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1.4 Drive system dismantle

1 Open rear hood assembly

2 Remove four fixed bolt of steering rocker arm.

Remove wiring connected drive system(like

motor, brake wiring)

Remove the connecting pin shaft between

connecting rod and frame.

5 Hoist the drive system.

Assembling order is opposite to the disassembling order.

Содержание CBD20-AC1S

Страница 1: ...ELECTRIC PALLET TRUCK CBD20 30 AC1S CBD20 30 AZ3S CBD20 30 AC1S I OPERATION AND MAINTENANCE MANUAL Original Instruction HANGCHA GROUP CO LTD 11 2019 Hi Range...

Страница 2: ...on and correct operation of the hi range electric pallet truck which will tell you how to operate safely and maintain preventively part two will tell you the structure working principle and maintenanc...

Страница 3: ...ravelling 44 6 4 Braking 47 6 5 Steering 47 6 6 Stopping 47 6 7 Loading 47 6 8 Unloading 48 6 8 Parking 49 7 Deposit the truck for long time 50 7 1 Deposit for long time 50 7 2 Start running after dep...

Страница 4: ...nit 84 2 3 Hydraulic unit dismantle 87 2 4 Dismantle the lifting cylinder from the truck or replace 88 2 5 Hydraulic system fault diagnosis and correction 89 3 Electric system 90 3 1 Principles of ele...

Страница 5: ...operation way it has two types as pedestrian type and platform type according to different steering way it has manual steering and electric steering electric steering is divided into DC steering The...

Страница 6: ...c system 24V Electric system CURTIS latest AC controller Control handle adopt CAN BUS system with simple wiring and reliable communication Four speed mode Truck travelling hour battery volume and faul...

Страница 7: ...ck tipping over Used on the road with good vision and equipment use license Max uphill grade when driving is 6 It is prohibited to travel crosswise or obliquely When go uphill with loads keep the load...

Страница 8: ...1 Control handle 8 Drive wheel 2 Instrument 9 Rear frame 3 Arm guard lock switch 10 Fork 4 Arm guard 11 Load wheel 5 Rear hood assembly 12 Key switch 6 Auxiliary wheel 13 Emergency stop switch 7 Peda...

Страница 9: ...5 1 4 Display and control 18 1 2 3 12 13 16 17 19 19 22 21 20 21 22...

Страница 10: ...to view in this paper the fault code table BDI indicator yellow LED When battery remaining power less than 20 the yellow LED indicator lights flashing warned depleted at the same time LCD display show...

Страница 11: ...on level able to adapt to a variety of complex environments Instrument graphic No Paramter name Description 1 Hour meter The number shows the current accumulated working hours of the vehicles with a m...

Страница 12: ...flashes 3 When the hour meter is in the main interface it is always displayed 4 Some models are not used so the speed is displayed as 0 5 It is panel screen printing color around the meter 6 When ther...

Страница 13: ...the other hand press the arm guard until it rotates to certain angle release arm guard lock switch and press the arm guard to lock position When open the arm guard push the arm guard lock switch with...

Страница 14: ...s to the fork side Truck travels to the handle side or pedal Press this control handle downwards Turn this button towards the side of body gradually with thumb Truck travels to the handle side or peda...

Страница 15: ...disrepair or abnormal wear according to necessity If there is disrepair on the load wheel or its inner bearing suspend the truck off the ground or jack the front outrigger off the ground replace the w...

Страница 16: ...1867 Overall length unfold the pedal L1 mm 2299 2299 Overall width b1 mm 800 800 Fork size s e L mm 64 170 1150 64 170 1150 Outside fork width b5 mm 540 680 540 680 Ground clearance center of wheelba...

Страница 17: ...b1 mm 800 800 Fork size s e L mm 64 170 1150 64 170 1150 Outside fork width b5 mm 540 680 540 680 Ground clearance center of wheelbase min m2 mm 25 25 Min right angle stacking aisle width1000 1200 ac...

Страница 18: ...e L mm 64 170 1150 64 170 1150 Outside fork width b5 mm 540 680 540 680 Ground clearance center of wheelbase min m2 mm 25 25 Min right angle stacking aisle width1000 1200 across forks Ast mm 24352 243...

Страница 19: ...15 m2 a 2 a 2 260 Ast c x L y L1 432...

Страница 20: ...shows the approximate location of the various identity resides Before operating the truck please understand the meaning of the various identities V kW mm kg kg kg kg ELECTRIC PALLET TRUCK MODEL TYPE...

Страница 21: ...27 Hoist label Fixed point when using the crane to handle equipment 28 Key switch is off 29 Emergency stop label means disconnect means connect 30 Hazard label Risk of trapping when cylinder extended...

Страница 22: ...near the battery when checking Be careful of scald when checking motor and controller 7 The controller equips with energy accumulator do not touch between B and B to avoid electric injury If you need...

Страница 23: ...k when the forks in high position 16 When handling bulky loads which restrict your vision please operate the machine in reverse or have a guide 17 Cause the wheels of pallet truck is small it is not a...

Страница 24: ...truck outdoors and exposed to the rain 28 Before dismantle or repair the truck remove the battery plug firstly 29 The truck should be used under the environment of the light is enough 30 Only in the e...

Страница 25: ...e lifting gear with sufficient capacity for truck weight see truck nameplate Do not stay under the truck when hoisting the truck When hoisting or laying down it should be stable and slow to avoid coll...

Страница 26: ...Sling the tensioning belt around the truck and attach it to the fastening rings of the transporting vehicle Use wedges to prevent the truck from moving Tighten the tensioning belt with the tensioner...

Страница 27: ...aged since the brake of the truck is closed under normal circumstances Appropriate vehicles should be used to remove the broken trucks WARNING Do not tow the broken trucks on the ground directly or el...

Страница 28: ...ack and make sure there is no covering on the battery At the same time you must open the filling cap of each single battery to keep good ventilation environment 7 The battery must be charged with DC T...

Страница 29: ...es of battery charger so as not to charge lithium batteries 4 Do not open the lithium battery cover maintenance lithium battery failure timely contact with the manufacturer 5 The battery is not used a...

Страница 30: ...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...

Страница 31: ...Otherwise it will hurt your eyes 30 Contact with skin The electrolyte inside the battery may cause skin infections inadvertent contact take off contaminated clothing and wash the infection with plenty...

Страница 32: ...ference of the battery 2 When charging it is necessary to have a professional staff to take care of it Make sure the plug and socket are in good contact during charging to ensure that the charging equ...

Страница 33: ...m 650 650 650 Width W mm 201 201 249 Height H mm 570 570 625 Allowable lightest kg 140 190 260 Allowable heaviest kg 240 270 285 WARNING Battery weight and dimensions have considerable influence on op...

Страница 34: ...he battery plug 38 from the charger Close the fill cap of each battery cell Connect the battery plug 38 with truck socket and cover the battery hood 14 After charging the truck can be used 39 14 38 WA...

Страница 35: ...c shock and cause personal injury Provide adequate ventilation during charging To avoid damage to charger cord plug and receptacle do not pull on charger cord plug Do not twist rock or bend plug sidew...

Страница 36: ...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...

Страница 37: ...in the following case a discharge voltage often drop down final voltage b discharge current is often larger c not charge in time after discharge d the electrolyte is mixed with impurity with a little...

Страница 38: ...attery The storage battery with a dobber When the red dobber rises the white line appears please stop replenishing The storage battery without a dobber When the electrolyte is above 15 20mm of the ele...

Страница 39: ...in to D30 the specific gravity at the standard temperature of 300 C Dt the specific gravity at the temperature of t0C t the temperature of the distilled water during convert The specific gravity refer...

Страница 40: ...7 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...

Страница 41: ...wo hoisting hole of the battery tank 37 and fix it Use the crane to pull out the battery vertically Installation is in the reverse order of operations Check for correct mounting position and correct c...

Страница 42: ...ll Light Green light The SOC is over 80 less than 100 the green light flashes When SOC 100 the green light is always on Battery 5 digit Yellow light Battery charging process indicator 4 Operating Inst...

Страница 43: ...er confirmation power off and recharging 6 Storage condition Temperature 40 90 Humidity 5 95 Keep away from inflammable explosive and corrosive chemicals Avoid strong vibration and impact 7 After sale...

Страница 44: ...iven below should be observed while the truck is in a stage of 100 hours of operation Avoid the new battery over discharging in early period Perform specified preventive maintenance services completel...

Страница 45: ...pear interference when move movement point wear whether severe 5 Hydraulic oil check Open the hood check if the oil level within the scales Add oil when insufficient 6 Battery check Check the battery...

Страница 46: ...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 12 Horn Press the h...

Страница 47: ...sconnect switch 13 Turn on the key switch 12 If you need to stand on the pedal to operate for the stand on type truck you need open the pedal 7 and arm guard 4 CAUTION Make sure the work ground is har...

Страница 48: ...protective boots When enter narrow area as lift first get fork go Keep road clean and wipe greasy dirt water or other easily causes slipping dirty Travelling on the slope When going uphill and downhil...

Страница 49: ...pedal Operation way is as pedestrian type truck When adopt this way truck will travel at low speed 2 Stand on operation but fold the arm guard When adopt this way truck will travel at medium speed 3 S...

Страница 50: ...e truck Open the pedal Step on the pedal Swivel the control handle to driving range F Adjust the direction speed control button 19 to the desired direction Control truck speed by direction speed contr...

Страница 51: ...h hands and decline to some degree move the handle to left or right to release truck steering When turn to left the truck turns left When turn to right the truck turns right Caution When truck turns t...

Страница 52: ...e deposit area Raise the loads to correct height Travel forward put the load on the unloading position and then stop Make sure the loads are right above drop the forks slowly until the forks are out o...

Страница 53: ...the following steps Drive the truck to safe area or appointed area Fully lower the forks Turn off the key switch 12 and remove the key Press the emergency disconnect switch 13 Fold pedal 7 and arm gua...

Страница 54: ...rication grease Check electrolyte proportion and level once a month Carry out one equalizing charge once a month In order to avoid bearing rust run the truck every six months to observe if truck works...

Страница 55: ...g to the local environmental protection laws and regulations Draw up complete maintenance plan After CAUTION No fire You should shut off key switch and pull off the plug before service except some tro...

Страница 56: ...tery Electrolyte level Eyeballin g Electrolyte proportion Areomete r Battery quantity Terminal looseness Looseness of connecting wire Cleanness of the battery surface If there are tools on the battery...

Страница 57: ...ation and noise if the base is firm or or Whether the connection is correct and firm If temperature is normal and current is normal Driving system Service item Service required Tool D W M T S Reductio...

Страница 58: ...ice required Tool D W M T S Hydraulic reservoir Check for oil level change oil 166hrs for the first time Clean suction strainer Clean foreign matter solenoid valve Check for block return spring stuck...

Страница 59: ...est hammer Check for operation Check for oil leak Check lifting cylinder fixed bolt for looseness Fork Check forks for damage deformation or wear Check fork base and hook welding for defective cracks...

Страница 60: ...l 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 Reduction box C...

Страница 61: ...ainer After oil in the reduction box drains re tighten the drain plug 47 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...

Страница 62: ...rain the oil to the container After oil in the reduction box drains re tighten the drain plug 49 Add appointed gear oil L HM32 to allowable scale range In order to add oil easily add with help of funn...

Страница 63: ...lic hose for lifting system 1 2 High pressure hose hose for hydraulic system 2 Inner sealing element rubber matter of the hydrulic system 2 8 5 Screw down the wheel retaining nut Re tighten the wheel...

Страница 64: ...51 52 on the panel 5 with a wrench Lift the hood 5 remove it from the truck and place it securely next to the truck The panel is now disasdembled Instead of the installation sequence and disassembly...

Страница 65: ...EN1175 1 1998 A1 2010 Safety of industrial trucks Electrical requirements Part 1 General requirements for battery powered trucks EN1726 1 199 Safety standard for machinery industrial vehicle EN1757 2...

Страница 66: ...62...

Страница 67: ...Drive system is mainly consisted of connecting rod drive seat reduction box drive motor electromagnetic brake etc 1 Connecting rod 2 Drive seat 3 Steering gear wheel only for electric steering 4 Drive...

Страница 68: ...s 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 O...

Страница 69: ...output flange 5 Power transmission order is that 1 drive 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 rea...

Страница 70: ...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...

Страница 71: ...oard lock the lower nut to avoid looseness and the suggested tightening torque is T 10 2 12 4N m Rated power kW Rated voltage V Rated current A Max current A Rated speed r min Insulatio n grade Freque...

Страница 72: ...e Protectio n grade Temperature 0 2 24 13 3300 2000 0 562 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 b...

Страница 73: ...hot with smoke or electric contact sparking smoke turn off the power immediately for check Often check if the motor over heats Often check motor wiring contact screw for looseness sparking smoke or in...

Страница 74: ...up Motor starts hard and the motor speed is much lower than rated speed with rated load Power voltage too low Motor wrongly connected to Y Cage rotor open weld or crack Local coil of stator and rotor...

Страница 75: ...with stator Bearing overheat Over much or few grease Bad oil quantity and contains impurity Mismatch between bearing and journal or end cap too loose or too tight Eccentricity of bearing bore rub with...

Страница 76: ...brate Gap between brush and brush box is too large The distance between brush box and commutator working surface is too long The mica between commutator segments extrudes Brush material is not good Br...

Страница 77: ...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 Mounting screw 3 Fric...

Страница 78: ...5 thus generates braking torque For this moment there will be a to release the brake stator 11 connects the DC then the generated magnetic field draws the armature 8 move to the stator 11 spring 10 is...

Страница 79: ...ion 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 module 2 bef...

Страница 80: ...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...

Страница 81: ...fications Rated torque Rated power Rated air gap Max air gap Rotor min thickness Tightening torque of mounting screw 16 N m 30 W 0 2 mm 0 5 mm 8 1mm 9 0 N m When the brake is off power adjust three ho...

Страница 82: ...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...

Страница 83: ...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 voltage...

Страница 84: ...Remove four fixed bolt of steering rocker arm 3 Remove wiring connected drive system like motor brake wiring 4 Remove the connecting pin shaft between connecting rod and frame 5 Hoist the drive syste...

Страница 85: ...ulic unit left right lifting cylinder booster cylinder and rubber tube etc 1 Hydraulic unit 2 Left lifting cylinder 3 Right lifting cylinder 4 Booster cylinder 5 Pipeline assembly 6 Rubber tube assemb...

Страница 86: ...ump through coupling device hydraulic oil enters lifting cylinder through one way valve and forks lift When press the lowering button of the control handle lifting motor does not rotate the solenoid v...

Страница 87: ...83 CBD20 30 AC1S CBD20 30 AZ3S Hydraulic Schematic Diagram...

Страница 88: ...vel in the oil tank add oil after certain working cycle If pump absorbs air it may damage the pump and the sealer Replace new oil after truck adds hydraulic oil for the first time and travel 100 hours...

Страница 89: ...l condition but should not exceed the nominal pressure Here follow the adjustment ways Take apart the cover Connect oil pressure gauge to the pressure mouth Loosen main safety valve locking nut screw...

Страница 90: ...If pump absorbs air it may damage the pump and the sealer Replace new oil after truck adds hydraulic oil for the first time and travel 100 hours And then replace new oil every year about 1500hrs Hydr...

Страница 91: ...ismantle the connector of the hydraulic unit and the cylinder Remove the wiring on the motor contactor and control valve Remove the tightening bolt that fix hydraulic unit Take out hydraulic unit Asse...

Страница 92: ...Take apart the hood Dismantle piping joint from the cylinder Loosen the cylinder fixed bolt from cylinder Dismantle the pin shaft from the cylinder supporting point Take out the cylinder to replace or...

Страница 93: ...Adjust or replace 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 tempe...

Страница 94: ...90 3 Electric system 3 1 Principles of electrical system...

Страница 95: ...91...

Страница 96: ...92...

Страница 97: ...93...

Страница 98: ...2 2101 controller 2 SW80 24 contactor 3 Fuse 160A 100A Fig 3 1 Controller assembly Manual steering 1 1232 2301 controller 2 1220 2201 controller 3 SW180 24 Contactor 4 Fuse 275A 100A Fig 3 2 Controlle...

Страница 99: ...attery power supply system Be careful when operating the truck power supplied by battery Including but not limit to the following correct training wear goggles do not wear loose clothing and jewelry C...

Страница 100: ...the correspo nding fault code of LED flash Check if input signal normal us able encoder Check if the output signal from controller to motor is normal if two terminals output after accelerato r input...

Страница 101: ...t When the truck has fault the LED3 RED indicator light is on LCD displays fault type and code Get fault information by switching in handheld programmer Refer to Handheld Programmer Get fault informat...

Страница 102: ...t is off Controller power is not on or vehicle has dead battery or other severe damage LED light flashes yellow Controller is in normal working status LED light is often red Controller failed to super...

Страница 103: ...nditions that set and clear each fault Troubleshooting This fault codes provide the following information Fault code Display fault name on the Curtis programmer Display caused by the fault Probable fa...

Страница 104: ...eason 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...

Страница 105: ...torque reduces 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 disconn...

Страница 106: ...ver 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 Troubleshooting Correct open or short circuit...

Страница 107: ...le invalid Brake 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 st...

Страница 108: ...ult 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 l...

Страница 109: ...art the key switch 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 s...

Страница 110: ...the effective signal 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 s...

Страница 111: ...if it is caused by motor installing 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...

Страница 112: ...108...

Страница 113: ...Programmer display Probable fault reason Fault display 23 Motor Polarity Fault Steering stops Drive stops 1 Steering motor is the cathode 2 The encoder phase sequence counter 36 Motor Stalled Steerin...

Страница 114: ...to motor controller all motor controller information uploads to the handheld programmer Display screen It can show seven line test and pictures at the same time Menu navigation key Move the cursor on...

Страница 115: ...4 44 54 49 64 76 107 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...

Страница 116: ...112 Maintenance Record Date Repair maintenance content Serviceman...

Страница 117: ...HANGCHA GROUP CO LTD Address 88 Donghuan Road Lin an Economic Development Zone Zhejiang China 571 88926789 0086 571 88132890 http www hcforklift com mail sales hcforklift com...

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