Haklift HAVA1200ELE User manual

Haklift Oy
Asessorinkatu 3-7
20780 Kaarina, Finland
Tel. [phone]
[email protected]
www.haklift.com
Lifting Solutions Group
Axel Johnson International
Rev. 20181203
ORIGINAL INSTRUCTIONS –
KÄÄNNÖS ALKUPERÄISESTÄ
KÄYTTÖOHJEESTA – ÖVERSÄTTNING AV
ORIGINAL BRUKSANVISNING
ELECTRIC PALLET TRUCK
SÄHKÖINEN HAARUKKAVAUNU
ELEKTRISK MOTORLYFTVAGN
HAVA1200ELE

Haklift Oy
Asessorinkatu 3-7
20780 Kaarina, Finland
Tel. [phone]
[email protected]
www.haklift.com
Lifting Solutions Group
Axel Johnson International
Content
1. Safety regulations
2. Description
3. Operation
4. Operation, maintenance and charging of battery
5. Maintenance
6. Common faults and troubleshooting
7. Treatment of abandoned material
8. Accessories and spare parts
9. Electrical schematic diagram
10. Exploded views and parts lists
11. Original Declaration of Conformity

Haklift Oy
Asessorinkatu 3-7
20780 Kaarina, Finland
Tel. [phone]
[email protected]
www.haklift.com
Lifting Solutions Group
Axel Johnson International
Please read the manual carefully before operation.
This manual is a universal manual. We reserve the right to modify the technology of the
product. If there is anything in the manual that is not consistent with the actual product, the
actual product should be considered correct and the manual is only for reference.
1. Safety regulations
When operating the truck, one should always wear safety shoes.
When assembling or disassembling the truck, in order to avoid injury, one should always
wear safety goggles.
Attention!
 When the truck is damaged or a failure/malfunction will risk the safe operation, do not go on
operating the truck.
Attention!
This truck can only be used on hard and smooth ground. In the following environmental situations,
it is not allowed to operate the truck:
 The air contains dust or gas, which may be able to cause fire or explosion.
 In refrigerating warehouse or some low temperature, salt containing or other corrosive
environments.
 Rainy outdoor environment.
 Operation on granule or grassland.
Attention!
 When operating the truck, careful judgement should be conducted and one should operate
in a responsible manner.
 One should not operate the truck with oily hands or shoes.
 The operator must not wear loose clothes or jewelry.
Attention!
 When operating the truck, it should be ensured that the ground possess sufficient load
bearing capacity and the load here refers to the sum of the weight of the truck and the
weight of the goods.

Haklift Oy
Asessorinkatu 3-7
20780 Kaarina, Finland
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 When there is a protruding object on the truck or around it, which may cause human injury
or forklift damage, one must be very careful.
 It is strictly prohibited for people to stand/appear around the truck operation area, which
may cause human injury, for example, if the goods fall down.
Be careful!
 When handling goods on a slope, the operator must be very careful in operation. The
operator should operate in the upper part of the slope as shown in the figure above.
Warning!
 When turning, high-speed operation should be avoided to prevent the truck from turning
upside down.
 The goods should not be piled too high to avoid blocking the vision line.
 Braking should be conducted slightly and very carefully to prevent the goods from sliding off
the tray, which may damage the goods.
 It is not allowed for the truck to turn on a slope.
 Before pushing the truck into an elevator, the operator must ensure that the elevator is able
to bear the total weight of the truck and the goods, the total weight of the operator and other
people in the elevator. When entering the elevator, make sure that the goods enter first and
then the operator. When the truck and goods enter or leave the elevator, other people must
not stay in the elevator.
Be careful!
 The load weight should not exceed the truck’s rated load.
 When piling goods, the goods must not be piled too high to avoid goods falling down or
truck turning over when handling.
 It is strictly prohibited to use this truck to transport or lift human being.
 No other people should stay around the truck operation area to avoid injuries and deaths
when the truck suddenly fails in operation.
 When operating the lever or pushing the truck, one must make sure the hand is put above
the lever.
 It is not allowed to put any part of the body under the truck forks or the load.

Haklift Oy
Asessorinkatu 3-7
20780 Kaarina, Finland
Tel. [phone]
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Axel Johnson International
Attention!
 When parking the truck, the forks should be lowered to the minimum height.
 It is not allowed to park the truck on a slope.
 It is not allowed to park the truck in emergency passageway.
 It is not allowed to park the truck in a place blocking traffic or affecting operation.
 It is not allowed to operate the truck in a rainy environment.
 When nobody takes care of the truck, please turn off the general power supply.
2. Description
This truck is suitable to be operated on indoor, hard and smooth ground. It is not allowed to
operate the truck for unsuitable applications.
 The ambient air temperature does not exceed +40ºC or fall below -10ºC;
 Hard, flat ground is required;
 It is forbidden to use this truck in a flammable and explosive or acid-base and other
corrosive environment;
 The loaded max. gradeability is 3%.

Haklift Oy
Asessorinkatu 3-7
20780 Kaarina, Finland
Tel. [phone]
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Model Unit HAVA1200ELE
Drive type Electric
Operation type Walkie
Rated load Q (kg) 1200
Load center distance C (mm) 600
Height, fork lowered h13 (mm) 80
Thread Y (mm) 1269/1339
Wheel PU
Wheel dimensiom, front mm Φ250
Wheel dimension, rear mm Φ80
Wheel number, front/rear (x = driving wheel) 1X-2/4
Lift height h3 (mm) 110
Min./Max. height of operation handle in the
driving position h14 (mm) 635/1200
Overall length l1 (mm) 1651/1721
Length of fork face l2 (mm) 501
Overall width b1 (mm) 550/680
Fork dimension s/e/l (mm) 45/160/1150(1220)
Fork width b5 (mm) 550/680

Haklift Oy
Asessorinkatu 3-7
20780 Kaarina, Finland
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3. Operation
Energization
 Connect the interface of lithium battery.
 Turn on the electric switch.
Model Unit HAVA1200ELE
Wheelbase ground distance h1 (mm) 35
Aisle width for pallet 1000x1200 crosswise Ast (mm) 1850/1920
Aisle width for pallet 800x1200 lengthwise Ast (mm) 1900/1920
Turning radius Wa (mm) 1452/1522
Traveling speed, laden/unladen km/h 4/4.5
Max. gradeability, laden/unladen % 3/8
Driving motor power kW 0.6
Lifting motor power kW 0.8
Battery voltage/rated capacity V/Ah 48/20
Traveling brake Electric
Noise level at operator’s ear, according to
DIN12053 dB(A) 70
The connectors are connected
with each other.
Turn on the electric
switch with keys.

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Lifting and lowering
 Lifting: Press the lifting button on the handle.
 Lowering: Hold the knob tightly to lower.
Travelling
 Turn the handle to travelling scope;
- A and C is braking;
- B is travelling;
 Rotate the accelerator slowly to start to move the truck (for safety, abrupt acceleration is
forbidden)
Lift
Lowering knob
Reverse Forward

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Braking
 Release the accelerator when travelling normally and the truck stops slowly by the
regenerative brake of the motor until the brake locks the wheel.
 Turn the handle to A or C quickly when emergency braking and the brake locks the wheel
to achieve the emergency braking.
Emergency reversing
 The red button at the end of the handle is the emergency reversing button. The truck will
stop immediately and start to move backwards for a distance when the body touches the
emergency reversing button. It is a safety button which avoids the extrusion of the truck and
protect the operator from injury when meeting obstacles.
Parking
 Release the speed button to stop running. The truck will slow down until the brake locks the
wheel.
 Lower the forks to the lowest position.
 Close the electric switch.
 Disconnect the battery wire off the truck if parking for a long time.
Disconnect the battery wire off
the truck if parking for a long
time.
Emergency reverse button

Haklift Oy
Asessorinkatu 3-7
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Tel. [phone]
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4. Operation, maintenance and charging of the battery
4.1 Battery type and safety precautions
4.1.1 Battery type: Lithium battery; battery voltage 48V; environmental protection battery, no Hg
and Cd etc.
4.1.2 Precautions:
a) Ambient temperature for the battery is -10 ~ 45ºC.
b) Charge every 3 months during a long time battery storage.
c) Before using a new battery or if it has been stored for long periods of time, fully charge the
battery before use.
d) Do not short circuit the battery, which may permanently damage the battery.
e) Do not burn or destroy the battery, which may cause toxic gases to release or explode.
f) Do not weld the battery directly.
g) Do not expose the battery to an unfavorable environment, such as extreme temperature, deep
cycle, or often overcharge / over discharge.
h) If the battery is hot, do not touch it until it has cooled down.
i) When removing the battery, grasp the plug by hand instead of stay wire.
j) After the battery is used, if the battery is hot and recharging it, cool it down in a ventilated
environment.
k) Do not put the battery in water or seawater.
l) Do not try to separate, squeeze or hit the battery, the battery will heat or fire. Batteries lye is
harmful to the skin and eyes, and will damage the clothes.
m) Keep the battery away from children and contact the doctor immediately if it is found to be
swallowed.
4.2 Quick replacement of the battery
Step 1: Turn off the electric switch.
Step 2: Pull the puller of the battery connector, unplug the battery connector. (Note: Operator must
hold the puller when unplugging the battery connector, not allowed to unplug the wire directly.)

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Step 3: Hold the battery puller, unplug the battery off the truck.
Step 4: Install the new battery, insert it into the mounting groove.
Step 5: Insert the battery connector.
4.3 Precautions of battery charging
a) Special Li-ion charger supplied by the manufacturer must be used: voltage AC 220V/50Hz,
output voltage DC 54.6V, output current 6.0A. Specifications are marked on the charger.
b) Do not reverse charge the battery.

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c) Stop charging immediately if found the battery hot during charging, recharge after cooling down
naturally.
d) Operator must hold the puller when unplugging the battery connector, it is not allowed to unplug
the wire directly.
4.4 Power display
 Green lamp always on: 70%-100%
 Yellow lamp always on: 40%-70%
 Red lamp always on: 10%-40%
 Red lamp flashes: Empty
- When the red lamp is on, please prepare to drive
the truck to charge; red lamp flashes as a warning,
prompting the truck is about to stop working,
please immediately charge the battery. If continue
to use, lithium battery interior will carry out the
power disconnect protection, then it will not be
able to travel.
5. Maintenance
The truck’s ability to operate satisfactorily depends on the carefulness of the maintenance. When
the maintenance is neglected, human safety may be endangered and property may be damaged.
When the truck is in operation, routine inspection should be conducted frequently and
abnormalities should be removed in time. Do not operate a truck with a defect or malfunction to
ensure personnel safety and prolong the service life of the truck.
Maintenance: The maintenance of the truck is usually divided into three levels, routine
maintenance, level 1 maintenance and level 2 maintenance.
Routine maintenance: Once every day, the main content is to keep the surface clean and examine
if the power supply cable is damaged.
Level 1 maintenance: 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:
Red
lamp Yellow
lamp Green
lamp

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a. Mechanical maintenance should be conducted every half a year. The main contents are to
replace lubricating oil for the transmission gear and bearing of the drive wheel, apply lubricant to
various rotating joints, while examining if the fastening items are loose, if the wheels are rotating
flexibly, if the fork rises and declines normally. The operation noise of the truck after maintenance
should be no greater than 70dB.
b. Maintenance of the hydraulic system: Once every 12 months. Examine if the oil cylinders are in
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. ISO oil standard is applied to hydraulic oil. When
the ambient temperature is -5 ~ 40ºC, HL-N32 is adopted and when the ambient temperature is -35
~ -5ºC, 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 equipment are reliable, if the switches are normal and if the insulation of the
electric equipment is in normal condition (The insulation resistance of electric equipment and the
truck body should be greater than 0.5MΩ.)
6. Common faults and trouble shooting
The table below provides some common failures of the truck in operation and the trouble shooting:
No. Faults Analysis of cause Trouble shooting
1 Hydraulic oil
leakage.
1. Failed oil seal.
2. Slight damage or wear
on the surface of one or
two components.
3. Loose connection.
1. Replace the oil seal.
2. Replace the damaged
components.
3. Re-tighten the
connection .
2 Fork does not lift.
1. Too great viscosity of
hydraulic oil or hydraulic
oil has not been injected.
2. Foreign matters in the
oil.
3. The hydraulic power
unit is damaged.
1. Replace hydraulic oil.
2. Remove the foreign
matter in oil or replace
hydraulic oil.
3. Replace the hydraulic
power unit.
3 Fork does not
lower.
Manual lowering valve is
not adjusted well.
Adjust the position of
lowering valve screw.

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4 The motor is
unable to operate.
1. Power supply switch
has not been turned on.
2. Battery has completely
discharged.
3. Brake has not been
released.
4. Burnt fuse.
1. Insert key and turn on
power supply.
2. Charging.
3. Examine the stroke
switch on the lever if it is
pressed because of
collision and if the
braking switch has been
reset.
4. Replace the fuse.
5 The charger is
unable to charge. Damaged charger. Replace the charger.
7. Treatment of abandoned materials
The abandoned batteries and hydraulic oil should not be placed carelessly and must be treated
according to the relevant local regulations and laws. Attention must be paid to environmental
protection.
8. Accessories and spare parts
No. Name Application Model and
specification
Q’ty Remark
1 Key to the electric
switch
Unlock the
electric switch
2
2 Fuse Electric system 1
3 Fuse Electric system 1

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9. Electrical schematic diagram

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10. Exploded views and parts lists
Electric pallet truck (Lithium battery)
No. Parts No. Name Q'ty ERP Remarks
1 CBD12W.01-00 Steering gear assembly 1 31060201259
2 GB/T 70.1-2008 Screw M6X12 1 0908240019
3
CBD12W.02A-00
Truck frame assembly
550X1150 1 51020111049
Truck frame assembly
550X1220 1 51020111050
CBD12W.02A-680-
00
Truck frame assembly
685X1150 1 51020111051
Truck frame assembly
685X1220 1 51020111052
4 GB/T 818-2000 Screw M4X12 6 0908280059
5 GB/T 93-1987 Washer 4 10 0908370003

Haklift Oy
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6 CBD12W-02 Line buckle 2 51020111053
7 CBD15W-18 Coil 1 0904170065
8 GB/T 894.1-1986 Circlip for shaft 16 4 0908320013
9 BFA-01 Pin 2 0906070037
10 GB/T 893.1-1986 Circlip for hole 20 2 0908310006
11 CBD12W.04-00 Connecting rod and 1 31060201255
1 31060201256
Rocker arm assembly 1 31060201257
1 31060201258
12 CBD12W-03 Shaft 1 0906010094
13 DF-04 Pin 20x152 2 0906040005
14 GB/T 879.1-2000 Pin 5x32 4 0908500029
15 BF-05 Reverse assisted wheel 4 0904040004
16 CBD12W-04 Cover 1 120701109
17 GB/T 97.1-2002 Washer 4 6 0908350008
18 GB/T 70.1-2008 Screw M4X40 2 0908240007
19 CBD12W.03-00 Lithium battery assembly 1 0606560 refer to electrical
s
y
stem
20 CBD12W-05 Platen 1 51020111054
21 GB/T 95-2002 Washer 6 3 0908350011
22 GB/T 93-1987 Washer 6 4 0908370007
23 GB/T 70.1-2008 Screw M6X16 2 0908240022
24 KLS4815GN Controller 1 0604493 refer to electrical
s
y
stem
25 GB/T 818-2000 Screw M4X25 2 0908280034
26 CBD12W.13-02 Terminal 1 0599461 refer to electrical
s
y
stem
27 GB/T 889.1-2000 Lock nut M6 2 0908010006
28 WEC-05 Small wheel 2 0904040016
29 GB/T 5782-2000 Hexagon screw M6X55 2 0908420332

Haklift Oy
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Steering gear assembly
No. Parts No. Name Q'ty ERP Remarks
1 CBD12W.01.01-00 Handle assembly 1 31060201080
2 WA-01 Shaft 20X100 1 0906990042
3 GB/T 879.1-2000 Pin 5x32 2 0908500029
4 CBD12W.01.02-00 Oil cylinder assembly 1 31030401230
5 GB/T 818-2000 Screw M4X10 4 0908280071
6 CBD12W.01-01 Cover 1 120701106
7 CBD12W.01-02 Motor housing 1 120701107

Haklift Oy
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8 GB/T 818-2000 Screw M5X10 2 0908280013
9 700M-12 Screw M12X1.5 1 061309066
10 JB/T982-77 Washer 12 2 0902010005
11 CBD12W.01-03 Rigid pipe (in) 1 061311037
12 GB/T 5783-2000 Screw M6X20 2 0908420268
13 GB/T 93-1987 Washer 6 2 0908370007
14 720B-04 Screw G1/4″-19 2 061309065
15 JB/T982-77 Washer G1/4 5 0902010020
16 CBD12W.01.06-00 Pump 1 0602331 refer to electrical system
17 CBD12W.01-04 Mud guard 1 120701108
18 DM250BLD600-
48RY1 Motor 1 0603608 refer to electrical system
19 CBD12W.01.04-00 Support base
assembl
y
1 51020111056
20 CBD12W.01-05 Right support 1 51020111060
21 GB/T 5783-2000 Screw M8X20 2 0908420029
22 GB/T 93-1987 Washer 8 10 0908370011
23 CBD12W.01-06 Left support 1 51020111055
24 GB/T 810-1988 Round nut M60X2 1 0908070023
25 GB/T 858-1988 Washer 60 1 0908390013
26 CBD12W.01-07 Washer 1 31050216061
27 GB/T 301-1995 Bearing 51113 1 0907030003
28 GB/T 276-1994 Bearing 6013-2RS 1 0907020003
29 CBD12W.01-08 Rigid pipe(out) 1 061311036
30 CBD12W.01-18 Joint 1 31050216072
31 JB/T982-77 Washer 14 2 0902010006
32 SGAMX.2-08 Screw 1 061309130
33 CBD12W.01-09 Screw 1 0909160091
34 CBD12W.01.07-00 Brake 1 060706132 refer to electrical system
35 CBD12W.01-10 Brake support 1 31050216062
36 GB/T 70.1-2008 Screw M8X40 2 0908240052
37 GB/T 70.2-2008 Screw M8X30 4 0908520018
38 CBD12W.01-11 Fixed plate 2 51020111058
39 CBD12W.01-12 Base 1 31050216063
40 GB/T 70.1-2008 Screw M4X12 2 0908240243
41 GB/T 93-1987 Washer 4 2 0908370003
42 CBD12W.01-14 Check block 1 51020111057
43 GB/T 93-1987 Washer 3 2 0908370002
44 GB/T 818-2000 Screw M3X25 2 0908280035

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45 XV-155-1C25 Microswitch 1 060901001 refer to electrical system
46 CBD12W.01-15 Platen 1 51020111061
47 GB/T 1096-2003 Flat key 8X7X14 1 0908460082
48 CBD12W.01-16 Anti-vibration sleeve I 1 31050216073
49 CBD10A3B-12 Wheel 2 0905020152
50 GB/T276-94 Bearing 61902-2RS 6 0907030027
51 GB/T894.1-1986 Circlip for shaft 15 4 0908320012
52 CBD10A-08 Wheel shaft 2 0906190002
53 CBD10A3B-07 Universal wheel
carria
g
e 2 31050217001
54 SF-1.2815 Bush 2 0907040142
55 GB/T301-1995 Bearing 51102 2 0907030020
56 CBD15W.8-01 Spring 5X27X40 2 0906130028
57 GB/T 893.2-1986 Circlip for hole 28 2 0908310058
58 GB/T 889.1-2000 Nut M10 2 0908010009
59 CBD12W.01-17 Wiring block 1 0904170093 refer to electrical system
60 GB/T 70.2-2008 Screw M4X35 2 0908520026
61 CBD12W.01-19 Anti-vibration sleeve II 1 31050216074
62 CBD12W.01-20 Screw 1 0909160099
63 GB/T 70.3-2008 Screw M6X12 5 0908510008
64 CBD12W.01.03-02 Brake disc 1 0909990089