SolidHub HE1200/3 Quick reference guide

ASSEMBLY & OPERATING INSTRUCTIONS
Electric Forklift
HE1200/3
Before using, please read this manual and please do not use the Forklift before the installation is complete!

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GENERAL Foreword 3
Safety Instructions 3
Technical data 4
Overview of the main components 5
Safety devices and warning signs 5
Nameplate 6
Maintenance 6
Operating instructions 7 – 8
Charging and replacing the battery 9
Regular inspections 10
Checklist for maintenance/inspection 11
Troubleshooting 12
PARTS LIST Wheel System 13
Mounting the frame cover 14
Omnidirectional wheel mounting 15
Drive installation 16 – 17
Handle Assembly 18
Hydraulic system 19
Electrical assembly 20
Mounting the fork 21
Lifting system 22 – 23
CONTENT

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FOREWORD
Congratulations on the purchase of your new electric forklift HE1200/3, this easy to use forklift is made of high quality
materials, specially designed for long lasting and reliable operation. For your own safety and for the correct operation of the
truck, please read and follow these operating instructions before using the truck. It is best to keep this operating manual in
a safe place. Check the truck for transport damage. Damaged electric forklifts must not be used.
The stacker is used to electrically raise and lower the transport load to the desired height. Improper handling can result in
injuries or damage to the machine. The operator/user must ensure correct use, ensuring that the electric lift truck is only
used by trained and authorised persons.
SAFETY INSTRUCTIONS
• Read the warning signs on the truck and the instructions in this manual before use.
• Do not operate the truck unless you are familiar with it and trained to do so.
• Do not use the truck unless you have checked that it is in perfect condition. Pay particular attention to the chain, wheels,
drawbar, chassis, control unit, mast, battery, etc.
• Do not use on very dirty floors or in explosive environments.
• Only use on level ground. Do not work on slopes.
• Do not transport persons on the forks.
• When lifting the forks, make sure that nobody stands or walks under the forks.
• Wear gloves when using the forks.
• Do not move the truck when the goods are lifted to a height above 300 mm.
• When transport/lifting goods, keep a safety distance of 600 mm between all persons.
• Always distribute the weight of the goods equally between both forks. Never use only one fork. The centre of gravity of
the goods should be in the middle of the two forks.
• Observe the goods during transport. If the goods become unstable and threaten to fall/tilt, stop operation immediately
with the emergency stop button.
• Do not load beyond the maximum capacity.
• Operation must be carried out with at least 50 lux lighting.
• Suitable for indoor operation at a room temperature between +5°C and +40°C.
• Carry out the maintenance work according to the regular inspection.
• The battery should be charged in a dry and ventilated place and away from open fire.
GENERAL

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Modell HSE1200/3
Load capacity kg 1200
Load centre distance (C) mm 600
Fork length (L) mm 1150
Single fork width (e) mm 160
Total fork width (b5) mm 550/570/650/695
Lowered fork height (h5) mm 86
Length fixed forks mm 928
Length fixed forks single (including the front double frame) mm 124
Inner width between fixed forks mm 262/387
Outer width between fixed forks mm 534/659
Aisle width for pallets 1000×1200 transverse mm 2068
Aisle width for pallets 800×1200 in longitudinal direction mm 2034
Turning radius (Wa) mm 1336
Wheel size, front, number mm ø80×70, 4
Wheel size, rear wheel, number mm ø210×70, 1
Additional wheels, number mm ø150×58, 1
Total length (with pedal out) (L1) mm 1755
Total width (b1) mm 795
Extended mast height (h1) mm 3424
Lowered mast height mm 2000
Lift (h3) mm 3000
Battery voltage (dimensions) mm 2×12V/100AH (260/169/215)
Power control 24V/90A
Charger capacity 24V/10A
Hoist motor 2.2kw lifting speed, loading/unloading:100/150mm/s
Lowering speed, loaded/unloaded:150/130mm/s
Drive motor 0.75kw Driving speed, loaded/unloaded:4.0/4.2km/h
TECHNICAL DATA
GENERAL

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SAFETY DEVICES AND WARNING SIGNS
AFor load hooks
BWarnings: - Do not stand under the fork
- No riding on forklift trucks
CSymbol for load curve
DNote: Read and follow the instructions
FNameplate
(3) Emergency stop switch, drawbar button
(14) Safety switch, belly switch
The truck has an emergency stop switch (2) which stops
all lifting, falling and driving functions and disables
the electromagnetic brake. Pull the switch out again
after pressing this function.
Insert the key (16) and turn it clockwise.
For safety and to prevent unauthorised use, the key
must be turned anticlockwise and pulled out.
Follow the instructions on the safety labels.
Please replace damaged or missing security stickers immediately.
No. Name No. Name
1 The top cover 11 Lift button
2 Emergency stop button 12 Accelerator (butterfly switch)
3 Safety net 13 Horn
4 The mast mounting 14 Safety switch (belly switch)
5 The charger interface 15 The electricity meter
6 Actuator housing 16 Key switch
7 Inner housing 17 The drive wheel
8 The handle arrangement 18 Steering wheel
9 Lifting cylinder 19 Fork
10 Lowering button 20 Load wheel
OVERVIEW OF THE MAIN COMPONENTS
GENERAL
A
B
C
F
(14)
(3)
D
E

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HYDRAULIC OIL
Please check the oil level every six months. The oil should be hydraulic
oil: ISO VG32, its viscosity should be 32cSt at 40°C, the total volume is about 4.0 litres.
DAILY INSPECTION AND MAINTENANCE
Check the forklift daily before use, paying particular attention to the wheels and axles. Foreign objects such as cloths, etc.
can block the wheels, fork, mast or chain. After finishing the work with the forklift and before checking, unload the forks
and lower them to the lowest position.
• Visual inspection for damage to pipes, wires, scratches, deformations or cracks.
• Check for leaks in the hydraulic system.
• Check the condition of the vehicle when driving straight ahead.
• Check the chain and roller for damage or corrosion.
• Check that the wheel moves smoothly.
• Press the emergency stop button to check the emergency brake function.
• Check brake function, check handle lever switch.
• Press the buttons to check the lifting and lowering function.
• Check that there is no damage and that the protective grille is correctly installed.
• Check the horn.
• Check that all screws and nuts are tightened.
• Check the function of the key switch.
• Check the speed limit switch (symbol: turtle).
DAILY INSPECTION AND MAINTENANCE
Use engine oil or grease to lubricate all moving parts.
MAINTENANCE
NAMEPLATE
1Name, Type
2 Configuration Number
3 Rated Capacity (kg)
4 Max Lift Height
5Rated Voltage
6 Serial Number
7Total Weight
8 Total Weight (without battery) (kg)
9 Battery Weight maximum (kg)
10 Battery Weight minimum (kg)
11 Number of Manufacture License
GENERAL
1
2
3
4
5
6
7
8
9
10
11
6

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OPERATING INSTRUCTIONS
When operating this truck, please observe the warning and safety instructions. Make sure that you always look in the
direction of travel and that no goods or objects obstruct or restrict your view.
Make sure that the goods are placed stable and safe for transport in the middle of the fork. To start, turn the key clockwise,
position „On“ (16). Press the horn button to start the signal tone (13).
PARKING
Never park the truck on a slope or sloping terrain! This truck is equipped with an electromagnetic parking brake and a
parking brake.
When not in use, always set the fork to the lower position and park the truck in a safe area. Turn the key counterclockwise
to the „off“ position and remove the key.
LOAD CURVE
The load curve shows a given load centre C [mm].
and the horizontal load capacity of the largest load Q [kg] and
the lifting height corresponding to the vehicle is H [mm].
The white marking on the frame can indicate the access area
reach. For example: a load centre distance C is
600 mm, the maximum lifting height H2900mm, the maximum
Load capacity from Q to 800kg.
LIFTING OF LOADS
Never load the truck beyond the specified capacity. The maximum load capacity of this truck is 1200 kg.
To move, place the fork completely under the goods to be lifted and press the lifting button (11) until you reach your
desired lifting height.
LOWERING OF LOADS
Gently press the down button and watch the product. As soon as the weight has been reduced and the pallet stands
securely, carefully pull out the fork.
GENERAL
load Q [kg]
load centre distance C [mm]
load curve

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CONTROL SYSTEM
Start the truck, bring the tiller to an inclined position („F“). Operate the direction lever on the tiller (12): Forward „V“ or
Reverse „R“. By carefully moving the direction lever, you control the speed until the desired speed is reached.
Position the directional lever in the centre to slow the truck down to a complete stop/parking position. If the truck is
stopped permanently, apply the parking brake.
Always drive carefully and keep your eyes on the road - adjust the speed if necessary.
APPLY THE BRAKES
The load braking performance depends on the ground conditions and the load of the truck.
Activate the brake function as follows: The truck brake is activated by moving the direction lever (12) back to position
„0“ or by releasing this lever. Or by moving the direction lever in the opposite direction until it begins to move in the other
direction.
When the tiller is moved up or down into the braking zone (B), the vehicle braking is activated. When the emergency stop
switch is pressed, the handle is automatically moved to the braking zone and the parking brake is activated. The large red
safety button on the head of the tiller means that this function can also be triggered with the upper body. The truck slows
down and comes to a standstill until reverse (R).
TROUBLESHOOTING
If there is a fault and/or the truck does not work, please stop using the truck and press the emergency stop button (2). Park
in a safe area, turn the key switch (16) counterclockwise and remove the key.
Immediately inform your responsible employee and/or contact customer service.
IN CASE OF EMERGENCY
In case of an emergency, press the emergency stop switch (2). All electrical functions are stopped. Maintain a safety
distance.
GENERAL
V
R
V
R
R
V R

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CHARGING AND REPLACING THE BATTERY
• Only qualified personnel should repair or recharge the battery. Please be sure to follow the operating instructions.
• These batteries are maintenance-free and must not be refilled with water.
• Battery recycling must comply with state laws and regulations. Please comply with these regulations.
• Improper handling, e.g. use near fire or gas, can cause an explosion! For this reason, the storage of flammable materials
or flammable liquids in the battery charging area is prohibited. Smoking is prohibited and the area must be well
ventilated.
• Before charging or installing the battery, park the truck safely (parking position).
• Perform maintenance before connecting the wiring harness correctly and without interference to other parts of the
vehicle.
• The truck is equipped with battery fluid acid battery 2 x 12V / 100Ah.
• Only the use of the sealed lead acid battery is permitted, the additional battery weight has an influence on the behaviour
of the vehicle.
• Note: Please observe the maximum operating temperature of the battery.
REPLACEMENT OF THE BATTERY
Park the truck safely, lock the truck with the key (16) and press the emergency stop switch (2). Loosen the 2 screws on
the main cover, remove the outer main cover. First loosen the screws (negative terminal indicator as ‚-‘), then the screws
(positive terminal indicator as ‚+‘) and the wiring harness.
Next, unscrew and remove the battery holder. When removing the battery, do not touch any circuit boards or cables! For
reassembly, reverse the order. Connect the positive pole of the battery to prevent damage to the truck.
POWER METER / VOLTMETER
Discharge with 4 LED display for indication
CHARGING THE BATTERY
After approximately 4 hours (normal load) the battery of the electric truck must be charged. Only charge the battery in well
ventilated places. When charging is complete, disconnect the plug from the mains and store it safely in the chassis. If the
battery is completely discharged, the charging process takes about 7 hours.
GENERAL

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REGULAR INSPECTIONS
Only qualified and trained personnel may service the truck. Before maintenance, please remove any goods from the forks
and move them to the lowest position (parking position of the forks).
Only use special cranes/hoists to lift the truck. Be sure to position an additional safety device (such as a jack, wedge or
wood) under the truck.
Special care must be taken when servicing the handlebars. The gas spring is under pressure. Carelessness during
maintenance is a source of accidents.
Please use only approved original spare parts.
Please note that leakage of hydraulic oil can lead to machine failure and possibly to an accident.
Have only one technician, trained for work on the pressure regulating valve, carry out the work. If you need to replace a
wheel, please follow the above instructions. The impeller must be round and must not show any abnormal wear. Regularly
service the electric forklift using the checklist provided in the instruction manual.
LUBRICATION POINTS
The illustration shows the points which must be greased regularly. Grease specification: DIN51825,
standard grease.
No. Name
1 The wheel bearing
2 The steel frame
3 Chain
4 Hydraulic system
5 Steering bearings
6 The gearbox
INSPECTION AND REFILLING OF THE
REQUIRED HYDRAULIC OIL TYPE
Anti-hydraulic oil 32
The viscosity is 32 - 38
Based on the model, the oil quantity is approx. 2.5
to 3.0 liters.
Waste oil, used batteries or other special materials
must be recycled under national law.
GENERAL

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CHECKLIST FOR MAINTENANCE/INSPECTION
Monthly intervals
1 2 6 12
1 Check the hydraulic oil cylinder, the piston is quiet and no fluid is leaking •
2 Check the hydraulic connections and hoses for damage and leaks •
3 Check the hydraulic oil level and top up oil if necessary •
4 Replace hydraulic oil after 12 months or 1500 operating hours •
5 Check and adjust the pressure valve function (1000 kg +0/ +10%) •
Mechanics
6 Check the fork for deformation or cracks •
7 Check the chassis for deformation or cracks •
8 Check that all screws are tightened properly •
9 Check the chassis and chain for corrosion, deformation or damage, replace the chain if necessary •
10 Check the gearbox for noise and leakage •
11 Check the wheels / rollers for deformation and/or damage, replace defective wheels if necessary •
12 Lubricating the steering •
13 Control and lubrication centre •
14 Check grease nipple •
15 Replace protection and/or protection board, if damaged •
Electrics
16 Check if wires are damaged •
17 Check electrical connections and the terminal •
18 Testing the emergency stop switch function •
19 Check the electric motor for noises •
20 Check display/indicators for function •
21 Check fuses and replace if necessary •
22 Test of the acoustic signal •
23 Check the contacts •
24 Check that the frame is tight (insulation test) •
25 Check the function and wear of the accelerator •
26 Check the drive motor of the electrical system •
Brake system
27 Check the brake performance; if necessary replace the brake discs or adjust the distance between
the brakes •
Battery
28 Check the battery voltage •
29 Clean and check for corrosion or damage •
30 Check whether the battery housing is damaged •
Battery charger
31 Check if the power cable is damaged •
32 Start protection program check during charging •
Functions
33 Test of the signal tone •
34 Checking the Electromagnetic Brake with Air Gap •
35 Testing the emergency brake function •
36 Test of reverse braking and regenerative braking function •
37 Testing the large red emergency stop switch on the drawbar (belly switch) •
38 Check the steering function •
39 Check the lifting and lowering function •
40 Check the functions of the drawbar •
41 Check the key switch for damage
42 The limit switch for the detection speed (the lifting height is >~300mm) •
Miscellaneous
43 Check that all labels are legible and complete •
44 Check whether the protective grille is damaged •
45 Check the drawbar if it is worn for height adjustment or replacement •
46 Perform a test run •
GENERAL

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GENERAL
Problem Reason Solution
The forks cannot be
lifted to the maximum
height
Overloading of the max. load capacity The maximum load capacity is indicated on the rating plate
Battery is too weak Charging the battery
The fuse is out Check and possibly replace the fuse
The hydraulic oil is not sufficient Check and if necessary top up the hydraulic oil
The oil pressure is too low; oil leaks Check and if necessary replace sealing hoses
and / or cylinder
No oil Oil level is too low Increase the oil level
The forks cannot
be lowered
Shut-off valve is dirty/blocked Check the hydraulic oil and cleaning control valve.
Change the hydraulic oil as necessary.
Removing electromagnetic valve opens or
is damaged
Check or replace solenoid valve
The truck does not
respond
The battery is being charged When the battery is fully charged Pull
the power plug.
The battery is not connected Connect the battery correctly to the charger
The fuse is out Check the fuse and replace it
where appropriate.
Low battery Charging the battery
The emergency stop switch is activated Pull the button to reset the emergency stop
The drawbar is not in the correct position Moving the tiller out of the braking zone
Forklift only travels in
one direction Accelerator / connections are damaged Check the accelerator and the connection
Stacker runs
very slowly
Low battery Check the charge level of the battery and charge it
The electromagnetic brake is activated Release the electromagnetic brake
The drawbar is not connected correctly or the cable is damaged Check wiring
The truck suddenly
starts
Damage to the controller Replace the controller
The accelerator is not returned to the center position Repair or replace the accelerator
TROUBLESHOOTING
GUARANTEE
The warranty of one year from date of invoice covers material, manufacturing or construction defects. Damages,
which are due to natural wear and tear, improper handling or unauthorized modification are not covered by the warranty.

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PARTS LIST
No. Code No. Name Quantity
1 CLJ1030.01.01 Steel frame 1
2 GB/T 879.1-2000 Elastic cylindrical pin ø 5× 35 8
3 DFL25.1-14D Connection plate 4
4 CL10-4H Front axle (2) 4
5 SL20.1-9 Washer 8
6 GB/T 276-94 Deep groove ball bearing 6204 8
7 CL10-5 Small wheel 4
8 GB/T 70.1-2000 Hexagon socket head cap screws M12× 40 4
9 GB/T 93-1987 Spring washer ø 12 4
10 GB/T 95-2002 Flat washer ø 12 4
11 CL10.5.5k Steering wheel 1
12 GB/T 6184-2000 Hexagon lock nut M12 4
12
9
10
8
11
WHEEL SYSTEM
1
5
6
7
2
3
4
65

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PARTS LIST
No. Code No. Name Quantity
1 GB/T 818-2000 Phillips screw M6× 16 6
2 SPN10.0-6 Protective cover clip 6
3 SPN1016.0-4 Protective cover 1
4 CLJ1030.06-2 Large flat-head Phillips screw 1
5 CLJ1030.06-4 Cover 1
6 CLJ1030.06-3 Lower cover plate of the handle 1
5
4
6
MOUNTING THE FRAME COVER
2
3
1

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PARTS LIST
No. Code No. Name Quantity
1 CL10.5.5.1G Welded seam of the flange 2
2 GB/T 91-2000 Split pin ø 3.2× 45 2
3 CL10.5.5-2 Dust cover 2
4 JB/T 7940.1-1995 Straight hydraulic grease nipples M6 2
5 GB/T 301-1995 Pressure ball bearing 51111 2
6 GB/T 276-94 Deep groove ball bearing 6205-2Z 2
7 CL10.5.5-3 Seal 2
8 M20× 1.5 Slotted nut 2
9 CL10.5.5-4G Frame 2
10 GB/T 889.1-2000 Hexagon lock nut M14 2
11 GB/T 276-94 Deep groove ball bearing 6204-2Z 4
12 CL10.5.5-6 axle sleeve 2
13 CL10.5.5-7 Wheel 2
14 GB/T 5780-2000 Hexagon head screw M14× 100 2
8
OMNIDIRECTIONAL WHEEL MOUNTING
1
14
13
12
11
10
2
3
4
5
7
6

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PARTS LIST
32
27
28
29
DRIVE INSTALLATION
14
33
15
17
18
19
20
21
22
16
23
24
25
26
30
31
34
35
36
37
38
39
40
41
42
1
2
3
4
5
6
7
8
9
10
12
13
11

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PARTS LIST
No. Code No. Name Quantity
1 GB/T13871-92 Oil seal TCø 42×ø 20× 7 1
2 GB/T276-94 Bearing 6004RS 1
3 GB893.1-86 Locking ring for bore ø 42 1
4 ZD-HZDC-310-002 chassis components 1
5 GB894.1-1986 Ringshield ø 15 1
6 ZD-HZDC-320-002 Rotor 1
7 ZD-HCDC-340-001 Brush-shaped yoke part 1
8 GB/T276-94 Bearing 6201RS 1
9 GB/T70.1-2000 hexagon socket head screw M5× 16 3
10 GB/T93-1987 Spring washer ø 5 3
11 ZD-HCDC-361-001 Rear cover plate 1
12 ZD-HCDC-330-001 Brushes 4
13 ZD-HCDC-380-001 Protective ring 1
14 ZD-HZDC-362-001 Brake 1
15 GB/T1096-2003 Key 5× 5× 8 1
16 1115-200001-0B Cover 1
17 GB/T70.1-2000 hexagon socket head screw M6× 20 8
18 GB/T93-1987 Spring washer ø 6 8
19 GB/T70.1-2000 hexagon socket head screw M8× 35 5
20 GB/T93-1987 Spring washer ø 8 5
21 GB/T70.1-2000 hexagon socket head screw M5× 20 6
22 GB/T93-1987 Spring washer ø 5 6
23 GB/T1096-2003 Key 5× 5× 14 1
24 GB894.1-1986 Ringshield ø 16 1
25 1115-200005-0B Small cogwheel 1
26 1121-210001-00 Box 1
27 GB/T13871-92 Oil seal
TCø155× ø172× 10 1
28 1115-200002-0B Toothed ring 1
29 GB/T276-94 Bearing 61824-2RS 1
30 1115-220000-0B Drive wheel 1
31 GB/T276-94 Bearing 61824-2RS 1
32 6118003 Dust cover 1
33 JX6-2 Terminal box 1
34 JB/T7940.1-1995 Oil filler cap 1
35 GB/T1096-2003 Key 5× 5× 20 1
36 GB/T119.1-2000 Bearing ø 5× 15 2
37 GB/T13871-92 Oil seal TCø16× ø28× 7 1
38 GB/T276-94 Bearing 61905-2Z 1
39 1115-200004-0B Large cogwheel 1
40 GB/T276-94 Bearing 16003-2Z 1
41 GB894.1-1986 Ringshield ø 15 1
42 1115-200003-0B Cogwheel 1

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PARTS LIST
No. Code No. Name Quantity
1 TY-01.20 Handle 1
2 CLJ1030.01.02.01 Grip lever 1
3 CS1232.8-1 Crash Roll 1
4 GB/T 70.1-2000 Hexagon socket head cap screws M8× 35 1
5 SL13.03-09 Sleeve 1
6 CJF17-05PA Proximity switch 1
7 GB/T 93-1987 Spring washer ø 3 2
8 GB/T 70.1-2000 Hexagon socket screws M3× 25 2
9 CLJ1030.01.02.02 Spring Washer Assembly 1
10 GB/T 6177.1-2000 Hexagon nuts with flange M8 1
11 GB/T 70.1-2000 Hexagon socket screws M10× 20 1
12 GB/T 70.3-2000 Countersunk flat head screw with hexagon socket M8× 20 1
13 SL13.03-03 Stop block 1
14 SL13.03-02 Connector 1
15 TY-02.22 Housing ø 18×ø 16× 10 2
16 SL13.03-07 Connecting axle 1
17 SL13.03-04 Spring washer 1
18 GB/T 818-2000 Phillips-head screw M4× 10 2
19 GB/T 77-2000 Hexagon socket set screw with flat point M6× 8 1
20 GB/T 70.1-2000 hexagon socket head screw M8× 25 1
20
HANDLE ASSEMBLY
10
9
11
3
1
4
8
5
27
6
14
13
16
15
17
1819
12

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PARTS LIST
No. Code No. Name Quantity
1 CLJ1030.05 Oil cylinder module 1
2 GB982-77 Seal ø 18 1
3 CLJ1030.04-1 Rubber hose 1
4 SPN10.8-6 Oil connection 1
5 CLJ1030.01.03.03 Aggregate 24V/2.2KW 1
6 CL10.4-3H 90° connection 1
6
5
HYDRAULIC SYSTEM
4
1
32

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PARTS LIST
No. Code No. Name Quantity
1 GB/T 70.1-2000 Hexagon socket head cap screws M3× 20 2
2 TY-01.2 Charging socket 1
3 TY-01.18 Horn DC24-ø125 1
4 GB/T 95-2002 Flat washer ø 8 5
5 GB/T 93-1987 Spring washer ø 8 5
6 GB/T 70.1-2000 Hexagon socket head cap screws M8× 12 1
7 SL13.01.05.02 Electrical control assembly 1
8 GB/T 70.1-2000 Hexagon socket head cap screws M4× 40 1
9 GB/T 70.1-2000 Hexagon socket head cap screws M4× 35 1
10 TY-02.32 Fuse holder 1
11 GB/T 95-2002 Flat washer ø 4 2
12 GB/T 93-1987 Spring washer ø 4 2
13 GB/T 70.1-2000 Hexagon socket head cap screws M4× 16 2
14 TY-01.4 Backup CNP-100A 1
15 GB/T 41-2000 Hexagon nut M8 2
16 GB/T 70.1-2000 Hexagon socket head cap screws M8× 25 2
17 CLJ1030.01.03-1 Battery Limitation Panel 1
18 DC100AH-12V Battery 2
19 TY-01.14 Emergency stop switch 1
15
ELECTRICAL ASSEMBLY
1
19
10
2
3
4
5
6
7
8
9
4
5
11
12
13
14
16
5417
18