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Fault diagnosis

Fault

Probable cause

All copper sheet blacken

Pressure of the brush is not right

Commutator segments blacken in

group according to certain sequence

·Short circuit of commutator segments

·Short circuit of armature coils

·The welding of commutator segments and armature

coils is not good or short circuit.

Commutator segments blacken, but

without sequence

·Center line shift of the commutator

·Rough, un-round of the commutator surface

Wear, color change and fracture of

brush

·Motor vibrate

·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.

·Trade mark of brush is not right

Large spark

·Overloaded of motor

·Commutator is not clear

·Commutator is not smooth or round

·Mica plate or part commutator segment extrude

·Brush does not grind well

·Brush pressure is not large enough

·Incorrect brush trade mark

·Brush locked in the brush box

·Brush carrier loosen or vibrate

·Incorrect pole polarity and sequence

Brush and brush wire overheat

·Large brush spark

·Electrical brush and flexible conductor have bad contact

·Small flexible conductor area

Noise in the brush

Uneven commutator surface

Содержание CBD20-AMC1

Страница 1: ...ELECTRIC PALLET TRUCK CBD20 AMC1 OPERATION AND MAINTENANCE MANUAL Original Instruction HANGCHA GROUP CO LTD 3 2018 Mini Range ...

Страница 2: ...ck Part one of this manual is about the brief introduction and correct operation of the mini 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 maintenance of the electric pallet truck To ensure safety and exert the truck s potential all the personnel that in charge of operation maintenance and ...

Страница 3: ...2 6 Product plates and warning labels location 13 3 Safety Instructions 15 4 Transport 18 4 1 Lifting by crane 18 4 2 Securing the truck during transport 19 4 3 Transport 20 5 Battery 21 5 1 Safe operation rules for battery use 21 5 2 Maintenance of the Battery 21 5 3 Battery charging 23 5 3 1 Power interface 23 5 3 2 Battery charging steps 23 5 3 3 Additional charge 24 5 4 Replacing battery 25 6 ...

Страница 4: ...6 1 2 Assemble and use notice 47 1 3 Fault and troubleshooting 47 1 4 Drive Motor 48 1 5 Electromagnetic brake 52 1 5 1 Electromagnetic brake working principle 53 1 5 2 Electromagnetic brake installation 54 1 5 3 Maintenance 55 1 5 4 Adjust the Air Gap of the Brake 56 1 5 5 Common fault and troubleshooting 58 2 Hydraulic system 59 2 1 Hydraulic system working principle 59 2 2 Hydraulic system faul...

Страница 5: ...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 1 2 Use as required Pick and place goods with trays Transport goods with trays Do not carry people Do not over load Do not push or pull loads Do not work together on the same goods by multiple pallet trucks ...

Страница 6: ...is 8 When going uphill with loads keep the loads in front when going downhill keep people in front It is prohibited to travel crosswise or obliquely Please read others safety rules in this manual it is important to your personal safety working staff and goods safety WARNING It s prohibited to use the truck in the area of the explosion Special equipment and authorisation are required if the truck i...

Страница 7: ...ld storage remove it from the cold storage immediately and repair in buffer zone or maintenance area 1 5 Proprietor responsibilities For the purposes of the present operating instructions the proprietor is defined as any natural or legal person who either uses the industrial truck himself or on whose behalf it is used In special cases e g leasing or renting the proprietor is considered the person ...

Страница 8: ...of the vehicle it also needs to make corresponding modification to vehicle nameplate decals logo and brochures In the event the truck manufacturer is no longer in business and there is no successor in the interest to the business the user may arrange for a modification or alteration to a powered industrial truck manufacturer and the user shall a Arrange for the modification or alteration to be des...

Страница 9: ...rking time should not surpass one hour Users can get relevant information as rated load from the product model CBD20 AMC1 Meaning CBD Electric pallet truck 20 Rated load capacity 100kg A Product serial number M Mini Range C1 Controller type The following determinations have been made for travel direction specification Forward direction Left Right Rear direction ...

Страница 10: ...el battery adopted to provide convenient usage The compact body and semicircular design provide an ideal operation in limited space and the ability of walking upright greatly increases the convenience in the container Side battery change is standard feature Reliability 5 pivot design provide longer working life Imported waterproof connectors all wires and cables are protected greatly improve the r...

Страница 11: ...t the pump motor from damaging dramatically and more energy saving Maintenance Built in charger and maintenance free gel battery you don t need to worry about them Integrated battery indicator hour meter and self diagnostic instrument Full openedhood easy accessibility of all components is easy for service All shafts installed lubricated shaft sleeve and oil cup provide convenient maintenance and ...

Страница 12: ...r 12 Wire fixator 4 Drive wheel cover 13 Battery charging plug built in plug 5 Caster wheel 14 Display battery charge level indicator 6 Drive wheel 15 Hood 7 Fault indicator 16 Emergency stop switch 8 Charging light indicator with built in charger 17 Key switch 9 Side door built in battery 11 10 17 16 15 14 13 12 1 4 2 3 5 6 5 7 8 9 ...

Страница 13: ...9 2 4 Display and control 7 8 21 20 19 20 21 22 23 22 17 16 14 13 18 2 ...

Страница 14: ...ator and the truck total work hour indicator 16 Emergency stop switch Cut the connection with the battery close all electric function and brake 17 Key switch Switches the control current ON and OFF The truck cannot be operated by unauthorized persons when the key has been removed from the switch 18 Upright traveling button Press the button the control lever in vertical state truck can run 19 Horn ...

Страница 15: ...ttery s discharge status is displayed through the instrument s 10 cell LED bar A grid of LED bars corresponds to 10 of the battery capacity As the capacity of the battery decreases the 10 cell LED lights up from right to left 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 Fully ch...

Страница 16: ...00 Dimensions Lift height h3 mm 120 Fork height lowered h13 mm 80 Overall length L1 mm 1728 Overall width b1 mm 680 Fork dimensions s e L mm 50 160 1150 Distance between fork arms b5 mm 560 Ground clearance center of wheelbase m2 mm 30 Min right angle stacking aisle width1000 1200 across forks Ast mm 2240 Min ringht angle stacking aisle width 800 1200 across forks Ast mm 2150 Outer turning radius ...

Страница 17: ... curve plate warning labels must be legible if identification is unclear and must be replaced The figure below shows the approximate location of the various identity resides Before operating the truck please understand the meaning of the various identities 30 29 33 24 31 32 25 26 27 28 27 28 ...

Страница 18: ...indicator 26 Charging light indicator Overnight charging recommend after use 27 Manufacturer s logo 28 Hoist label Strap points for crane lifting 29 Emergency stop label press this button when in emergency thus the truck power is off 30 Key switch OFF position is off ON position is on 31 Please cut off the electricity when charging 32 Series tonnage label A series rated capacity is 2t 33 Walking u...

Страница 19: ...f the oil grease or water on the soleplate foot pedal and control lever No smoking or any spark smoke 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 check or clean the controller connect load like contactor coil or horn or bulb or resistance betwe...

Страница 20: ...ure no people around 13 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 14 Avoid sudden drive stop or turn 15 Do not drive the truck when the forks in high position 16 When handling bulky loads which restrict your vision please operate the machine in reverse or h...

Страница 21: ...lative humidity less than 90 20 Altitude should not exceed 2000m 22 After power off brake works and the truck can not be towed dragged 23 Please obey the requirement in this manual and the truck label when operation Check label identification plate replace damaged or fallen ones 24 Fire extinguisher shall be equipped at the work site Users can choose truck equipped with fire extinguisher Driver an...

Страница 22: ...se 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 collision or accident Procedure Park the truck securely Secure the lifting slings to the strap point and prevent them from slipping Crane slings should be fastened in such a way that they do not come int...

Страница 23: ...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 WARNING The truck or trailer must have fastening rings Use wedges to prevent the truck Only use tension belt or fastening belt of good nominal strength 35 ...

Страница 24: ...truck firmly on the transport vehicle with belt and block the wheel to avoid relative motion during transportation 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 Do not tow ...

Страница 25: ...ot mix the old and new batteries Do not use when under overload high humidity or heavy grade When charging do not wrongly connect the battery polarity otherwise it may damage the battery After battery scrap please return to the recycle bin unified handling may not arbitrarily discarded 5 2 Maintenance of the Battery Do not fill water for battery maintenance when it is in service Inspect the batter...

Страница 26: ...at depth of discharge is around 50 It should not be more than 80 Make the battery fully charged and store it if the truck remains unused It is also suggested to charge the battery once a week when the truck is unused Battery capacity is based on environmental temperature 25 Therefore it s a normal phenomenon that the range decreases when the temperature goes down The battery capacity decreases by ...

Страница 27: ...arging steps Procedure Park the truck securely Remove the charging plug 13 together with the wire fixator 12 from the hood 15 The battery charging plug 13 is inserted into the appropriate electrical outlet To charge the battery until the charging light indicator 8 green on the battery is full charged LED red on Charging mode LED green on Full charged LED yellow flash Charger fault LED yellow on Ba...

Страница 28: ...24 5 3 3 Additional charge Charger structure enables to continue charging the partially charged battery in use 13 12 8 15 ...

Страница 29: ...sides respectively pull the battery 35 Pull the battery 39 from the frame Install the battery in the reverse order Pay attention to the battery loading position and wiring is correct WARNING Battery box is very heavy be careful to avoid damage Disposal to the waste battery should accord with local environment regulation When replacing the battery ensure that a battery of the same specification dim...

Страница 30: ...given 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 completely Avoid sudden stop start or turn Limited load is 70 80 of the rated load Often check and fasten the fasteners of each joint part After the break in ends replace hydraulic oil ...

Страница 31: ...ism Check the fork and linkage mechanism see whether bended or crazed Whether appear interfere 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 cover board See whether the battery fixed reliably Check the terminal for loose or damage Otherwise adjust or replace 7 Ins...

Страница 32: ...forward or backward push the handle to vertical position or press to level position to check the brake condition 11 Steering system Left or right turn the handle to make the truck run around 3 turns and then check if the steering system is normal 12 Horn Press the horn button to check sound 13 Appearance Check the truck appearance for clean rust or paint spalling 14 Others Check whether there is a...

Страница 33: ...re operation and make sure each function and state is normal Pull up the emergency stop switch 16 Plug the key into key switch 17 turn to ON position in clockwise The instrument displays battery capacity Truck goes into running state 17 16 OFF O N ...

Страница 34: ...ctive boots When enter narrow area as lift first get fork go Keep road clean and wipe greasy dirt water or other dirty easily causes slipping Travelling on the slope When going uphill and downhill without load keep the fork to downhill direction when going uphill and downhill with load keep the fork to uphill direction WARNING No turn inclines when going uphill and downhill Never park on the slope...

Страница 35: ...wivel into the braking range slowly or nor enter braking range do check the reason and eliminate the fault Replace gas spring if necessary 7 5 Steering Hold the left and right handle of control handle with both 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 7 6 Stopping Rele...

Страница 36: ...ads Adjust fork height to make the forks are in the tray 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 Travel forward put the load on the unloading position and then stop Make sure the loads are right above drop the forks slowly ...

Страница 37: ...33 Travel backward and make the fork out of the load Drop down the forks to proper position ...

Страница 38: ...4 7 9 Park the truck securely Procedure Drive the truck to safe area or appointed area Fully lower the forks Turn off the key switch 17 and remove the key Press the emergency stop switch 16 17 16 OFF O N ...

Страница 39: ...atch on the piston rod surface Apply anti rust oil to piston rod or easily rusty axle Cover the whole truck At least once a month to fully charge 8 2 Start running after deposit for a long time Remove rust preventive oil on exposed parts Clean impurity and water of the hydraulic oil tank Recharge battery fit on truck and connect Carefully check before start Inspect starting travelling slowing down...

Страница 40: ... at will and carry on handling according to the local environmental 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 No fire You should shut off key switch and pull off the plug before service except some trouble shooting Clean the electric part with compre...

Страница 41: ... least every 1 5 months 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 Battery D W M T S Y 1 Check the battery and battery components 2 Check the battery capacity 3 Check the battery fixed situation 4 Check battery cable connections are secure 5 Clean the battery surface Ch...

Страница 42: ...ystem 2 Check that hydraulic ports hose and pipe lines are secure check for leaks and damage 3 Check cylinders and piston rods for damage and leaks and make sure they are secure 4 Check hydraulic oil level and top up if necessary 5 Test relief valve and adjust if necessary 6 Lubricate the truck according to the lubrication schedule 7 Replace the hydraulic oil after 2000 service hours biannually Li...

Страница 43: ...ruck securely Unscrew the hood screws 41 Lift the hood 15 The wire fixate 12 and the battery charging plug 13 from the hood 15 to take off on The hood is removed Installation and removal process is reversed WARNING Remove or installing a hood carefully clip hand 41 15 12 13 ...

Страница 44: ...ive wheel cover Procedure Unscrew the drive wheel cover 4 of the four screws 40 remove the drive wheel cover The drive wheel cover is removed Installation and removal process is reversed WARNING Remove or installing the drive wheel cover carefully clip hand 40 40 4 ...

Страница 45: ... A Hydraulic oil Normally L HM32 High and cold environment L HV32 Hydraulic system C Grease Automobile general 3 lithium base lubricant Nozzle and lubrication CAUTION Into the fuel tank of hydraulic oil must be filtered and the injection volume of the hydraulic oil tank does not exceed the maximum scale A C C C C C C C ...

Страница 46: ...aintenance work to complete preparations before the operation Remove the hood Check the fuse 42 43 values are correct if necessary replace No Designation Control circuit Specification 42 Fuse Pump motor 50A 43 Fuse Controller 50A 43 42 ...

Страница 47: ...ay when unscrewing the bolts and remove the bolts respectively Strike the edge of the driving wheels with a rubber hammer and remove the old driving wheels from the drive unit CAUTION Strike the edge of the driving wheels evenly and symmetrically Do not scratch the outer surface of inner ring gearbox and the inner surface of the driving wheels Install new driving wheels Apply lubricating oil to th...

Страница 48: ... Safety of industrial trucks Electrical requirements Part 1 General requirements for battery powered trucks EN1726 1 1998 Safety standard for machinery industrial vehicle EN12053 2001 EN1175 1 1998 EN13059 2002 EN1757 2 2001 harmonized standard Main safety elements are in accordance with 2006 42 EC machinery directive as well as EN1175 1 1998 A1 2010 EN1726 1 1998 EN1757 2 2001 standard Electronic...

Страница 49: ...45 ...

Страница 50: ...oad kg 1000 Drive motor Rated voltage V 48 Rated power kW 0 8 Rated current A 21 Rated speed r min 3300 Working system S2 45min Insulation grade F Protection grade IP44 Using the environment temperature 10 40 Brake Rated voltage V 24 Rated power W 25 Rated braking torque N m 8 Rated Air Gap mm 0 15 0 30 Pre tension torque of the mounting screw Nm 5 5 ...

Страница 51: ... is 2 5 2 3 space of the inner chamber 1 3 Fault and troubleshooting Fault Probable cause Corrective action Abnormal gear noise when travelling Over large gear clearance Adjust Lack grease Replenish Over large gear wear Replace Abnormal noise when turning Rotary rolling bearing damage Replace Insufficient rotary rolling bearing grease Add grease Brake ineffective or invalid Inching switch loosen o...

Страница 52: ...oke 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 insulation aging Use and maintenance Stator parts and brush neutral position has been adjusted before sold so users should not dismantle or adjust at will Check if motor rotates flexibly or abrades Check if motor outlet or terminal connection is co...

Страница 53: ...rder not to affect its heat dissipation Check the motor at least once half year according to the following way a Check the outer part and clean dust on the motor b Clean and replace bearing listen if there is abnormal noise during running c Check brush abrasion and replace if necessary Replacement of the Brushes Brushes must be replaced when they are seriously worn or damaged All brushes should be...

Страница 54: ...50 After polishing crocus cloth and cleaning commutator motor should work under limited speed to ensure safety until the brush working surface polishes ...

Страница 55: ...rush 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 Trade mark of brush is not right Large spark Overloaded of motor Commutator is not clear Commutator is not smooth or round Mica plate or part commutator segment extrude Brush does not grind well Brush pressure is not larg...

Страница 56: ...h 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 3 Brake Pad 5 Friction Disk 2 Stator Module 4 Shaft Sleeve 6 Dustproof Cover Fig 2 3 Electromagnetic brake parts 1 2 3 4 5 6 ...

Страница 57: ...rque is created There will be a air gap Z between the armature and the stator at that moment When the brake needs to be relaxed the stator is applied with direct current and the magnetic field would attract the armature 8 to move towards the stator The movement of armature compresses the pressure spring 10 which cause the loosening of the brake pad 3 by that time and the brake is released 1 Mounti...

Страница 58: ...g bolts of the friction bolts 12 Cover the shaft sleeve with the friction disk 3 Install the stator module 2 to the friction disk 5 with three mounting bolts of the brake 1 Note Remove the three rubber mats of the stator module which is for stable transportation Screw down the three mounting bolts 1 with a torque wrench 15 and check the air gap Z of the brake with a feeler gauge 16 Put on the dust...

Страница 59: ...ed voltage on the nameplate Deviation should not be more than 10 Make sure it is free from oil and dirt when installing and using the brake 1 5 3 Maintenance If work in high temperature environment for long time please prevent rust it may influence use if there is rust on the suction surface Do not touch the friction surface with hand no oil stain otherwise it cannot reach the maximum torque Gener...

Страница 60: ... the air gap between stator 1 and armature 2 to the rated Z by a feeler gauge Ensure air gap at all directions are same Specification Table Rated Current V Rated Power W Rated Torque N m Rated Air Gap mm Minimum Thickness of Rotor mm Pre tension Torque of the Mounting Bolt N m 24 25 8 0 15 0 30 6 4 5 5 On the condition of power disconnected through adjusting 3 mounting bolts of brake 1 and the hol...

Страница 61: ...500 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 ...

Страница 62: ... for 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 Check voltage and adjust Clutch or motor interfere to the brake Check control circuit eliminate interference High environment temperature Set ventilation High operating frequency Adjust to proper...

Страница 63: ...59 2 Hydraulic system 2 1 Hydraulic system working principle ...

Страница 64: ...lace 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 normal Bubble in the hydraulic oil Check the reason for the bubble and then take measures Forks can t lift Gear pump works Oil way block or damage Repair or replace Gear pump no work Lifting inching switc...

Страница 65: ...61 3 Electric system 3 1 Electrical schematic diagram ...

Страница 66: ... by battery Including but not limit to the following correct training wear goggles do not wear loose clothing and jewelry Carry out maintenance according to the following cleaning procedure Never clean the controller with high pressure washer Remove battery to disconnect power Connect load like contactor coil or horn between controller B and B to discharge controller capacity Clean dirt or corrosi...

Страница 67: ...rious faults Faults are listed alphabetically Note The status LED can only indicate one fault at a time If multiple faults are detected the highest priority fault code flashes until it is cleared Programmer Diagnostics The programming devices present complete diagnostic information in plain language Faults are displayed in the Faults Diagnostics menu and the status of the controller inputs outputs...

Страница 68: ... open 2 Main contactor coil drive wrong 2 4 Main On Fault 1 Main contactor coil wrongly turn off 2 5 no used 3 1 Wiring Fault 1 Incorrect throttle operation 2 Throttle port or its mechanical part has fault 3 2 Brake On Fault 1 Electromagnetic brake coil open 2 Electromagnetic brake drive short 3 3 Precharge Fault 1 Controller fault 2 Low battery voltage 3 4 Brake Off Fault 1 Electromagnetic brake ...

Страница 69: ...39 44 58 12 35 44 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 24 294 370 370 441 441 539 638 850 27 441 519 539 686 637 784 933 1244 Note Use entirely 8 8 grade bolt in the important joint position Bolt s grade can be found in the head of the bolt if it can...

Страница 70: ...Maintenance Record Date Repair maintenance content Serviceman ...

Страница 71: ...HANGCHA GROUP CO LTD Address 666 Xiangfu Road Hangzhou Zhejiang China Fax 0086 571 88926789 0086 571 88132890 ZIP 311305 Web http www hcforklift com E mail sales hcforklift com ...

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