Hangcha 1-1.5t Service Manual

CPD10/15/18/20/25/30J CPD10/15/18/20/25/30J D1 CPD10/15/18/20/25/30/35J C1 CPD10/15/18/20/25/30/35J C2 CPD40/45/50J D1 CPD40/45/50J C2

1～5t J Series Counterbalanced Battery Forklift Truck

OPERATION AND MAINTENANCE

MANUAL

Original Instruction

HANGCHA GROUP CO., LTD.

Dec. 2010 5th edition

Truck model

Tow electric

control

Rise electric

control

Rated capacity（t）/

load centre distance（mm）

CPD10/15/18/20/25/30J

1244(CURTIS)

EVC255(CURTIS)

1.0/500,1.5/500,1.8/500,2.0/500,

2.5/500,3/500

CPD10/15/18/20/25/30J D1

ACS(Danaher)

ACS((Danaher)

CPD10/15/18/20/25/30/35J C1

1238(CURTIS)

EVC255(CURTIS)

1.0/500,1.5/500,1.8/500,2.0/500,

2.5/500,3/500,3.5/300

CPD10/15/18/20/25/30/35J C2

1238(CURTIS)

1236(CURTIS)

1.0/500,1.5/500,1.8/500,2.0/500,

2.5/500,3/500,3.5/300

CPD40/45/50J D1

ACS(Danaher)

4.0/500,4.5/500,5.0/500

CPD40/45/50J C2

1238(CURTIS)

4.0/500,4.5/500,5.0/500

FOREWORD

Thanks for you purchasing our J series battery forklift truck.

Four wheel counterbalanced battery forklift truck is our company‟s new product. It has the character of

small turning radius, beautiful shape, small dimensions, low gravity, good stability, superior performance.

This operation manual is the explanations that how to use 1-5tJ 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.

As the improvements of products of our company, maybe there are some differs between this operation manual with your forklift truck.

If you have any questions please keep touches with HANGCHA GROUP CO., LTD. sales department or let the agents know.

Dec. 2010 5th edition HANGCHA GROUP CO., LTD.

CONTENT

Foreword

1. Name of main parts or component ......................................................................................... 1

2.Instrument and Controls .......................................................................................................... 2

Meter Panel ......................................................................................................................... 3

Controls ............................................................................................................................... 8

3.Body and Others .................................................................................................................... 10

4.Safety instructions ................................................................................................................. 12

5.The structure and stability of truck ....................................................................................... 17

6.Running-in of the new truck .................................................................................................. 20

7.Daily maintenance ................................................................................................................. 21

8.Driving and operation ............................................................................................................ 25

Driving .............................................................................................................................. 25

Traveling ........................................................................................................................... 25

Turning .............................................................................................................................. 25

Stopping or parking ........................................................................................................... 26

Loading .............................................................................................................................. 26

Stacking load ..................................................................................................................... 27

Un-stacking load ............................................................................................................... 27

Check after operation ........................................................................................................ 28

9.Deposit .................................................................................................................................. 29

10.Storage battery ..................................................................................................................... 30

The Automatic Watering System of the Forklift Battery................................................... 38

11.Maintenance summarization ................................................................................................ 42

Preventive maintenance schedule ...................................................................................... 43

Replace the key safe parts termly ...................................................................................... 49

Table for bolt‟s tight torque ............................................................................................... 50

Table for oil used in the truck ............................................................................................ 50

12.Truck‟s convey, lifting, towing ............................................................................................ 51

13.Parameters ........................................................................................................................... 52

14.Scutcheon ............................................................................................................................ 61

15.The use, assembly and safe rules of attachment .................................................................. 66

16.Related safety instruction and standard ............................................................................... 68

17.Maintenance record ............................................................................................................. 70

1. Fork

2. Fork carriage

3. Mast

4.Lifting cylinder

5. Overhead guard

6.Steering wheel

7. Seat

8. Counterbalance

9. Rear wheel

10. Chassis

11. Left and Right battery cover hood

12. Front wheel

1. Name of main parts or component

2.Instrument and Controls

1. Steering wheel

2. Direction switches

3. Parking brake lever

4.Emergency disconnect switch

5. Adjusting lever

6. Brake pedal

7. Accelerator

8. Key switch

9.Turning signal switch

10. Lifting lever

11. Tilting lever

12. Meter panel

13. Horn button

CPD10/15/18/20/25/30/35JC1

CPD10/15/18/20/25/30/35JC2

Meter Panel

CPD10/15/18/20/25/30J CPD40/45/50J C2

A、Battery warning

As the following diagram shows, from the left to the right, the battery decreases from full state to the only one case, which represents that the battery leaves only 20%. Thus the whole battery indicator bar will twinkle, and the state indicator lamp will be bright, now please stop working and charge immediately.

gradient and so on is much higher. It is applied for transporting mass of good in

short time and climbing big gradient slop， but it costs more energy，so the mode will not be

used in normal state except emergency.

Mode P is power mode. All kinds of index are lower than that of super mode. It is applied for the case of long distance transporting and needing higher power or speed.

Mode E is economical mode. All the parameters are optimized. Working in this mode can save power so it is applied for a long time work after charging, and it is suggested to work in this mode in normal work-time.

Mode SPE is safe mode. Thus the max vehicle speed is limited to about 7km/h. It is applied for working in busy storage and cabined room. Notice: the default mode is mode E. after power cutting every time, the work mode resets to mode E no matter which mode it is before power cutting, but the switch key is still in the mode before turn off.

The mode can be switched through the mode switch button (G) among the mode of S, P, E, SPE, as the above diagram shows.

C、Parking brake indicator lamp

Notice：Charging in time is very important,

otherwise it will affect the lift-span of battery！

B、Mode indication

When using the parking brake, the lamp will

As the diagram shows, the pictures

be bright.

from the left to the right represent the mode of S, P, E, SPE respectively；

Mode S is super mode, thus the truck‟s

D、State indicator lamp

acceleration, deceleration rate, max climbing

When there is something wrong with the electrical controller, or operate improperly, the battery is in lower power, the lamp will be bright and twinkles.

E、Error code display area

Display the error code of electrical controller.

Notice：“TRAVEL” is the error code of tow electrical controller, “HYD” is the error code of pump controller. “TRAVEL OK” means it works without error。

Notice： the error code of tow electrical controller refers to the appendix.

F、Work-time accumulate timer

When the truck key switch turns on, the left hour timer will start to time. The minimal resolution is 10% of an hour, the other two hour timers are not used.

CPD10/15/20/25/30/35J D1

S P E E

AT%

CPD40/45/50J D1

The meanings of 6 indicators:

Communicate indicator (A)

Only lights on when record program, usually it is no use.

Error indicator (B)

When operation is wrong or the truck is in trouble, error code will display on the dashboard. The error indicator lights on.

Low battery warning (C)

When battery quantity is lower than 20% of maximum capacity, the indicator lights are on, at the same time, buzzer beep. When LED shows no power, please charge battery as quick as possible.

Speed limited indicator (D)

When this lamp lights, it meanings the truck working at low speed mode. The maximum speed of truck decreased. Press button 1, you can switch the high speed and low speed mode.

IME

Accelerate indicator (E)

When this lamp lights on, it means the truck working at low acceleration mode. The maximum acceleration decreased. Press button 2, you can switch the high acceleration and low acceleration mode.

Parking brake indicator (F)

When pulling on the parking brake lever, this lamp lights on.

Entrance button (G)

Backup button (J)

This button is no use for operator.

Backup button (K)

This button is no use for operator

Switch button of hour indication（L）

Push this button, it will display the total hours of truck, as follow figure:

This button is no use for operator.

Speed limited button (H)

Press this button to switch the high speed and low speed.

Accelerator limited button (I)

Press this button to switch the high acceleration and low acceleration.

Push again, it switch to the total traction hour.

Push the button once again, it switch to speed display mode.

Dashboard display LED (M)

When turn on the key switch, the system will self-diagnose, the lamp will lights on one by one. After self-diagnose, LED will display truck speed and battery

capacity. You can know your truck‟s

working condition through the LED dashboard.

Key switch

The key switch has two “on/ off” position, you should push the Direction switch lever to neutral and loose the accelerator pedal, then turning the key switch to “on” position clockwise.

Caution!

1. Turning the key switch “on” does not

make the forklift truck move, if the Direction switch lever is not in the neutral position or the accelerator pedal is pushing.

2. Error code maybe appear, don‟t worry

about it.

3. The Direction switch lever should be returned to neutral and move you foot from the accelerator pedal. Then the truck can be operated.

4. Then the error code should be disappeared.

Forward

Left turning lamp flashes

Neutral

Lamp goes off

Backward

Right turning lamp flashes

Connector Position

battery

Far light 0 × 1 ×

Rear big lamp switch (optional)

Rear big lamp switch (push\pull) has only one shift.

× Means connected

Caution!

This light does not relate to key switch position, so please don‟t forget to turn off the rear big lamp when you leave the truck.

Horn button [13]

Press the rubber cover at the center of steering wheel to sound horn. The horn sounds even when the key switch is in the “off” position.

Combined light switch [9]

This combined light switch is composed of turning light switch and big/small lamp switch. Turning light indicates the traveling direction. When turn on the switch, the lamp flashes.

Caution!

The turn signal lever does not automatically return to the neutral position. Reset it by your hand.

Big/small lamp switch has two shifts. First shift small lamp lights on; second shift big and small lamp both light up.

Emergency disconnect switch [4]

When happen emergency, presses down the emergency disconnect switch, and then the main power of the truck will be cut off, the truck stops working.

Caution!

Please don‟t use the emergency

disconnect switch to substitute the function of key switch.

Fuse box J\JC1\JC2 Series

1st is a diode preventing from connecting in reverse. 2nd is a control circuit fuse (10A). 3rd and 4th are fuses for light and horn circuit. (10A respectively) 5th is light fuse 10A. 6th is spare fuse 10A.

JD1 系列

1st is control circuit10A. 2nd is main contact circuit fuse 10A. 3rd is instrument fuse 10A. 4th and 5th is light fuse 10A. 6th is spare fuse 10A.

Caution!

When replace a new fuse, please choose the same capacity fuse of the old one.

Controls

Steering wheel [1]

The steering hand-wheel is operated in the conventional manner, that is, when the wheel is turn right, the truck will turn to the right; when the wheel is turn left, the truck will turn to the left. The steer wheels are located at the rear of the truck. These cause the rear of the truck to swing out when a turn is made.

Warning!

This truck is provided with the power steering, so heavy hand-wheel operation is caused when the steering motor comes to a stall. To put the power steering in operation again, restart the steering motor without delay.

Parking brake lever [3]

pressed, the forklift trucks moved forward. When the lever is pushed backward, the forklift trucks moved backward.

Caution!

While traveling, if change the

Forward- Reverse lever, electric braking will operate，speed will lower until stop， then travel to the opposite direction.

Warning!

Turning the key switch “on” does not

make the forklift truck move, if the Forward-Reverse lever is not in the neutral position or the accelerator pedal is being pressed. In this case, the Forward-Reverse lever should be returned to neutral and move you foot from the accelerator pedal. Then the truck can be operated.

Use this parking brake lever to park the lift truck. And the parking brakes are applied on the front two wheels by pulling up on this lever. To release the parking brakes, move the lever forwards.

There is a micro switch at the left side of the parking brake lever, tense the lever makes running invalid.

For the truck of CE: if you leave the seat without tensing the lever, it will warn and remind you to tense the lever.

Warning!

If parking on a grade is unavoidable, be sure to block the wheel.

Forward-reverse lever [2]

The forward-reverse lever is used for switching between forward and backward moves. When the lever is pushed forward and accelerator pedal

Lifting lever [10]

The forks can be raised or fell by pulling backwards or pushing the lever. Lifting speed can be controlled by tilt backwards angle of lever and the lowering speed can be controlled by tilt forwards angle of the lever.

Tilting lever [11]

The mast can be tilted by operation of this tilt lever. Pulling on this lever backwards will tilt the mast backwards, and pushing it forwards will tilt the mast forwards. The tilt speed can be controlled by tilt angle of the lever.

Caution!

The tilt lock mechanism built in the hydraulic control valve does not allow the mast to tilt forwards while the electricity is being shut down even if the tilt lever is pushed forwards.

Pedals Brake pedal [6]

Press this pedal to slow or stop the truck. At the same time, the brake light comes on.

Caution!

No permitted to press the brake pedal and the accelerator pedal at same time, otherwise, it is harmful to the traveling motor.

Accelerator pedal [7]

As the accelerator pedal is slowly pressed, the drive motor start turning and the forklift truck will start to move. According to the force applied to the pedal, the speed is adjusted with not steps.

Warning!

Before open the key switch to press the accelerator pedal, the more function digital indicator shall show alarm information. Then you must release the accelerator pedal.

Caution!

Loosen the accelerator pedal when truck is working, truck can make soft brake

3.Body and Others

Seat

Adjust operator‟ seat to the position

where is comfortable for you and provides easy controls. Before

proceeding with work, adjust operator‟s

seat and make sure that it is securely

locked. Adjust the operator‟ weight

through rock- suspends system level. The rear of the seat is adjustable.

Seat switch (only for trucks exporting to Europe or option)

For the safe of truck, when you leave the seat longer than 5 seconds, the truck will stop traveling.

Safety belt

Please keep back and waist close to seat as far as possible, and fix safety belt at the same time.

Inspect whether bolts fixed belt are loose or not. Do not use belt with a knot. Do not make belt press on stiff or fragile things, and do not make belt attrite with sharp things to avoid wearing. Do not make seat backrest too be tilted; otherwise safety belt may not extend correctly.

Do not remove any part of belt at will. Please often inspect the belt used frequently, if found any abnormal, replace it at once. And the life for use is 3-5 years, scrap it ahead of schedule if found any abnormal.

There is a safety belt on the seat, before you operate the forklift truck, please fasten the seat belt to protect yourself.

Overhead safe guard

The overhead guard used is strong enough to meet safety standard, and protects the operator from falling materials. The top gap is used to lift the batteries. It is forbidden for use a truck that does not with safeguard.

Hood

The hood can be swung up fully to provide easy examining and maintenance of

the storage batteries.

You can lift up the hood with little effort with an aid of hood damper. To lock the hood, push down on the front of hood until it covered.

Caution!

Be careful do not to catch you fingers in the hood when closing it. Depress the spring insurance before you close the hood, then press the head of the hood.

Left & Right battery cover hood

The battery is covered hood, one left and one right. When you want to take off the hood, you should take off the knob at first.

Fork stopper

Fork stoppers are locked the forks in position. To adjust fork spacing, pull up fork stoppers, turn 90°and shift the forks to the desired position. The fork spacing should be adjusting according to loads to be handled.

Warning!

The forks should be set symmetrically to machine centerline and fork stoppers should always be locked again.

There are one gap on the below beam. It is used to attach goods. It is forbidden to lock the fork on the gap position, to prevent the fork fall off from the gap.

In the middle of the above beam, a bolt used to prevent fork works here. Please change the bolt as soon as it is damaged.

Change fork

Take down the old fork: Firstly, locate the fork to the middle, decline it to the ground and make the mast forward, then operate the truck traveling backward, the fork will be taken down.

Change new fork: Firstly, make the

fork dead against the truck and forklift‟s

mast to the bottom, then operate the truck traveling forward, aim at the two gaps and beams, and raise the mast. Adjust the position of the fork.

Safety step and safety grip

The safely steps are provided on both side of the truck body. The safely grip is provided on the front left pillar of the overhead guard. Use the safely step and safely grip when mounting and dismounting the truck.

Brake fluid reservoir cup

The brake fluid reservoir cup is located at the meter board.

Caution!

The brake fluid is poisonous, be careful do not drop down. When add brake fluid, be careful do not let dirt and other thing drop into reservoir cup.

Head lights and combination lights

Two headlights and combination lights (turn signal, show width lamp) are installed at the front side of the truck. Take care of the lights, and wipe dirt, if any, and replace any damaged light immediately.

Rear combination lights

The combination lights at the rear side serve as turn signal, show width lamp, brake lamp, and back-up lamp. Pay attention to keep them from being damaged or covered with dust, if any, clean or replace immediately.

Steering column tilting angle adjuster

The tilting angle of the steering column is adjustable to suit individual operators. Turn the hand lever upward to release the steering column and locked by turning it downward.

Hydraulic oil reservoir cap

The hydraulic oil reservoir cap is located at the right rear end, below the battery hood; open the right side battery hood when adding oil. After fill in clean hydraulic fluid, tighten lock the cap.

Air leakage plug

There is an air leakage plug on the oil tank to let air in the tank goes out.

You‟d better often check the plug and see

whether been jammed.

Chair disconnecting switch

When the operator leaves seat, this switch cut off, and the power of truck is cut off.

Safety seat belt (for the trucks exporting to Europe or option)

There is a safety belt on the seat, before you operate the forklift truck, please fasten the seat belt to protect yourself.

Rear big lamp (for the trucks exporting to Europe or option)

The rear big lamp is set on the safeguard. If it is broken, please replace a new one at once.

4.Safety instructions

1. Only trained and authorized

operator shall be permitted to operate the truck.

2. Inspect the truck at periodic

intervals for oil or water leak, deformation, lousiness, etc. If neglected, short life of components will be caused and in the worst case a fatal accident would occur.

·make sure having replaced good

parts during periodic check.

·Wipe off oil, grease or water from the floor board and foot and hand controls, if any.

·Strictly prohibit smoking and spark nearby the storage battery when checking it.

· If maintenance on high position, such as mast, front and rear lamp, please be careful to prevent fall down or be clamped.

·Be careful do not be scalded when inspect the motor, controller and etc.

3·whatsoever in trouble, you must

stop the forklift, hang a mark of “danger” or “trouble” and take off the key, at the

same time inform the manager. Only after the trouble is removed, you may use the forklift.

·If trouble occurs when lifting cargo, to Climb or descend, or the storage battery electrolyte, the hydraulic fluid, the brake fluid has the revelation, please organizes the personnel to repair immediately.

4. Operator must wear helmet, safety

shoes and work clothes.

5. Because there will bring exploding gas in the bosom of the battery, prohibit any flame nearby it absolutely.

·Do not let any tools close the two terminal of the battery to avoid spark or short circuit.

6. The movement road of forklift should be solid and smooth coagulation road or similar to the road suitable for vehicle. Recheck the state of working ground.

The considered climatic conditions when the forklift designs are: Temperature - 20℃-50℃; the wind speed does not surpass 5m/s; the air relative humidity is not bigger than 90% (temperature 20℃). The forklift is not suitable in the flammable explosive working conditions.

7. Never mount or dismount the moving truck. Use the safety step(s) and safety grip facing the truck when mounting or dismounting the truck.

8. Never attempt to work the

controls unless properly seated.

Before starting, adjust the seat so you can get easy access to all hand and foot control.

9. Before starting up, make sure that:

·Please fasten seat bolts.

·The parking brake lever is applied

securely.

·The forward-reverse lever is in

neutral.

·Before staring, make sure no one is

under, on and close to the truck.

·Don‟t step the accelerate pedal or

control the lifting lever or tilting lever before turning on power.

10. Operate the controls smoothly.

Avoid sudden stops or turns.

· It is dangerous to make a sharp brake. Otherwise the truck has the possibility of overturn.

11. Pay attention to the route of the truck; be sure to make a wide sight.

12. Never allow other person(s) to ride on the forks, pallets or on the truck.

13. Taking account of the shape and material of loads to be handled, use a proper attachment and tools.

·Avoid hoisting the load, with wire rope hung on the forks or attachment, since the wire rope may slide off. If needed, a qualified personnel for slinging operation should perform, making use of a hook or crane arm attachment.

·Take care not to protrude the forks out of the load. The protruded fork tips may damage or turn over the adjacent load.

14. Know the rated capacity of your lift truck and its attachment, if any, and never exceed it.

·Do not use a man as an additional counterweight. It‟s quite dangerous.

15. Keep your mind on your work.

16. Keep your head, hands, arms,

feet and legs within the confines of the

operator‟s compartment. Never stretch

out for any reason.

17. The pallet and skid used should be strong enough to endure the load. Never use damaged or deformed ones.

18. We afford all type of attachment, such as rotating roll clamp, bale clamp, side shifter, and crane jib etc. You should refit the truck under ours license if you want. It is forbidden to refit it by yourself.

19. Safeguard protect you do not be hurt by the goods fallen. Load bracket protect you load goods smoothly. It is forbidden to use truck without safeguard or load bracket.

20. It is forbidden to walk down the fork or the attachment.

·It is forbidden to walk up the fork or stand on the fork.

21. It is forbidden to put your hands, arms or head stretch between the mast and safeguard. Once clamped, the life has danger.

·It is forbidden to put your hands in inner and outer mast.

22. The goods is liable to drop turning or passing rough road when it departures the center. And the forklift may turn over more probably.

23. Don‟t stack loads on forks in such a way that the top of loads exceeds the load backrest height. If unavoidable, make sure the load is fastened. When handling bulky loads that restrict your vision operate the truck in reverse or have a guide. When lead by a guide, make sure you understand hand, flag, whistle or other signals. When handling long loads such as pipe, lumber etc or in the case of the Large-sized model, or operate with long attachment, be extremely careful of load end swing at corners or in narrow aisles. Be alert for others.

24. Use minimum forward and

reverse tilt when stacking and un-stacking loads. Never tilt forward unless load is over stack or at low lift height.

· When stacking loads on a high place, once make the mast vertical at a height of 15 to 20 cm above the ground and then lift the load farther. Never attempt to tilt the mast beyond vertical when the load is raised high.

·To un-stack loads from a high place, insert forks into the pallet and drive backwards, then lower the load. Tilt the mast backwards after lowering. Never attempt to tilt the mast with the load raised high.

25. It is dangerous to travel with forks higher than appropriate position regardless of whether loaded or not. Keep the good traveling posture. (When traveling, the forks should be 15 to 30 cm above the ground or floor and the mast tilted backward)

·Do not operate the side shift mechanism, if equipped, when the forks are raised and loaded, since this will cause the truck to be unbalanced.

26. Watch for branches, cables, doorways, or overhangs. Pay caution when working in congested areas.

·Slow down and sound horn at cross aisles and other locations where vision is restricted.

·When make a turn, be sure the speed of the truck is lower than the 1/3 max. of allowable speed.

27. Affirm keeping some distance from roadside and flat roof.

28. Before driving over a dock-board or bridge-plate, be sure that it is properly secured and strong enough to sustain the weigh.

29. When operating loaded truck, have the rear end of your machine pointed downhill.

·When operating unloaded truck, have the rear end of your machine pointed upgrade.

Do not make a turn on the grade, in

order to avoid overturn.

30.the goods is liable to drop turning or passing rough road when it departures the center. And the forklift may turn over more probably.

31. Never lift loads with the truck

inclined. Avoid loading work on a grade.

32. Never permit anyone to stand or walk under upraised forks or other attachments if machine is so equipped. If unavoidable, use a safety stand or block to prevent a possibility of fork attachments falling down or moving unexpectedly.

33. Inspect the surface over which you will run. Look for holes, drop-offs, obstacles, and look for rough spots. Look for anything that might cause you to lose control, bog down or upset.

·Clear away trash and debris. Pick up anything that might puncture a tire or let the load lose balance.

·Slow down for wet and slippery roads. Stay away from the edge of the road. If unavoidable, pay more attention.

·Do not operate the truck when the weather is execrable, such as windy, thunder storm, snow and etc. Especially when wind speed is higher than 5m/s, don‟t operate the truck outside.

34．An accumulator is required for controller. Forbid to touch within B+ and B- to prevent from wounding by electricity. Before checking or cleaning, please connect loads (contactor circuit or horn for example) between B+ and Bfirst to discharge for capacitor of controller.

35. Pulling the hand brake when parking on flat. If necessarily parking on ramp, you should place the wedges under wheels.

·Descending the fork to the ground and keeping a little forward tilting, shut off key switch and take off key.

·Pull out the battery plug.

·The parking place must be far away from fireworks.

36. You can tow the forklift to the

safe place with towing pin when the

forklift can‟t run.

·Don‟t tow the truck which steering

system or brake system has been damaged.

37. There is operating method and warning label on the truck. Please operate the truck obey the rules on the label and this manual. Often inspect the nameplate, when damaged or lost please replace it.

38. Fire extinguisher must be prepared at working place. Users can select fire extinguisher along with truck, and it usually is fixed on rear supported leg of safety shelf, it is easy to pick.

Driver and manager should be familiar with the position and operation of fire extinguisher.

39. Please use stock when conveying little goods, it is forbidden to use fork directly.

40．The work road surface for forklift should be stability and unknit, cement, blacktop or beton. If there are snow, ice, water or other eyewinker, bar. Eliminate all, then work. Otherwise the truck will be out of control and lead the safety accident.

41. 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.

42. After take-down the hood, water tank cover board, overhead, backrest of mast, unallowed to operate the truck or

load cargo.

43. There are enough light at truck work ground. At night, open the head lamp to collocate enough lamp-house.

44. 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 theorganisation that accomplished the tasks.

5.The structure and stability of truck（Prevent the forklift to turn over!）

It is very important for operator to know the truck‟s structure and relationship between

load and stability.

Caution the structure of the truck

The basic structure of the truck is mast (include mast and forks) and body (include tire).

The lift truck keeps the balance of weight between the truck body and the load on the forks with the center of the front wheels as a fulcrum when the rated capacity load is placed in position.

Due care should be paid to the gravity center of loads and forklift to maintain the stability of the truck.

Caution Load center

There is difference in gravity because of the loads‟

shape, such as box, board and large roller. It is very important to distinguish the difference of the gravity center of loads for evaluating the truck‟s stability.

Warning!

If the truck will turn over, do not attempt to get out of the truck because the speed of overturn is much faster than your speed. You should hold the steering wheel handle, stretch your feet, and this practice will let you in the seats. Operator fastens the safety belt please.

The load center distance is defined that: the distance between the load center and the fork carriage or the front of the fork carriage. The max. load means the maximum load the truck can charge at the normal load center distance. The relation between the max. load and load center distance shows on the capacity chart. You should reduce the weight of load if the load center distance inclines to the fork carriage.

The max. load（weight and load center distance）

Caution

Caution Gravity center and stability

The combined gravity center that is composed of the forklift center and the load gravity center determine the stability of lift trucks.

When unloaded, the barycenter does not change; when loaded, the barycenter is determined by the truck and the load‟s center.

The barycenter is also determined by the tilting and lifting of the mast.

The combined center is determined by these factors:

Load‟s size, weight and shape

The lifting height

The tilting angle

The acceleration

The radius of turning

The road and grade‟s angle

The attachments

Caution! The stability zone of the barycenter

In order to make the truck stable, the combined center must be in the triangle which is made up of two points that the two front wheels attach ground and the midpoint of the back axle.

If the combined center is in the front driving axle, the two front wheels become two fulcrums, the truck will overturn. If the combined center departures the triangle, the trucks shall overturn in the corresponding direction.

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Hangcha 1-1.5t Service Manual

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