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HANGCHA CDD10-AMC1 Operation And Maintenance Manual
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HANGCHA CDD10-AMC1 Operation And Maintenance Manual

Electric stacker
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Mini Range
CDD10/12-AMC1
ELECTRIC STACKER
CTD10/12-AMC1
CDD10/12-AMC1-SZ
CTD10/12-AMC1- SZ
CDD10/12-AMC2
CTD10/12-AMC2
OPERATION AND MAINTENANCE
MANUAL
Original Instruction
HANGCHA GROUP CO., LTD.
12 /2022

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Summary of Contents for HANGCHA CDD10-AMC1

  • Page 1 Mini Range CDD10/12-AMC1 ELECTRIC STACKER CTD10/12-AMC1 CDD10/12-AMC1-SZ CTD10/12-AMC1- SZ CDD10/12-AMC2 CTD10/12-AMC2 OPERATION AND MAINTENANCE MANUAL Original Instruction HANGCHA GROUP CO., LTD. 12 /2022...
  • Page 2 FOREWORD Thank you very much for purchasing the A series mini range electric stacker of Hangcha Group . A series mini range electric stacker 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 Ⅰ：Operation and Maintenance ................... 1 Notice for use ..........................1 1.1 General ............................1 1.2 Use as required ......................... 1 1.3 Normal service condition ......................2 1.4 Attachment installation or modification to the truck ..............3 Truck Introduction ........................4 2.1 General ............................4 2.2 Main part introduction ........................6 2.3 Display and control ........................11 2.3.1 Display .............................13...
  • Page 4 Maintenance ........................... 51 9.1 Maintenance general .......................51 9.2 Periodic maintenance schedule ....................52 9.3 Truck used oil and lubrication ....................57 9.4 Replace hydraulic oil ....................... 58 9.5 Replace wheels ........................59 9.5.1 Replace drive wheel ....................... 59 9.5.2 Replace load wheels .......................60 9.5.3 Replace auxiliary wheel ......................

  • Page 5: Part Ⅰ：operation And Maintenance

    Part Ⅰ：Operation and Maintenance Notice for use 1.1 General 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 6: Normal Service Condition

    1.3 Normal service condition Truck use occasion and specified conditions： – Used in specified area as factory, tourist attraction and recreation place. – Used on the flat ground, that is fixed and owns enough carrying capacity(protect operation and lifting). – It's prohibited to operate across the raised or hollow as the small wheel diameter may easily cause truck tipping over.

  • Page 7: Attachment Installation Or Modification To The Truck

    1.4 Attachment installation or modification to the truck Without authorization by the manufacturer, it is not allowed to modify the truck privately. The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after written approval by the manufacturer has been obtained.

  • Page 8: Truck Introduction

    Truck Introduction 2.1 General A series mini range electric stacker described in this manual should work under low working strength and its continuous working time should not surpass one hour. Users can get relevant information as rated load from the product model. Model CTD10-AMC1-SZ as an example: CTD10-AMC1-SZ Mode...
  • Page 9 – Drive unit adopts wheel type, with compact and simple structure. – Permanent-magnetic drive motor owns excellent performance. – High performance electromagnetic brake. Braking system – It owns three emergency braking functions as release brake, reverse brake and electromagnetic brake to ensure travelling safety. –...

  • Page 10: Main Part Introduction

    2.2 Main part introduction CDD10/12-AMC1、CDD10/12-AMC2...
  • Page 11 CTD10/12-AMC1、CTD10/12-AMC2...
  • Page 12 CDD10/12-AMC1-SZ...
  • Page 13 CTD10/12-AMC1 -SZ...
  • Page 14 Item Description Item Description Control handle Truck frame Control lever Battery charger plug(Built-in charger) Emergency stop switch Load wheel Charging indicator Fork Under cover Mast Drive wheel Key switch（with keys） Upper cover Instrument Auxiliary wheel...

  • Page 15: Display And Control

    2.3 Display and control...
  • Page 16 编号 名称 功能 Control handle Control truck steering and braking Interrupt the circuit and stop the operation of all Emergency stop switch electric functions. The vehicle is forced to brake. Display the operating status of the built-in charger. Red light flashing: charging charging indicator Steady green light: charging is complete or waiting for the battery...

  • Page 17: Display

    2.3.1 Display Charging indicator[14] It displays charger running state – Red light flashes-it is charging – Yellow light is on- charging fault – Green light is on- charging finishes. Instrument [15] 10 LED display bars display battery discharging status. One LED means 10% battery power. As the battery power reduces, 10 LED will light up one by one from right to left.

  • Page 18: Control

    2.3.2 Control Control handle [1] It connects and controls current. Key switch has two positions, “OFF” and “ON”. When it is at “OFF” position, the truck functions will be prohibited. When turn the Control truck steering and braking. switch to “ON”, the current is connected. When turn the control handle right and left, it When the driver leaves the truck, pull out the can realize the truck right and left turn.
  • Page 19 it means the truck changes to low speed Truck travels to the handle side(or pedal) – travel mode. When in low speed mode, the Press this control handle downwards. truck will travel in low speed, 40% of max. Turn this button towards the side of body travelling speed.
  • Page 20 control handle. Press the lifting button, and the forks move up; press the lowering button, the forks go down. When the capacity of batteries is consumed up to 80%, the lifting function will be locked.

  • Page 21: Standard Technical Data

    2.4 Standard technical data The following technical data are all standard data. Our company reserves the right of alteration and extension. CDD10-AMC1 CDD12-AMC1 Model CDD10-AMC2 CDD12-AMC2 Operator type Pedestrian Pedestrian Load capacity Q (kg) 1000 1200 Load center c(mm) Wheelbase y(mm) 1197.5...
  • Page 23 CTD10-AMC1 CTD12-AMC1 Model CTD10-AMC2 CTD12-AMC2 Operator type Pedestrian Pedestrian Load capacity Q (kg) 1000 1200 Load center c(mm) Wheelbase y(mm) 1197.5 1197.5 Weight Service weight with battery Tyre type Tyre size/Quantity,operator side Φ250×80/1 Φ250×80/1 Tyre size/Quantity,load side Φ85×70/4 Φ85×70/4 Auxiliary wheel size/Quantity Φ125×50/1 Φ125×50/1 Tread, operator side...
  • Page 25 Model CDD10-AMC1-SZ CDD12-AMC1-SZ Operator type Pedestrian Pedestrian Load capacity Q (kg) 1000 1200 Load center c(mm) Wheelbase 1273 1273 y(mm) Weight Service weight with battery Tyre type Tyre size/Quantity,operator side Φ250×80/1 Φ250×80/1 Tyre size/Quantity,load side Φ85×70/4 Φ85×70/4 Auxiliary wheel size/Quantity Φ125×50/1...
  • Page 27 Model CTD10-AMC1-SZ CTD12-AMC1-SZ Operator type Pedestrian Pedestrian Load capacity Q (kg) 1000 1200 Load center c(mm) Wheelbase 1273 1273 y(mm) Weight Service weight with battery Tyre type Tyre size/Quantity,operator side Φ250×80/1 Φ250×80/1 Tyre size/Quantity,load side Φ85×70/4 Φ85×70/4 Auxiliary wheel size/Quantity Φ125×50/1 Φ125×50/1 Tread, operator side...
  • Page 29 Mast configuration table CD(T)D10/12-AMC1 Max. load Max Lifting Ground Lowered Extended (Load center at 600mm) Mast type height clearance,fork Height Height Free lift (h3+h13) 1.0t 1.2t 1500 1585 1979 1986 1493 1000 1200 Single cylinder 1750 1835 2229 2236 1743 1000 1200 simple mast...

  • Page 30: Product Plates And Warning Labels Location

    MAX .LIFT HEIGHT YEAR OF MANUFACTURE HANGCHA GROUP CO.,LTD. Ad d: L in' an E co no mi c Dev el op me nt Z one ,Z he ji an g, Chi na L ic en se No .：T S2 51 00 02- 20 16...
  • Page 31 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. Hydraulic oil label: Add hydraulic oil. Series tonnage label：A series, rated capacity is X×100kg Manufacturer’s logo Emergency stop label: press this button when in emergency, thus the truck power is off.

  • Page 32: Safety Instructions

    the battery when checking. Safety Instructions – Be careful of scald when checking motor Only trained and authorized operator and controller. shall be permitted to operate the truck. 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 or bulb or resistance)
  • Page 33 12) Goods are not allowed to deviate the fork center, when goods is deviating the fork center, turn or pass uneven road, you are easily to fall. Meanwhile, possibility of turnover will increase. Internal battery may generate explosive gas, it’s prohibited any flame close the battery.
  • Page 34 18) It’s forbidden to put the head, hand, foot 23) Fire extinguisher shall be equipped at or body into the space between the the work site. Users can choose truck chassis and lifting component, once equipped with fire extinguisher. Driver clipped, it is dangerous to your life.

  • Page 35: 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 by crane WARNING ...

  • Page 36: Securing The Truck During Transport

    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 37: How To Remove A Broken Truck

    How to remove a broken truck It’s not allowed to tow the forklift truck on the ground directly when the truck is broken down or damaged since the brake of the truck is closed under normal circumstances. Appropriate vehicles should be used to remove the broken trucks. WARNING ...

  • Page 38: Battery

    Battery The truck equips with two maintenance-free colloidal batteries. When the battery temperature reaches 25℃～30℃, its service life is the longest. Lower temperature reduces battery available capacity and higher temperature shortens battery service life. Per battery weighs about 25kg. 5.1 Safe operation rules for battery use –...
  • Page 39 For instance, the maximum starting current should not exceed 87.5Ah for a battery with 70Ah rated capacity. Do not operate a truck when the working current is far higher than its rated capacity, or else it would shorten the endurance of the truck and the service life of the battery as well.

  • Page 40: Battery Charging

    5.3 Battery charging That is, during truck operation the battery discharge process, the battery over-discharge is prohibited. After the truck is running, it is timely to charge the battery. WARNING  The truck comes with charger, the charger charging power supply must be single-phase power frequency AC power.It’s prohibited to use DC, AC two phase/three phase and other non single phase AC to charge the battery.

  • Page 41: Check Charging State

    5.3.3 Check charging state During charging, in order to well know the battery charging state, do the following operation： – Pull up emergency stop switch. – Switch the key switch to “ON” position and start the truck. – Check battery capacity through instrument. –...

  • Page 42: Replacing Battery

    5.4 Replacing battery Procedure: – Park the truck securely. – Take down the hood. – Remove battery cable connector. – Screw off two sets of screws, and remove battery baffle.
  • Page 43 – Take out the battery Mount the battery according to opposite order. Check for correct mounting position and correct connection of the battery. WARNING  Battery is very heavy, be careful to avoid damage.  Disposal to the waste battery should accord with local environment regulation. ...

  • 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： –...

  • Page 45: 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. Close the hood Oil leak and liquid leak check Battery check Park the truck, and check the truck for –...
  • Page 46 When the truck run forward or backward, etc. 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 47: Start Up

    7.2 Start up Procedure: – Carry out check before operation and make sure each function and state is normal. – Pull up the emergency stop switch（3）. – Plug the key into key switch（14）, turn to “ON” position in clockwise. The instrument displays battery capacity.

  • Page 48: Travelling

    7.3 Travelling 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 the truck.Or hold the handle with both hands and push the truck go forward. CAUTION ...
  • Page 49 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. ...

  • Page 50: Braking

    7.4 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 51: Unloading

    – Raise the loads several centimeters to make sure if the loads are firm. – Travel the truck off the area. – Drop the load to lower position. 7.8 Unloading Procedure: – Approach the deposit area. – Raise the loads to correct height.
  • Page 52 – 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

    7.9 Parking Procedure: – Drive the truck to safe area or appointed area. – Fully lower the forks. – Turn off the key switch（14）, and remove the key. – Press the emergency stop switch (3).

  • Page 54: Deposit The Truck For Long Time

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

  • Page 55: Maintenance

    Inspection and maintenance are usually ignored, you’d better find out 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 56: Periodic Maintenance Schedule

    9.2 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 1000 hours(or 6 months) 〇 —Check, revise, adjust ×...

  • Page 57: Driving System

    Motor Service Tool Service required item Clean the foreign body on the motor 〇 〇 〇 〇 Clean or replace the bearing 〇 Check carbon brush 〇 〇or× 〇or× commutator worn, whether spring is normal Whether the connection is correct 〇...

  • Page 58: Brake System

    Brake system Service Service required Tool item Check for brake condition when the 〇 〇 〇 〇 〇 control handle on horizontal position and vertical position. Check inching switch 〇 〇 〇 looseness or damage. 〇 〇 〇 Check the installation for fastening. Check the surface abrasion for 〇...
  • Page 59 Lifting assy Service Service required Tool item Check chain for tension, damage or 〇 〇 〇 〇 〇 rust 〇 〇 〇 Add lubrication for chains Check chain wheel for deformation 〇 〇 〇 or damage Check chain wheel bearing for 〇...
  • Page 60 Others Service Service required Tool item 〇 〇 〇 〇 Wire damage or looseness Wire Looseness of electric 〇 〇 〇 circuit joint Emergency 〇 〇 〇 〇 〇 disconnect Check for work condition switch Direction and 〇 〇 〇 〇...

  • Page 61: Truck Used Oil And Lubrication

    9.3 Truck used oil and lubrication Filler plug for hydraulic oil Lubrication surface Drain plug Code Designation Mark, code Remark Normally：L- HM32 Hydraulic oil Hydraulic system High and cold environment：L- HV32 Automobile general 3 # lithium base Grease Nozzle and lubrication lubricant Grease SHELL ALVANIA R3...

  • Page 62: Replace Hydraulic Oil

    9.4 Replace hydraulic oil Procedure: – Open the fuel tank cap（48）. FILL LINE – Put the drain plug (49) into a container for holding the hydraulic oil. – Unscrew the oil drain plug (49) and empty the FILL LINE hydraulic oil. –...

  • Page 63: Replace Wheels

    a rubber hammer and remove the old 9.5 Replace wheels driving wheels from the drive unit. 9.5.1 Replace drive wheel Procedure: – Dismantle the drive unit from the truck. CAUTION  Strike the edge of the driving wheels – Remove the 12 socket hexagon screws evenly and symmetrically.

  • Page 64: Replace Load Wheels

    9.5.2 Replace load wheels Procedure: – Lift the fork to certain height. – The legs with square pieces of wood from the top, so that the load wheels off the ground. – Screw out the bolt. – Take out axle. –...

  • Page 65: Replace Auxiliary Wheel

    9.5.3 Replace auxiliary wheel Procedure: – Open the hood. – Tilt the auxiliary wheel from the truck with a square block and make the auxiliary wheels are slightly off the ground. – Screw out the 3 sets of bolts which is used to fix the auxiliary wheel assembly.

  • Page 66: Replace The Key Safe Parts Periodically

    9.6 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 High-pressure hose, hose for hydraulic system Inner sealing element, rubber matter of the hydrulic system...

  • Page 67: Part Ⅱ：structure, Principle And Maintenance

    Part Ⅱ：Structure, Principle and Maintenance Drive Unit 1.1 Drive unit structure and principle This truck adopts hub-type drive unit(see fig.2-1). This structure owns high efficiency, large drive ratio range, compact structure and small volume. 1.Housing 2.Bearing 6006 3.Gear shaft 4.Driven gear 5.Flat key 6.Circlip for hole 55 7.End cap...
  • Page 68 Drive unit deliver route(see fig.2-2): drive unit directly drives by driving the driving gear directly through motor. Delivery sequence is from 15(drive motor) to 13(driving gear) to 4(driven gear) to 3(gear shaft) to 22(annular gear), and then drive the driving wheel output. Drive system does not need gear shift, and reversing operation directly relies on positive inversion of motor to realize forward or reverse shifting.

  • Page 69: Dismantle Drive Unit From The Truck

    1.2 Dismantle drive unit from the truck Procedure: – Park the truck securely. – Take down the hood. – Dismantle handle wiring, motor cable, brake cable, decorative cover, down hood and handle tube etc. – Dismantle stand and joint support.
  • Page 70 – Unscrew nut and gasket. – Hoist the truck and take out the drive system. – Remove 4 bolts, separate drive unit from drive connecting shaft.

  • Page 71: Assemble And Use Notice

    1.3 Assemble and use notice – When assemble, scrub the oil seal on the product. Avoid product damage, no disassemble at will. – Avoid each fitting surface and exposed gear impact, thus influence installation. – Normal working oil temperature is ≤70℃. –...

  • Page 72: Drive Motor

    1.5 Drive motor Wiring Diagram of Motor 24VDC Black 24VDC Black Motor use notice – Keep clean and dry around the motor, and do no place other objects on or in the motor. – Do not use with overload. – Never coexist with strong magnetic object.
  • Page 73 commutator segments and carbon powder on the commutator surface with soft clean white cloth, when there is grease on the surface, immerse the cloth in alcohol to wipe(park). – Check if all fasteners are tight. – Brush carrier should be fastening and no loose. If turn or remove the brush carrier needed, only mark can loosen the end cap bolt.
  • Page 74 polishing. – After polishing crocus cloth and cleaning commutator, motor should work under limited speed to ensure safety until the brush working surface polishes.
  • Page 75 Fault diagnosis Probable cause Fault 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 76: Electromagnetic Brake

    1.6 Electromagnetic brake The spring-loaded electromagnetic brake is applied in the truck which is a single disk brake with double friction surfaces. By use of the pressure spring, powerful braking torque would be generated when power off. The brake could be released by the electromagnetic effect. 1.Mounting Bolt of the Brake 2.Stator Module 3.Brake Pad...

  • Page 77: Electromagnetic Brake Working Principle

    1.5.1 Electromagnetic brake working principle Motor shaft (9) is connected with shaft sleeve (4) by passing through the flat key. And shaft sleeve (4) is connected with brake pad (3) by passing through the splines. When the stator (11) is block out, the force produced by the pressure spring (10) would act on the armature (8) which makes rotated the brake pad (3) driven by the motor shaft connected closely between the armature (8) and cover plate (5).

  • Page 78: Electromagnetic Brake Installation

    1.5.2 Electromagnetic brake installation – Put the flat key (13) into the key groove of the motor shaft (9). Press the shaft sleeve (4) to the motor shaft (9) and fasten it with the inner spring. – Install the friction disk (5) to the end face of the motor by using three mounting bolts of the friction bolts (12).

  • Page 79: Maintenance

    WARNING  No broken wire sheath, or else the circuit might be damaged.  Do not process the locating surface or the holes of the production without authorization, or else the magnet loop would be influenced.  Do not over press when fitting the motor shaft. Make sure no damage on the friction surface and wipe off the burr of the mounting holes and surfaces.

  • Page 80: Adjust The Air Gap Of The Brake

    1.5.4 Adjust the Air Gap of the Brake Rated air gap Z grows with the friction. In order to there is sufficient braking torque, the air gap must be set before it reaches to the maximum value. The air gap can be adjusted by several times. When the thickness of brake pad becomes the minimum value(see the specification table below), the brake pad must be replaced.
  • Page 81 Under the general operating conditions, the first set of the air gap is usually after 1500 to 2000 hours service of the brake and it is suggested to adjust the air gap every 6 months. If it comes to a poor working condition, such as frequent use of brake and repeated emergency stops，the air gap should be set when the brake the shorten the adjustment interval for the first time.
  • Page 82 1.5.5 Schematic diagram of braking The forklift truck 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 83: Common Fault And Troubleshooting

    1.5.6 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 84: Hydraulic System

    Hydraulic system Hydraulic system is mainly composed of hydraulic unit, rubber tube and lifting cylinder. 1. Hydraulic unit 2. Rubber tube 3. Lifting cylinder Fig. 2-6 Hydraulic system...

  • Page 85: Hydraulic System Working Principle

    2.1 Hydraulic system working principle Lifting the Loading Press the lifting button of the control lever and the oil pump motor starts. It passed the torque from motor to gear pump through the transmission shaft. The gear pump absorbs the hydraulic oil from the fuel tank and passes the oil to the lifting cylinder through non-return valve.
  • Page 86 CDD10/12-AMC1、CTD10/12-AMC1、CDD10/12-AMC2、CTD10/12-AMC2...
  • Page 87 CDD10/12-AMC1-SZ、CTD10/12-AMC1-SZ...

  • Page 88: Hydraulic Unit

    2.2 Hydraulic unit The truck adopts combined hydraulic unit(see fig.2-7), which mainly consists of DC motor, coupling flange, cartridge, pump tank and other components. Carbon brush Suction tube Electric relay Filter Motor Tank Coupling Screw Flange Filter cap Relief valve Pump Protect cap Solenoid...
  • Page 89 Adjust Safety Pressure of Overflow Valve Generally, users do not need to adjust the safety pressure of overflow valve because it is set already before delivery. Here below states the adjusting method of the safety pressure. Procedure: – Park the truck securely. –...
  • Page 90 Manually Lowering the Unloading When the battery runs out or the electromagnetic valve fails to work , and the loading can not be lowered mechanically, the emergency lowering device of the hydraulic unit can be applied manually to lower the loading. Procedure: –...

  • Page 91: Hydraulic Unit Dismantle

    2.3 Hydraulic unit dismantle – Park the truck, drop the fork to lowest position, turn off the key switch and press emergency disconnect switch. – Dismantle the hood. – Remove pipe joint. – Remove the wiring on the motor, contactor and solenoid valve.
  • Page 92 – Remove hydraulic unit fixed stand, and then take out hydraulic unit. Assembling order is opposite to the disassembling order.

  • Page 93: Dismantle The Lifting Cylinder From The Truck Or Replace

    2.4 Dismantle the lifting cylinder from the truck or replace – Turn off the key switch, pull out the battery plug. – Take apart the hood. – Dismantle piping joint. – Dismantle one end of lifting chain.
  • Page 94 – Remove cylinder fixed plate. – Remove chain seat and take out cylinder. Assembling order is opposite to the disassembling order.

  • Page 95: Hydraulic System Fault Diagnosis And Correction

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

  • Page 96: Electric System

    Electric system Electric system of this truck is double wire system, all circuits do not ground. Working voltage is DC24V. Instrument Interlock switch Emergency disconnect switch Controller Truck wiring harness 10. Horn 11. Fan Fuse protector 12. Charger Fuse protector 13.

  • Page 97: Electrical Schematic Diagram

    3.1 Electrical schematic diagram CDD10/12-AMC1、CTD10/12-AMC1...
  • Page 98 CDD10/12-AMC1-SZ、CTD10/12-AMC1-SZ...
  • Page 99 CDD10/12-AMC2、CTD10/12-AMC2...

  • Page 100: Drive Motor Controller

    3.2 Drive motor controller 3.2.1 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. It’s suggested to keep the controller clean and dry, periodically check and get rid of diagnose historical files.

  • Page 101: Fault Code Table

    3.2.2 Fault code table Fault menu of handheld programmer in diagnosis and fault guild: This fault codes provide the following information: – Fault code – Display fault name on the Curtis programmer – Display caused by the fault – Probable fault reason When there is fault, if it’s affirmed not the wiring error or truck malfunction, you can try to restart through key switch.
  • Page 102 1212E FAULTS When the controller detects a fault, the controller operates in a manner that is safe in the presence of that fault. Depending on the severity of the fault, the controller’s response can range from reducing current to shutting down the vehicle. Some faults are set by multiple conditions.
  • Page 103 Defective temperature sensor controller Lower controller Shut down throttle temperature is at least temperature to under the Controller 15°C higher than the temperature cutback point. Severe temperature cutback point Overtemp for 48ms. 0x2142...
  • Page 104 FLASH CODE FAULT NAME TYPE SET CONDITION CLEAR CONDITION FAULT ACTIONS POSSIBLE CAUSES CAN INDEX • Throttle wiring fault The throttle AD data is out Cycle the keyswitch. Shut down throttle of range for 48ms. • Incorrect throttle type setting Throttle Fault •...
  • Page 105 FLASH CODE FAULT NAME TYPE SET CONDITION CLEAR CONDITION FAULT ACTIONS POSSIBLE CAUSES CAN INDEX • Defective motor The armature current is Cycle the keyswitch. Shut down motor greater than 90% of the Shut down main • Defective controller Stall Detected current limit and the motor contactor 0x2231...
  • Page 106 FLASH CODE FAULT NAME TYPE SET CONDITION CLEAR CONDITION FAULT ACTIONS POSSIBLE CAUSES CAN INDEX The motor speed is greater than the ramped speed curve for more than 80ms during interlock braking. The motor speed is greater than the ramped speed curve for more than 80ms while the vehicle decelerating...
  • Page 107 FLASH CODE FAULT NAME TYPE SET CONDITION CLEAR CONDITION FAULT ACTIONS POSSIBLE CAUSES CAN INDEX • Incorrect operation sequence The lift input is active Cycle the keyswitch. Shut down lift when the keyswitch is • Defective switch Pump turned on. Fault The lower input is active Cycle the keyswitch.
  • Page 108 FLASH CODE FAULT NAME TYPE SET CONDITION CLEAR CONDITION FAULT ACTIONS POSSIBLE CAUSES CAN INDEX CANbus is overloaded. During the operational Cycle the keyswitch Shut down throttle NMT state, RPDO1 did or send an NMT reset Clear related data PDO Timeout not receive a message command.
  • Page 109 FLASH CODE FAULT NAME TYPE SET CONDITION CLEAR CONDITION FAULT ACTIONS POSSIBLE CAUSES CAN INDEX • Invalid parametervalue A parameter marked as Cycle the keyswitch. Shut down motor [PCF] in the Programming Shut down main • Defective FRAM Parameter Menu Parameters chapter contactor Fault was set but the keyswitch...
  • Page 110 FLASH CODE FAULT NAME TYPE SET CONDITION CLEAR CONDITION FAULT ACTIONS POSSIBLE CAUSES CAN INDEX The Pot Hi Switch Function Cycle the keyswitch. parameter specifies value other than Pot Hi Input but the Throttle Type parameter specifies a 3-wire pot throttle. The Inching Input Source Cycle the keyswitch.
  • Page 111 SUPERVISOR_HARDWARE_FAULT PRIMARY_INIT_CAN_OBJ PRIMARY_INIT_ILLEGAL_CAN_SIZE PRIMARY_INIT_CAN_SIZE PRIMARY_INIT_TIMEOUT PRIMARY_WRITE_OBJECT PRIMARY_WRITE_SIZE PRIMARY_WRITE_TIMEOUT PRIMARY_WRITE_CRC PRIMARY_WRITE_ACK...

  • Page 112: 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...

  • Page 113: Maintenance Record

    Maintenance Record Date Repair, maintenance content Serviceman...
  • Page 114 Relevant safety command and standard (CE models) The TRUCKS covered are conform to the following European Directives and standards: 2006/42/EC Machinery Directive 2014/30/EU EMC Directive EN ISO 12100:2010 Safety of machinery — General principles for design — Risk assessment and risk reduction EN ISO 3691-1:2015+A1:2020 Industrial trucks —...

  • Page 115: Ec Declaration Of Conformity

    EC DECLARATION OF CONFORMITY Original Declaration MANUFACTURER: Name HANGCHA GROUP CO., LTD. Address 666 Xiangfu Road, Lin'an District, Hangzhou City, Zhejiang Province 311305, P.R. China TECHNICAL DOCUMENT WAS COMPILED BY: Name Andy Yang Address Die das technische Datenblatt erstellt hat Mariechen-Graulich-Straße 12a, 65439 Flörsheim am main Germany Tel: 0049-61453769188...

  • Page 116: Revision Table

    Revision Table Revision Version no. Date Note Nov 2022 Original...
  • Page 117 HANGCHA GROUP CO. , LTD. ■Address For: OVERSEAS USERS ■ 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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