Hangcha Forklift 1t 3 5t Series Internal Combustion Operation Maintenance Manual
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1t-3.5t R Series Internal Combustion
Counterbalanced Forklift Truck
OPERATION AND MAINTENANCE MANUAL
Original Instruction
HANGCHA GROUP CO., LTD.
Jun. 2011 5th EDITION
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FOREWORD
This operation manual is the explanations that how to use 1t-3.5t R series forklift
truck correctly. It will instruct you how to operate safety and precautionary
maintenance. To ensure safety and exert the truck‘s potential, all the personnel that in
charge of operation, maintenance and management must read this manual thoroughly
before starting work with the forklift.
Compared with 1t-3.5t N series internal combustion forklift truck, 1t-3.5 t R series
forklift truck has the following strengths: enhancing the power, improving the outline,
using buffer steering axle, in addition, besides the TCM and NISSAN main
transmission are configured in our trucks, we also configure Okamura main
transmission in our trucks. And there is different between masts of import and export
trucks, N series masts are used in the import trucks, R series masts are used in export
trucks.
This manual also applies to container forklift truck and forklift truck assembled
attachments.
Our product design will update and perform better, so the content in this manual
may be not the same as the forklift you owned.
If you have any questions please keep touches with HANGCHA GROUP CO.,
LTD.
sales department or let the agents know.
○
C Jun. 2011 5th EDITION HANGCHA GROUP CO., LTD.
Content
Foreword
1. General Rules······································································································1
2. Name of main parts or component·······································································3
Instruments········································································································3
Switches ············································································································5
Controls ·············································································································6
Others ·············································································································10
3. Safety instructions ·····························································································14
4. Maintenance ······································································································20
8 hour (daily or every shift) check ····································································20
Weekly maintenance (40 hours) ······································································23
Maintain monthly (166 hours) ··········································································27
Maintain semiannually (1000 hours) ································································29
Maintain annually (2000 hours) ·······································································31
Other ···············································································································32
5. Structure and stability of truck············································································35
6. Operation ···········································································································37
Star-up ·············································································································37
Traveling··········································································································38
Pick up ············································································································39
Stacking load ···································································································39
Remove load ···································································································40
7. Deposit ··············································································································41
8. Maintenance ······································································································43
Preventive maintenance schedule···································································43
Maintenance of chassis and body ···································································45
Table for bolt‘s tight moment············································································46
Periodic replacement of key safe parts····························································47
Table for the oil used in the truck ·····································································48
Lubrication system drawing ·············································································50
Environment protection ···················································································50
Scutcheons ·····································································································51
9. Truck‘s convey, lifting, towing ·············································································57
10. Type signification ·····························································································58
11. Performance parameters of R series IC forklift ················································61
12. Operation, disassembly and installation of cab ················································79
13. Operation and notice about LPG forklift ···························································81
14. Operational method of lead acid battery ··························································92
15. Use, installation and safety rules of attachment···············································94
16. Related safety instruction and standard···························································96
17. Maintain record ······························································································100
1. General Rules
To make the truck and you safety, operator should obey these rules below:
1. Only trained and authorized operator shall be permitted to operate the truck.
2. Before start truck you should check all control and alarm device, if there are any
damaged or objection, you could not operate it until repaired it.
3. When carry the load, the weight should not much overload. The fork shall insert
in the load entirely and well proportioned. It is not permitted use only one fork to
load.
4. You should operate the truck smoothly when start, turning, travel, brake and
parking. On a slick or wet road, you should decrease speed when turning.
5. Load travel should lower the goods down and tilt the mast backwards.
6. Be carefully when traveled on a grade. If the slope angle is bigger than 10%,
travel forward up slope and backward down slope. Never turn sideways and stack
load on an incline.
7. Notice the foot passenger, barrier, pothole and the clearance upside.
8. It is prohibit picking up a man or standing on the fork.
9. No permitted to stand or walk under the fork.
10. No permitted to operate the truck or attachment on other position except the
operator‘s seats.
11. Do not carry the load unpackaged. Be carefully to carry these goods with large
size.
12. Notice the load not drop from the load bracket for those trucks that overall
maximum lift height is higher than 3 meters. If necessary, make some protective
measure.
13. Travel with load as low as possible and tilt back the mast.
14. Before driving over a dock-board or bridge-plate, be sure that it is properly
secured and strong enough to sustain the weight.
15. Make sure that there is no naked flame near the area, never smoke. The driver
should not remain seated when adding fuel.
16. The truck with attachments should be treated as a loaded truck.
17. When leave the truck, you should let the fork down, make the shift lever neutral
shut down the engine and cut the power. Parking on a grade, make sure to
tighten the brake lever. If necessary, use a block when parking on a grade for a
long time.
18. If the truck suddenly get out of order, or for leakage of electrolyte，hydraulic oil or
brake oil, when lifting goods or grade climbing, it needs to rush to repair and let
the truck be in safe state, then connect with maintainer or sales representative.
19. In the process of install and assemble, it will be noise and libration. Please
choose the right tool and assembly method. Depress the noise and libration as
soon as possible to reduce the noise pollute to circumstance.
20. The work road surface for forklift should be stability and unknit, cement, blacktop
or beton. If there are snows, ice, water or other eyewinker, bar. Eliminate all, and
then work. Otherwise the truck will be out of control and lead the safety accident.
21. Move the truck to the place which respects traffic when it anchors. If the reason is
brake or turn system, move it by a suitable truck (Reference the part of truck
move); Other reasons, use a suitable truck to traipse, tie the cord outside of truck.
Please abide by the traffic regulations when traipse the truck on calzada.
22. After take-down the hood, water tank cover board, overhead, backrest of mast,
unallowed to operate the truck or load cargo.
23. There are enough light at truck work ground. At night, open the head lamp to
1
collocate enough lamp-house.
24. Only in the event that the truck manufacturer is no longer in business and there is
no successor in the interest to the business, the user may arrange for a
modification or alteration to a powered industrial truck provided, however, that the
user shall:
a) Arrange for the modification or alteration to be designed, tested and
implemented by an engineer(s) expert in industrial trucks and their safety;
b) Maintain a permanent record of the design, test(s) and implementation of the
modification or alteration;
c) Approve and make appropriate changes to the capacity plate(s),decals, tags
and instruction handbook;
d) Affix a permanent and readily visible label to the truck stating the manner in
which the truck has been modified or altered together with the date of the
modification or alteration, and the name and address of the organisation that
accomplished the tasks.
2
2. Name of main parts or component
1. Mast 2. Lifting cylinder 3. Backrest 4. Fork
5. Overhead guard 6. Steering wheel 7. Seat 8. Cover hood
9. Counterbalance weight 10.Rear wheel 11. Tilting cylinder 12. Front wheel
Instruments
3
Hour meter [1] Glow indicator (C) [Diesel truck]
This meter measures working time Turn the key to ―ON‖ position and
of engine. Use meter to schedule the indicator lights up for a moment.
lubrication and maintenance periods. After the indicator goes out, turn the key
to ―Start‖ position.
Water temperature gauge [2]
This gauge indicates the oil Sedimentor indicator (D) [Use in W9、W13、
temperature in the torque converter W15A diesel truck]
transmission box. In normal status, the In normal state, once the starter is
pointer is in green zone. (60℃ ~115℃) set to ―ON‖ position, this lamp lights
up. After the engine is started up, it
Caution goes out.
If the pointer points red zone, This lamp lights up when water in
please stop the truck at once. sedimentor reaches to a certain level,
Decrease the engine speed to make the while the engine is running.
engine cool. Check the cooling fluid if If this lamp continues to stay lit or
enough and the fan belt‘s elasticity if fit. lights up during the engine running,
stopping the engine and discharge
Fuel gauge [3] water immediately.
The gauge indicates the fuel level in Caution
the tank when the key is at ┃(ON) Fuel injection pump will be
position. damaged if continue working when the
light is up.
Charge (A)
This lamp indicates the battery Engine coolant temperature [E]
condition of charge. The lamp comes In normal state, once the starter is
on when the ignition switch is set at set to ―ON‖ position, this lamp lights
―ON‖, but it goes out as the engine up. After the engine is started up, it
starts and accelerator pedal is pressed. goes out.
During work time if the oil
Caution temperature exceed the normal rang
If the light continues to stay lit or (60℃~120℃) the indicator light on.
lights up during operation, the charging Caution
rate is low and should be checked
If the pointer enters the red
immediately.
range, stop the operation instantly and
slow down engine speed to cool the
Oil pressure alert lamp (B)
This lamp indicates the pressure coolant and wait until the pointer goes
condition of engine lube oil. Although it into the green range, and have a check
lights up when the engine switch is set then.
at ―ON‖, once the engine starts up and
the accelerator pedal is pressed, this
lamp goes out.
Caution
If this light continues to stay lit or
lights up during operation, the pressure
is lower than 0.05Mpa and should be
checked immediately.
4
Switches
Diesel engine
Turn the key to ―ON‖ position and
the indicator lights up for a moment.
After the indicator goes out, turn the key
to ―Start‖ position.
Caution
1. Do not keep the starter switch in the
―┃‖(ON) position while engine is shut
down. This result in a discharge
battery.
Key [4] 2. With the engine running, do not turn
the starter switch into the (START)
OFF (O) position, since there is a danger of the
This is the position at which the key starter motor being damaged.
inserted or drawn out. 3. Do not keep the starter engaged for
Gasoline engine and diesel engine more than 5 seconds at a time. Wait
stop at this position. about 120 seconds before trying again.
ON (┃)
The electric circuit is closed with the Turn signal lever [5]
starter switch at ―┃‖(ON). After the Use this lever which is at the right
engine is started, the key is at this side of turning rod to indicate the turning
position. direction of the truck. R-turn right,
START ( ) N-neutral, L-turn left.
As the key is placed in the ―START‖ The turn signal level does not
position, the starter motor is engaged.
When removing hand off key, it is automatically return to the neutral
automatically returned to the ―ON‖ position unlike general passenger cars.
position by spring force. Reset it by hand.
5
Hangcha Forklift 1t 3 5t Series Internal Combustion Operation Maintenance Manual
Full download: http://manualplace.com/download/hangcha-forklift-1t-3-5t-series-internal-combustion-operation-maintenance-m
Light switch [6] Horn button [7]
This light switch can be pulled out at Press the rubber cover at the center
two steps. of steering wheel to sound horn.
Light Near Far Clear
Power
Stage light light -ance
0 ×
1st × × ×
nd
2 × × ×
(×) means connected
Controls
8. Clutch pedal (frictional clutch type) 9. Inching pedal (torque converter type)
11. Accelerator pedal 12.Forward reverse and Speed slect lever
10. Brake pedal (frictional clutch type)
13. Shift lever 14. Tilt lever 15. Lift lever
16. Steering hand wheel 17. Parking brake lever
18. Forward reverse lever (Torque converter type Non-electric-switch)
19.Choke 20. Forward reverse lever(Torque converter type Switch)
21. Guy head 22.Emergency Stop Label
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