ELECTRIC STACKER
CDD12/14/16-AC1-L
CDD12/14/16-AC1S-L
CDD12/14/16-AC1S-LI
CDD12/14/16-AZ3S-L
OPERATION AND MAINTENANCE MANUAL
Original Instruction
HANGCHA GROUP CO., LTD.
11/2020
A
Series
Page 1: ...ELECTRIC STACKER CDD12 14 16 AC1 L CDD12 14 16 AC1S L CDD12 14 16 AC1S LI CDD12 14 16 AZ3S L OPERATION AND MAINTENANCE MANUAL Original Instruction HANGCHA GROUP CO LTD 11 2020 A Series...
Page 2: ...ts lifting arms Part 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 safe...
Page 3: ...ers graph 25 2 5 3 Double decker mode load chart 25 3 Safety Rules 26 4 Transport 29 4 1 Lifting the truck by crane 29 4 2 Securing the truck for transport 30 4 3 Transport 31 5 Battery 32 5 1 Attenti...
Page 4: ...1 2 Motor 75 1 3 Electromagnetic brake 82 1 3 1 Working principle 83 1 3 2 Brake installment 84 1 3 3 Brake air gap adjustment 86 1 3 4 Maintenance 87 1 3 5 Common fault and troubleshooting 88 2 Hydra...
Page 5: ...er type of use is beyond the scope of application and can result in damage to personnel the industrial truck or property 1 2 Correct application Lifting and lowering of loads Transporting the lowered...
Page 6: ...ck in the area of the explosion Special equipment and authorisation are required if the truck is to be used in extreme conditions e g cold stores Cold storage truck should meet the followings when wor...
Page 7: ...ater on the truck surface after the truck left the cold storage only after the surface is dry or the condensate water is complete dry can the truck enters the cold storage again Shorten the maintenanc...
Page 8: ...eat of the battery or function invalid or service life being shortened Do not operate the electric truck with lithium battery at the temperature above 55 or below 20 Do not dismantle the battery box u...
Page 9: ...ment the functions of the truck is permitted only after written approval by the manufacturer has been obtained If necessary the approval of local authorities has to be obtained Without the prior writt...
Page 10: ...n be stacked or unstacked up to 5 5m high and transported over long distances The rated capacity of the truck is shown on the nameplate or the data capacity plate 2 1 1 Truck models meaning The rated...
Page 11: ...10 11 12 13 14 15 Item Component Item Component 1 Tiller 9 Emergency Disconnect switch 2 Meter 10 Key switch 3 Lock switch 11 Battery panel 4 Safety side arms 12 Load wheels 5 Drive wheel 13 Wheel arm...
Page 12: ...shaped design of truck base offers much higher passing ability Chassis welded by high performance steel plate guarantees enough load capacity Stamping molded fork has higher strength and impact resist...
Page 13: ...control and higher efficiency The CANBUS structure makes communication of the entire machine faster and more reliable Multi function instrument owns electric quantity display time and fault diagnosis...
Page 14: ...10 2 3 Displays and Controls 17 18 18 19 20 21 22 23 24 25 2 3 9 10 17 1 18 19 20 18 24 21 22 23 6 4...
Page 15: ...ect switch Disconnects the battery supply All electric functions are cut out and the industrial truck decelerates 10 Key switch and key Activates the industrial truck by switching on the control volta...
Page 16: ...Control Display Symbol Function 24 Wheel arm lower button Lowers the wheel arms at a constant speed 25 Low speed indicator light When the indicator light is always on it means the truck is in low spe...
Page 17: ...the Operator or Service Technician thereby finding the fastest solution to the problem Hourglass Symbol It is normally off it blinks when the Hour Meter is working Hour meter An alpha numeric liquid c...
Page 18: ...maining power Service indicator red LED When the controller to detect fault information the red LED indicator light flashing at the same time LCD display shows two digits of the fault code When there...
Page 19: ...o Paramter name Description 1 Hour meter The number shows the current accumulated working hours of the vehicles with a maximum of 5 digits unit h 2 Speed display Display current vehicle speed in km h...
Page 20: ...erface See the corresponding part of the manual for the specific fault code 2 3 2 Open or down the safety side arms Open the safety side arms Push the lock switch 3 with one hand and the other hand li...
Page 21: ...height h4 mm 3242 3242 3242 Initial lift h5 mm 125 125 125 The lowest highest position of the handle h14 mm 1314 1314 1314 Height lowered h13 mm 90 90 90 Overall length pedal folded I1 mm 2083 2083 2...
Page 22: ...I1 mm 2135 2135 2135 Length to face of forks I2 mm 985 985 985 Overall width b1 mm 800 800 800 Fork dimensions DIN ISO 2331 fork dimensions s e I mm 60 185 1150 60 185 1150 60 185 1150 Distance betwee...
Page 23: ...h13 mm 90 90 90 Overall length pedal folded I1 mm 2135 2135 2135 Length to face of forks I2 mm 985 985 985 Overall width b1 mm 800 800 800 Fork dimensions DIN ISO 2331 fork dimensions s e I mm 60 185...
Page 24: ...20 y 65 3 683 h13 h5 I2 h1 I1 b1 b5 e 160 I x Wa...
Page 25: ...4090 2682 4682 90 800 800 850 4300 4390 2832 4982 90 750 750 800 4500 4590 2932 5182 90 700 700 750 Full free duplex mast 2000 2090 1635 2635 1090 1200 1400 1600 2500 2590 1885 3135 1340 1200 1400 16...
Page 26: ...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 pleas...
Page 27: ...l decal 29 Warning label it is forbidden that the operator s foot is not on the platform during operation 30 Rated capacities only for double decker mode 31 Rated capacities and load centres graph wit...
Page 28: ...9 Serial No 45 Weight without battery kg 40 Load center mm 46 Max allowbabl battery weight kg 41 Battery voltage V 47 Min allowable battery weight kg 42 Rated drive power kW 48 Year of manufacture 43...
Page 29: ...T HEIGHT 2 7m LIFT HEIGHT 3 0m LIFT HEIGHT 3 3m LIFT HEIGHT 3 7 3 8 m LIFT HEIGHT 3 5 3 6 m LIFT HEIGHT 4 0m LIFT HEIGHT 4 3m LIFT HEIGHT 4 5m LIFT HEIGHT 4 7m LIFT HEIGHT 5 0m LIFT HEIGHT 5 2m LIFT H...
Page 30: ...edal and control stick No smoking or any spark smoke near the battery when checking Be careful of scald when checking motor and controller 8 The controller equips with energy accumulator do not touch...
Page 31: ...erate the machine in reverse or have a guide 18 Cause the wheels of pallet truck is small it is not allowed to run on the street and only for driving in specified stacking place 19 It s forbidden to p...
Page 32: ...cation method 27 Use tray when carrying small items do not place on the fork directly 28 Do not wash the inner of the truck do not place the truck outdoors and exposed to the rain 29 Before dismantle...
Page 33: ...om slipping Crane slings should be fastened in such a way that they do not come into contact with any attachments when lifting Load the truck and park it securely at its destination 50 WARNING Wear sa...
Page 34: ...ansporting truck Park the truck securely Strap the belts 51 around the truck and tension them sufficiently Using the wedge fixed wheels when necessary The truck can now be transported 51 WARNING The l...
Page 35: ...ading platform or hoisting device Fix the belt to the forklift and fully tightened block the wheels if necessary Then the forklift can be transported How to remove a broken truck It s not allowed to t...
Page 36: ...trolyte is in shortage Inspect electrolyte level every week When electrolyte level is low you must add distilled water to the level appointed WARNING The shortage of the electrolyte will cause the sto...
Page 37: ...ufacturer 5 The battery is not used at a loss of power To ensure the battery life should avoid the discharge depth of more than 80 of the rated capacity of the battery Whether it is partially discharg...
Page 38: ...or battery management system the power system in series or in parallel operation if necessary please contact this Company technical department to obtain the correct technical support 18 Prohibit the...
Page 39: ...erson does not use emetic Make sure mucus does not block the respiratory tract and do not eat other things to unconscious people 29 Contact with eyes Electrolyte inside the battery will cause eye irri...
Page 40: ...ight H mm 625 625 Min allowable battery weight kg 200 260 Max allowbabl battery weight kg 295 295 H L W WARNING Battery weight and dimensions have considerable influence on operational safety of the t...
Page 41: ...charger Connect the battery plug 53 with truck socket 52 and close the filler cap of each battery monomer Close the battery panel 11 securely The battery is now charged the truck can be used 53 54 11...
Page 42: ...roportion of voltage and electrolyte declines faster than most of other batteries Make equalizing charging in the following case a discharge voltage often drop down final voltage b discharge current i...
Page 43: ...tery with a dobber According to the dobber of the ventilation cover read the level position of the electrolyte 2 Replenish the distilled water Wear the blinkers rubber shoes and rubber glove Use the m...
Page 44: ...g the distilled water Adding too much will result in leakage of electrolyte and it will damage the truck when charging or discharging Draw it out with injector if adding too much 3 Reading the specifi...
Page 45: ...on 3 Conversion of the specific gravity The specific gravity at the standard temperature of 300 C should be converted as follow D30 Dt 0 0007 t 30 Therein to D30 the specific gravity at the standard t...
Page 46: ...e to assure the battery can be charge at best state To adjust the parameter of charger please see the following battery charging Lithium battery charging Model type SPC 24100 Input AC186 260V 50 60Hz...
Page 47: ...o change a frozen battery There s the danger of explosion Maintenance and repair must only be carried out by a qualified specialist who is familiar with the dangers involved and aware of relevance reg...
Page 48: ...plug the key Insert the charger power plug into a suitable power outlet Turn on the charger power switch Connect the charger plug to the lithium battery charging socket Start the charging process Unpl...
Page 49: ...t of the container Installation is the reverse order When reinstalling the battery note the proper installation position and make sure the battery is connected correctly Place the battery cable on the...
Page 50: ...be observed while the truck is in a stage of 100 hours of operation Avoid the new battery over discharging in early period Perform specified preventive maintenance services completely Avoid sudden sto...
Page 51: ...hood Loosen the hydraulic oil filler cap pull out dipstick and check if the oil level within the scales Add oil when insufficient Close the hood and open the battery cover 6 Battery check Check the ba...
Page 52: ...system is normal 12 Check chain tensity Lift forks up 100mm 150mm Press the middle of the chain and see if the left right tensity is the same Tensity adjustment screw off the nut adjust nut to keep th...
Page 53: ...folding platform 6 Pull the Emergency Disconnect 9 to unlock it Insert the key in the key switch 10 and turn it as far right as it will go The truck is operational OFF O N 10 9 4 6 CAUTION Make sure...
Page 54: ...tically returns to its original position Control the travel speed with the travel switch 18 CAUTION In pedestrian mode the truck can now operate again at normal speed Travelling in rider mode Procedur...
Page 55: ...F V R V R 0 18 7 4 Steering ESP electric steering power system is easier to operate due to less activation force required Procedure Move the tiller 1 to the left or right The truck is steered in the r...
Page 56: ...y uses regenerative brakes The truck brakes to a halt regeneratively via the coasting brake The brake then applies Braking with the tiller in the B zone Procedure Move the tiller up or down to one of...
Page 57: ...wo pallets Procedure Drive the truck carefully up to the pallet Slowly insert the forks into the first pallet until the fork shank touches the pallet The load unit must not extend by more than 50mm be...
Page 58: ...travel speed to the conditions of the route and the load you are transporting Travel at a constant speed Watch out for other traffic at crossings and passageways Always travel with a lookout at blind...
Page 59: ...from the pallet The load is lowered Depositing when transport two pallets Procedure Drive carefully up to the storage location Press the wheel arm lower button 24 make the wheel arms are clear of the...
Page 60: ...appointed area Fully lower the load handler and wheel arms Set the control handle to the Straight position Switch off the truck 12 and remove the key Press the Emergency Disconnect 13 Fold in the saf...
Page 61: ...y anti rust oil to piston rod or easily rusty axle Cover the whole truck Check specific gravity of electrolyte and liquid level once a month Do equalizing charge to the battery once a month 8 2 Start...
Page 62: ...nmental protection laws and regulations Draw up complete maintenance plan After you make maintenance you d better make a record Forbid to repair the forklift truck if you haven t been trained CAUTION...
Page 63: ...hs Every 500 service hours or at least trimonthly Every 1000 service hours or at least semiannually Every 2000 service hours or at least annually Standard maintenance interval Cold store maintenance i...
Page 64: ...Change oil Brakes D W M T S Y 1 Test brakes 2 Check magnetic brake air gap Steering D W M T S Y 1 Test electric steering and its components 2 Check tiller recuperating function 3 Bearing lubrication...
Page 65: ...ring system 6 Test relief valve and adjust if necessary 7 Replace hydraulic oil 8 Clean hydraulic oil filter Mast D W M T S Y 1 Visually inspect the mast rollers and check contact surface wear level 2...
Page 66: ...d plug Gear oil drain plug Lubrication part Grease nipples Code Designation Mark code Remark A Hydraulic oil Normally L HM32 High and cold environment L HV32 Hydraulic system B Gear oil GL 5 85W 90 Re...
Page 67: ...After oil in the reduction box drains re tighten the drain plug 66 Add appointed gear oil GL 5 85W 90 In order to add oil easily add with help of funnel and tube When oil overflows from the oil fille...
Page 68: ...e oil to the container After oil in the reduction box drains re tighten the drain plug 68 Add appointed gear oil L HM32 to allowable scale range In order to add oil easily add with help of funnel and...
Page 69: ...ng year Hydraulic hose for lifting system 1 2 High pressure hose hose for hydraulic system 2 Inner sealing element rubber matter of the hydrulic system 2 9 5 Screw down the wheel retaining nut Re tigh...
Page 70: ...ith a wrench Lift the rear panel assy 7 remove it from the truck and place it securely next to the truck The panel is now disassembled Mounting is performed in reverse order 7 58 58 WARNING It s prohi...
Page 71: ...m the mast and place it securely next to the truck The satety guard 16 is now disassembled Mounting is performed in reverse order WARNING It s prohibited to use the truck with not install safety guard...
Page 72: ...et 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 inst...
Page 73: ...trucks EN1175 1 1998 A1 2010 Safety of industrial trucks Electrical requirements Part 1 General requirements for battery powered trucks EN1726 1 1998 Safety standard for machinery industrial vehicle E...
Page 74: ...70...
Page 75: ...drive seat reduction box drive wheel drive motor and electromagnetic brake etc 1 2 3 6 9 8 7 4 5 1 Electromagnetic brake 2 Drive motor 3 Steering gear wheel only for electric steering 4 Steering pini...
Page 76: ...not need to shift but realize direction shift forward or reverse directly by motor positive inversion and is easy to use and maintain 1 Housing 2 Adjusting shim 3 Tapered roller bearing 4 Gasket 5 Oil...
Page 77: ...output flange 5 Power transmission order is that 1 driving motor 2 driving gear 3 driven gear 4 gear shaft 5 annual gear drive the wheel output Moreover this reduction box does not need to shift but r...
Page 78: ...d disassemble the product Prevent the assembling surface and exposed flange from being knocked or damaged otherwise it may influence the installment and use precision Working oil should keep clean the...
Page 79: ...en 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 power kW Rated voltage V Rated current A Max current A Rated spe...
Page 80: ...2 S2 10 B IP20 10 40 Motor wiring and direction of rotation Check motor turn from motor output shaft Red outgoing line connects power positive black outgoing line connects power negative output shaft...
Page 81: ...hould be as short as possible During motor travelling if there happen electric leakage speed drops suddenly severely vibrate too hot with smoke or electric contact sparking smoke turn off the power im...
Page 82: ...tact loosens and contact resistance is large Motor load too large or rotator locks Power voltage too low Small motor assembles too tight or bearing grease too hard Bearing seizing up Motor starts hard...
Page 83: ...e rub Power voltage too high or imbalance Wrongly stator winding or short circuit Big motor vibration during running Too big wear bearing clearance Uneven air gap Rotor imbalance Revolving shaft bend...
Page 84: ...g for overhaul use improper way that burn the iron core Rotor and stator core rub Motor overloads or start up frequently Cage rotor break Motor lacks phase two phases run After rewinding dipping paint...
Page 85: ...good or open weld Repair welding Short circuit armature coils or commutator segment Eliminate short circuit Abnormal speed Large loading moment Reduce loading moment Brush is not in neutral position A...
Page 86: ...ip 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 2 3 4 5 6 1 Mounting...
Page 87: ...this moment there will be a gap Z between armature 8 and friction disk assembly 3 When need to release the brake stator 11 connects the DC then the generated magnetic field draws the armature 8 move...
Page 88: ...lace friction disc 5 on the end face of motor Cover friction brake disc 3 to the shaft sleeve Install stator module 2 and three mounting screws 1 Note remove three fixed rubber gasket on the stator mo...
Page 89: ...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 Measure brake connected DC voltag...
Page 90: ...ed torque Rated power Rated air gap Max air gap Tightening torque of mounting screw 16 Nm 30 W 0 2 mm 0 3 mm 9 0 Nm When the brake is off power adjust three hollow screw 7 with the help of feeler gaug...
Page 91: ...on surface with hand no oil stain otherwise it cannot reach the maximum torque General use environment temperature is 10 40 Please check periodically and the check item if the switch motion is normal...
Page 92: ...or a while Oil dirt mixed in Clean oil dirt Large load Reduce load or replace large specification Large load change Adjust load peak or large the specification High temperature Too high exciting volta...
Page 93: ...c unit lifting cylinder and rubber tube etc 1 3 4 5 6 7 8 2 1 Hydraulic unit 2 Mounting bracket 3 Oil tube assembly 4 Oil tube assembly 5 Lifting cylinder 6 Oil tube assembly 7 Left lifting cylinder m...
Page 94: ...90 2 1 Hydraulic system working principle...
Page 95: ...otor direction it rotates in counterclockwise seen from the rear motor It is strictly prohibited motor reverse rotation and no oil rotation When add oil hydraulic oil must be filtered and the filter f...
Page 96: ...ace soft tube and clean the strainer Cavity caused by the high viscosity of hydraulic oil Replace new hydraulic oil whose viscosity suits pump running speed Work only when the oil temperature is norma...
Page 97: ...3 Electric system Electric system of this truck is double wire system all circuits do not ground Working voltage is DC24V 3 1 Principles of electrical system CDD12 14 16 AC1S L and CDD12 14 16 AC1S L...
Page 98: ...94 CDD12 14 16 AZ3S L...
Page 99: ...Key switch input voltage failed to charge the capacitor Troubleshooting Reset or re input interlock switch through VCL function precharge 15 Controller Severe Undertemp Motor stops working Main contac...
Page 100: ...1 Insufficient battery power 2 Setup error of battery parameter 3 Power consumption of non controller system 4 Too large battery impedance 5 Battery disconnects 6 Fuse protector disconnects or main co...
Page 101: ...r 1 output shut 1 Connected load open or short 2 Connecting pin stained 3 Wrong wiring Reason Driver 1 pin 6 is either open or shorted This fault can be set only when Main Enable set to OFF Troublesho...
Page 102: ...rake Pump stops working 1 Motor phase is open 2 Wrong wiring Reason Motor phase U V W detected open Troubleshooting Check phase and restart the key switch 38 Main Contactor Welded Motor stops working...
Page 103: ...lt threshold can be changed with the VCL function setup_pot_faults Troubleshooting Increase the pot wiper voltage 45 Pot Low Overcurrent Throttle invalid Full brake 1 Potentiometer impedance is too lo...
Page 104: ...52 TH PDO Timeout Motor stops Pump stops Handle control button all failure 1 Communication failures Handle damaged or poor contact communication circuit 68 VCL RunTime Error Motor stops Main contactor...
Page 105: ...gnal of motor encoder in LOS mode and set the parameter to Throttle Command 0 Motor RPM 0 87 Motor Characterization Fault Motor stops Main contactor stops EM brake stops Accelerator stops Brake Pump s...
Page 106: ...stalling make sure encoder work under normal condition Throttle Command 0 Motor RPM 0 94 Emer Rev Timeout EM Brake failure Throttle invalid 1 Emer Rev timeout activated due to EMR Timer overdue 2 Emer...
Page 107: ...alve or pump or traction request Alarm 02A28 Pump Vmn Low Pump motor output is too low with respect to pwm applied Valve pump traction stopped Lc opened Eb applied start up stby during pump function V...
Page 108: ...rt up stby pump request Warning 02A60 Capacitor charge Power capacitors voltage does not increase Valve pump traction stopped Lc opened Eb applied start up Valve or pump or traction request Alarm 02A6...
Page 109: ...request Warning 02A75 Cont Drv Ev3 Driver of Ev3 is open not able to close Ev1 stopped during Ev3 function valve Ev3 request Warning 02A75 Contactor Driver Driver of LC coil is damaged not able to cl...
Page 110: ...ing 02A92 Current gain The Maximum current gain parameters are the default values which means the maximum current adjustment procedure has not been carried out yet Controller works butwith low maximum...
Page 111: ...he controller hardware so it s necessary to replace the controller 06A01 HIGH CURRENT Exceed current exceeds limit hardware circuit current hardware limitations Check if the motor suits for eps dc0 no...
Page 112: ...ce between Q line and B is too small approach 30 start up stby traction Valve or pump or traction request Alarm 06A07 Q LINE SENSOR KO Stepper motor D LINE voltage is invalid 1 Check if stepper motor...
Page 113: ...by the slave contactor please replace the controller start up stby traction Valve or pump or traction request Alarm 06A18 KS OPEN The safety contactor of the slave contactor is not closed in time The...
Page 114: ...lines damage or break check the encoder mechanical and circuit function or the electromagnetic interference on the sensor bearing causes the Alarm if not the above reasons please replace the controlle...
Page 115: ...yet operated Solution ZAPI technician will set the current gain parameter correctly start up stby traction Valve or pump or traction request Alarm 06A44 CLOCK PAL NOT OK Clock fault Replace controller...
Page 116: ...SL Slave CAN BUS communication fault Replace controller start up stby traction Valve or pump or traction request Alarm 06A55 SL EPS NOT ALL Controller malfunction Replace controller start up stby trac...
Page 117: ...07 14 54 69 69 88 83 98 121 162 16 88 108 108 137 127 157 189 252 18 118 147 147 186 176 216 260 347 20 167 206 206 265 245 314 369 492 22 225 284 284 343 343 431 502 669 24 294 370 370 441 441 539 63...
Page 118: ...Maintenance Record Date Repair maintenance content Serviceman...
Page 119: ...CO LTD Address For OVERSEAS USERS Address 88 Donghuan Road Lin an Economic Development Zone Zhejiang China Fax 0086 571 88926789 0086 571 88132890 ZIP 311305 Web http www hcforklift com E mail sales h...
