WESCO INDUSTRIAL PRODUCTS, INC. Heavy Duty Semi Electric Pallet Truck. Part Number:

Transcription

1 WESCO INDUSTRIAL PRODUCTS, INC Heavy Duty Semi Electric Pallet Truck Part Number: Note: Operator MUST read and understand these operating instructions before using this Hand Pallet Truck.

2 Table of Contents 1 General Information Description Specifications Assembly and Adjustment Assembly Adjustment Operation Lifting Lowering Braking Parking Maintenance Battery Replacement Battery Charging Scheduled Maintenance Troubleshooting Pilot Light Indications Common Troubleshooting General Assembly 1 Part Information General Assembly 1 Part Diagram General Assembly 1 Part List General Assembly 2 Part Information General Assembly 2 Part Diagram General Assembly 2 Part List Drive Wheel Assembly Part Information Drive Wheel Assembly Part Diagram Drive Wheel Assembly Part List Fulcrum Bearing Assembly Part Information Fulcrum Bearing Assembly Part Diagram Fulcrum Bearing Assembly Part List Connecting Rod and Wheel Carrier Unit Part Information Connecting Rod and Wheel Carrier Unit Part Diagram Connecting Rod and Wheel Carrier Unit Part List Handle Unit Assembly Part Information Handle Unit Assembly Part Diagram Handle Unit Assembly Part List Pump Assembly Part Information Pump Assembly Part Diagram Pump Assembly Part Diagram Page 1 of 22

3 NOTE: All of the information reported herein is based on data available at the moment of printing. We reserve the right to modify our own products at any moment without notice and liability in any sanctions. So, it is suggested to always verify possible updates and changes. 1. GENERAL INFORMATION 1.1 DESCRIPTION Thank you for purchasing a Wesco Heavy Duty Semi-Electric Pallet Truck. This pallet truck is designed for lifting and transporting loads of 3,300 lbs. It features manual lift, power drive, a 62 turn radius and polyurethane drive/load wheels. The Wesco Semi-Electric Pallet Truck comes with a 1 year pump warranty. 1.2 SPECIFICATIONS Model Capacity 3,300 lbs Truck Weight 518 lbs Battery (2) 24V/38Ah Battery Charger 24V/8A Turn Radius 62 Travel Speed Under Load 2.8 miles/hour Fork Lowered Height 3 Fork Raised Height 7 Single Fork Width 6 Fork Length 48 Overall Width 27 Overall Length 69 Overall Height ASSEMBLY/ADJUSTMENT Materials and specifications are subject to change without notice. 2.1 Assembly For safe transportation and packing, before ex-factory of the forklift, the electric control lever is disassembled so that before operating, one should install the electric control lever and the erection steps are as follows: 1) Disassemble the elastic pin (item 1) from the bearing pin (item 2) and then pull out the bearing pin (item 2). 2) Insert lever (item 3) into A and connect lever and pump body (item 5) with bearing pin (item 2). 3) Put the chain (item 4) of the lever through the hole in the middle of the bearing pin (item 2). 1 2 A Figure 1 Figure 2 Page 2 of 22

4 2. ASSEMBLY (CONTINUED) 4) Put the screw and nut at the end of the chain (item 4) into the slot of the lever panel (item 6). Please See Figure 2 and Figure Figure 3 Figure 4 5) Place elastic pin (item 1) through bearing pin (Item 2) and affix. 6) Pull the lever to the horizontal position as shown in Figure 3. Pull out the pin and keep the pin (item 7) appropriately for using when replacing the lever next time. 7) Put the plug (item 11) of the lever through the ring (item 14) to connect socket (item 12) on the forklift body and tighten the screw sleeve on plug (item 11) to achieve reliable connection between plug (item 11) and socket (item 12). Please see Fig Figure Adjustment After the assembly of the unit is completed, try to maneuver the lever and operate the control handle, shown in figure 6, in different gears to see if the lifting, neutral and lowering of the forklift are operating correctly. Screw (item 9) in Fig. 4 is used to adjust the forklift. When the fork declines as soon as it rises, turn screw (item 9) counterclockwise slightly and then try again until the fork rises normally. If the fork is unable to decline after rising, turn screw (item 9) clockwise slightly and then try the forklift once again until it is able to decline normally. The hex nut (item 10) at screw (item 9) is a locking nut and before adjustment, locking nut (item 10) should be loosened first. After the adjustment is completed, the nut should be retightened. Page 3 of 22

5 3. OPERATION 3.1 Lifting Pull the handle to lifting position (shown in Figure 6) and pump lever up and down, load should be lifted. Lowering Neutral Lifting Figure Lowering Pull handle to lowering position (shown in Figure 6) and load should lower. Attention: the handle must be operated gently to lower the goods slowly to avoid possibly damage from a rapid drop. 3.3 Braking For emergency braking press the red raking button or raise or lower the driving lever to activate emergency brake. For slight braking release the travel button, press the two travel buttons at the same time or press the travel button for opposite moving direction to achieve slight braking. Emergency Braking Normal Travel Emergency Braking Figure Parking 1) Release travel button to stop the unit. 2) Release the lever and the stop braking on the lever will be automatically started up. 3) Lower the fork to the lowest position 4) Turn off the general power supply. Page 4 of 22

6 4. MAINTENANCE 4.1 Battery Replacement 1) Pull out the key to the electric lock 2) As shown in Fig. 8, pull out the battery chamber cover in the show direction. 3) As shown in Fig. 9, release the battery fixing clamp. 4) Cut off the connection between the battery wire and the battery. 5) Lift the battery out of the forklift. 6) Install new battery and ensure that the position of the new battery is identical with that of the replaced battery. 7) Examine the polarity of the battery and then connect the battery to the battery wire. 8) Fix the battery with battery fixing clamp. 9) As shown in fig. 8, press tightly the battery chamber cover in opposite direction. 10) Unlock the power supply lock, operate and detect. 11) The abandoned battery must be treated according to the relevant local stipulation and law. Figure Battery Charging 1) When the electricity indicator of the forklift indicates that the electricity of the battery is insufficient, charging should be conducted at once. 2) Turn off the electric lock switch; connect the end with socket of the connecting cable to the charging socket of the forklift and the other end to power supply socket and then start charging. 3) When the green pilot light of the charger turns on, it indicates that the battery is fully charged and in that case, the connecting cable can be pulled out and the forklift is in ready state. 4) If the battery is completely discharged, full charging must be conducted (about 12h). 5) After discharging, the storage battery cannot be placed for a long time and charging should be conducted as soon as the battery is discharged. 6) When the forklift is not in operation, the general power supply must be turned off, the electric lock must be pulled out and one supplementary charging must be conducted every six months during the period when the forklift is in storage. 7) It is strictly prohibited to open the storage battery air vent valve; otherwise, poor sealing will be incur and the capacity and service life of the battery will be affected. To power supply socket Charging pilot light Figure 9 Figure 10 Figure 11 Fully charged Insufficient charge, charge immediately Page 5 of 22

7 4. MAINTENANCE (CONTINUED) 4.3 Scheduled Maintenance Long term service life quality of the unit depends on proper maintenance. When maintenance is neglected, safety risks may increase and property may be damaged. When the unit is in operation, routine inspection should be conducted frequently and malfunctioning units should be removed from service for repair. Do not operate a forklift with problem to ensure safety and prolong its service life. Routine Maintenance: It should be conducted once every day. Keep the surface clean and examine if the power supply cable is damaged. Level 1 Maintenance: It should be conducted once every week. The maintenance contents, besides the contents of routine maintenance, should focus on if the operation of the components is normal, if the fastening items are loose, if there is any oil leakage, if there is any abnormal wearing in mechanical components, if there are abnormal temperature rise or sparks in electric equipment, etc. Adjustment and troubleshooting should be conducted if any abnormal situation is discovered. Level 2 Maintenance: It should be conducted periodically and overall inspection should be conducted according to following requirements: a) Mechanical Maintenance: It should be conducted every half a year. Replace the lubricating oil for the transmission gear and bearing of the drive wheel, apply lubricant to various rotating joints. Examine if the fastening items are loose, if the wheels are rotating fluidly and if the fork rises and declines normally. The operation noise of the forklift after maintenance should be no greater than 70db. b) Hydraulic System Maintenance: It should be conducted once every 12 months. Determine if the oil cylinders are in a normal state, if there is any internal or external leakage and if the hydraulic oil is clean. The hydraulic oil is usually replaced every 12 months. The ISO oil standard is applied to hydraulic oil. When the ambient temperature is 23~104 F (-5 ~ 40 C), HL-N32 is adopted and when the ambient temperature is -31~23 F (-35 ~ -5 C), HV-N20 low temperature hydraulic oil is used. The waste oil from the replacement should be treated according to the relevant local regulation and law. Examine if the operation of the load limit valve is normal. c) Electric Equipment Maintenance: It should be conducted every three months to examine if the connectors of electric equipments are reliable, if the switches are normal and if the insulation of the electric equipment is in normal condition ( 于 The insulation resistance of electric equipment and the forklift body should be greater than 0.5MΩ). Page 6 of 22

8 5. TROUBLE SHOOTING 5.1 Pilot Light Indications Figure 12 As shown in the Figure above, there is a failure pilot light on the forklift, which is able to indicate some common failures and the concretes are as follows: Failure pilot light flashes once within 4 seconds - Indicates too low power supply voltage and in that case, the forklift can only resume normal operation via charging. Failure pilot light flashes twice within 4 seconds - Indicates there is a problem in motor connection and in that case, the connecting wires and cables must be examined. Failure pilot light flashes three times within 4 seconds - Indicates the starting power is insufficient when the unit is started and in that case, the general power supply should be turned off and then turned on again. The unit should be able to resume normal operation. In that situation, the load should be reduced or manual assistance should be provided for start-up. Failure pilot light flashes four times within 4 seconds - Indicates that the load is too heavy after the unit is operating. The general power supply should be turned off and then turned on again and the unit is able to resume normal operation. In that situation, the load should be reduced. Failure pilot light flashes five times within 4 seconds - Indicates that the motor temperature is too high. The general power supply should be turned off and then turned on again after the motor cools and the unit is able to resume normal operation. Page 7 of 22

9 5. TROUBLE SHOOTING (CONTINUED) 5.2 Possible Problems/Solutions No Problem Causes Solutions 1 Insufficient lifting stroke - Insufficient hydraulic oil - Add appropriate filtered clean hydraulic oil - Excessive hydraulic oil added - Pump out appropriate quantity of hydraulic oil 2 Insufficient lowering stroke - Deformed or stuck rotating part - Replace the damaged components - Stuck plunger and guide bar sleeve 3 Fork does not decline after rising - Abnormal unloading device - Deformed or damaged components - Re-adjusting the unloading device, please see section Replace the deformed or damage components - Failed oil seal - Replace the oil seal 4 Hydraulic oil leakage - Slight damage or wear on the surface of one or two components - Loose connection - Hydraulic oil viscosity is too high or hydraulic oil has not been injected - Replace the damage components - Re-tighten the connection - Replace hydraulic oil 5 Fork does not rise - Foreign matter in oil - Abnormal unloading device - Remove the foreign matter in oil or replace hydraulic oil - Re-adjusting the unloading device, please see section 2.2 NOTE: DO NOT ATTEMPT TO REPAIR THE PALLET TRUCK UNLESS YOU ARE TRAINED AND AUTHORIZED TO DO SO. Page 8 of 22

10 6. GENERAL ASSEMBLY 1 PART INFORMATION Heavy Duty Semi-Electric Pallet Truck 6.1 GENERAL ASSEMBLY 1 PART DIAGRAM A4 A5 A2 A2 A3 A12 A20 A15 A12 A1 A6 A7 A8 A10 A11 A9 A13 A7 A19 A14 A17 A16 A15 Page 9 of 22

11 6. GENERAL ASSEMBLY 1 PART INFORMATION 6.2 GENERAL ASSEMBLY 1 PART LIST Item # WESCO Replacement Part/Kit Number Item Description Qty. A Handle Assembly 1 A2 Elastic Pin 5x32 3 A3 Press Axle 1 A4 Positional Cam 1 A Oil Pump Assembly 1 A6 Socket Head Cap Screw M8x50 1 A7 Lock Nut M8 3 A8 Supporting Seat Assembly 1 A9 Clip for Axle 1 A Lock Nut M12 2 A Axle 2 A12 Cross Recessed Screw M4x8 3 A13 Socket Head Cap Screw M8x40 2 A14 Drive Wheel Assembly 1 A15 Wire Clip 2 A16 Cross Recessed Screw M4x10 2 A17 Plug 1 A18 Wire Connecting Plate 1 A19 Connector 1 A20 Wire-Pressing Plate Wire Harness (9 Pin) 1 Page 10 of 22

12 7 GENERAL ASSEMBLY 2 PART INFORMATION 7.1 GENERAL ASSEMBLY 2 PART DIAGRAM B30 B31 B33 B34 B32 B15 B16 B17 B18 B18 B18 B23 B35 B34 Upper hole uses A11 Bolt & A10 Nut as shown on the General Assembly 1 shown on page 9. B14 B19 B21 B22 B21 B20 B24 B12 B26 B27 B28 B29 B13 B11 B11 B9 B3 B7 B25 B6 B24 B1 B2 B3 B4 Lower Hole takes L3 pin held on by L1 retaining rings as shown on the Connecting Rod And Wheel Carrier Unit Assembly shown on page 17. B5 B6 1 Page 11 of 22

13 7 GENERAL ASSEMBLY 2 PART INFORMATION 7.2 GENERAL ASSEMBLY 2 PART LIST Item # WESCO Replacement Part/Kit Number Item Description Qty. B Coulometer 1 B Switch Button 1 B Pan Head Screw M5x16 2 B Power Switch 1 B Locking Arm Unit, Right 1 B Combined Busher 16x18x20 4 B L-Pin Roll 2 B8 Hexagon bolt M6x12 2 B9 Locating Frame, Coulometer 1 B10 Nut M4 2 B11 Key * B12 Electric Lock 1 B Locking Arm Unit, Left 1 B14 Internal hexagon Screw M6x12 1 B15 End Cap, Left 1 B16 Frame Unit 1 B Charger 1 B18 Pan Head Screw M4x16 8 B Buzzer 1 B20 Fuse Base 1 B21 Flat Washer 8 4 B22 Spring Gasket 8 2 B23 Hexagon Nut M8 2 B24 Countersunk Screw M6x25 8 B25 End Cap, Right 1 B26 Hexagon Locknut M6 2 B Pinion 2 B28 Casing 2 B29 Hexagon Bolt M6x50 2 B Battery 12V 80Ah 2 B31 Battery Hoop 2 B32 Internal Hexagon Screw M6x12 4 B33 Doors Unit 1 B34 Cross Recessed Cheese Head Screw M6x10 7 B Electric Control Power Line ** Bushing: For Holes of B5/B13 Locking Arms 4 * includes items B11 & B12 sold together as a set ** Bushing used on B5 & B13 Locking Arms Page 12 of 22

14 8 DRIVE WHEEL PART INFORMATION 8.1 DRIVE WHEEL PART DIAGRAM D1 D2 D3 D4 D6 D7 D5 D34 D8 D9 D10 D9 D11 D12 D13 D13 D14 D15 D16 D17 D31 D32 D30 D29 D29 D28 D27 D26 D25 D33 D24 D15 D21 D23 D23 D23 D22 D20 D19 D18 Page 13 of 22

15 8 DRIVE WHEEL PART INFORMATION Heavy Duty Semi-Electric Pallet Truck 8.2 DRIVE WHEEL PART LIST Item # WESCO Replacement Part/Kit Number Item Description Qty. D1 Hex Bolt M8x20 5 D2 Spring Gasket 5 D Motor 1 D4 Flat Key 5x10 1 D5 Flat Key 3v3v16 1 D O-Ring 2.65x56 1 D7 Gear D8 Bearing D9 Gear D10 Gear D11 Flat Key 6x10 1 D12 Left Gear Box Body 1 D Hex Screw M6x35 3 D14 Combined Washer 10 2 D15 Screw Bolt 1 D16 Axle Stop 15 1 D Skeletal Oil Seal D18 Hex Screw M4x40 3 D19 Axial Stop 10 1 D Brake 1 D21 Hex Connecting Piece 1 D22 Oil Outlet Plug 1 D23 Hex Screw M6x30 6 D24 Hex Screw M6x35 3 D Circular Nut M25x1.5 1 D Flat Key 8x12 1 D27 Gear D28 Conic Roller Bearing D29 Right Gearbox Body Replacement Gasket & O-Ring for Right Gearbox Body (D29) 1 D30 Skeletal Oil Seal D Wheel Axis 1 D Bull Wheel 1 D33 Spring Gasket 3 D34 Washer 1 Page 14 of 22

16 9 FULCRUM BEARING ASSEMBLY PART INFORMATION 9.1 FULCRUM BEARING ASSEMBLY PART DIAGRAM S16 S16 S16 S17 S1 S2 S1 S4 S5 S6 S7 S8 S9 S12 S6 S10 S11 S3 S14 S13 S13 S15 S12 Page 15 of 22

17 9. FULCRUM BEARING ASSEMBLY PART INFORMATION Heavy Duty Semi-Electric Pallet Truck 9.2 FULCRUM BEARING ASSEMBLY PART LIST Item # WESCO Replacement Part/Kit Number Item Description Qty. S Bearing S Hole Stop 90 1 S Fulcrum Bearing Assembly 1 S Dust Proof Cover 2 S Axial Stop 15 2 S6 Bearing S Washer 1 2 S Trust Ball Bearing S Washer 2 2 S Hole Stop 32 2 S Universal Wheel Frame 2 S Axial Stop 15 4 S Bearing S Universal Wheel 2 S Wheel Axis 2 S Pan-Head Screw M5-9 3 S Masking Plate 1 Page 16 of 22

18 10 CONNECTING ROD AND WHEEL CARRIER UNIT PART INFORMATION 10.1 CONNECTING ROD AND WHEEL CARRIER UNIT PART DIAGRAM Page 17 of 22

19 5 CONNECTING ROD AND WHEEL CARRIER UNIT PART INFORMATION 5.2 CONNECTING ROD AND WHEEL CARRIER UNIT PART LIST Item # WESCO Replacement Part/Kit Number Item Description L Axial Stop 16 2 L Jointing Head 1 L Dual Slot Pin Axis 16x52 1 L Connecting Rod Assembly 1 L Bearing L Fork Wheel 80/74 1 L7 Wheel Axis 1 L8 Elastic Pin 5x32 1 L9 Wheel Frame 1 L10 Sleeve 16x18x15 2 L11 Elastic Pin 5x28 2 L Sleeve 16x18x15 2 L Dual Slot Pin Axis 16x100 1 L Elastic Pin 5x28 2 L15 Roller 2 L16 Pin Roll with Double Holes 1 L17 Backing Frame 2 L18 Bearing L19 Fork Wheel 2 L20 Wheel Axis 20x95 2 L21 Elastic Pin 20x95 4 Qty. Page 18 of 22

20 11 HANDLE UNIT ASSEMBLY PART INFORMATION 11.1 HANDLE UNIT ASSEMBLY PART DIAGRAM Page 19 of 22

21 11 HANDLE UNIT ASSEMBLY INFORMATION Heavy Duty Semi-Electric Pallet Truck 11.2 HANDLE UNIT ASSEMBLY PART LIST Item # WESCO Replacement Part/Kit Number Item Description Qty. H Locating Tab 1 H Elastic Pin 4x31 2 H3 Roller 1 H4 Elastic Pin 4x20 1 H5 Elastic Pin 6x31 1 H6 Elastic Pin 4x20 1 H7 Handle 1 H8 Handle Assembly 1 H9 Cylindrical Pin 1 H10 Elastic Pin 3x20 1 H11 Press Wheel 1 H12 Sleeve H13 Tension Bar Assembly 1 H14 Sleeve Sf-1F H15 Chain C C - H16 Locking Nut M5 1 H Self Tapping Screw St M4x25 4 H18 Hand Lever Wire Box 1 H Button 1 H Plastic Cover, Handle 1 H Bolt M3x10 2 H22 Switch Panel 1 H Stroke Switch 1 H24 Pan-Headed Screw M3x15 2 H25 Locking Nut M3 2 H26 Bolt M4x8 2 H Self Tapping Screw ST2.9x13 4 H28 Lever Wire Box Cover 1 H29 Hex+G60 Screw Cover 2 H30 Stroke Switch TZ H Switch 1 H Socket 1 H33 Bolt M3x8 4 H34 Nut M3 4 H35 Hand Lever Wire Box 1 H Lever Wire Box Cover 1 H37 Bolt M5x8 3 H Turn-Knob 2 H Accelerator 1 H40 Locking Nut M4 2 H41 Bolt M4 x 6 4 H42 Spring Washer 4 4 H Long and Thin Axle 1 H44 Square Shaft Accelerator 1 H45 Split Baffle Ring 2 Page 20 of 22

22 12 PUMP ASSEMBLY PART INFORMATION 12.1 PUMP ASSEMBLY PART DIAGRAM Page 21 of 22

23 12 PUMP ASSEMBLY PART INFORMATION Heavy Duty Semi-Electric Pallet Truck 12.2 PUMP ASSEMBLY PART LIST Item # WESCO Replacement Part/Kit Number Item Description Qty. P1 Sealing Screw M20 x 1 1 P2 Combined Washer 20 1 P3 Cone Spring 1 P4 Valve Core 1 P5 Valve Body 1 P6 Steel Ball P7 Base Frame No. 7 1 P8 Axial Stop 8 1 P9 Steel Ball 5 1 P10 Ball Seat 1 P11 Spring 2 x 8 x 16 1 P12 Pressure Regulating Screw M10 x 1 1 P13 Combined Washer 10 1 P14 Screw Plug M10 x 1 1 P15 Spring 1.2 x 9 x 20 1 P16 Striker 1 P17 O-ring 7 x P18 Combined Washer 20 1 P19 Striker Seat 1 P20 O-ring 8 x P21 Lever Panel 1 P22 Hex Nut M6 1 P23 Fastening Screw M6 x 25 1 P24 Pin Axis 8 x 58 1 P25 Combined Gasket 10 1 P26 Screw Plug M10 x 1 1 P27 Oil Seal 31.5 x 41.5 x 6 1 P28 O-ring 65 x P29 Guide Bar Sleeve 1 P30 O-ring 31.5 x P31 Dust Proof Washer P32 Plunger 31.5 x P33 Steel Ball ¾ 1 P34 Bowl Gasket 1 P35 Large Spring Cap 1 P36 Large Spring 5.5 x 48 x P37 Dust Proof Ring 18 1 P38 Oil Seal 18 x 26 x 5 1 P39 Dual Speed Pump Cylinder 1 P40 Copper Pin 4 x 25 1 P41 Cylindrical Pin 4 x 25 1 P42 Dual Speed Pump Internal Assembly 1 Page 22 of 22