HANGCHA HV110D Operation And Maintenance Manual
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HANGCHA HV110D Operation And Maintenance Manual

HANGCHA HV110D Operation And Maintenance Manual

Vertical mast a lift
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OPERATION AND MAINTENANCE
MANUAL
HV110D
Vertical Mast A Lift
HANGCHA GROUP CO.,LTD

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  • Page 1 OPERATION AND MAINTENANCE MANUAL HV110D Vertical Mast A Lift HANGCHA GROUP CO.,LTD...

  • Page 2: Table Of Contents

    Only trained and authorized personnel are allowed to operate the machine. This manual should be kept as part of the machine and always with the machine. If you have any questions, please contact HANGCHA group. Catalog Legend .........................
  • Page 3 4 Only trained / certified operators or experienced and knowledgeable supervisors can operate the machine. If there are ambiguous contents in this manual or you think it should be added，please contact us. Internet website： www.zjhc.cn E-mail： sales@zjhc.cn Service hotline： 400-884-7888 HANGCHA Group Co., Ltd All rights reserved. Second edition：Dec, 2021...
  • Page 4 Operation and Maintenance Manual DANGER Failure to comply with the instructions and safety rules in this manual will result in death or more serious injury Cannot operate, unless: ☑ You have understood and practiced the rules for safe operation of the machine in this operation manual.

  • Page 5: Classification Of Hazards

    Operation and Maintenance Manual Classification of hazards: The symbols, color standards and symbols used in product labeling of HANGCHA GROUP are as follows:...
  • Page 6 Operation and Maintenance Manual Safety warning sign — — Used to indicate the existence of potential personal injury.Observe all safety messages after the sign to avoid possible injury or death of personnel. Red sign——It is used to indicate that there is an emergency and dangerous situation.

  • Page 7: Safety Regulations

    Operation and Maintenance Manual safety regulations Conditions related to equipment use □ The ground of the workplace must be flat and firm， with free overhead equipment and sufficient distance between it and high-voltage lines. □ The ambient temperature should be between -20℃~ 40℃.Altitude≤1000m. □...

  • Page 8: Tipping Hazard

    Operation and Maintenance Manual 200KV-350KV 6.10m 350KV-500KV 7.62m 500KV-750KV 10.67m 750KV-1000KV 13.72m Consideration should be given to the effect of strong winds or gusts on the movement of the platform, the swing and relaxation of the wires. Keep away from the machine if it comes into contact with a live wire. Before cutting off the power, do not touch or operate the machine by people on the ground or platform.
  • Page 9 Maximum manual force model Applicable occasions Maximum manual Maximum number of force members HV110D outdoor 200N indoor 400N Limit switches cannot be changed or disabled. Do not change or damage any parts that may affect the safety and stability of the machine.
  • Page 10 Do not drive the machine on slopes that exceed the machine's slope and side slope ratings. The slope rating is only applicable to machines in the retracted state. model Maximum slope rating Maximum side in retracted state slope rating in retracted state HV110D...
  • Page 11 Operation and Maintenance Manual Note: Slope ratings are subject to ground conditions and traction. Danger of falling During operation, the personnel on the platform must wear full-body safety devices and fasten them to the approved rope fixing points with safety belt hook. Only one hook can be tied to each rope anchor point.
  • Page 12 Operation and Maintenance Manual When grasping the platform guard, be careful of the danger of squeezing. Only when there are no people or obstacles in the area under the platform, can the platform be lowered. Irrelevant personnel must leave the equipment beyond 1.8m to ensure the safety of rotary operation.
  • Page 13 Operation and Maintenance Manual Safety of storage battery Danger of burning The battery contains acidic substances, so you should wear protective clothing and glasses when using the battery. Avoid spillage or contact with acidic substances in the battery. Use soda and water to neutralize spilled acid substances in storage batteries.
  • Page 14 Operation and Maintenance Manual Danger of pollution Waste batteries must be disposed of in accordance with government regulations. Lock after each use 1 Choose a safe parking location, which can be on solid level ground, free of obstacles and away from heavy traffic.

  • Page 15: Legend

    Operation and Maintenance Manual Legend 1Forearm 9Pit protection device 2Platform controller 10 Chassis 3Platform guardrail 11Steering wheel 4Safety hook 12Red emergency stop button 5Platform entrance middle column 13Ground controller 6 Platform 14Hydraulic power unit (inside the housing) 7Driving wheel 15Mast 8 Mast emergency lowering handle 16Work indicator lamp...

  • Page 16: Label

    Operation and Maintenance Manual Label Use the pictures below to verify that the labels on the machine are easy to identify and properly positioned. The following table is a detailed list of the number and description of labels. Item Description Item Description Platform OperatingInstructions...
  • Page 17 Operation and Maintenance Manual Product performance parameters (Only for reference) Parameter item Unit Length 2.61 Width Height Ground clearance Ground clearance (pit protection device mm Machine weight 2930 Maximum working height 11.22 Maximum platform height 9.22 Maximum horizontal extension 7.89 Maximum Loading Capacity Wheelbase 1.22...

  • Page 18: Controller

    Operation and Maintenance Manual Controller Ground controller 1. LED display Diagnostic reading device and battery charging indicator 2. Red emergency stop button 3. Key switch Turn the key switch to the right "platform" icon position, platform controller will run; Turn the key switch to the middle "OFF"...

  • Page 19: Platform Controller

    Operation and Maintenance Manual Turn the switch up for swing arm lifting, switch center for mast lifting, switch down for mast rotation. Platform controller 1. Red emergency stop button 2. Table rotation function button 3. Mast lifting button 4. The horn button 5.

  • Page 20: Led Display

    Operation and Maintenance Manual 4 Press the horn button Press the horn button, the horn will beep, release the horn button, the horn will stop beeping. 5 Running low speed button The speed limit is low speed after this button is pressed. 6 Control handle Mast lifting function: press and hold the function enable switch on the platform control handle to enable the mast lifting function, move the control handle in the direction indicated by the blue lead,...

  • Page 21: Inspection Before Operation

    Operation and Maintenance Manual Inspection before operation Cannot operate unless： ☑ You have understood and practiced the rules for safe operation of the machine in this operation manual. 1Avoid dangerous situations. 2 Always perform a pre-operation check. Know and understand the safety rules before proceeding. 3 Always perform pre-use functional tests.
  • Page 22 Operation and Maintenance Manual Inspection before operation □Ensure that the manual is complete, easy to read and stored in the manual box in the platform. □Ensure that all labels are clear, legible and properly positioned. Refer to the "labels" section。 □...

  • Page 23: Workplace Inspection

    Operation and Maintenance Manual Workplace inspection Cannot operate unless: ☑ You have understood and practiced the rules for safe operation of the machine in this operation manual. 1 Avoid dangerous situations. 2 Always perform a pre-operation check. Know and understand the safety rules before proceeding. 3 Always perform pre-use functional tests.

  • Page 24: Functional Testing

    Operation and Maintenance Manual functional testing Cannot operate unless: ☑ You have understood and practiced the rules for safe operation of the machine in this operation manual. 1 Avoid dangerous situations. 2 Always perform a pre-operation check. Know and understand the safety rules before proceeding. 3 Always perform pre-use functional tests.
  • Page 25 Operation and Maintenance Manual 1 Select a solid, level and obstacle free test area. 2 Make sure the battery pack is connected. On the ground controller 3 Pull the red emergency stop button on the ground to the "on" position, and turn the red emergency stop button on the platform clockwise to the "on"...
  • Page 26 Operation and Maintenance Manual 13 Pull the red emergency stop button on the ground to the "on" position, and turn the red emergency stop button on the platform clockwise to the "on" position. ⊙Result: LED diagnostic reading device indicator light will be bright Test the horn 14Press the horn button.
  • Page 27 Operation and Maintenance Manual 27 Press the thumb rocker switch at the top of the control handle in the direction indicated by the yellow arrow on the control panel. ⊙Result: the turntable turns right. Test steering 28 Press the drive function selection button. 29 Press and hold the function enable switch on the control handle.
  • Page 28 Operation and Maintenance Manual 40 Lower the mast and lift the jib about 1m above the ground. 41Press the drive function button, press and hold the function on the control handle, and then use the switch to slowly move the control handle to the full drive position. ⊙Results: the maximum driving speed should not exceed 14cm / s when the platform is raised.
  • Page 29 Operation and Maintenance Manual ⊙Result: the turntable turns right. Jib lifting / lowering 54 Find the jib lifting valve. 55 Press and hold the button above the jib lifting valve with a wrench, and swing the handle up and down at the same time. ⊙Results: the forearm should be lifted.

  • Page 30: Operating Instructions

    Operation and Maintenance Manual Operating instructions Cannot operate unless: ☑ You have understood and practiced the rules for safe operation of the machine in this operation manual. 1 Avoid dangerous situations. 2 Always perform a pre-operation check. Know and understand the safety rules before proceeding. 3 Always perform pre-use functional tests.
  • Page 31 Operation and Maintenance Manual Mast descent 3 Pull the emergency descent control button outward. Forearm descent 4Turn the valve on the forearm cylinder counterclockwise. Rotating turntable 5Find the turntable left/right turn valve. 6The handle is inserted into the pump's manual operation hole. 7Press and hold the button on the left / right turn valve of the turntable with a wrench, and swing the handle up and down at the same time.

  • Page 32: Manual Operation

    Operation and Maintenance Manual 24Use the thumb rocker switch located at the top of the control handle to turn the steering wheel. Drive 25Press the drive function selection button. 26Press and hold the function enable switch on the handle. 27Increase speed: slowly move the control handle away from the center position. Reduce the speed: slowly move the control handle to the center position.
  • Page 33 Operation and Maintenance Manual Determine the slope： Measure the slope with digital inclinometer or follow the steps below。 You need the following tools: Woodworking ruler Straight wood block with a length of at least 1m Tape measure Place the block on the slope. At the end of the downhill, place the Woodworking ruler on the upper edge of the block and lift the end of the block until it is level.

  • Page 34: Charge The Battery

    ☑ Charge with the correct AC input voltage indicated on the charger. ☑ Only use batteries and chargers approved by Hangcha. Instructions for filling and charging dry batteries 1Open the cover during battery charging. 2Remove the battery ventilation cover from the battery vent and remove the plastic seal.
  • Page 35 Operation and Maintenance Manual 5 Connect the charger plug to the AC power supply to charge. Charging cannot be interrupted at the beginning. A charging cycle takes about 10 hours, and the battery power must reach 70% - 80%. 6 The charger indicates that the battery is full. 7 Remove the battery vent cover and check the battery electrolyte level.

  • Page 36: Transportation And Lifting Instructions

    Operation and Maintenance Manual Transportation and lifting instructions Observe and obey： ☑ When using the crane to lift the machine, please maintain normal judgment and planning to control the movement of the machine. ☑ Only qualified personnel with high-altitude lifting operation can load and unload the machine. ☑...
  • Page 37 Operation and Maintenance Manual Lift the machine with a forklift Make sure that the controller and cover are fixed safely and reliably. Remove all moving parts from the machine. Fully lower the platform and the platform must remain closed during all shipment. Put the forklift foot in the correct position.

  • Page 38: Maintenance

    Operation and Maintenance Manual Long term storage instructions Machines that have not been used for a long time should be properly stored. The ambient temperature should be in the range of - 20 ℃~40 ℃. Ambient humidity ≤ 90% 1 When the machine is parked indoors, it should choose a solid and flat ground. If it is parked outdoors, it should be covered with dustproof cloth to avoid rain and dust.

  • Page 39: Maintenance Schedule

    Operation and Maintenance Manual Observe and obey: ☑ The operator can only perform the routine maintenance items specified in this manual. ☑ According to the requirements specified by the manufacturer, regular maintenance and inspection shall be completed by qualified maintenance technicians. Maintenance symbol legend Use the following symbols in this manual to help express the relevant meanings in the usage instructions.
  • Page 40 Operation and Maintenance Manual Pre-delivery preparation reports Basic principle The distributor is obliged to complete the preparation before delivery. Pre delivery preparation is a priority before each product is delivered. The purpose of this check is to find out whether there are obvious problems with the equipment before it is used. Damaged and modified equipment is never allowed to be used.

  • Page 41: Maintenance Inspection Report

    Operation and Maintenance Manual Signature of inspector Title of inspector Inspection company Maintenance inspection report Model Serial number Date Chronometer Owner Inspection unit (to be Signature of inspector Title of inspector Inspection company Explain ▪Use one report per inspection. ▪ Select the appropriate checklist based on the items to be checked. □Daily or every 8 hours □Quarterly or every 250 hours □Every six months or every 500 hours...
  • Page 42 Operation and Maintenance Manual A-4 functional testing 40 hours later A-5 Maintenance after 30 days Checklist B B-1 Battery B-2 wires B-3 Tires and hubs B-4 Emergency stop B-5 Lubricate the chain and B-6 Key switch B-7 horn Actuator brake B-9 Driving speed in retracted B-10 Driving speed in lifting B-11 Working light...

  • Page 43: Check Before Operation

    ¤Results: the label was missing, blurred or damaged. Stop the machine before replacing the label. 4 After the manual is used, the object will return to its original position. Tip: if you need to replace the manual or label, please contact Hangcha company or Hangcha dealers.
  • Page 44 Operation and Maintenance Manual It is very important to operate the machine that the hydraulic oil level is in the right position. If the hydraulic oil is in an improper position, the hydraulic components may be damaged. Through daily inspection, the inspector can determine the change of hydraulic oil level, which can indicate the problems existing in the hydraulic system.
  • Page 45 Operation and Maintenance Manual Check the battery This inspection is conducted every 250 hours or once a quarter, whichever comes first. Good battery condition is very important for the performance and operation safety of the machine. Incorrect electrolyte level and damaged cables or connectors can cause damage and dangerous conditions to machine parts.
  • Page 46 Operation and Maintenance Manual 2 Turn the key switch to the ground control position, pull the red emergency stop button on the ground to the "on" position, and turn the red emergency stop button on the platform clockwise to the "on" position. 3 Lift forearm to about 2.5m above the ground.
  • Page 47 Operation and Maintenance Manual Keeping tires and wheels in good condition is essential for safe operation and good performance. Failure of tires and hubs may cause the machine to tip over. If not found in time and repair can also cause damage to the parts. 1 Check the tread and side of the tire for scratches, cracks, punctures and other abnormal wear.
  • Page 48 Operation and Maintenance Manual 2 Visual inspection of debris or foreign matter inside and outside the mast. If necessary, clean with mild cleaning solvent. 3 Lubricate the bearing between the sprocket and the sprocket shaft with grease in the lifting state. 4 Lubricate the chain and sprocket with oil gun.
  • Page 49 Operation and Maintenance Manual ⊙Result: the horn sounds. Test drive brake function This inspection is conducted every 250 hours or once a quarter, whichever comes first. The correct brake action is very important to the operation safety. The brake should be stable without delay, bump and abnormal noise.
  • Page 50 Operation and Maintenance Manual Normal drive function is essential for safe operation. Drive functions should respond quickly and smoothly to the operator. Delay, turbulence and abnormal noise should not occur during normal operation. Drive speed tests must be performed on solid, horizontal, and obstruction-free ground. 1 Draw two lines with a distance of 12.2 meters on the ground as the starting line and the finishing line.
  • Page 51 Operation and Maintenance Manual 8 Drive the machine to the maximum speed and start timing when the reference point crosses the starting line. 9 Keep driving at full speed and record the time to cross the end line. The time is less than 87 seconds.
  • Page 52 Operation and Maintenance Manual This inspection is conducted every 250 hours or once a quarter, whichever comes first. Operation alarm is used to alert ground personnel and operators that equipment is in operation. 1 Turn the key switch to the ground control, pull the red emergency stop button on the ground to the "on"...
  • Page 53 Operation and Maintenance Manual The hydraulic tank cap with smooth exhaust is very important to achieve good mechanical properties and service life. Dirty or clogged exhaust cover may lead to poor performance of the machine, and the bad working environment should be checked frequently. 1 Open the cover.

  • Page 54: Equipment Required

    Operation and Maintenance Manual 1 When adjusting the chain length, please select the mast to be raised. As shown in the figure above, tighten the nut to make the upper mast move upward. After adjusting the chain length, tighten the double nuts together. 2 When two chains pull the same mast, they bear the lifting weight at the same time.
  • Page 55 Operation and Maintenance Manual Check whether there are foreign bodies on the chain and guide plate。 ● ● Check the chain for signs of corrosion. Chains with any of the following defects must be replaced. ● Check chain extensibility. ● The chain length of 12 sections is not allowed to exceed 2% of the original chain length. ●...
  • Page 56 Operation and Maintenance Manual Replace the chain The chain must be replaced every 7 years. For further comments and suggestions, please contact the after-sale service department. Checklist step C Test platform overload system This inspection is performed every 500 hours or 6 months, whichever comes first. Check immediately when the machine is overloaded.
  • Page 57 Operation and Maintenance Manual 8 Use suitable hoisting device to safely and reliably remove the loaded heavy block. ⊙ Result: the alarm did not sound. The system function is normal. ¤ Result: Alarm sound, calibration platform overload system. 9 Test all functions on the ground controller. ⊙...
  • Page 58 Operation and Maintenance Manual Note: this operation should be carried out when the machine is retracted. 1 Open the cover. 2 Disconnect the battery pack from the machine. Danger of electric shock/burn Operation in a live circuit may cause serious injury or death. Remove rings, watches and other accessories during operation.
  • Page 59 Operation and Maintenance Manual Electric system fault diagnosis and correction Code Fault Restricted Corrective action action Initialization Disables All ECU may fail. Replace ECU. Fault Motion Communication Disables All Check whether the communication cable is plugged in. Fault Motion Replace ECU and PCU if the cable is connected. Invalid Option Disables All Set the correct platform configuration parameters.
  • Page 60 Operation and Maintenance Manual Enable Switch ON Platform pressed before the power is turned on. If so, please at power-up Control consider changing the handle and PCU. Fault Platform Joystick Lift Slows to Make sure it is in the middle position before power on. not in neutral at Elevated If it is, please consider changing the handle and PCU.
  • Page 61 Operation and Maintenance Manual Over 80% Load Warning Only The platform load is close to the rated weight. It is not Warning recommended to increase the load. Over 90% Load Warning Only The platform load is very close to the rated weight. It is Warning recommended not to increase the load.
  • Page 62 Operation and Maintenance Manual Schematic Hydraulic Schematic...

  • Page 63: Electrical Schematic

    Operation and Maintenance Manual Electrical Schematic...
  • Page 64 Operation and Maintenance Manual Maintenance record sheet Maintenance record sheet...
  • Page 65 Operation and Maintenance Manual Maintenance record sheet...

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