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HANGCHA A Series Operation And Maintenance Manual
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HANGCHA A Series Operation And Maintenance Manual

Initial lifting pallet stacker
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Initial lifting pallet stacker
OPERATION AND MAINTENANCE MANUAL
Original Instruction
HANGCHA GROUP CO., LTD.
11/2022
A
Series
CDD12/14/16-AC1-L
CDD12/14/16-AC1-LI
CDD12/14/16-AZ3-L
CDD12/14/16-AZ3-LI
CDD12/14/16-AC2-L
CDD12/14/16-AC2-LI

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  • Page 1 Series CDD12/14/16-AC1-L Initial lifting pallet stacker CDD12/14/16-AC1-LI CDD12/14/16-AZ3-L CDD12/14/16-AZ3-LI CDD12/14/16-AC2-L CDD12/14/16-AC2-LI OPERATION AND MAINTENANCE MANUAL Original Instruction HANGCHA GROUP CO., LTD. 11/2022...
  • Page 2 Part Ⅰ of this manual is about the brief introduction and correct operation of the A series high range stand-on electric stacker with initial lift, which will tell you how to operate safely and maintain preventively;...

  • Page 3: Table Of Contents

    Contents Part Ⅰ: Operation and maintenance .....................1 Correct Use and Application ....................1 1.1 General ............................1 1.2 Correct application ........................1 1.3 Approved application conditions ....................2 1.4 Cautions for the use of cold storage truck ................3 1.5 Cautions for the use of lithium battery truck ................4 1.6 Proprietor responsibilities ......................5 1.7 Attachment installation or modification to the truck ..............
  • Page 4 Drive system ........................... 59 1.1 Reduction box ..........................60 1.1.1 Working principle ........................61 1.1.2 Dismount and assemble order ....................62 1.1.3 Notice to installment and use ....................62 1.1.4 Fault and troubleshooting ....................... 62 1.2 Motor ............................63 1.3 Electromagnetic brake ......................67 1.3.1 Working principle ........................68 1.3.2 Brake installment ........................69 1.3.3 Brake air gap adjustment ......................71 1.3.4 Maintenance ..........................72...

  • Page 5: Part Ⅰ: Operation And Maintenance

    Correct Use and Application 1.1 General The A-series initial lifting stacker is a new product developed by Hangcha for warehousing and logistics applications. It adopts the latest communication control technology. It has excellent performance, comfortable operation, safe and reliable, and low maintenance costs. It is suitable for loading and unloading in warehouses, supermarkets, and workshops.

  • 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: Cautions For The Use Of Lithium Battery Truck

    1.5 Cautions for the use of lithium battery truck － Never charge below 0℃; － If the lithium battery needs to interrupt or suspend charging, do not hot plug, avoid current arc to damage charging base; － Charge the lithium battery immediately after per discharge to avoid battery loss; －...

  • Page 9: Proprietor Responsibilities

    1.6 Proprietor responsibilities For the purposes of the present operating instructions the “proprietor” is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties.

  • Page 10: Truck Introduction

    Truck introduction 2.1 Application The A-series initial lifting stacker is a new product developed by Hangcha for warehousing and logistics applications. It adopts the latest communication control technology. It has excellent performance, comfortable operation, safe and reliable, and low maintenance costs. It is suitable for loading and unloading in warehouses, supermarkets, and workshops.

  • Page 11: Main Parts And Functional Description

    2.2 Main parts and Functional Description 2.2.1 Main part introduction Item Component Item Component meter Bearing wheel Operating handle Forward leg Hood Fork Emergency stop button Lift mast Protective net Battery cover...

  • Page 12: Functional Description

    2.2.2 Functional Description  Appearance The A series pallet truck adopts professional appearance industrial design, the whole vehicle has smooth lines, full of dynamic feeling, full consideration of ergonomics, and conforms to the latest appearance design trend. A large number of steel plate stamping and injection molding processes are used, which are durable and meet environmental protection requirements.
  • Page 13 At the same time, it has the function of preventing sliding on the ramp to ensure safe operation. The reverse brake button on the head of the handle can effectively prevent the driver from being injured when driving backwards and encounters an emergency. It has a lowering intelligent buffer function, which automatically slows down the lowering speed when the fork is less than 100mm off the ground, effectively protecting the safety of the goods.

  • Page 14: Displays And Controls

    2.3 Displays and Controls...
  • Page 15 Item Control/Display Symbol Function Used to display battery charge/discharge status, meter operating hours and fault information. Control vehicle steering and braking. Shake to braking area (B): Forklift mechanical braking. Joystick Shake to the driving area (F): The mechanical brake is released and the driving function is ready.

  • Page 16: Display

    2.3.1 Display 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 variety complex...
  • Page 17 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; It is panel screen printing color around the meter;...

  • Page 18: Standard Technical Specifications

    2.4 Standard technical specifications The following technical specifications are all standard data. Technical modifications and additions reserved. CDD12-AC1-L CDD14-AC1-L CDD16-AC1-L CDD12-AC1-LI CDD14-AC1-LI CDD16-AC1-LI CDD12-AZ3-L CDD14-AZ3-L CDD16-AZ3-L Manufacturer Model CDD12-AZ3-LI CDD14-AZ3-LI CDD16-AZ3-LI CDD12-AC2-L CDD14-AC2-L CDD16-AC2-L CDD12-AC2-LI CDD14-AC2-LI CDD16-AC2-LI Operator type Walking Walking Walking Para...
  • Page 19 4.35 Wa(mm) 16353） 16353） 16353） Turning radius Travel speed, km/h laden/unladen Lift speed, mm/s 0.12/0.21 0.16/0.25 0.13/0.22 laden/unladen perfor mance Lowering speed, mm/s 0.34/0.32 0.32/0.32 0.26/0.20 laden/unladen Max.gradeability, 8/16 8/16 7/16 laden/unladen Drive motor rating S2 60min Lift motor rating at S3 Battery pack 24/240 24/240...
  • Page 20 Mast Specification： 1.2t/1.4t/1.6t Fork lift Max. fork Mast Mast Load capacity at 600mm Free lift Type height height lowered extended height (h3+h13) 1.2t 1.4t 1.6t 2000 2090 1582 2582 1200 1400 1600 2500 2590 1832 3082 1200 1400 1600 2700 2790 1932 3282...

  • Page 21: Product Plates And Warning Labels Location

    2.5 Product plates and warning labels location Plates and labels such as nameplate, load charts, warnings and strap points must be legible at all times. Replace if necessary. 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 22 Hydraulic oil filling port Emergency power off switch label: "O" means off, "I" means on. Series tonnage label: A series, rated lifting capacity is X×100kg Product nameplate: The rated lifting capacity indicated on the nameplate is the maximum weight of goods that the forklift can load and unload under the equipment conditions indicated on the nameplate.

  • Page 23: Nameplate

    2.5.1 Nameplate Item Description Item Description Model-type Rated capacity (kg) Serial No. Weight without battery (kg) Load center (mm) Max. allowbabl battery weight (kg) Battery voltage (V) Min. allowable battery weight (kg) Rated drive power (kW) Year of manufacture Max. lifting height (mm) Note: For queries regarding the truck or ordering spare parts always quote the truck serial number (39).

  • Page 24: Truck Rated Capacities And Load Centers Graph

    2.5.2 Truck rated capacities and load centers graph The rated capacities and load centers graph draws the load center position and the rated load weight change curve when the lift height of the truck is given. RATED CAPACITIES AND LOAD CENTRES GRAPH RATED CAPACITIES AND LOAD CENTRES GRAPH RATED CAPACITIES AND LOAD CENTRES GRAPH SUBTRACT 700kg WITH SIDESHIFTER...

  • Page 25: Safety Rules

    Safety Rules – No smoking or any spark, smoke near the battery when checking. Only trained and authorized operator shall – Be careful of scald when checking motor be permitted to operate the forklift. and controller. The controller equips with energy accumulator, do not touch between B+ and B- to avoid electric injury.
  • Page 26 10) Internal battery may generate explosive your vision, please operate the machine in gas, it’s prohibited any flame close the reverse or have a guide. battery. Never allow the tools close two 18) Cause the wheels of pallet truck is small, poles of the battery to avoid spark or short it is not allowed to run on the street, and circuit.
  • Page 27 Additional lighting equipment is necessary – The weather condition: temperature: to operate the truck in areas of insufficient -5℃～40℃, wind speed: less than 5m/s; lighting. air relative humidity: less than 90% （20℃） . 31) Jump out from the pedal far-away from Altitude should not exceed 2000m.

  • Page 28: 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 the truck by crane Procedure: –...

  • Page 30: Securing The Truck For Transport

    4.2 Securing the truck for transport Correctly fix the forklift truck to avoid move when using truck or trailer. Procedure: – Move the truck onto the transporting truck. – Park the truck securely. – Strap the belts around the truck and tension them sufficiently. Using the wedge fixed wheels when necessary.

  • Page 31: Transport

    4.3 Transport The forklift truck is designed for material handling only and is inappropriate for long-distance transportation. If needed, the forklift truck must be transported by ship, train or lorry, block tires with solid chocks, and bind body firmly. – Place the truck on the long-distance transportation tool through loading platform or hoisting device.

  • Page 32: Battery

    When electrolyte level is low, you must Battery add distilled water to the level appointed. 5.1 Attention for using battery WARNING No firing  The shortage of the electrolyte will Explosive gas can be produced in the internal cause storage battery of storage battery, smoking, flame and sparkle overheated, even cause the system...
  • Page 33 Measures in summer In summer, water in the electrolyte is easy to evaporate, therefore, electrolyte must often be inspected if electrolyte is low, you must add distilled water to the level appointed. CAUTION  Do not over fill distilled water. Spilt electrolyte will cause corrosion and electricity leakage.

  • Page 34: Dimension / Weight

    5.2 Dimension / Weight Item 1.2t-1.4t 1.6t Length (L） Width (W) Height (H) Min. allowable battery weight Max. allowbabl battery weight 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 35: Charging The Battery

    5.3 Charging the battery Procedure: － Drive the truck to appointed charging place, park the truck and render if safe. － Open the battery panel (6). － Remove the battery plug (53) from the truck socket (52). － Open the filler cap of each battery monomer. －...
  • Page 36 with a little harm; Daily charging e. It often be charged deficient or has not ·The storage battery that has been made first been used for a long time; charging and used in normal condition, then charged again, it is named daily charging. f.
  • Page 37 1． 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 38 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. Numerate reading 3）...
  • Page 39 temperature seasons, that will hurt charger, if necessary can pause charge. If you don’t want use automatic option, 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 40: Changing The Battery

    5.4 Changing the battery Procedure: – Park the truck securely. – Open the battery panel (6. – Disconnect the battery connector (53) from the truck connector (52). Place the battery cable on the tray so that it cannot be severed when the battery is pulled out. –...

  • Page 41: 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 42: Operation

    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 the truck for Close the hood, and open the battery cover hydraulic oil, gear oil or electrolyte leak.
  • Page 43 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 steering system is normal.

  • Page 44: Starting Up

    7.2 Starting up Procedures： － Pull the Emergency Disconnect (4) to unlock it. － Insert the key in the key switch (5) and turn it as far right as it will go. The truck is operational. CAUTION  Make sure the work ground is hard enough to support the truck. ...

  • Page 45: Travel

    7.3 Travel WARNING  No turn, inclines when going uphill and downhill.  Never park on the slope.  Slow down when going downhill and ready for braking.  Travel according to regulated route.  The road should keep clean, no slipping The truck has two travel modes: －...

  • Page 46: Steering

    7.4 Steering ESP(electric steering power) system is easier to operate due to less activation force required. Procedure: － Move the tiller (2) to the left or right. The truck is steered in the required direction.

  • Page 47: Brakes

    7.5 Brakes The brake pattern of the truck depends largely on the travel route conditions. The driver must take this into account when travelling. The truck can brake in different ways: － By inversion braking (controller) － By regenerative braking (coasting) －...

  • Page 48: Lifting Load

    7.6 Lifting load Lift one pallet Procedure: － Drive the truck carefully up to the pallet. － Slowly insert the forks into the pallet until the fork shank touches the pallet. The load unit must not extend by more than 50mm beyond the fork tips. －...

  • Page 49: Transporting Load

    7.7 Transporting load Procedure: － Load unit positioned correctly on the forks. － Mast lowered for transport (approx. 150mm-500mm above the ground). － Accelerate and decelerate gradually. － Adapt your travel speed to the conditions of the route and the load you are transporting. －...

  • Page 50: Depositing Load

    7.8 Depositing load Depositing when transport one pallet Procedure: － Drive carefully up to the storage location. － Press the “Lower load handler” button (22). Avoid depositing the load to avoid damaging the load and the load handler. － Carefully lower the load handler so that the forks are clear of the load. －...

  • Page 51: Parking The Truck Securely

    7.9 Parking the truck securely Procedure: － Drive the truck to safe area or appointed area. － Fully lower the load handler and wheel arms. － Set the control handle to the " Straight position". － Switch off the truck (5) and remove the key. －...

  • Page 52: Deposit The Truck

    Deposit the truck 8.1 Deposit the truck for long time － Fully check the truck, especially check the wheel damage. － Check fluid oil and electrolyte for leakage. － Apply lubrication grease. － Check the joint face of cylinder piston rod for looseness, and if scratch on the piston rod surface.

  • Page 53: Maintenance

    Inspection and maintenance are usually ignored, you’d better find 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 54: 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 55 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 56 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. ●...

  • Page 57: Truck Used Oil And Lubrication

    9.3 Truck used oil and lubrication Filler plug for hydraulic oil Hydraulic oil drain plug. Gear oil add plug Gear oil drain plug Lubrication part Grease nipples Code Designation Mark, code Remark Hydraulic system Normally：L- HM32 1.2t:8.5L Hydraulic oil 1.4t:10L High and cold environment：L- HV32 1.6t:11L Gear oil...
  • Page 58 Change the gear oil – Park the truck at level ground. – Wipe off oil add and drain plug. – Unscrew oil add plug (65). – Place an appropriate container under oil drain plug (66), unscrew oil drain plug (66), and drain the oil to the container.

  • Page 59: Change Hydraulic Oil

    Change hydraulic oil – Park the truck at level ground. – Wipe off oil add and drain plug. – Unscrew oil add plug (67). – Place an appropriate container under oil drain plug (68), unscrew oil drain plug (68), and drain the oil to the container. –...

  • Page 60: Replace The Key Safe Parts Periodically

    9.4 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. Key safe part’s description Term of using (year) Hydraulic hose for lifting system 1～2 High-pressure hose, hose for hydraulic system...

  • Page 61: Removing The Rear Panel Assy

    9.6 Removing the rear panel assy Procedure: – Park the truck securely. – Undo the four groups of bolts (58) on the rear panel assy (7) with a wrench. – Lift the rear panel assy (3), remove it from the truck and place it securely next to the truck. The panel is now disassembled.

  • Page 62: Install The Load Bracket

    9.7 Install the load bracket This truck does not equip with load backrest as standard, but leaves four threaded holes for installment. If load bracket (59) is needed, tighten with four combined bolts (58). Warning  Be careful when installing the load bracket.

  • Page 63: Part Ⅱ: Structure, Principle And Maintenance

    Part Ⅱ: Structure, Principle and Maintenance Drive system Drive system is vertically arranged and rigid coupled with the frame. Drive system is mainly consisted of drive seat, reduction box, drive wheel, drive motor and electromagnetic brake etc. 1. Electromagnetic brake 2.

  • Page 64: 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 65: Working Principle

    1.1.1 Working principle Simple figure of reduction box is as Fig.2-3, motor driving gear 1 drives driven gear 2, driven gear 2 drives driving 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 66: 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; －...

  • Page 67: Traction 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=10.2Nm～12.4Nm. Rated Rated Rated...
  • Page 68 Motor use notice － Parts of stator have been adjusted; users mustn’t unpack and adjust randomly. － 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 69 Fault Probable cause hard. Bearing seizing-up. Power voltage too low. △Motor wrongly connected to Y Cage rotor open weld or crack Motor starts hard, and the motor Local coil of stator and rotor wrongly or oppositely speed is much lower than rated connected.
  • Page 70 Fault Probable cause Rotor imbalance Revolving shaft bend. Iron core deforms or loosens. Housing or basic capacity is insufficient. Motor foot screw loosen Open circuit of cage rotor open welding, open circuit of wound rotor, or winding fault with stator. Over much or few grease Bad oil quantity and contains impurity.

  • Page 71: 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.

  • Page 72: Working Principle

    1.3.1 Working principle 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 73: 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. –...
  • Page 74 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 75: Brake Air Gap Adjustment

    1.3.3 Brake air gap adjustment Rated air gap ”Z” will be large for wear. Make sure the brake get enough brake torque, readjust air 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.

  • Page 76: 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 77: Common Fault And Troubleshooting

    1.3.5 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 78: Braking Diagram

    1.3.6 Braking diagram The forklift driving motor is equipped with an electromagnetic brake. When the forklift is parked, the electromagnetic brake is released, the brake pads firmly lock the motor shaft, and the forklift is in a mechanical braking state. battery Traction motor Brake switch...

  • Page 79: Hydraulic System

    Hydraulic system Hydraulic system is mainly composed of hydraulic unit, lifting cylinder and rubber tube etc. 1. Left lifting cylinder 2. Hose assembly 3. Multi-way valve assembly 4. Hose assembly 5. Email 6. Right lifting cylinder 7. Intermediate tank 8. Install the bracket Fig.

  • Page 80: Hydraulic System Working Principle

    2.1 Hydraulic system working principle...

  • Page 81: 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. Notice －...

  • Page 82: Hydraulic System Fault Diagnosis And Correction

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

  • Page 83: Electric System

    Electric system Electric system of this truck is double wire system, all circuits do not ground. Working voltage is DC24V.

  • Page 84: Principles Of Electrical System

    3.1 Principles of electrical system CDD12-16-AC1-L...
  • Page 85 CDD12-16-AC1-LI...
  • Page 86 CDD12-16-AZ3-L...
  • Page 87 CDD12-16-AZ3-LI...
  • Page 88 CDD12-16-AC2-L...
  • Page 89 CDD12-16-AC2-LI...

  • Page 90: Fault Code Table

    3.2 Fault code table 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 Troubleshooting ： restart the key Main connector disconnects 2.

  • Page 91: Troubleshooting

    Programmer display Deep fault Code Probable fault reason reason/troubleshooting Fault display 5. Fuse protector disconnect, or the capacitor voltage. main contactor disconnect. Reason ： When MOSFEET axle Severe Overvoltage 1. Setup error of battery parameter. Motor stops working 2. High battery impedance. working, capacitor voltage...
  • Page 92 Programmer display Deep fault Code Probable fault reason reason/troubleshooting Fault display Digital Out 7 Overcurrent 1. External load impedance is too Reason：Digital Output 7 current The Digital Out 7 driver is not low. exceeds15mA. active Troubleshooting：Adjust load, set “set_digout()” by VCL, and restart. Reason ：...
  • Page 93 Programmer display Deep fault Code Probable fault reason reason/troubleshooting Fault display Throttle invalid 3. Wrong wiring. fault only occurs when “EM brake Brake Type” set to 0. Troubleshooting：Correct open or 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.
  • Page 94 Programmer display Deep fault Code Probable fault reason reason/troubleshooting Fault display fault threshold(can be changed with the VCL function 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...
  • Page 95 Programmer display Deep fault Code Probable fault reason reason/troubleshooting Fault display throttle input sequence setting. throttle cause 2. Wiring, switch key, interlock, sequencing fault. ： 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...
  • Page 96 Programmer display Deep fault Code Probable fault reason reason/troubleshooting Fault display Accelerator stops Interlock stops 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...
  • Page 97 Programmer display Deep fault Code Probable fault reason reason/troubleshooting Fault display exceed the range setting value is an illegal value. Troubleshooting：Reset and restart the key switch. VCl/OS Mismatch 1. The controller VCL does not Reason：The controller VCL does Motor stops match OS.
  • Page 98 Programmer display Deep fault Code Probable fault reason reason/troubleshooting Fault display Troubleshooting：Adjust to proper value and switch KSI. ZAPI controller fault code Node setting: traction is 02, oil pump is 05, steering is 06, meter is 16, master is 03, slave is 04.
  • Page 99 Machine status Restart Alarm/ Alarms Error Code Description Effect when the test is procedure Warning done The EVP driver isdamaged 02A48 EVP driver open or the EVP coil impedance EVP stopped Continuous Key-on recycle Warning is too low Press the lift and drop 02A49 LIFT + LOWER Pump stopped...
  • Page 100 Machine status Restart Alarm/ Alarms Error Code Description Effect when the test is procedure Warning done Battery is <= 20% when the Valve, pump, traction Valve or pump or 02A66 Battery Low parameter BATTERY stopped, Lc opened, start-up,stby, traction Alarm traction request CHECK is set>0 Eb applied...
  • Page 101 Machine status Restart Alarm/ Alarms Error Code Description Effect when the test is procedure Warning done value recorded, and the direction/enable switches are opened. Incorrect pump starting start-up, standby, 02A79 Pump inc start Pump stopped Pump request Warning sequence traction start-up, 02A79 Incorrect start...
  • Page 102 Machine status Restart Alarm/ Alarms Error Code Description Effect when the test is procedure Warning done then this fault disappears. 1) Check if zero proximity switch is correctly installed; 2) Check if zero EPS NOT Valve or pump or 06A00 Zero is not found proximity switch start-up,stby, traction...
  • Page 103 Machine status Restart Alarm/ Alarms Error Code Description Effect when the test is procedure Warning done well connected;4) Replace the controller. When the motor receives the travelling command, the motor W phase current is 0. 1)Check if the controller fuse is POWER normal;...
  • Page 104 Machine status Restart Alarm/ Alarms Error Code Description Effect when the test is procedure Warning done controller. This warning is signaled if the detected motor voltage amplifier Valve or pump or 06A09 VMN NOT OK VMN fault start-up,stby, traction Alarm output is not between traction request 2.2V and 2.8V when...
  • Page 105 Machine status Restart Alarm/ Alarms Error Code Description Effect when the test is procedure Warning done is signaled when no closing message within 1.5 second. Bus messages between Replace the main and slave controller. Valve or pump or 06A21 MICRO SLAVE start-up,stby, traction Alarm microprocessors have...
  • Page 106 Machine status Restart Alarm/ Alarms Error Code Description Effect when the test is procedure Warning done BAD ENCODER Encoder phase sequence Interchange encoder Valve or pump or 06A26 start-up,stby, traction Alarm SIGN is wrong. A and B phases. traction request GAIN EEPROM EEPROM memory current Replace the...
  • Page 107 Machine status Restart Alarm/ Alarms Error Code Description Effect when the test is procedure Warning done MOTOR Valve or pump or 06A48 motor temperature hot start-up,stby, traction Alarm TEMPERAT. traction request This signal is alarmed MOTOR when the steering motor Check the controller Valve or pump or 06A49...

  • Page 108: Attachment：table For Bolt's Tightening Torque

    Attachment：Table for bolt’s tightening torque 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 88～108 108～137 127～157 189～252 118～147 147～186 176～216 260～347 167～206 206～265 245～314 369～492 225～284...

  • Page 109: Maintenance Record

    Maintenance Record Date Repair, maintenance content Serviceman...

  • Page 110: Relevant Safety Command And Standard (Ce Models)

    Relevant safety command and standard (CE models) The model with CE certification which accords to the following directive and standard: Machinery Directive 2006/42/EC (The European Council of the Laws of the Member States concerning Machinery), EN ISO 12100:2010 (Safety of machinery — General principles for design — Risk assessment and risk reduction), , EN ISO 3691-1:2015+A1:2020, EN 16307-1:2020, EN 1175:2020, EN 12053:2001+A1:2008, etc.

  • Page 111: Revision Table

    Revision Table Revision Version no. Date Note Nov 2022 Original...
  • Page 112 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...

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