Sovan's CBD25T User manual

CBD25T/CBD30

Electric Pallet Truck

Operation Manual

Parts Catalogue

2012-01

Welcome to choose “Sovan's” electric pallet truck!

We hope our electric trucks will bring great convenience to

your work!

Please read the manual carefully before operation.

This manual is a common manual. We reserve the right to modify

technology of the electric pallet truck. If there is anything in the

manual that is not consistent with the actual truck, the actual truck

should be considered correct and the manual is only for reference。

********************************************************

Warning

Operators must strictly conform to ISO3691“Safety Specifications of Motor Industrial Vehicles”.

Untrained personnel are notallowed to operate the truck。

********************************************************

Content

Brief introduction……………………………………………………………………..……1

Ⅰ.Technical parameters…………………………………………………..…………..2

Ⅱ.Structure description…………………………………………………………………4

Ⅲ.Safety norms……………………………………………………………………………..6

Ⅳ.Drive and operation………………………………………………………..………..11

Ⅴ.Storage battery and charge……………………………………………………..13

Ⅵ.Inspection before operation…………………………………………………....16

Ⅶ.Inspection after operation……………………………………………….……...16

Ⅷ.Periodic maintenance and repair………………………………………….….17

Ⅸ.The store and transportation of forklift…………………………………..22

Ⅹ.The tow of the pallet truck……………………………………………...........23

Ⅺ.The disassembly and assembly of some parts……………………….24

Ⅻ.Common fault and trouble shooting………………………………………..27

Appendix: Motor industrial vehicle—Safety norms………………………32

Brief introduction：

CBD25T/CBD30 series electric pallet truck is powered by storage battery, and driven by motor. This kind of truck

travels by means of gear drive. The fork is lifted by means of DC motor and hydraulic transmission, which

motivate hydraulic cylinder up and down to lift fork and goods together. As this truck is electrically driven for

traveling and lifting, it possesses many characteristics, such as labor-saving, high efficiency, stability in operation,

simple and easy operation, safety and reliability, little noise, environmental friendly, etc. And the driving mode for

this kind of truck is stand driving and steering operation of handle steering. This truck adopts 24V large capacity

battery cell, which greatly extends service time within one charge.

The kind of truck is applicable for goods transportation on hard and flat ground.

Allowed environment for using

a. Height above sea level shall not be over 1200m;

b. Ambient temperature shall not be higher than +40℃ and no lower than -25℃；

c. When the ambient temperature reaches +40℃, the relative humidity should not exceed 50%; at a lower

temperature, higher relative humidity is allowed；

d. Hard and flat ground。

e. It is prohibited to use the truck in a flammable, explosive or corrosive environment with acid and alkali.。

Description：

The instruction manual shall be kept by the operator, and shall be read by the operator until he gets a full

understanding.

The instruction manual is composed of correct operation, convenient and simple maintenance, and routine

inspection.

The instruction manual shall be carefully read before operation, for purpose of correct drive and suitable

maintenance to ensure safe and effective material transportation.

The instruction may be in disagreement with practical product due to product innovation.

The instruction manual shall be accompanied with in case of truck leasing or transfer.

Please come into contact with our sales department in case of any problem.

Description of symbol：Regulations of the following symbols are of great importance to your safety and others

as well

Danger

Indicates an impending danger. Deaths or severe injuries would be

resulted without any precaution or avoidance. You must observe

those requirements.

Warning

Indicates a potential danger. Deaths or severe injuries would be

resulted without any precaution or avoidance. You must observe

those requirements.

Caution

Indicates a potential danger. Moderate injuries would be resulted

without any precaution or avoidance. You must observe those

requirements.

Notice You shall pay attention to statements that are in direct or indirect

relation with personal security and truck maintenance.

Ⅰ.Technical parameters：

1． CBD25T/CBD30 Outline drawing：

2、Main technical parameter

Char

acter

istics

1.1 Manufacturer(abbreviated)

1.2 Model CBD25T CBD30

1.3 Driving model ：Electric(storage battery),

diesel, gasoline, fuel gas motor-driven motor-driven

1.4 Driving model （Manual, Walking, Stand

driving, Seat driving ,Order picking） Stand driving Stand driving

1.5 Rated load Q(kg) 2500 3000

1.6 Load center distance

(mm)

600 600

1.8 Front overhang

(mm)

933 933

1.9 Tread

(mm)

1491 1491

Weig

2.1 Service weight(with battery) kg 860 860

2.2 Axle load, front/rear, laden kg 1240/2120 1360/2500

2.3 Axle load, front/rear, unladen kg 640/220 640/220

Whe

chas

sis

3.1 Wheels (rubber, high elasticity, pneumatic

tyre, polyurethane wheel) polyurethane

wheel

polyurethane

wheel

3.2 Wheel dimension, front φ250×80 φ250×80

3.3 Wheel dimension, rear φ82×173 φ82×173

3.4 Additional wheel(dimension) φ127×57 φ127×57

3.5 Wheel number, front/rear（x = driving wheel） 1X+2/4 1X+2/4

3.6 Tread, front

10(mm)

691 691

3.7 Tread, rear

11(mm)

455 455

Dime

nsion

4.4 Lift height

3(mm)

135 135

4.9 Min. /Max. height of operation handle, in

driving position

14(mm)

1041/1374 1041/1374

4.15 Height, lowered

13(mm)

82 82

4.19 Overall length

1(mm)

2143 2143

4.20 Length to fork face

2(mm)

923 923

4.21 Overall width of truck body

1(mm)

936 936

4.22 Fork dimension S/e/l(mm) 55x230x1220 55x230x1220

4.25 Overall width of fork

5(mm)

685 685

4.32 Wheelbase ground distance

2(mm)

27 27

4.33 Aisle width, with pallet 1000x1200 crosswise

(mm)

2343 2343

4.34 Aisle width, with pallet 800x1200 lengthwise

(mm)

2343 2343

4.35 Turning radius

a(mm)

1860 1860

Perfo

rman

Data

5.1 Traveling speed, laden/unladen Km/h 7.5/8 6/6.5

5.2 Lifting speed, laden/unladen m/s 0.03/0.04 0.03/0.04

5.3 Descending speed, laden/ unladen m/s 0.05/0.045 0.05/0.045

5.7 Gradeability, laden/unladen % 6/8 6/8

5.8 Max. gradeability, laden/unladen % 8/20 8/20

5.10 Traveling brake regenerative

brake regenerative brake

Moto

6.1 Driving motor power kW 1.5 2.2

6.2 Lifting motor power kW 1.5 1.5

6.3 Battery voltage/rated capacity V/Ah 24/300 24/300

6.4 Battery weight Kg 300 300

6.5 Battery dimension（LXWXH） mm 810×212×665 810×212×665

8.4 Noise level at operator’s ear, according to

DIN12053 dB(A) 70 70

Ⅱ.Structure description：

1．Structure of the entire truck：

1 power switch； 2 lifting button； 3 horn button； 4 accelerator knob； 5 operation handle；

6 emergency reverse button；

7 multi-functional instrument 8 electric lock； 9 electric control unit； 10 driving unit； 11

platform； 12 steering power unit；

13 hydraulic power unit； 14 storage battery； 15 handrail； 16 handrail control box； 17 tool

pallet； 18 backrest

2 Function introductions

of instrument and

operational control

pieces:

⑴⑴ instrument:

1. battery capacity

indicator；

2. fault indicator；

3. low-speed

indicator；

accumulative working time

and fault code indicator

This instrument is a

combination of battery

capacity indicator, LCD hour

meter, fault code and

low-speed indicator, with

the battery capacity indicator of five segments of colorful LED display. When the storage battery is fully

charged, the five battery capacity indicators will be green. With battery capacity consuming up, the five

indicators will go out one by one. When battery discharges by 70% capacity, the last indicator will flicker

and shows “energy storage” alarm. When the battery discharges by 80%, the last indicator becomes red

and shows “energy exhaust”. After the external power supply is cut off, the internal battery can generally

keep storage memory of 10 years. The life service time for monitoring of this instrument is 99999.9 hours

recorded on LCD displays. Hour meter resets automatically and continue to time and display. Only if it is

connected to battery, LCD hour meter will start working. This instrument possesses high reliability under

extremely bad environment。

⑵Steering system:

The steering system mainly composes of operation handle, steering device shaft, support bearings,

potentiometer and steering power unit. The system is used to control travel direction of the truck。

⑶Braking:

the traveling brake of this truck is regenerative braking, with parking brake of electromagnetic brake.

When the accelerator is released during the traveling of the truck, the controller will carry out regenerative

braking at first. This kind of brake can turn the dynamic energy to electric energy which can be recharged to

battery. When the truck is stopped, the electromagnetic arrester will be out of power and braked again. This

type of regenerative brake with electromagnetic brake not only prolongs the service time of storage battery

but also reduces the wearing of the brake plate, which extends the service time of brake

The position of operation handle is divided

into 3 areas, i.e. area A , area B and area C which

have different operational functions separately.

area A： When the operation handle is in area A, the

truck will be in a state of braking.

Then acceleration knob for traveling can not work but

can only conduct lifting or lowering operation.

area B： When the operation handle is in area B, the

truck will be in a state of traveling. When the

accelerator knob is turned to one direction, the truck

will travel in this direction. When the accelerator knob

is turned in another direction, the truck will travel in

another direction. When the accelerator knob is

released during

truck traveling, regenerative braking will take effect, making the truck slow down to stop.

area C：When the operation handle is in area C, the truck will be in a state of traveling. When the accelerator

knob is turned to one direction, the truck will travel in this direction. When the accelerator knob is turned in

another direction, the truck will travel in another direction. When the accelerator knob is released during truck

traveling, the truck will be in a state of free sliding.

When the operation handle is placed in area B or area C, the truck can conduct traveling operation

as well as lifting operation. However, traveling and lifting operation can not realized at the same time, with the

traveling operation as the preferential function。

⑷Operation control:

1) Lifting and lowering operation: Press the lowering button of the forks, the forks will descend. While the

lifting button is pressed, the fork will rise。

1．Lifting button 2. Lowering button 3. Accelerator knob

4. Emergency reverse button 5. Horn 6. Slow-down button

2) Accelerator knob: It is used to control the travel direction and speed of the electric truck. Before

operation of the truck, firstly turn the operation handle to area C shown as above. When the handle is

placed in area A, the truck will be powered-off and braked. At this time, the truck can not drive. When the

operation handle is placed in area C and the acceleration knob is turned in one direction, the truck will

travel in that direction. Meanwhile the truck will be accelerated with the increasing of rotation amplitude

of the knob. When the

accelerator knob is turned in

another direction, the truck will

travel in another direction.

Likewise， the truck will speed

up with the increasing of

rotation amplitude of the knob.

3) Horn button ： Horn of the

truck will be turned on if you

press the button。

4) Emergency reverse button:

when the operation handle is

placed in area B and the

emergency reverse button is

pressed, the truck will travel in an opposite direction away from the operator immediately. This is a safety

switch which can avoid the operator from being squeezed under unexpected condition。

5) Slow-down button: When this button is pressed, the truck will travel at an extremely slow speed. This

button is applicable for operation on especially narrow field or on the condition that the truck needs to be

accurately located.。

6) Electric lock：It is used to control switching-on and switching-off of main power supply of the truck. Key

of the electric lock shall be kept by the truck driver or personnel who have been specially assigned. Be

sure to cut off the main power supply when you leave the truck, and take the key of electric lock, for fear

occurrence of accident due to operation carried out by others。

7) Power switch：It is used to control emergency power-off of the truck. Pulling up the switch, then main

power supply will be cut off, and inserting down represents switching-on. If your truck were out of

control due to some reason, please immediately pull up the switch to cut off power supply for sake of any

occurrence of accident。

As for the operation button on operation handle and handrail control case, the same buttons

have the same control function, which is convenient for easy operation。

1. Horn

button

2. Rise

button

3.Tortoise

climb button

4.Descend

button

5.battery

main switch

Ⅲ. Safety Norms：

Warning

Please pay attention to the following items first before operation of the truck：

⑴ This electric truck is only limited to utilization indoor with a hard flat floor. Operation in inflammable,

explosive environment or corrosive environment such as acid or alkaline condition shall be strictly

forbidden.

⑵ Only drivers who have received formal training or are authorized can be allowed to drive the truck.

⑶ Read this instruction carefully before operation so as to master the performance of the truck; check the

truck whether it is in its normal condition before each operation. It is forbidden to use faulty truck; repair

by untrained persons is forbidden as well.

⑷ Overloading operation is forbidden.

⑸ As for goods carrying and operation, center of gravity of the goods must be within range of the two forks.

It is forbidden to transport loose goods.

⑹ The truck shall travels slowly when forks pass in or out of pallet.

⑺ It is strictly forbidden to press the lifting or lowering button during the traveling of the truck. Meanwhile,

don’t switch lifting and lowering buttons rapidly or frequently, because rapid and frequent lifting or

lowering will cause damage to the truck and goods.

⑻ Don’t load heavy goods on the forks rapidly.

⑼ Don’t lay the goods on the truck for a long time!

⑽ It is strictly forbidden to make sharp turn on narrow aisle. When it is turning, slow down the truck so as

to ensure the safety of personnel and goods.

⑾ Descend the forks to the lowest position when the truck is not used.

⑿ It is strictly forbidden to put any part of the body under heavy goods and forks.

⒀ This truck is suitable to be used on flat ground or flat platform. Don’t put the truck on the slope for a long

time.

⒁ Overloading operation is forbidden. Otherwise the wheel will skid, resulting in the damage of wheel and

motor as well as danger of the human body and goods.

⒂ It is strictly forbidden to use the truck under stipulated voltage of 20.4V.

（16）It is strictly forbidden to conduct charge by connecting the plug to AC power directly。

1. Safety operation norms：

⑴Training of driver：

Notice

Even though each electric pallet truck may have the same technical parameters, there may

be differences on features of braking and acceleration as well. Never drive the truck until you get

familiar with all those operations。

⑵Wear of the driver during truck driving：

Notice

Please put on safety shoes and protective clothes. Do not wear clothes that are too loose

for sake of being caught, which would result in danger.

⑶ Rules that must be observed；

Notice

Never drive the truck when you are tired or un-concentrated, with an injection of drug, or

after a liquor drinking。

Safety rules and regulations shall be observed during operation or maintenance of the truck。

This manual suits for next models

Table of contents

Other Sovan's Truck manuals

Sovan's

Sovan's JF User manual

Sovan's

Sovan's CTD10R-E User manual

Popular Truck manuals by other brands

Sealey

Sealey CST801 quick start guide

RAM

RAM 1500 2019 owner's manual

BT Ergomover 620 AC-TT Operator's manual

Still

Still EXU-16 Original instructions

Lift-Rite

Lift-Rite Titan Series Owner's Manual, Operating Instructions Manual, and Replacement Parts Manual

SAC

SAC TURBO-MAX 6046 Operator's manual

Noblelift

Noblelift PS E12BSL Instruction handbook

Noblelift

Noblelift PTE12N Instruction handbook

Noblelift

Noblelift PT20H Instruction handbook

Daewoo

Daewoo Novus M2SEF manual

jcb

jcb 506-23 Operator's manual

Tico

Tico Pro-Spotter Service manual

Dawson

Dawson Truck Mate Operator's manual

freightliner

freightliner Columbia Driver manual

Mack

Mack M359 manual

Super Products

Super Products Camel 1200 (Ejector Unloading) Operator's manual

Vestil

Vestil CARPET-D instruction manual

STAXX

STAXX EPT15H Operation manual