MANUAL ET13MH ET15MH PL3000EA

Transcription

1 OPE RATI ON&S E RVI CE MANUAL ET13MH ET15MH PL3000EA

2 WARNING! WARNING! Do not use the truck before first reading through this MANUAL. NOTE! Keep for future reference. 1

3 Operation & Service Manual FOREWORD Thank you for purchasing the hybrid pallet truck ET15MH. It is designed to make your work more efficient, simpler and safer! This manual gives you a guide of proper use, safe operation and maintenance of the hybrid pallet truck. It is very important that you learn how to handle the truck in a safe way by carefully reading and understanding the content in this manual. In this way, the truck can be fully made use of and keep you away from danger. Remarks: With the continuous updating and improvement of our products, it may have some slightly difference between the product(s) you purchased and the description in this manual. Moreover, this manual will be various due to special requests from different clients. The product which our company applies for the production license is a specialized motor vehicle, can be only used at the factory area, tourist attractions, amusement parks and other specific areas, etc. under the rule of "Special Equipment Safety Supervision Regulations". If you have any questions, please do not hesitate to contact our sales department or local dealers. 2

4 WARNING! WARNING! TO PREVENT YOURSELF OR OTHERS FROM SERIOUS RISK OF INJURY, PLEASE STRICTLY OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS These trucks may become hazardous if adequate maintenance is neglected. Therefore, adequate maintenance facilities, trained personnel and procedures should be provided. Operation, Maintenance and inspection shall be performed in conformance with the following practices: 1.A scheduled planned maintenance, lubrication and inspection system should be followed. 2.Before leaving the truck: Do not park the truck on an incline. Fully lower the load forks. Press the emergency stop switch. 3.Before starting to operate the truck: Operator must be in operating position Place directional control in neutral. Check the lifting, steering, speed control, handling, alarm and braking function before operation. 4.Avoid fire hazards and have fire protection equipment present. Do not use open flame to check lever, or for leakage of electrolyte and fluids or oil. 5.Brakes, steering, control, alarm and safety devices shall be periodically 3

5 Operation & Service Manual checked and maintained in good condition. 6.Check label, identification plate, replace damaged or fallen ones, make sure they are clean and legible. 7.All devices of lifting system should be regularly checked and maintained to ensure the safe operating condition. 8.All hydraulic systems should be checked regularly. Cylinder, hydraulic valve and other hydraulic components should be no leakage before use. 9.Truck shall be kept in a clean condition to minimize and avoid the fire hazards. 10.Modifications and additions which affect capacity and safe truck operation shall not be performed by the customer or user without manufacturers prior written approval. The nameplate and safety signs on the vehicle should have corresponding change after modified of the vehicle. 4

6 Specified Use Specified Use The truck described in the manual is an industrial truck designed for lifting and transporting goods. It must be used, operated ad maintenance in accordance with the present instructions. Any other type of use is beyond the scope of application and can result in damage to personnel, the truck or property. In particular, avoid overloading the truck with loads which are too heavy or placed on one side. The data plate attached to the truck or the load diagram are binding for the maximum load capacity. The industrial truck must not be used in fire or explosion endangered areas, or areas threatened by corrosion or excessive dust. It s strictly prohibited to use the truck in rainy or wet environment. Proprietor responsibilities: For the purposes of the present operator manual 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 who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties. The proprietor must ensure that the truck is used only for the purpose it is intended for and that danger to life and limb of the user and third parties are excluded. Furthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The proprietor must ensure that all truck users have read and understood this operator manual. Failure to comply with the operator manual shall invalidate the warranty. The same applies if improper work is carried out on the truck by the 5

7 Operation & Service Manual customer or third parties without the permission of the manufacturer s customer service department. Accessories Installation: The mounting or installation of additional equipment which affects or supplements the performance of the industrial truck requires the written permission of the manufacturer. In some cases, local authority approval shall be required. Approval of the local authorities however does not constitute the manufacturer s Approval. 6

8 WARNING! Content Content 1. Truck Description / Application Components Control Handle Battery Discharge Indicator Emergency switch-off Handle Installation Information label Technical Specification and Dimensions Standard Version Specifications Dimensions Transport and Commissioning / Transport Using the truck for the first time During Break-In Operation / Safety Regulations for operation Operate and Run the truck Preparing

9 Operation Content & Service Manual Driving Lifting, transporting and depositing loads Parking the truck securely Battery Charging and Maintenance / Replace of lithium battery Charging the battery Smoking and naked flames must be avoided when working with batteries Charging preparation Charging step Storing the truck / Storing the truck Put into operation after storage malfunction/failure help / 21 2

10 1. Truck Description 1. Truck Description 1.1 Application The truck is designed to transport goods on level surfaces. It can lift open bottom or diagonal board pallets as well as roll cages beyond the area of the load wheels. Applicable ambient temperature: Suitable for 5-40 environment. If a long time working in less than 5 environment, cold storage or in the extreme conditions of temperature and humidity changes in the use of truck, you must install additional special equipment, and obtain permission from the manufacturer. 1.2 Components No. Item 1 Control Handle 2 BDI (Battery Discharge Indicator) 3 Emergency Switch-off 4 Li-Battery 5 Chassis 1

11 Operation & Service Manual Control Handle No. Item Function a Driving Knob control the driving direction and speed b Horn Triggers a warning signal c d Anti-reverse Button BDI (Battery Discharge Indicator) Safety function which, when activated, to stop and reverse. Display battery condition, remained battery and maintenance reminding Battery Discharge Indicator The battery indicator can show the battery condition and remained battery. As shown on the right: "1" refers to the LED indicator, which shows the remained battery 2

12 1. Truck Description Battery Discharge Indicator 1 Pull the emergency switch-off to start the pallet truck, when the battery is fully charged, the battery indicator LED light is on. When the battery power reduces, the color of the light changes When the light color is green, the remained battery is 100%-70%. When the light color is blue, the remained battery is 70%-30%. When the light color is red, the remained battery is 30%-10%. The truck should be charged in time. When the light flashes, the remained battery is 10%-0%. The truck should be charged immediately, and could not load capacity. When starting the truck, if the LED light flashes in turn of red, green, blue and lasts for 1 minutes, it means the pallet truck has worked for 200 hours, it needs maintenance and service. Some check points of maintenance: 1.Check if there is any loose of the nut. Tighten the nut if there is any loose. 2.Check whether the drive chain needs lubrication. 3.Check if the wheel has bad wear, to replace the wheels; 4.Check if the brake is abnormal, check if the brake clearance is abnormal, need to repair if any; 5.Check if the drive shaft bush needs to replace. Reset the 200h Maintenance Indicator The indicator can be reset by: 1. Press the emergency switch-off when the power is cut off, and Operate the directional know down to B direction. 2. Restart the truck by pulling emergency switch-off. 3

13 Operation & Service Manual Emergency switch-off The power is completely cut off and the truck stopped when pressing the emergency switch off Handle Installation 1.Put the handle (1) hole in align with the hydraulic system mounting hole. Put on D20 washer on both side of the handle. 4

14 1. Truck Description 2.Install the handle pin (3), make sure the hole of elastic pin is in align with the hydraulic system mounting hole. 3.The pressure relief chain (5) passes through the middle hole of the handle pin shaft, and connect with the pressure relief plate of hydraulic system 4.After the completion of the above procedures, lower down the handle to lowest position, remove the spring fixed shaft (4), the handle installation is completed. 5.Handle wire harness installation: handle wire harness passes through the handle tube. Note that the wire harness must install the winding plot, otherwise there may be damage to the wire harness. Common errors in binding. 1. Wire harness go through the outside of the hydraulic system 2. Wire harness go through the outside of the handle. 5

15 Operation & Service Manual 1.3 Information label The rated capacity on the label is the max. load capacity by the truck in the label listed equipment. Any change to the truck or other equipment may change rated capacity. Please provide the model number when consulting any question or ordering spare parts for the equipment. Model Number Example: ET - 15MH. Identifying code Loading Capacity: 15=1500kg 6

16 1. Truck Description 1.4 Technical Specification and Dimensions Technical specification details in accordance with GB/T Technical modifications and additions reserved Standard Version Specifications Item Model ET15MH 1 Load Capacity 1500kg/3000lbs 2 Load Center 600mm/(24 ) 3 Travel Speed (km/h) Laden 4.5 Unladen 5 4 Gradeability (%) Laden 3 Unladen 5 5 Parking Brake Electromagnetic 6 Service weight (Kg) Battery Inc Motor (Kw) Drive 0.45 Lifting N/A 8 Tyre Type (Drive/Load) PU/PU 9 Tyre Size, drive (mm) Ф150x70 10 Tyre Size, load (mm) 2xΦ80x60 11 Battery Voltage/Capacity (V/Ah) 24/ 20 Battery weight (Kg)

17 Operation & Service Manual Dimensions Item Metric Imperial Y Wheelbase 1170mm/1240mm 46 /48.8 h3 Lifting Height 200mm 8 H2 Fork height, lowered Min 85mm 3.3 h4 Height of tiller arm Min 785mm 31 Max 1250mm 49 L1 Overall Length 1540mm/1610mm 60.6 /63.4 b1 Overall Width 540mm/680mm 21 /27 s Thickness 50mm 2 e Fork size Width 160mm 6.3 L Length 1150mm/1220mm 45 /48 b1 Fork Width, outside 540mm/680mm 21 /27 h5 Ground Clearance 35mm 1.4 Wa Outer Turning Radius 1320mm/1390mm 52 /55 Ast 1000х1200mm pallet crossways 1980mm х1200mmpallet crossways 1860mm 73 8

18 2. Transport and Commissioning 2.1 Transport 2. Transport and Commissioning Lifting the truck by crane 1.Only use crane handling equipment gear with sufficient capacity. 2. Loading weight>net weight of truck (battery weights included). Loading weight include not only weight of truck, but also the pallet or box. 3. Pallet(box) should be big enough and strong enough to bear whole truck. Park the truck securely Make sure forks are positioned properly for the pallet. Move forward slowly to insert forks into the pallet as far as possible and then stop the truck. Warning! To avoid damage to the forks when you move the trucks to pallet. In order to keep the truck out of being scraped, please move the truck in open and flat area. To avoid collapse when lifting or lowering the pallet(box). 9

19 Operation & Service Manual 2.2 Using the truck for the first time Only operate the truck with battery current. Preparing the truck for operation after delivery or transport as following procedures Check the equipment to make sure it s complete. Check the hydraulic system Install the battery if necessary. Do not damage battery cables. Charge the battery When the truck is parked for longer, the surface of the tires will flatten. The flattening will disappear after a short period of operation. 2.3 During Break-In We recommend operating the truck under light load conditions for the first stage of operation. The requirements below should be observed within the first100 hours operation. 1Prevent the new battery from over discharging in the beginning period of operation. Please charge in time when remained power is around 30%. 2Perform specified preventive maintenance service carefully and completely. 3Avoid sudden stop, starts or turning 4Oil changes and lubrications are recommended to do as specified. 5Limited load is 70-80% of the rated load. 10

20 3. Operation 3. Operation 3.1 Safety Regulations for operation Driver Authorization The truck may only be operated by trained personnel, who have been demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorized to operate the truck by the proprietor or his representative. Driver s rights, obligations and responsibilities. The driver must be informed of his duties and responsibilities and be instructed in the operation of the truck and shall be familiar with the operator manual. The driver shall be afforded all due right. Safety shoes must be worn with pedestrian operated trucks. Unauthorized Use of Truck: The driver is responsible for the truck during the time it is in use. He shall prevent unauthorized persons from driving or operating the truck. It is forbidden to carry passengers or lift personnel. Damage and Faults: The supervisor must be immediately informed of any damage or faults to the truck. Trucks that are not safe for operation (e.g. wheel or brake problems) must not be used until they have been rectified. Repairs: The driver is not allowed to carry out any repairs or alterations to the truck without the necessary training and authorization to do so. The 11

21 Operation & Service Manual driver must never disable or adjust safety mechanisms or switches. Hazardous area: A hazardous area is defined as the area in which a person is at risk due to truck movement, lifting operations, the load handler (e.g. forks or attachments) or the load itself. This also includes areas which can be reached by falling loads or operating equipment. Unauthorized persons must be kept away from the hazardous area. Where there is danger to personnel, a warning must be sounded with sufficient notice. If unauthorized personnel are still within the hazardous area, the truck shall be brought to a halt immediately. Safety Devices and Warning Signs: All the rules stated in this brochure with regard to the safety devices, warning signs and warning instructions shall be strictly observed. 3.2 Operate and Run the truck Preparing Before the truck can be commissioned, operated or a load unit lifted, the driver must ensure that there is nobody within the hazardous area. Checks and operations to be performed before starting daily work. - Visually inspect the entire truck (in particular wheels and load handler) for obvious damage. 12

22 3. Operation Driving Start the truck Move the tiller arm down to travel position (M). Select desired travel direction (Forward or Reverse), the parking brake is released automatically. Start gently by accelerating slowly until you reach the desired speed. The more the control handle rotates, the faster the speed becomes. Upright Function Before start the truck, press the emergency switch off and then operate the knob to A direction. Then pull the emergency switch on and the upright moving function is activated. Operate the directional knob, and the truck can move forward or backward easily at upright position. 13

23 Operation & Service Manual Cancel Upright Function The upright function can be canceled by restart the truck. WARNING! When Upright function activated, the truck can be moved by press button 1 or knob 2. Thus, it s prohibited to have people or obstacles standing in front of the truck, in case of any damage to people or goods. Steering Apply the control handle to the left or right as your purpose. Parking Emergency stop: Drawing back the emergency switch-off. All electrical functions are deactivated. 14

24 3. Operation Automatic Braking When the control handle is released, it automatically sets itself to the upper brake zone (B) and automatic braking ensues. It can be set by pressing the control handle to the lower brake zone(b) WARNING! If the travel switch moves slowly or not at all to the upper brake zone, the truck must be taken out of service until the cause of this fault is be rectified. Regenerative braking The travel switch will return to its initial position (speed=0) when the switch is released. If the travel switch is set to "0", the truck automatically brakes regenerative. When the speed below 1Km/h, the brake will be working and motor brake stops. WARNING! If the travel switch move slowly or not at all to 0, the truck must be taken out of service until the cause of this fault is be rectified. Inversion braking You can set the travel switch to the opposite direction when travelling. The truck brakes regeneratively until it starts to move in the opposite direction. WARNING! In hazardous situations set the control handle to the brake position or set the travel switch to the opposite direction. Specific measures should be taken based on the actual situation. 15

25 Operation & Service Manual Brake Release(Option) Original position: pallet jack drive by power Release position: pallet jack use as manual jack, without power driving. 16

26 3. Operation Lifting, transporting and depositing loads Unsecured and incorrectly positioned loads can cause accidents WARNING! Before lifting a load, the driver must ensure that it is correctly palletized and that the capacity of the truck is not exceeded. -Instruct other people to move out of the hazardous area of the truck. Stop working with the truck if people do not leave the hazardous. -Only carry loads that have been correctly secured and positioned. Use suitable precautions to prevent parts of the load from tipping or falling down. -Do not transport with bad handbarrow (as truck and stock). -Never stand underneath a raised load handler. -Do not stand on the load handler. -Do not lift other people on the load handler. -Move forks to the bottom of load as closer as possible. WARNING! For longer working life of cylinder, do not lift the fork to the maximal height when loading. 17

27 Operation & Service Manual Lift Press Lift button (1) to the height you need. Lower Press Lower button (3) to the lowest position Parking the truck securely The pallet truck must be securely parked as regular when driver needs to leave, even in a short time. Press lower button, fully lower the load handler. Turn off the key switch and remove the key. WARNING! The truck should be securely parked as regular. Fully lower the load. Prohibited to park in incline. 18

28 4. Battery Charging and Maintenance 4. Battery Charging and Maintenance Check if the lithium battery in the pallet truck whether it is full of charge. For the safety of transportation, the truck is not fully charged, and it should be charged after first using. 4.1 Replace of lithium battery When replacing the battery, ensure that a battery of the same specification, dimension and weight is fitted Warning! -Battery has high voltage and energy. Do not bring short circuit. Do not approach tools to the two poles of the battery, which can cause the sparkle. Cut the power when maintenance or service the pallet truck. -Do not change the weight and size of battery, otherwise to influence the gravity of truck. Over more or less of battery weight will reduce the stability and break performance. 4.2 Charging the battery Smoking and naked flames must be avoided when working with batteries. Use manufacturer supplied charger to charge the battery, insufficient charge or over charge will damage the battery. 19

29 Operation & Service Manual Maximum charging current: Battery (Ah) Charger (A) 20 4/10A Warning! Negative connect is forbidden for lithium battery to avoid explosion danger Charging preparation Pallet truck must be charged soon after running, not exceed more than 24 hours. (1) After pallet truck stop, press the emergency button, remove the key. (2) Pull out the charging plug and plug into the suitable power source (3) Connect the AC power and start to charge. WARNING! To charge the battery, the truck must be parked in a closed and properly ventilated room. When charging, the tops of the battery cells must be exposed to provide sufficient ventilation. Cut off the power before remove the charger outlet Charging step Check whether the condition is according with "Safety regulations for Charging the battery". Indicator of charger turns to green. No significantly shorten working time. 20

30 5. Storing the truck 5.1 Storing the truck 5. Storing the truck The truck must be stored in a frost-free dry space. The plug should be pulled out if the truck is stored for longer time. 5.2 Put into operation after storage - Clean the truck completely, then fixed the battery. - Charge the battery. - Put the truck into use. 21

31 Operation & Service Manual 6. malfunction/failure help This section is intended to help users determine and troubleshoot simple faults or problems caused by operational errors. FLASHING LEDS Trip Type Possible causes 1 Low battery voltage - Check the condition of the batteries. - Check the wiring to the batteries for any possible damage or loose connection. - Replace batteries and/or wiring / connections if they have become defective. 2 Motor open circuit - Check motor brushes are not worn or damaged. - Replace motor brushes, in case they have worn or become faulty. - Check motor connections for possible damage or short circuits (both at the motor and controller connections). - Check motor for possible damage. - Replace motor, in case it has developed a fault. 3 Motor shorted to battery - Check motor brushes are not worn or damaged. - Replace motor brushes, in case they have worn or become faulty. - Check motor connections for possible damage or short circuits (both at the motor and controller connections). - Check motor for possible damage. - Replace motor, in case it has developed a fault. 22

32 6. malfunction/failure help FLASHING LEDS Trip Type Possible causes 6 Sleep Model - Turn controller off and then on to awake the system. - To disable Sleep Mode, program the parameter Sleep Timer to 0 minutes. 7 Belly button active at Startup - Check state of Belly Button input, pin 9 of 14W tiller connector. - Check program settings for Belly Button are correctly programmed. - Check operation of Belly Button Switch - replace if faulty. 8 Possible Controller Error - Check overall wiring for any loose connections or faults. - Check batteries for any problems. - Check motors for any problems. 9 Short circuit/ open circuit in brake - Check the solenoid brake connections for possible short circuits. - Check the solenoid brake for possible damage. - Replace solenoid brake, in case it has developed a fault. 10 High battery voltage - Check the condition of the batteries. - Check the wiring to the batteries for any possible damage or loose connection. - Replace batteries and/or wiring / connections if they have become defective. 23