park the truck securely. Open the arm guard(4).Only for the stand on type Put down the folding pedal (7).Only for the stand on type Undo the four groups of bolts(51)/ (52)on the panel(5)with a wrench. Lift the hood(5),remove it from the truck and place it securely next to the truck.

  • Page 65: 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 67: Part Structure, Principle And Maintenance

    Part Structure, Principle and Maintenance Drive system Drive system of stand-on type truck adopts four connecting rods to couple with the frame, and divided into manual steering and electric steering. Drive system is mainly consisted of connecting rod, drive seat, reduction box, drive motor, electromagnetic brake etc..

  • Page 68: Reduction Box

    1.1 Reduction box The truck used reduction box, light and controllable vehicle driving device, which adopts two grades reduce speed gear, namely grade-one cylindrical gear and grade-two spiral bevel gear. This reduction gear box owns traits like small size, light weight, large transmission ratio, small radius of gyration, high efficient and simple structure, which enables turn on site and equip with motor vertically that cause the radius of gyration on the carriage is small.

  • Page 69: Working Principle

    1.1.1 Working principle Simple figure of reduction box is as Fig.2-2, motor driving gear 1 drives driven gear 2, driven gear 2 drives drive spiral bevel gear 3 to transfer to driven spiral bevel gear 4, then the driven spiral bevel gear 4 drives the output of output flange 5.

  • Page 70: Dismount And Assemble Order

    1.1.2 Dismount and assemble order Dismount and disassemble the reduction box according to the following order: Dismantle driving wheel (wheels); Open oil discharging bolt and discharge the oil; Disassemble swing bearing and top shell articles; Disassemble driven cylindrical gear Open the cover, disassemble driven spiral bevel gear and output flange etc. 1.1.3 Notice to installment and use Before installing, you should wipe the oil on the surface of the shell.

  • Page 71: Motor

    1.2 Motor Traction motor Traction motor is three phase AC motor, maintenance-free, but needs periodical check and clean. When tighten the upper nut on the wiring board, lock the lower nut to avoid looseness, and the suggested tightening torque is T=10.2 12.4N.m. Rated Rated Rated...
  • Page 72 Steering motor DC steering motor is permanent magnet brush motor with planetary reduction box. Output shaft Output shaft bearing Annular gear Second stage planet gear Split type planet carrier First stage planet gear Motor shaft Motor shaft bearing Motor housing Motor stator Motor rotor Motor rear cover...
  • Page 73 Motor use notice The motor is only used in the work condition specified on the nameplate and in the operational manual. Otherwise there is danger of electric shock, injure and device damage. Parts of stator have been adjusted Keep clean and dry around the motor, place no other material on its inner or outer. Wipe off the sand and other adhesion on the housing in order not to affect heat dissipation.
  • Page 74 AC Motor fault diagnosis Fault Probable cause Power is not on(at least two phase off) After power is on, the motor does not rotate, Fuse fusing(at least two phase fusing) but without noise, odor or smoke. Overcurrent relay adjusts too small Wiring error of control equipment Lack one phase power, or reverse connection of stator coil one phase...
  • Page 75 Fault Probable cause Insulation paper of rotor and stator or slot wedge rubs. There is foreign body as sand in oil or bearing wear. Stator and rotor core loosen. Bearing lack oil. Abnormal noise when motor runs Air duct stuffing or fan rubs the fan housing. Stator and rotor core rub.
  • Page 76 DC Motor fault diagnosis Fault Probable cause 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.

  • Page 77: Electromagnetic Brake

    1.3 Electromagnetic brake The adopted brake of this truck is spring weighted electromagnetic brake. This brake is one-chip brake, owns two friction surfaces. It can generate strong brake torque through compressed spring in the state of power off, and electromagnetic induction realizes brake release. 1.Mounting screw 2.Stator 3.

  • Page 78: Working Principle

    1.3.1 Working principle Motor shaft(9) connects shaft sleeve(4)through flat key; shaft sleeve(4) connects friction disk assembly(3) through spline. When the stator (11) is off power, spring (10) generated force works on the armature(8), friction disk assembly(3) that drives the shaft(9) to rotate, grips between armature(8) and friction disk(5), thus generates braking torque.

  • Page 79: Brake Installment

    1.3.2 Brake installment Place flat key(12) to the key groove of motor shaft(9), press shaft sleeve(4) to the shaft(9), and fix with inner snap ring(13). Place friction disc(5) on the end face of motor. Cover friction brake disc(3) to the shaft sleeve. Install stator module(2) and three mounting screws(1).
  • Page 80 WARNING No damage on the outer of wire to avoid circuit damage. Never process the locating face and hold of the product to avoid magnetic return path. Mount on the motor shaft lightly, no damage the friction surface, get rid of burr from mounting hold and face, install shaft sleeve on the shaft, and fix with snap spring.

  • Page 81: Brake Air Gap Adjustment

    1.3.3 Brake air gap adjustment gap before the air gap reach the largest air gap value. Air gap can be adjusted repeatedly, when the thickness of friction braking plate reaches the allowable minimum thickness (refer to specification table), replace the friction disk assembly. When the air gas exceeds maximum air gas value, it may cause the brake unable to release, friction braking plate burn out, braking force or retentivity decreases, noises increase, or even cause severe accident.

  • Page 82: Maintenance

    1.3.4 Maintenance If work in high temperature environment for long time, please prevent rust, it may influence use if there is rust on the suction surface. Do not touch the friction surface with hand, no oil stain, otherwise it cannot reach the maximum torque.

  • Page 83: Fault And Troubleshooting

    1.3.5 Fault and troubleshooting Fault Probable cause Corrective action Power is obstructed Connect Too low exciting voltage Check voltage and adjust. Brake does not work Improper air gap Adjust air gap 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 84: Drive System Dismantle

    1.4 Drive system dismantle 1 Open rear hood assembly 2 Remove four fixed bolt of steering rocker arm. Remove wiring connected drive system(like motor, brake wiring) Remove the connecting pin shaft between connecting rod and frame. 5 Hoist the drive system. Assembling order is opposite to the disassembling order.

  • Page 85: Hydraulic System

    Hydraulic system Hydraulic system is mainly composed of hydraulic unit, left/right lifting cylinder, booster cylinder and rubber tube etc.. 1. Hydraulic unit 2. Left lifting cylinder 3. Right lifting cylinder 4. Booster cylinder 5. Pipeline assembly 6. Rubber tube assembly 7.

  • Page 86: Hydraulic System Working Principle

    2.1 Hydraulic system working principle Brief introduction to the working principle of hydraulic system When press the lifting button of the control handle, lifting motor works, drive the hydraulic pump through coupling device, hydraulic oil enters lifting cylinder through one-way valve, and forks lift. When press the lowering button of the control handle, lifting motor does not rotate, the solenoid valve open by this time, hydraulic oil in the lifting cylinder through solenoid valve and governor valve returns to the oil tank, and the forks drop.
  • Page 87 CBD20/30-AC1S, CBD20/30-AZ3S Hydraulic Schematic Diagram...

  • Page 88: Hydraulic Unit

    2.2 Hydraulic unit The truck adopts combined hydraulic unit, and is composed of DC motor, relay, coupling, valve seat and valves(solenoid directional valve, safety valve, one-way valve, governor valve and oil blockage), gear pump, pipeline, oil filter and fuel tank etc. Maintenance Keep clean on the element and the pipeline, avoid dirty go into the system.
  • Page 89 Pressure adjustment of overflow valve Hydraulic unit pressure has been adjusted before sold, and users do not need adjust under in general conditions. If needed, user can adjust the pressure through pressure regulating valve knob according to the actual condition, but should not exceed the nominal pressure. Here follow the adjustment ways Take apart the cover.
  • Page 90 Maintenance Keep clean on the element and the pipeline, avoid dirty go into the system. Keep the oil level in the oil tank , add oil after certain working cycle. If pump absorbs air, it may damage the pump and the sealer. Replace new oil after truck adds hydraulic oil for the first time and travel 100 hours.

  • Page 91: Hydraulic Unit Dismantle

    2.3 Hydraulic unit dismantle Dismantle the hood. Dismantle the connector of the hydraulic unit and the cylinder. Remove the wiring on the motor, contactor and control valve. Remove the tightening bolt that fix hydraulic unit. Take out hydraulic unit. Assembling order is opposite to the disassembling order.

  • Page 92: Dismantle The Lifting Cylinder From The Truck Or Replace

    2.4 Dismantle the lifting cylinder from the truck or replace Take apart the hood. Dismantle piping joint from the cylinder. Loosen the cylinder fixed bolt from cylinder. Dismantle the pin shaft from the cylinder supporting point. Take out the cylinder to replace or repair. Assembling order is opposite to the disassembling order.

  • Page 93: Hydraulic System Fault Diagnosis And Correction

    2.5 Hydraulic system fault diagnosis and correction Fault Probable cause Corrective action No oil Low oil level Fill to the specified oil level pumps from Clean oil pipe and oil tank. If hydraulic oil is Blocking of strainer the pump dirty, please change it.

  • Page 94: Electric System

    Electric system 3.1 Principles of electrical system...

  • Page 98: Controller

    3.2 Controller 1. 1232-2101 controller 2. SW80/24 contactor 1. 1232-2301 controller 2.1220-2201 controller 3. Fuse 160A/100A 3.SW180/24 Contactor 4.Fuse 275A/100A Fig.3-1 Controller assembly Manual steering Fig.3-2 Controller assembly DC steering...

  • Page 99: Maintenance

    3.2.1 Maintenance Motor controller, fuse protector and fuse are installed on the electronic control mounting bracket, when mounting the controller, apply heat conduction silicon grease to its bottom. 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.

  • Page 100: Diagnosis And Troubleshooting

    3.2.2 Diagnosis and troubleshooting Diagnosis procedure Truck cannot travel Check if the controller LED light flashes Flash Light is off If normally flashes Switch in encoder Normal flashing way Fault flashing way Display No display If battery has electricity If motor is normal Check Check If other...
  • Page 101 Get the fault information from three ways Get fault information from the instrument: When the truck has fault, the LED3(RED) indicator light is on, LCD displays fault type and code. Get fault information by switching in handheld programmer. Refer to Handheld Programmer. Get fault information by observe controller built-in LED indicator lights.

  • Page 102: 1232 Controller Diagnosis And Troubleshooting

    3.2.3 1232 Controller diagnosis and troubleshooting 1232 Controller can detect fault and wrong information under various condition. Diagnostics Diagnostics information can be obtained in three ways by reading the two fault codes displayed on the instrument (the first two fault code for drive controller, the second two fault code for steering controller) by observing the fault codes issued by the Status LEDs by reading the display on the programmer...
  • Page 103 In the handheld Undervoltage Cutback LED status indicator light shows as follows Yellow Yellow first digit second digit The numerical codes used by the yellow LED are listed in the troubleshooting chart (Table 6), which also lists possible fault causes and describes the conditions that set and clear each fault. Troubleshooting This fault codes provide the following information: Fault code...
  • Page 104 1232 controller fault code table Programmer display Deep fault Code Probable fault reason reason/troubleshooting Fault display Controller Overcurrent 1. External short of phase U,V,W Reason Phase current exceeds Motor stops working motor connections limited current Main connector disconnects 2. Motor parameters do not match. Troubleshooting restart the key EM brake shutdown...
  • Page 105 Programmer display Deep fault Code Probable fault reason reason/troubleshooting Fault display Severe Overvoltage 1. Setup error of battery parameter. Reason When MOSFEET axle Motor stops working 2. High battery impedance. working, capacitor voltage Main contactor disconnects Battery disconnects when exceeds the minimum voltage Electromagnetic brake disconnects regenerative breaking.
  • Page 106 Programmer display Deep fault Code Probable fault reason reason/troubleshooting Fault display Motor Temp Hot Cutback otor temperature reaches or Reason Input voltage value of Driving torque reduced. exceeds parameter limit, thus motor temperature sensor is 0 or cause current output reduce. larger than 10V.
  • Page 107 Programmer display Deep fault Code Probable fault reason reason/troubleshooting Fault display short circuit, restart output. Coil3 Driver Open/Short 1. Connected load open or short. Reason Driver 3 output (pin 4) is Driver 3 output shut 2. Connecting pin stained. either open or shorted 3.
  • Page 108 Programmer display Deep fault Code Probable fault reason reason/troubleshooting Fault display setup_pot_faults() Troubleshooting Reduce the throttle pot wiper voltage Throttle Wiper Low 1. Throttle pot wiper voltage too low Reason Throttle pot wiper(pin Throttle invalid 16) voltage is lower than the low fault threshold(can be changed with the VCL function setup_pot_faults()
  • Page 109 Programmer display Deep fault Code Probable fault reason reason/troubleshooting Fault display direction or throttle input fault. Troubleshooting Re-input according to correct sequence. Emer Rev HPD 1. Emer Rev already finished, but Reason After Emer Rev finishes, Throttle invalid the throttle, forward or reverse each input does not return to input and interlock do not return to neutral, that cause the fault.
  • Page 110 Programmer display Deep fault Code Probable fault reason reason/troubleshooting Fault display Driver 1-4 stop PD stops Brake Pump stops PDO Timeout 1. Time between CAN PDO Reason Time between CAN PDO Interlock stops messages received exceeds PDO messages received exceeds PDO CAN NMT State set to Timeout Period Timeout Period...
  • Page 111 Programmer display Deep fault Code Probable fault reason reason/troubleshooting Fault display restart the key switch. VCl/OS Mismatch 1. The controller VCL does not Reason The controller VCL does Motor stops match OS. not match OS. Main contactor stops Troubleshooting Update new EM brake stops VCL and OS.
  • Page 113 Curtis controller 1220 diagnosis and troubleshooting 1220 controller is capable of detecting faults of various kinds of cases.As shown in troubleshooting table, steering controller failure usually affect the traction controller. You can get controller fault information in two ways: through the instrument display on two two fault code to obtain the fault information (the first two fault code for walking controller, the second two fault code for steering controller);...
  • Page 114 1311 Handheld Programmer 1311Handheld Programmer is a handheld tool that allows user programming, testing and diagnosing the traction motor controller, refer to the following picture. Program setting handheld terminal owns one menu navigation key, one data Inc/Dec key and three bookmark keys to control all programmable functions.

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    Attachment Unit N·m Grade 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 88 108 108 137 127 157 189 252...
  • Page 116 Maintenance Record Date Repair, maintenance content Serviceman...
  • Page 117 HANGCHA GROUP CO. , LTD. Address: 88 Donghuan Road, Lin'an Economic Development Zone,Zhejiang, China -571-88926789 0086-571-88132890 http://www.hcforklift.com -mail: sales@hcforklift.com...

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