Operating Instructions for Models &

Transcription

1 ! WARNING Do not use the truck before reading and understanding these operating instructions. NOTE! Keep for future reference. Operating Instructions for Models &

2 CONTENTS Foreword Safety Operation Regulation Technical Specifications Main Purpose and Application Technical Features illustration of Labels and Data Plate on the Truck Transportation and Commissioning Carried by Crane Commissioning Maintenance, Charge and Replacement of Battery Maintenance Charge of Battery Battery indicator Operation instructions CONTROL HANDLE Startup of Truck Operation of the Truck Maintenance of the Truck Safety Operation and Environmental Protection Safety Rules for Maintenance of Pallet Truck Maintenance and Inspection SL-LPT13 Maintenance List Operation Specification of Repair and Maintenance Storage of Pallet Truck ELECTRICAL DIAGRAM and HYDRAULIC FLOW DIAGRAM CIRCUIT DIAGRAM CONNECTION DIAGRAM HYDRAULIC FLOW DIAGRAM Parts List FORK FRAME LIST ELECTRIC COMPARTMENT PARTS LIST HYDRAULIC AND ELECTRIC SYSTEM CONTROL HANDLE PARTS LIST

3 8.5 DRIVING WHEEL PARTS LIST Foreword Welcome to use the low lift pallet truck. For your safety and correct operation, please carefully read this instruction book and warnings on the truck before using it. This Operation Instruction of the truck is edited for you to completely acquire and master the safety operation of the truck. Specifications of different types of the trucks are described in this Operation Instruction. During operation and maintenance, please apply the relevant parts for the type of the truck. Safety specification and special notice are marked with the following signs: Safety specification must be observed before use to avoid personal injure. 2.! ---- Notice must be observed before use to avoid equipment damage General notice and specification before use.! The majority of this truck consists of steel, it can be completely recycled. Waste material in conjunction with repairs, maintenance, cleaning or scrapping, must be collected and disposed of in an environment-friendly way and in accordance with the directives of respective countries. Such work must be carried out in areas intended for this purpose. Recyclable material should be taken care of by specialized authorities. Environmentally hazardous waste, such as oil filters, batteries and electronics, will have a negative effect on the environment, or health, if handled incorrectly. All of the information reported herein is based on data available at the moment of printing. Our products are constantly being developed and renewed, we reserves the right to modify our own products at any moment without prior notice and incurring in any sanction. So, it is suggested to always verify possible updates. 2

4 1.1 Requirement on operator 1 Safety Operation Regulation The truck must be operated by trained person, who can demonstrate the moving and operating of the truck to user and can instruct vividly the user how to operate the truck. 1.2 Right, obligation and responsibility of operator The operator must fully understand his right and obligation and has received the training of the truck operation. At the same time, the operator must master the related descriptions in Operation Instruction. In operation of walking control truck, the operator should wear safety boots. 1.3 Forbidden use by unauthorized person During operation, the operator must be responsible for the truck and prevent unauthorized person in driving or operating the truck. The truck is strictly forbidden to lift or carry person. 1.4 Failure and fault In case of any failure or fault, please notify the administrator immediately. In case that truck can not work safely (such as wheel worn-out or brake fault), please stop using the truck until they are properly repaired. 1.5 Repair Without professional training and specific authorization, the operator is forbidden to repair or change any part of the truck. Any change of installation position of switches and safety devices is strictly forbidden by operator to avoid efficiency decrease of the truck.! All spare parts from original manufacturer are qualified by Quality Assurance Authorities. To ensure the safety and reliability of truck operation, only spare parts from manufacturer can be applied. The parts replaced, including oils and fuels, must be disposed according to related environmental protection regulations. 1.6 Danger area Danger area refers to: the area where the truck or its lifting device (such as fork or attachment) is working or lifting, which brings potential dangerous factors to person; or the area for load transportation. Generally, the range of danger area extends to the point of load lowering or truck attachment lowering. Unauthorized person must be kept away from danger area. For any circumstance with potential danger to person, the operator must give warning notice. If someone still stays in 3

5 danger area while being requested to leave, the operator must stop the truck immediately. 1.7 Work in hazardous environments A truck operating in an area where there is a risk, or in any other high risk area, should be specially equipped for the purpose.! The truck is not normally equipped for these situations. 1.8 Safety device and warning sign Enough importance should be attached to safety device, warning sign and warning notice introduced above in Operation Instruction. 1.9 Driving in public areas The truck should not be driven on public roads outside a specific area Distance between vehicles Remember that the vehicle in front of you may brake suddenly. Keep a reasonable distance Passengers Passengers should not ride on the truck unless otherwise indicated on the truck Use in elevator and operation on loading platform The truck may only be driven into an elevator and operation on loading platform if it has been authorized. The elevator and loading platform with enough load capacity without affecting truck operation can be used for transportation of truck under the permission of truck user. The operator must confirm this point before entering elevator or loading platform. The cargo should be placed in front side at a proper position when the truck enters elevator to avoid touch to the walls of elevator. In case of simultaneous use of elevator by the truck and passengers, passengers must enter the elevator after proper parking of the truck and walk out of elevator before moving of the truck Operation in narrow aisle and working area In particular circumstance when the truck is passing a narrow aisle, unauthorized person must leave away the working area and cargo must be placed in a special vessel Operation management Driving speed must be applicable for local condition. Low speed is requested for curve driving, narrow aisle passing, swing door passing or driving in blocked field. The operator must be capable to measure the braking distance to front truck by sight and control his truck continuously. Sudden brake (except in emergency), quick U-turn and overtaking in blocked field are prohibited. Operation with body reaching out of truck and carrying person are strictly forbidden Visibility The operator must stare at driving direction to ensure legible sight for the road condition ahead. In case that cargo carried interrupts the sight, reverse driving is requested. If it 4

6 doesn t help in this way, there must be another person walking ahead of truck to give guidance and warning Passing slope The permitted slope in narrow aisle for truck passing must be clean and anti-slip. Driving on slops stipulated in technical specifications (instruction manual) is permitted. The cargo carried must face to upward direction of slope. U-turn or parking on slope is prohibited. On passing slope, driving is requested at low speed. At the same time, the operator must be always prepared for brake Floor Load Carefully check notices or directives about the max. floor load or max. wheel pressure to ensure that these are not exceeded Transports The truck should always be driven with the height of forks to the lowest position except when placing or removing load. Stand-on or sit-on truck had better be driven in the opposite direction of the forks when possible. This will allow better visibility and maneuverability. Driving with the forks pointing forward may cause the truck to maneuvers unexpectedly Load characteristics: The cargo should be carried correctly, safely and reliably. Carrying of cargo with stacking height exceeding top of truck or protection shield is strictly forbidden Truck on another vehicle s loading platform or on a gangway Before the truck is driven from a loading bay and onto the platform of a lorry or wagon, you should always check the maximum load capacity of the gangway. There should also be devices that prevent the gangway from sliding. The driver also should remember to check the maximum load capacity of the vehicle that you intend to drive onto. There should also be devices (e.g. brake blocks) that prevent the vehicle from moving Parking The truck should not be left unattended other than in specified parking areas. The truck should always be parked on a level surface. The forks must be lowered to their lowest position. Always turn the ignition to the OFF position. Unauthorized personnel should not use the truck. Always remove the ignition key from the electrical lock when leaving the truck. If the truck is left unused for a prolonged period without it being recharged, e.g. between two shifts, the battery plug should be disconnected. 5

7 1.22 Signaling Use the signal horn to attract attention Protective shoes Protective shoes should be worn when working with truck according to EU standard EN- 345:1-S The additional units / Trailers Authorized representative should be contacted if, after delivery, the truck is equipped with additional units, tows hitch equipment for trailers or other accessories which could influence the stability or braking capacity of the truck. 2 Technical Specifications 2.1 Main Purpose and Application WP-LPT pallet truck is specially designed for conveyance on level road. With compact structure, WP-LPT pallet truck is quite applicable for plant, workshop, wharf and small warehouse. At the same time, it can be used to load / unload cargo on the trucks Load capacity is marked on truck data plate. 2.2 Technical Features The specification sheet 6

8

9 & pallet truck: Characteristics Weight Wheels types Dimensions Performance Electric motor Other 1.2 Model of manufacture Power supply (electric, diesel, petrol, gas, mains electric) electric 1.4 Type of operation (hand, pedestrian, stand on, rider seated, order picker) pedestrian 1.5 Capacity / rated load Q k g Load centre distance C m m Load distance X m m Wheelbase y m m Weight (including battery) kg Axle loadings laden drive end / load end kg 760/ Axle loadings unladen drive end / load end kg 222/ Tyres (rubber, Vulkollan, pneumatic, polyurethane) polyurethane 3.2 Tyre size drive end mm Φ252x Tyre size load end mm 2xΦ84x70/Φ84x Castor wheels (dimensions) 2xΦ100x Wheels, number(x=drive wheel) drive end/load end 1x -2/ 2/1x -2/ Track width (front) drive end b10 mm Track width(rear) load end b11 mm Lift height h3 mm Tiller height in neutrality position h14 mm Fork height lowered h13 mm Overall length l1 mm Length to front face of fork l2 mm Overall width b1 mm Fork dimensions s / e / l mm 47 / 160 / Overall fork width b5 mm Floor clearance,centre of wheelbase m2 mm Working aisle with 800x1200 pallet lengthwise Ast mm turning radius Wa mm Travel Speed laden / unladen km / h 5.0 / Lifting speed laden / unladen mm/s 27 / Lowering speed laden / unladen mm/s 42 / Gradeability laden / unladen % 5/ Brakes Electric-magnetic 6.1 Drive motor kw Lifting motor kw Battery acc. To BS, no 1 ) no 6.4 Battery voltage, norminal capacity K5 1 ) V/Ah 2x12 / Battery weight +/-5% kg 48 Battery dimensions l /w / h 1 ) mm 260 / 170 / Type of drive control MOSFET Control 8.4 Sound level,at driver s ears db(a) <70 Turning angle 205 8

10 *) Load section lifted/lowered +55 mm **) Diagonal according to VDI+204mm WP-LPT22 LPL20 electric electric electric Pedestrian Pedestrian Pedestrian / / / / / / / / / /108 polyurethane polyurethane polyurethane Φ230x75 Φ230x75 Φ230x75 2xΦ84x70/Φ84x93 2xΦ84x70/Φ84x93 2xΦ80x70/Φ80x93 2xΦ100x40 2xΦ100x40 2xΦ100x40 1x -2/ 2/1x -2/ 4 1x -2/ 2/1x -2/ 4 1x -2/ 2/1x -2/ / / / / / / / 160 / 1150(1220) 60 / 160 / 1150(1220) 60 / 160 / 1150(1220) 540/ / / / / / / / / / / / / 35 19/35 18 / / 27 30/27 35 / 40 10/16 9/15 10/16 Electric-magnetic Electric-magnetic Electric-magnetic (AC) 1.0(AC) VBS 3VBS 3VBS 24 / / / / 196 / / 196 / / 196 / 570 MOSFET Control MOSFET Control AC MOSFET Control AC <70 <70 <

11 1 ) 24V, 280Ah battery can be chosen, at this time, battery acc. to BS standard, battery dimensions l /w / h is 677 / 244 / Technical data-standard version Description of the technical data according to VDI Technical modifications and additions reserved EN standard Durative noise level must be < 70dB(A); Refer to ISO4871 Standard Noise surrounding the truck is evaluated in average complying with standard rules. Noise on traveling, lifting and racing is measured by hearing. Electromagnetic Compatibility (EMC) Manufacturer confirms the tests of electromagnetic emission, immunologic interference and electrostatic elimination are evaluated complying with EN12895 and other standard included. Any change of parts in electrical system should be performed on written approval by manufacturer Application Conditions Surrounding temperature: Operation duration: 5~40 During continuous operation of the truck under the condition below 5 or in low temperature and high humidity, special protections should be taken for some certain instruments. 2.3 illustration of Labels and Data Plate on the Truck No. Description 15 Lifting button sign of truck 16 Lowering button sign of truck 17 Horn button sign 18 Forward / backward traveling button sign of truck 19 No Seating on the truck sign 10

12 20 Truck data plate 21 Hoisting position sign of the truck pallet truck 11

13 MODEL LPT20 NO. CAPA CITY 2000kg WEIGHTWITHOUT BATT ERY 335KG BATT ERY 24V, 210Ah BATT ERYWEIGHT 185kg pallet truck: NOBLEL I FT Please understand the meaning of data plates before use. In case of quality problems or purchase of spare parts, please indicate the series No. and part code on the data plate. 3 Transportation and Commissioning 3.1 Carried by Crane! The load capacity of hoisting equipment applied should be adequate. (Carried weigh more than net weight of truck; refer to truck data plate) Hoisting position is specially designed on chassis by manufacturer for convenience of conveyance. Place the truck at a safe position Point of strength of the crane must be attached to hoisting position 12

14 ! Point of strength of the crane must be attached to hoisting position to avoid slip of the truck; During hoisting, the hoisting equipment applied must be attached to hoisting position without touching the truck. 3.2 Commissioning! Only battery can be applied as power of the truck. AC power will damage the electric circuit. The length of connecting cable for the battery should be less than 6m. For normal operation of the truck after delivery or transportation, the following procedures should be carried out: Check if the assembly of all the truck parts is complete and satisfying the requirement. If necessary, install the battery and avoid damage of battery cable. Charge the battery immediately. If the consumer expects to apply a maintenance-free battery as substitute, please check if the type of battery capacity meter matches the battery (or on approval of aftersales service of the manufacturer) 4 Maintenance, Charge and Replacement of Battery 4.1 Maintenance The various Rechargeable sealed Lead Acid battery (VRLA) is used in this pallet truck, it needs less maintenance. 4.2 Charge of Battery The & pallet trucks are equipped with a specified charger to charge the battery.! Before connecting to charge the battery, make sure the battery charger, emergency switch and electric lock switch at off position. Please charge the battery in a dry and airy circumstance and keep away from fire source. Under idle state of the truck, battery charge should be performed no less than once per month. The battery of pallet truck should be charged duly and regularly. When Capacity Consumed alarm flashes on battery capacity meter during operation, please charge the battery immediately. 13

15 pallet truck: fully automatic charge: fully automatic and smart charger is applied for the pallet truck. When the plug on connecting plate of the truck is pulled out and connected to the power, charger indicator lights in red. The charger will adjust the current according to residual capacity of the battery automatically, which ensures the course of charge in the best state. After charge of battery, the charger indicator lights in green and charge course stops with power off automatically. The charge course generally lasts 5-7 hours pallet truck: Press emergency parking switch to off position Open the cover of battery case Take out the connector plug of battery on the truck Now, open all the water feeding cock caps Connect the output plug of charger with the connector (input) plug of battery, and then turn on the switch of charger! It is prohibited to charge the battery before it is used up. Otherwise, hurt to battery may be caused. During charge course of battery, all water feeding cock caps of each battery cell must be opened to keep airy condition. Before charge, make sure no metal object on the battery and check if any obvious fault on joints of all the cables and plugs. All safety instructions, including supply rules and charge preparation procedures, should be observed strictly Initial charge 1) If the electrolyte of the battery has be poured out, the acid should be poured in, which is confected by exclusive sulphuric acid and exclusive water of lead acids, and the specific gravity of confected electrolyte is (at normal temperature of 25 o C). Pour configured electrolyte into the battery, with fluid level 15-20mm higher than protective slice.! Only when the cell temperature drops below 35 o C, it can be connected to DC and charged. 2) Initial charges are conducted in 2 stage: A, when terminal voltages of the cells is less than to 2.4V, the current should be 0.5I 5 A; B, when its voltages rise to 2.4V, the current should be converted into stage 2, 0.25I 5 A. Continue to charge until air bubbles come out from the electrolyte, keep cell voltage( under constant current) steady for 3 hours. 14

16 When the electrolyte density reaches , it will remain unchanged within 3 hours. At this moment, the total quantity of electric charge should be 4-5 times the rated capacity, and the charging time will be 70 hours Balance charge When in using, no uniformity of voltage capacity, electrolyte and concentration may occur. Through balanced charge, such no uniformity can be eliminated, and all cells can be of uniform conditions. On following condition, balance charge should be used: 1) Cell s whose discharge voltages are usually below the final voltage (1.7V/cell). 2) Cells with heavy discharge current (e.g. the driving motor and lifting motor operate synchronously). 3) Battery do not timely be recharged after discharged. 4) Under charged battery or battery not used for a long time. Steps for balance charge 1) Charge with the current of 0.1I 5 A. 2) When the voltage reaches 2.5V and the air bubbles come out from the electrolyte, keep charging with the current of 0.05 I 5 A. 3) When the battery is fully charged, stop charging for half an hour. Then keep on charging with the current of I 5 A for 1 hour. 4) After stop charging for half an hour, keep charging with the current of I 5 A for 1 hour again. 5) Repeat step 4 unless the air bubbles come out from the electrolyte as soon as the charger is connected to the power supply.! Balance charge is essential monthly for the battery in use. 4.3 Battery indicator Battery capacity meter: Discharging status of battery is indicated on battery capacity meter with ten indicator bars for each 10% increase. With the consumption of battery capacity, the lighting bars will descend downwards from the top. The mark of Alarm will appear when: residual capacity of standard battery at 30%, the mark of Alarm appears. Now the battery is capable for charging. The mark of Alarm and a flash Stop will appear when: residual capacity of standard battery at 20%, the mark of Stop appears and keeps flashing. Now, the lifting function of 15

17 truck is automatically cut off and locked. Capacity Sufficient Charge Required Capacity Insufficient If the battery capacity meter indicates capacity insufficient soon after lifting system works, the lifting function will be resumed only after recharging the battery to at least 70% of the capacity. 5 Operation instructions 5.1 CONTROL HANDLE 1 LOWER Button 2 FWD/BWD Tuning Knob 3 HORN Button 4 REVERSING Button 5 RAISE Button 16

18 5.2 Startup of Truck The operator must confirm no person staying in danger area before starting & operating the truck or lifting cargo. Routine Check before Startup Check if any cosmetic defect of truck (especially for wheel and pallet) Check if battery fixed firmly and cable connected properly Startup of Truck Rotate and turn on emergency parking switch Insert key into electric lock switch and turn right to position I Battery capacity meter indicates the current capacity Check the function of horn Check the braking function of control handle Now, the preparation before startup of truck is done. 5.3 Operation of the Truck Operation of Startup, Driving and Parking Enough caution must be attached for startup and driving of truck, especially when the person body reaching out of truck. During driving, it is prohibited to carry any other person. Emergency parking Press emergency parking switch and then all electric control functions are cut off. Forced braking Release the control handle, and then the truck is automatically braked (emergency stop). The control handle will turn into above braking range (B1). In case of slow turning of control handle into braking range, be sure to find out the fault and repair it. If necessary, please replace the gas spring of the handle. Startup Battery case must be covered and checked to be reliable before startup of truck. Start the truck Driving speed is controlled by controller. Turn the control handle into driving range F, adjust the controller to the direction required and the truck is moving towards the selected direction. 17

19 Driving Swing the control handle leftwards or rightwards to drive. Driving on Slope! The cargo carried must face to upward direction of the slope. Take safety measures to the downward slip direction of the truck: when control button at 0 position, please pull the handle backwards immediately and release it according to actual requirement to enable the electromagnetic brake to work automatically and control the speed and direction of truck (for downward slip). Braking The operator must fully understand the braking performance is subject to the road condition. There are three types braking for the truck: Electromagnetic braking (control handle) Reverse current braking (controller) Sensor braking (release braking) Electromagnetic braking In emergency, truck must be braked by electromagnetic braking (control handle) only. Turn the control handle upwards or downwards to braking range (B1) and (B2), the driving motor is braked mechanically. After release of control handle, it will turn into above braking range (B1) automatically. After parking of truck, electromagnetic braking takes the function of parking braking. Reverse current braking! In case of control system or driving power unworkable, it is possible to use reverse braking. Rotate the controller against the direction of driving until the truck is stopped. Release the controller 18

20 Inertia braking After release of controller, it returns back to 0 position and the truck is braked by inertia of motor. The ratio of speed reduction is subject to the position of controller.! If inertia braking is removed by maintenance staff and the controller is set at 0 position, the truck can be braked only by electromagnetic braking and reverse current braking Operation of cargo loading / unloading! Before loading the cargo, the operator must check to confirm the cargo is properly placed on the pallet and the weight of cargo within load capacity of the truck. Carrying cargo in full load for a long time is prohibited. Forks should extend to bottom of cargo completely to the greatest degree. The operation of Up or Down button will lead to lifting or lowering at a fixed speed. Lifting of forks Press control button Fork Lifting until required height is achieved. Lowering of forks Press control button Fork Lowering to lower the forks to required height. 6 Maintenance of the Truck 6.1 Safety Operation and Environmental Protection The instructions in the chapter of Operation of Inspection and Maintenance should be performed based on the time interval specified in Maintenance List. Any part on the truck, especially safety device, can not be changed without permission. Change of operation speed of the truck is strictly forbidden. All spare parts from original manufacturer are qualified by Quality Assurance Authorities. To ensure the safety and reliability of truck operation, only spare parts from manufacturer can be applied. The parts replaced, including oils and fuels, must be disposed according to related environmental protection regulations. 6.2 Safety Rules for Maintenance of Pallet Truck Maintenance staff: Repair and Maintenance of the truck should only be performed by qualified professionals trained by manufacturer. The after-sales service department of manufacturer has dispatched special technicians who can be commissioned to sign on the 19

21 maintenance record in the maintenance service appointed by manufacturer. Lifting of truck: For lifting of the truck, the hoisting equipment should be safe and reliable (especially the hoisting position). When the truck is lifted, necessary measures should be taken to avoid slip and turnover of the truck (wedge block or wood block can be applied). The truck can be lifted by hoisting equipment only when the forks are fixed and connecting cable with enough strength is applied. Cleaning operation: Flammable fluid is strictly forbidden in cleaning of the truck. Before cleaning work starts, safety measures must be taken to avoid sparkle (e.g. caused by short circuit). Any operation of battery should be performed after cutting off the power of the battery. All electric elements and electronic assemblies can only be cleaned by weak wind blower or compressed air, or by in conductive and anti-static brush.! If the truck is cleaned by water jet cleaner or high pressure cleaner, all electric elements and electronic assemblies should be covered in advance to avoid humidity which will cause fault of function. Cleaning by steam nozzle is prohibited. Operation of electrical system: Operation of electrical system of the truck should be performed by trained professionals only. Before any operation of electrical system, protection measures to avoid electric shock should be properly taken. During operation of battery, separate the socket of battery apart to cut off the power of the truck. Operation of Welding: To avoid damage of electric and electronic assemblies, the assemblies should be removed away from the truck before welding. Installation: After repair or replace the hydraulic components, electric elements and electronic assemblies, please install and confirm them at original positions. Wheels: The quality of wheels take great effect on the stability and driving performance of the truck. Any change of wheels should be discussed with and approved by the manufacturer. During replacement of wheels, the truck must be kept horizontally as original state (wheels must be replaced by pairs, e.g. both left and right). Lifting chains: Without lubrication, the lifting chains will be soon worn out. The time interval in maintenance manual is applicable for normal operation condition. In case of poor operation condition (dust, temperature), it is necessary to feed lubrication regularly. Hydraulic oil pipe: Oil pipe should be replaced every six years. Together with replacement of hydraulic assembly, the oil pipe of hydraulic system should be replaced. 6.3 Maintenance and Inspection 20

22 Complete and professional maintenance is an important part for safety operation of pallet truck. Any negligence of maintenance of stipulated time interval will cause failure of truck and cause potential danger to person and equipment.! The maintenance cycle stated in instruction manual refers to the normal condition with single shift operating. Under dusty condition, temperature varying greatly or under multiple shifts operating, the maintenance cycle should be shortened. Please perform according to below maintenance list in compliance with each maintenance cycle as specified as followings: W1 = every 50 working hours, at least one per week M3 = every 500 working hours, at least once per three months M6 = every 1000 working hours, at least once per six months M12 = every 2000 working hours, at least once per 12 months During commissioning of truck, the following additional operations should be done: 50 hours to 100 hours of initial operation or 2 months after initial operation: Check if any loosened nut on wheels and tighten it if necessary Check if any leakage of hydraulic parts and tighten it if required Replace hydraulic filter & Maintenance List Maintenance Time Interval Standard= W M M M Refrigerating house=# Chassis and 1.1 Inspection of any damage of bearing parts truck frame 1.2 Inspection of all joints of bolts 2.1 Inspection of noise and leakage of driving system Driving part 2.2 Inspection of oil level of driving system 2.3 Replace lubrication # 3.1 Inspection of wearing and damage state Wheel part 3.2 Inspection of bearings inside wheels and ensure compact fit with wheels a) Steering system 4.1 Inspection of steering operation motion Braking system 5.1 Inspection of performance and adjust it # 5.2 Inspection of reset function of gas spring and any 21

23 Lifting equipment Hydraulic system Electrical system Motor Battery Lubrication Integrated measurement leakage or damage 5.3 Inspection of wearing state of brake wheel 5.4 Inspection of brake connection and adjust it if necessary 6.1 Inspection of performance, wearing and adjust it 6.2 Inspection by sight of any block of loading wheel 6.3 Inspection of any wearing or damage of edge of forks and pallet 7.1 Inspection of performance # 7.2 Inspection of any leakage or damage of all joints b) # 7.3 Inspection of any leakage or damage of hydraulic cylinder, safety and reliability of attachment 7.4 Inspection of oil capacity # # # 7.5 Replace hydraulic oil and filter d) # 7.6 Inspection of adjustment function of pressure regulator 8.1 Inspection of performance 8.2 Inspection of safety and reliability of connection of all cables, and if any damage 8.3 Inspection of Amperage of fuse 8.4 Inspection of safety, reliability and function of switches and unlocking cam equipment 8.5 Inspection of connector, replace the worn part if necessary 8.6 Inspection of function of alarm equipment # 9.1 Inspection of wearing state of carbon brush 9.2 Inspection of safety of motor attachment 9.3 Clean motor frame with vacuum cleaner, inspection of wearing state of commutator 10.1 Inspection of density and capacity of acid, voltage of battery 10.2 Inspection of safety device of connection terminal, applicability of grease 10.3 Clean connector of battery, inspection of compactness of fit 10.4 Inspection of damage of battery cable, replace it if necessary 11.1 Paint grease to the truck according to the time schedule of lubrication feeding 12.1 Inspection of the fault in grounding of electrical system # # # # # # 22

24 Demonstration 12.2 Inspection of driving speed and braking distance 12.3 Inspection of lifting and lowering speed 12.4 Inspection of safety device and closing device 13.1 Commissioning under load rating 13.2 After above maintenance, the truck is certificated to be reliable for operator # a)about 100 hours after initial operating, check if any loosened nut on wheels and tighten it if necessary b)about 100 hours after initial operating, check if any leakage of hydraulic parts and tighten it if required d) 500 hours after initial operating 6.5 Operation Specification of Repair and Maintenance Preparation of truck to be repaired or maintained Prepare all necessary safety measures to avoid possible accident during the course of repair and maintenance by finishing the following preparations: Parking the truck safely Press emergency parking switch and cut off the power of the battery. When the operation is done after lifting of forks or lifting of truck, protection measures should be taken to avoid slip or turnover of forks or truck. In case of lifting of truck, please refer to the related instructions in the chapter Transportation and Commissioning Inspection of hydraulic oil capacity pallet truck: Preparation of truck to be repaired or maintained. Remove the four screw (2) and (10). Open the left and right half cover (1) and (3). Check the capacity of hydraulic oil in oil tank. The installation procedures are done in contrary sequence. 23

25 During inspection of hydraulic oil capacity, forks and carriage must be lowered to the min. height pallet truck: Preparation of truck to be repaired or maintained. Open the left and right half shield (4) and (5). Check the capacity of hydraulic oil in oil tank Inspection of electric fuse Preparation of truck to be repaired or maintained. Open the left and right half shield (1) and (3). Consult the chart to check the current rating of all fuses, and replace it if necessary Code Protection Purpose Value FU Main circuit fuse 200A FU1 Traveling control fuse 10A FU2 Lifting control fuse 6A Use of truck after maintenance Finish the following operation before use of truck: Clean the truck Check braking function Check the function of emergency parking switch Check the function of horn 6.6 Storage of Pallet Truck In case of storage duration of the truck over 2 months, the truck should be parked in an anti-freezing and dry place. Before storage, all necessary measures should be taken properly. During and after storage, the following measures should be taken:! During storage, the pallet truck should be raised to keep the wheels apart from ground completely. In this way, the wheels and bearings inside wheels are protected from damage. 24

26 In case of storage duration of the truck over 6 months, please contact the maintenance service of manufacture for other additional measures Operations to be done before storage Clean the pallet truck thoroughly Check braking function Check hydraulic oil capacity, feed it up if necessary Paint oil or grease to all parts for protection Consult detailed Lubrication List to feed lubrication to the truck Recharge the battery Cut off and clean the battery, paint grease to battery electrodes Besides above, the instructions provided by battery supplier are also to be observed Measures to be taken during storage Every two months: charge the battery! Operation of battery of pallet truck: It is important to recharge the battery regularly. Otherwise, complete consumption of battery will cause automatic discharge and even damage the battery Re-commissioning Clean the pallet truck thoroughly Consult detailed Lubrication List to feed lubrication to the truck Clean the battery, paint grease to electrode bolt and connect the battery Recharge the battery Check if any moisture in gear oil, replace it if required Check if any moisture in hydraulic oil, replace it if required Start the pallet truck Operation of battery of pallet truck: In case of fault of electrical system, paint all exposed electrical connection with contact cleaner. Repeat this step to eliminate the oxide layer on connecting parts of operating controller. Electromagnetic braking test should be immediately performed after recommissioning. 25

27 6.6.4 Faults Diagnosis In this chapter, we will introduce how to find out and handle some of uncomplicated faults to the user as specified in the following sheet: Fault Reason Treatment Truck is unable to move Cargo is unable to be lifted Cargo is unable to be lowered Lifting is unable to stop Traveling toward one direction Traveling too slow Sudden startup of truck - Disconnection of battery - Check connection of battery and connect it if connector necessary. - Electric lock switch at 0 - Put electric lock switch at 1 position position - Emergency parking switch - Turn on the emergency parking switch off - Battery capacity consumed - Check battery capacity and charge battery if necessary - Control handle not within - Turn control handle into driving range F driving range F - Fuse damaged - Check fuse FU and FU1 - Truck is unable to be - Refer to treatment listed for Truck is unable operated to move - Hydraulic oil shortage - Check hydraulic oil - Fuse damaged - Check Fuse FU2 - Battery capacity only 20/30% - Charge battery - Poor connection or damage - Check lifting micro switch or replace it of lifting micro switch - Control valve is blocked up - Check hydraulic oil and clean control valve. by dirty fluid Replace hydraulic oil if necessary - Lowering electromagnetic - Check lowering electromagnetic valve or valve off or damaged replace it - Lifting micro switch damaged - Turn off power and replace lifting micro switch - Poor connection of micro - Check micro switch on control handle and switch and connecting cable connecting cable - Battery capacity shortage, - Check battery capacity indicator, electromagnetic brake too electromagnetic brake and related cables tight or poor connection of related cables - Controller damaged - Replace controller - Non - reset of forward / - Repair to reset the button or replace it backward button If there is any fault cannot be eliminated through above treatment, please notify aftersales service of manufacturer for trained professionals disposal. 26

28 Pallet Truck: 7 ELECTRICAL DIAGRAM and HYDRAULIC FLOW DIAGRAM 7.1 CIRCUIT DIAGRAM 7.2 CONNECTION DIAGRAM 27

29 1 B+ Battery positive 13 SA Switch of brake 2 B- Battery negative 14 YB Electromagnetic brake 3 MU Pump motor 15 A1,A2,A3,A4 Connection board 4 FU Power fuse 16 P Battery indicator 5 Accelerator Accelerator 17 KM Relay for lifting 6 M Traction motor 18 YD Electromagnetic valve of lowering 7 FU1 Fuse of control current 19 H horn 8 S1 LOWER button 20 D3, D4, D5 Diode 9 S2 RAISE button 21 SM Power switch 10 S5 HORN button 22 FU2 Fuse of lifting and lowering switch 11 S6 REVERSING button 23 P Module of volt meter 12 SU Lifting limit switch 24 SY Key 7.3 HYDRAULIC FLOW DIAGRAM 28

30 8.1 FORK FRAME LIST 8 Parts List 29

31 Fork Frame List No. Art No. Description Qty Fork frame Rock - arm Bushing Split pin Shoulder bushing Bushing Grease Cup Pushing rod Long shaft Screw Fixing plate Bushing Shaft Elastic pin Locking nut Enter roller Bolt Elastic pin Sfaft of frame Frame of roller Shaft Elastic pin (for single type) Washer (for single type) Bearing (for single type) Loading roller (for single type) Axle for roller (for tandem type) Linking plate (for tandem type) Elastic pin (for tandem type) Washer (for tandem type) Bearing (for tandem type) 8 30

32 Loading roller (for tandem type) Grease Cup ELECTRIC COMPARTMENT PARTS LIST 31

33 ELECTRIC COMPARTMENT PARTS LIST No. Art No. Description Qty. No. Art No. Description Qty Screw Screw Cover of bearing Screw O - ring Long shaft Screw Elastic pin Screw Right rotating arm Elastic washer Left rotating arm Seat of bearing Bushing Bearing Snap ring O - ring Washer Protect sleeve Bushing Shaft Secluded washer Linking board Bearing Baffle Snap ring Driving wheel kits Steering wheel 2 frame Screw Bolt Cable Dust cover Plate Washer Screw Axle for wheel Elastic washer Bearing Pole Sleeve Box body Steering wheel Spilt pin Locking nut Linking plate Snap ring Bushing Shaft Shaft Bushing 4 32

34 Locking board Air spring Screw Spring Axle Cap of spring HYDRAULIC AND ELECTRIC SYSTEM 33

35 HYDRAULIC AND ELECTRIC SYSTEM No. Art No. Description Qty. No. Art No. Description Qty Half cover, left Rubber washer Screw Fixing plate for charger Half cover, right Emergency switch Screw Screw Plug Nut Protect sleeve Bolt Battery indicator Horn Power key Nut Emergency switch Piston rod Screw Dust ring Fixing plate for controller Y - ring Cover Cylinder body Controller Seal washer Screw Joint Nut Pipe Battery Joint Fixing plate for battery Pump unit Elastic washer Washer Screw Fixing ring for 1 34

36 cylinder Screw Screw Charger CONTROL HANDLE PARTS LIST 35

37 CONTROL HANDLE PARTS LIST No. Art No. Description Qty Screw Washer Hand wheel Axle sleeve Button Button for horn Cover Axle of handle Controller Bolt Elastic washer Handle arm Screw Air spring Screw Micro switch Screw Handle Reversing button Control cable Handle connector Should bushing Shaft Elastic pin Elastic washer 2 36

38 Locking nut Cover Screw DRIVING WHEEL PARTS LIST 37

39 DRIVING WHEEL PARTS LIST No. Part No. Description Qty. No. Part No. Description Qty Retaining ring Wheel Bearing Washer Key Bolt Axle with gear Dust ring Body of wheel Cover Gear Washer Retaining ring Bolt Retaining ring House of gear Key Washer Key Bolt Retaining ring Dust ring Motor Washer Screw Brake Bearing Screw Gear Screw Ring Washer Inner gear Cover Bearing O - ring Retaining ring Screw Bearing Washer 1 38

40 O - ring Cover Pallet Truck: 7 ELECTRICAL DIAGRAM and HYDRAULIC FLOW DIAGRAM 7.1 CIRCUIT DIAGRAM 7.2 CONNECTION DIAGRAM 39

41 Please find hereby a legend of the electrical machine plant 1 B+ Battery positive 13 SA Switch of brake 2 B- Battery negative 14 YB Electromagnetic brake 3 MU Pump motor 15 A1,A2,A3,A4 Connection board 4 FU Power fuse 16 P Battery indicator 5 Accelerator Accelerator 17 KM Relay for lifting 6 M Traction motor 18 YD Electromagnetic valve of lowering 7 FU1 Fuse of control current 19 H horn 8 S1 LOWER button 20 D3, D4, D5 Diode 9 S2 RAISE button 21 SM Power switch 10 S5 HORN button 22 FU2 Fuse of lifting and lowering switch 11 S6 REVERSING button 23 P Module of volt meter 12 SU Lifting limit switch 24 SY Key 7.3 HYDRAULIC FLOW DIAGRAM 40

42 8.1 FORK FRAME LIST 8 Parts List 41

43 Fork Frame List No. Art No. Description Qty Fork frame(1150x540) Fork frame(1220x540) Fork frame(1150x685) Fork frame(1220x685) Rock - Arm (540) Rock - Arm (685) Bushing Split pin Shoulder bushing Bushing Grease Cup Pushing rod (1150) Pushing rod (1220) Long shaft Screw Fixing plate Bushing Shaft Elastic pin Locking nut Enter Roller Bolt Elastic pin Shaft Frame of Roller Shaft for roller Elastic pin (for Single type) Washer (for Single type) Bearing (for Single type) Loading roller (for Single type) Shaft (for Tandem type) Link plate (for Tandem type) Elastic pin (for Tandem type) Washer (for Tandem type) Bearing (for Tandem type) Loading roller (for Tandem type) Cover of battery Lock nut 2 42

44 Washer Screw Plug (male) Plug (female) Box of battery Battery 24V/210AH Charger Grease Cup ELECTRIC COMPARTMENT PARTS LIST 43

45 ELECTRIC COMPARTMENT PARTS LIST No. Art No. Description Qty. No. Art No. Description Qty Holding rod for handle Bushing Screw Retaining ring Elastic washer Washer cable Bushing Driving wheel kits Washer Bolt Bearing Elastic washer Snap ring Box body (540) Steering wheel frame Box body (685) Bolt Control panel Dust cover Screw Washer Axle Axle Screw bearing Screw Washer Snap ring Steering wheel Bushing Locking nut Axle Snap ring Linking plate shaft Peripheral board Bushing Screw Air spring Pedal kits Spring Long shaft Cap of spring Elastic pin Right rotating arm 1 44

46 Left rotating arm HYDRAULIC AND ELECTRIC SYSTEM 45

47 HYDRAULIC AND ELECTRIC SYSTEM No. Art No. Description Qty. No. Art No. Description Qty Cover, left Screw Screw Nut Cover, right Battery indicator Connection slot Power key Screw Emergency switch Fixing plate for controller Piston rod Nut Dust ring Elastic washer Y - ring Controller Cylinder body Screw Seal washer Bolt cylinder mounting bracket Elastic washer Joint Horn O - ring Nut Pipe Bolt Bolt Screw Pump unit Nut Clip for cable Micro switch 1 46

48 8.4 CONTROL HANDLE PARTS LIST 47

49 CONTROL HANDLE PARTS LIST No. Art No. Description Qty Screw Washer Hand wheel Axle sleeve Button Button for horn Cover Axle of handle Controller Bolt Elastic washer Handle arm Screw Air spring Screw Micro switch Screw Handle Reversing button Control cable Handle connector Should bushing Shaft Elastic pin Screw 3 48

50 Dust cover Screw Anti-vibration pad PEDAL PARTS LIST No. Art No. Description Qty. No. Art No. Description Qty Pedal body Air spring Bolt Bolt Spring Nut Bolt Anti-vibration pad Bushing Shaft Locking nut Elastic pin Linking plate Rubber gasket 1 49