Hangcha 1-3.5t R Maintenance Manual

1-3.5t R Series Internal Combustion

Counterbalanced Forklift Truck

OPERATION AND MAINTENANCE MANUAL

Original Instruction

ZHEJIANG HANGCHA ENGINEERING MACHINERY CO., LTD.

DEC.2009 4th EDITION

FOREWORD

This operation manual is the explanations that how to use 1-3.5t 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 1-3.5t N series internal combustion forklift truck, 1-3.5t 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 ZHEJIANG HANGCHA ENGINEERING MACHINERY CO., LTD. sales department or let the agents know.

CDEC.2009 4

○

EDITION

Content

Foreword

1. GENERAL RULES.....................................................................................................................1

2. NAME OF MAIN PARTS OR COMPONENT........................................................................3

Instruments..............................................................................................................................3

Switches....................................................................................................................................5

Controls....................................................................................................................................6

Body and others.......................................................................................................................9

3. SAFETY INSTRUCTIONS......................................................................................................13

4. MAINTENANCE......................................................................................................................19

8 hour (daily or every shift) check.......................................................................................19

Weekly maintenance (40 hours)...........................................................................................22

Maintain monthly (180-200 hours)......................................................................................25

Maintain semiannually (1000 hours)...................................................................................27

Maintain annually (2000 hours)........................................................................................... 29

5. STRUCTURE AND STABILITY OF TRUCK.......................................................................33

6. OPERATION.............................................................................................................................35

Star-up....................................................................................................................................35

Traveling ................................................................................................................................36

Pick up....................................................................................................................................37

Stacking load..........................................................................................................................37

Remove load ..........................................................................................................................38

7. DEPOSIT...................................................................................................................................39

8. MAINTENANCE......................................................................................................................41

Preventive maintenance schedule........................................................................................41

Maintenance of chassis and body.........................................................................................43

Periodic replacement of key safe parts................................................................................45

Table for the oil used in the truck ........................................................................................46

Lubrication system drawing.................................................................................................48

Environment protection........................................................................................................49

Scutcheons .............................................................................................................................50

9. TRUCK’S CONVEY , LIFTING, TOWING...........................................................................58

10. TYPE SIGNIFICATION........................................................................................................59

11. PERFORMANCE PARAMETERS OF R SERIES IC FORKLIFT..................................62

12. OPERATION, DISASSEMBLY AND INSTALLATION OF CAB.....................................81

13. OPERATION AND NOTICE ABOUT LPG FORKLIFT...................................................83

14. OPERATIONAL METHOD OF MAINTENANCE FREE LEAD ACID BATTERY......95

15. USE, INSTALLATION AND SAFETY RULES OF ATTACHMENT...............................97

16. RELATED SAFETY INSTRUCTION AND STANDARD (FOR TRUCKS EXPORTING

TO EUROPE OR OPTION)........................................................................................................

17. MAINTAIN RECORD..........................................................................................................103

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

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. 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 Rear wheel 11. Tilting cylinder 12. Front wheel

10.

Instruments

Hour meter [1]

This meter measures working time of engine. Use meter to schedule lubrication and maintenance periods.

Water temperature gauge [2]

This gauge indicates the oil temperature in the torque converter transmission box. In normal status, the

pointer is in green zone. (60~115℃)

Caution

If the pointer points red zone, please stop the truck at once. Decrease the engine speed to make the engine cool. Check the cooling fluid if enough and the fan belt ’s elasticity i f fit.

Fuel gauge [3]

The gauge indicates the fuel level in the tank when the key is at (ON) position.┃

Charge (A)

This lamp indicates the battery condition of charge. The lamp comes on when the ignition switch is set at “ON”, but it goes out as the engine starts and accelerator pedal is pressed.

Caution

If the light continues to stay lit or lights up during operation, the charging rate is low and should be checked immediately.

Oil pressure alert lamp (B)

This lamp indicates the pressure condition of engine lube oil. Although it lights up when the engine switch is set 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.

Glow indicator (C) [Diesel truck]

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

Sedimentor indicator (D) [Use in W9、

W13、W15A diesel truck]

In normal state, once the starter is set to “ON” position, this lamp lights up. After the engine is started up, it goes out.

This lamp lights up when water in sedimentor reaches to a certain level, while the engine is running.

If this lamp continues to stay lit or lights up during the engine running, stopping the engine and discharge water immediately.

Caution Fuel injection pump will be damaged if continue working when the light is up.

Engine coolant temperature [E]

In normal state, once the starter is set to “ON” position, this lamp lights up. After the engine is started up, it goes out.

During work time if the oil temperature exceed the normal

rang(60~120℃) the indicator light on.

Caution

If the pointer enters the red range, stop the operation instantly and slow down engine speed to cool the coolant and wait until the pointer goes into the green range, and have a check then.

Switches

Key [4] OFF (O)

This is the position at which the

key inserted or drawn out.

Gasoline engine and diesel engine

stop at this position.

ON ( )┃

The electric circuit is closed with the starter switch at “”┃ (ON). After the engine is started, the key is at this position.

START ( )

As the key is placed in the “START” position, the starter motor is engaged. When removing hand off key, it is automatically returned to the “ON”

position by spring force.

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.

2.With the engine running, do not turn

the starter switch into the (START) position, since there is a danger of the starter motor being damaged.

3.Do not keep the starter engaged for

more than 5 seconds at a time. Wait about 120 seconds before trying again.

Turn signal lever [5]

Use this lever which is at the right side of turning rod to indicate the turning direction of the truck. R-turn right, N-neutral, L-turn left.

The turn signal level does not automatically return to the neutral position unlike general passenger cars. Reset it by hand.

Light switch [6]

This light switch can be pulled out

at two steps.

Light Stage

Power

Near light

Far

light

0 ×

1st × × ×

2nd × × ×

(×) means connected

Clear

-ance

Horn button [7]

Press the rubber cover at the center of steering wheel to sound horn.

Controls

8. Clutch pedal (frictional clutch type) 9. Inching pedal (torque converter type)

10. Brake pedal 11. Accelerator pedal 12. Forward reverseand Speed slect lever (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 line 20. Forward reverse lever(Torque converter type

Switch)

Clutch pedal [8] (frictional clutch type)

Press the clutch pedal fully, the operator can uncouple the engine and transmission.

When the clutch pedal released, it allows power to flow through the clutch from the engine to transmission.

Caution:

Do not run the lift truck with the clutch in a half-clutch condition as much as possible.

Inching pedal [9] (Torque converter type)

As the inching pedal is pressed, the oil pressure in the hydraulic clutch drops accordingly (the needle of the oil pressure gauge swings to the left) allowing the operator to perform inching operation. Use this pedal to inch the truck while operating the hoist system at a high speed.

When pressed to the full, this inching pedal serves as a brake pedal also.

Caution:

Do not use the inching pedal too much. Long time use or use as rest would cause high temperature of transmission oil, or result in slipping of clutch.

Accelerator pedal [11]

Press down the accelerator pedal, engine rotating speed increase, traveling speed of truck increased. On the contrary, when loosen the pedal, engine rotating speed and truck traveling speed will decrease.

Forward-reverse [12] Speed-select lever [13]

Machinery transmission

[12]F-front N-neutral R-backward [13]1-low N-neutral 2-high

Machinery gear box have four shifts, tow

are frontward and tow are backward.

Before gear-shifting, be sure to press the clutch pedal to the full. Always brake to a full stop before reversing the direction of travel. Shifting the level in reverse the back-up lights turn on.

Tilt level [14]

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 and accelerator pedal effort.

Caution

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

Lift lever [15]

Control the forks’ up or down.

Pulling: up, Pushing-down.

Lifting speed can be controlled by tilt backwards angle of lever and accelerator pedal, the lowering speed can be controlled by tilt forwards angle of the lever.

Steering wheel [16]

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 turned left, the truck will turn the left. The steer wheels are located at the rear of the truck. These cause the rear of 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 engine comes to a stall. To put the power steering in operation again, restart the engine without delay.

Parking brake lever [17]

Direction to driver

Pull the parking brake lever backward to park, push it forward to release, must pull the parking brake lever backward before driver leaving truck.

Forward reverse lever [18] [Non-electric-switch] F-forward N-neutral R-backward

Torque converter type truck have a forward shift and a backward shift. When shift must stop the truck first.

Caution

Do not fail to place the forward-reverse lever in the neutral position before starting the engine.

Choke line [19]

To pull out the choke line, the engine will stop. Some of the model

forklift has no choke line. When turn off the key switch, the engine will stop.

Forward-reverse lever [20]

[Electrical Switch]

The forward reverse lever of truck installed with electronic reserving is set on the left of turning rod。

Forward—Forward N—neutral

allocation

—backward

After

Caution:

Do not forget to place the forward-reverse lever in the neutral position before starting the engine.

Body and others Load bracket

Load bracket can ensure stabilization when loading the goods. It’s forbidden to use the forklift truck without the load bracket. Seat and seat adjusting lever

Adjust operator’s seat to position, which is comfortable for you and provides easy access to all hand and foot controls. The seat is unlocked by moving the adjusting lever to the right. Before proceeding with work, adjust operator’s seat and make sure that it is securely locked.

Warning!

a. Before adjusting the lever, you’d

better turn off the key switch.

b. Must stop the truck to adjust the

seat .

Seat weight support adjusting

Use spanner to adjust the bolt which is at the back of seat, or adjust the knob for supporting the weight on seat at the lift side of seat, adjust the hanging’s weight basing on person’s weight.

It’s better to sit on the seat when adjusting.

Seat switch While you are on the vehicle and

wearing the Safety belt, at the same time, your back and waist should close to the seat as much as possible. Check whether the bolts which fixed seat belt were loose frequently. It is forbidden to use the Safety belt when the belt was tie a knot. Do not let the belt press on the hard or fragile objects. And also do not make friction with the sharp edge to avoid damaging the belt. Do not let the seat back tilted too much; otherwise the safety belt will not be able to correctly elongation. The components which are on the safety belt can not be removed randomly. If the safety belt used frequently, you

should always do exterior inspection, when found something abnormal, please immediately replace new belt. The belt can be used for 3 to 5 years, when found something abnormal, it should be scrapped early.

Overhead guard

The overhead guard used is strong enough to meet safety standard, and protects the operator from falling materials. It’s forbidden to use forklift without overhead guard.

Hood and snap close

To avoid opening the hood at discretion, a snap close is set here. Open the snap close first then the hood can be open. Guy head To avoid opening the hood at discretion, the hood only can be opened by specified tools. The guy head is the specified tool.

Hood

The hood can be swung up fully to provide easy maintenance service. 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 covers.

! Caution

△

While maintaining under the cover hood, the engine must be flameout to avoid hands or other parts of the body being clamped by running assembly. The engine can be no-flameout only when human body does not touch parts under cover hood, and to examin e where the fault is by hearing.

Radiator cover hood

Must use special tools (socket spanner)

to open radiator cover hood. You can open the radiator cover hood even close the engine hood, so to inspect the coolant fluid.

Caution

Before open the hood, the handle of

the snap close should be pulled out first.

Use caution not to catch your

fingers in the hood when closing it.

Caution:

Retighten the bolt on the cover hood.

Radiator cap and coolant reservoir

The reservoir is located inside the

hood.

The radiator is located under the

cover plate at the rear of the hood.

Warning!

Do not open the radiator cap abruptly while water’s temperature is higher than 70℃. Turn the cap a little to the left to relieve the pressure in the pressure in the radiator, and then remove the cap.

Do not wear glove when removing radiator cap.

The antifreeze fluid is dangerous for your health, if touched to skin, please wash clean by water. Do not allow children access to antifreeze.

Fork stopper

It’s used to adjust fork spacing and to lock the forks in position. Pull up fork stoppers, turn 90°, according to loads to handle the forks spacing.

Warning!

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

The lower beams of fork have a hatch to load or unload forks.

The fork is forbidden to fix on the location where the hatch locates. Check the bolt at the middle of the fork bracket which is used to prevent load fork at the hatch.

Steering column tilting angle adjustment

The tilting angle of the steering wheel is adjustable to suit individual operators. The steering column is unlocked by pushing down the lever at the left side of turning rod, then adjust the angle suit to the driver, and pull up the lever to lock.

Caution: a. After stop the truck and pull on the parking brake lever then to adjust the tilting angle of steering column. b. After adjust the angle and pull the steering wheel to make sure tighten the lock rod.

Safety step and safety grip

The safety steps are provided on both sides of the truck body. The safety grip is provided on the front left pillar of the overhead guard. Use the safety step and safety grip facing the truck when get on and get off the truck.

Brake fluid reservoir

The brake fluid reservoir is

provided at the left of the cabinet.

Hydraulic fluid reservoir cap

The hydraulic fluid reservoir cap is located at the right side in the hood. Fill hydraulic fluid through this filler port. The cap is provided with the dipstick. After fill in clean hydraulic fluid, lock the cap.

Fuel reservoir cap

The fuel reservoir cap is located at the rear left side of the truck body. The fuel reservoir cap has the breather inside it to allow air to enter the reservoir. Check to see that the breather is in good condition every time addition of fuel is made.

Warning!

--- Fuel handling---

1.Stop the truck, shut down the engine

and apply the parking brake securely. Make sure that there is no naked flame near the area. Never smoke. The driver should not remain seated when adding fuel.

2.After addition of fuel is finished, securely close the reservoir cap. A loose cap could cause fuel leak or fire hazard in the worst case.

3.Before attempting to start the engine, make certain that the fuel reservoir cap is securely tightened and that no fuel is split on or around the truck.

4.For the purpose of fuel level inspection, never use naked flame such as a match or lighter.

Rearview mirror

There are two rearview mirrors on the safeguard for operator to see rear accident.

3. 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, the life of the truck will be shortened and in the worst case a fatal accident would occur.

Make sure to replace the “key safe

parts” at periodical inspection.

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

Shut down the engine before inspecting the engine and its allied components. Especially use caution to the engine fan.

When inspecting the radiator or muffler, exercise caution not to get burnt.

3. Any time you find that the trucks are not functioning properly, operation of the truck should be halted and the condition reported to the supervisor.

should be prepared.

Never fill the fuel tank with the

engine running.

5. Warm up the temperature of water to 70℃ before operation; and cool down the temperature of water to lower than 70℃ after work.

If the temperature of the water tank is higher than 70℃ , never open the tank cap.

6. When using your tr uc k in an enclosed space, make sure there is enough ventilation. If needed, use a ventilation fan. Don’t work in a closed working space because of the tail gas of truck is dangerous to health.

It’s forbidden to use truck under a circumstance of flammability and easy to blast.

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.

When doing maintenance in the high place (such as mast, front and rear lights) should be care of slide and clamped.

If any warning lamp comes on, move to a safe place and check or repair the trouble.

When doing maintenance, take care of edges and corners to lacerate hands, head and other parts of body.

The sign of defect should be put on the defecting forklift truck.

4. Don’t use an open flame to check level, or for leakage, of fuel, electrolyte or cooling water.

Never smoke while inspecting the battery, handling fuel or working on the fuel system. There is a danger of explosion.

At working place fire extinguisher

8. Never attempt to work the controls unless properly seated.

Before staring, adjusting the seat so you can get easy access to all hands and foot controls.

9. Before staring, make sure no one is under, on and close to the truck.

The forward-reverse lever is in neutral.

10. Park the truck on a level surface and apply the parking brake securely. If

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

Put the forks on the ground or floor and tilt a little forwards. Shut down the engine and remove the key.

11. Operate the controls smoothly-don’t jerk the steering wheel. Avoid sudden stops, starts or turns.

12. Control speed and observe traffic signs.

When traveling on public roads or streets, obey all local traffic regulations

13. Pay attention to the route of the truck , be sure to make a wide sight.

14. Never allow other person(s) to ride

14.Does not allow other people sitting on the forks, pallets or on the truck.

16. Keep your mind on your work.

17. Keep your head, hands, arms, feet and legs within the cab. Never let them out of cab for any reason.

18. When handling bulky loads, which restrict your vision, operate the truck in reverse or have a guide.

19. Slow down and sound horn at cross aisles and other locations where vision is restricted. The speed should be keep slower than 1/3 of max speed.

15. Before driving over a dock-board or bridge-plate, be sure that it is properly secured and strong enough to sustain the weigh. Check the ground or floor condition of working area in advance.

20. Keep fluid cans, row cotton, paper or chemicals away from the truck during operation since there is a danger of their firing or exploding due to exhaust gas from the muffler.

21. Use head lights and required work light and clearance lights at night. And travel at a low speed.

22. The work surface should be solidity and flatness such as cement road surface, bituminous macadam and beton road surface.

The climatic conditions that the trucks designed for are: temperature is –20℃—50 ; wind speed is lower than ℃ 5m/s; air relative humidity is less than 90%(20 ).℃

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, use extreme caution. Rugged surface would cause vibration of truck and noise. The high air pressure of tyres will cause vibration and noise, too.

Do not operate the truck when the weather is execrable, such as windy, thunder storm, snow and etc.

23. 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.

Never turn sideways on an incline. There is danger of the truck turning over.

24. When running down on a grade, use engine idle speed. At the same time use the brake pedal intermittently.

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.)

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.

A truck with attachments should be considered as with loads.

26. Travel with load as low as possible and tilted back.

27. Avoid braking too sharply or descending on a grade at a high speed. There is danger of loads falling down or the truck turning over.

28. Always brake to full stop before reversing direction of travel.

29. 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.

Do not use a man as an additional

counterweight. It’s quite dangerous.

31. ZHEJIANG HANGCHA ENGINEERING MACHINEARY CO., LTD. offers a variety of attachments, such as forks, bucket, rotating roll clamp, load grab or hinged forks. Don’t use such attachments and special equipment for applications other than specified.

32. Safeguard is used to prevent us from hitting of the higher goods. Load bracket is used to ensure loading stable. The forklift truck without two items is forbidden to be used.

33. Never permit anyone to stand or walk under upraised forks or other attachments if machine is so equipped.

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

Never permit anyone to stand on

the forks.

34. Don’t put your head or body into the interspace of mast and safeguard, what may cause life risk

Don’t put your hand into the interspace of inner mast and outer mast

35. When load is to be retrieved from a pile, enter the area squarely. Engage forks into the pallet carefully.

36. Don’t enter into loads at a high speed. Always make certain that your load is stable before lifting the forks.

Be sure to once stop in front of the load to be lifted, and make certain that there is no obstacle, then engage the load by driving forwards.

37. Make certain that your load is well stacked and evenly positioned across both forks. Don’t attempt to lift a load with only one fork.

On the truck with an attachment such as a load grab, make certain that the load is securely and correctly grabbed, and pull the loading control level to the full (increase to relief pressure).

38. Never lift loads with the truck inclined. Avoid loading work on a grade.

39. Don’t stack loads on forks in such a way that the top of loads exceeds the load backrest height. If unavoidable, make the load stable securely. When handling bulky loads that restrict your vision, operate the truck in reverse or have a guide.

40. Use minimum forward and reverse tilt when stacking and unloading 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 unloading loads from a high place, insert forks into the pallet and drive backwards, then lower the load. Tilt the mast back after lowering. Never attempt to tilt the mast with the load raised high.

41. Don’t tow the truck that its engine is in trouble, or steering system doesn’t work correctly or its braking system has been disabled.

Obey the communication rules on the road when towing the truck.

42. Dress the overalls or other protective uniforms, suck as safety helmet, safety shoes etc. Don’t dress necktie or other accouterments.

43. The workplace should be equipped

fire extinguisher. In order to get the

with fire extinguisher easily, it’s usually installed on the safety frame rear supporting leg. The operator should be familiar with position of the fire extinguisher and its application.

44.

Not allowed to carry small goods with

fork, should carry small goods with pallet.

45. Markings on the machine describe warning and methods to operate the lift truck. When operating the machine, observe and follow all markings on the machine in addition to this operator’s manual.

Replace damaged or missing decals and name plate.

4. Maintenance

More details for maintenance see 《Preventive maintenance schedule》.

8 hour (daily or every shift) check

1). Check leaks: electrolyte, hydraulic oil, brake fluid, coolant, oil in hydraulic transmission gear box.

Check if the engine, connector of hydraulic pipe, radiator and driving system are leakage or not. Do not use an open flame to check level, or for leakage, of fuel, electrolyte or cooling water.

! Warning!

△

Don’t attempt to operate the truck if leaked fuel is found through pre-operational check. Correct the leak before starting engine

2) Check appearance

Check the lamps and meters are normal or not. Check the tires, air pressure and bolts

are loose or not. Check whether tires are damaged or pressure of tires is normal or not.

3) Check fuel mass

4） Engine oil level check Caution

When checking the engine oil, should let the forklift truck on the level ground.

When check the engine oil, it is exact when the engine is cool.

Remove the dipstick, clean the rod and reinstall. Pull it out again and check the oil level. The level should be within the mark on the dipstick.

5) Check water level in the radiator

Inspect the small reservoir tank to see the coolant level is between Min and Max position when the engine is cool. If there is no coolant any more in the reservoir tank, please add some coolant to radiator, its freezing point is -35℃,and add sub-radiator to MAX position.

! Warning!

△

When the water temperature of the engine is higher than 70 degree, please do not open the pressure cap of the radiator. Loosen cap slowly to allow steam to

The fuel level gauge is provided on the indicator panel. Check that fuel level is sufficient for the day’s work. The fuel filler port is provided at the rear left pillar of the overhead guard.

escape. After that, tighten cap securely. It is good practice to use thick waste cloth or the like when removing the cap. Avoid putting on gloves, since you may get burnt at your hand if hot water splashes on it.

Caution

Adding clean water to radiator. If you use antifreeze, use the same brand of antifreeze.

Pay attention to water reservoir and cooling system in the hot season..

! warning

△

·antifreeze is harmful to person, if swallow, disgorge at once and go to hospital.

·do not let children add antifreeze.

6) Hydraulic oil level

Check the oil level in the hydraulic

oil tank.

The oil level should be in the place

between two slots,

7) Brake fluid level check

Check the fluid level in the brake fluid reservoir. The level should be between the two seams of the reservoir. When adding fluid, due care should be taken prevent air entering the brake tube.

Caution

When adding fluid, due should be taken to prevent dirt or water from entering the reservoir.

Brake fluid is dangerous to health, you should avoid touching it by skin.

Replacing of brake oil

A. Lay forklift truck at designated

ground, and lay it on level ground, fall down fork to ground, loosen park brake, put transmission gear neutral position, cut off engine.

B. Remove rubber dustproof cap of

oil-drain port, insert tube into oil-drain port and wasted oil collection bottle, and loosen oil-drain screw, at the same time, the other person on truck press brake pedal again and again. So the brake oil flows out from oil-drain port, watch the liquid level of brake fluid reservoir, add new oil as the fallen liquid level until the oil from oil-drain port is clean, and then screw down screw of oil-drain port.

C. The person on truck press down brake

pedal to the end and keep it, at the same time, the person at the oil-drain port loosen oil-drain port screw, tell the person on truck to release brake pedal when the brake oil flows out and screw down oil-drain port screw. Repeat above operation several times till there is no bubble in the brake oil. Watch the liquid level in brake oil reservoir; add new brake oil as the

liquid level is falling. Notice ： The truck of Korea transmission system: The brake oil(in the brake oil can) is Mobil Delvac hydraulic oil SAE10W。 Other types: choice HZY3 brake oil (add

when leaving the factory) or DOT3 brake oil.

8) Head lamp check

Make sure that the head lamp is lighting when the key is at “ON” position.

9) Turn signal check

Make sure that the turn signal operates properly by moving the turn signal lever.

10) Hand brake check

drive truck slowly.① loosen hand brake lever, stop the ②

truck, and truck has no deviation.

11) Back-up lamp and buzzer check

The back-up lamp comes on and buzzer sounds when the shift lever or directional control lever is placed in reverse position.

12) Turning

Operate the truck running slowly.

Turn the steering wheel to left and right 3 round respectively.

Check that the steering forces are equal in right and left.

13) Horn

Press the horn button to make certain the horn sounds is normal or not.

14) Drivers seat adjustment

Make sure the driver’s seat is properly located. If not properly, shift the adjusting lever to back and move the driver’s seat to a position which provides easy access to all foot and hand controls.

15) Shift lever(s) check

Check the shift lever(s) for looseness and operation for smooth.

16) Lifting lever, tilting lever and

attachment lever check

Check the loading levers (for lift, tilt and optional attachment) for looseness and smooth operation.

Increase the rotate speed of engine , make certain that the lifting lever, tilting lever and attachment lever in good work

condition.

17) Instruments and sensors

Make sure that hour meter, water temperature indicator, oil temperature indicator, transmission fluid sensor and fuel sensor etc., properly.

18) Brake pedal, inching pedal and

clutch pedal check

Drive truck slowly, press down brake pedal, and brake lamp lights.

Drive truck slowly, press down inching pedal, the speed of truck becoming decrease, and press downward more ,truck will be braked and stop

Check function of clutch pedal, see page 5《clutch pedal》。

19) Tire pressure

Turn the tire valve cap counter clock-wise and move it. Using a tire pressure gauge, measure the inflation pressure, and adjusting it to the specified pressure, if needed. After making sure there is no sir leakage from the tire valve, reinstall the cap. Check that each tire does not get damaged at the tread surface or side face or bending at the rim.

! Warning!

△

Since the forklift truck needs tires that have a high inflation pressure to carry heavy loads, even a small bending of rims or damage at the tread surface could cause an accident.

! Warning!

△

When using an air compressor, first adjust the air pressure of the compress-or. Failure to do so will cause a serious accident, since the compressor delivers the maximum pressure.

! Warning

△

Please maintain the air cleaner when truck

works 50-250 hours. After six times, please change air cleaner. Note：If the working condition is bad, the cycle of maintain and change air cleaner need more frequency.

The badly work condition with dust, the cycle of maintain and change air cleaner will be short. Advice maintains one time between 8-50 hours; change it between 100-300 hours.

Maintain method:

1. Take apart the cover of air cleaner.

2. Take out air cleaner.

3. Clean the inside or outside of dust

by compress air.

All nuts and bolts should be properly installed and tighten before inflating tire and rim assembly. An inflated tire contains potentially explosive energy. Don’t over inflate.

Tire pressure GB/T2982-2001:

Driving

Truck type

1-1.8t 790KPa 1000KPa 2-2.5t 860KPa 860KPa 3-3.5t 830KPa 790KPa

Weekly maintenance (40 hours)

Increase the below content base on

maintain daily.

1) Air cleaner

wheels

（Front

wheel）

Turning

wheels （Rear

wheel）

! Caution：

△

1、Please wear defend glass to avoid the dust fly up into your eyes.

2、 It will damage the engine if not maintain and change air cleaner on time.

2) Fan belt tension check

Stop the engine.

Use finger to press the belts at the midway between the water pump pulley and the generator pulley by 10kg press, and check the drop distance if is up to standard.

Engine

A498BT1-1

Drop distance

（mm）

10-15

K21，K25 11-13

WF491GP 汽油机 New 5-7，old 7-9

4TNE92 4TNE98

ISUZU

C240PKJ-30

TD27

New 8-12，old

10-14

8-12

New 9-11，old

11-13

Warning!

If the belt has already been pulled long, cut out or has no surplus, it should be changed.

If the engine is still running, it’s not permitted to carry on this check avoiding fingers or sleeves being caught up in.

Check if there have leakage of oil ②

cylinder and tubing.

Check the rollers’ rotation.③ Check the mast if there have crack ④

and bend.

Operate the lever of ⑤ lifting, tilting and attachment, check the mast if it’s in good condition, and pay attention to system operating sound.

5） Lift chain tension check ①Raise the fork about 10-15 cm above

the ground and make it vertical. ②Press middle of the chain by thumb. Make certain the tension for the right and left chains are even. ③Adjust the tension: Loosen the lock nut 1, screw the nut 2 and adjust the chain to make the equal tension, turning the adjusting nut 1 of the chain anchor pin.

3) Power shift transmission fluid level

Open the inspections cover and remove the filler cap. Inspect the lever gauge to make sure that the fluid level is on the upper mark of the gauge.

4) Mast and forks

Check the mast and forks to make sure:

①There is no crack and bend on the forks, and the forks are installed on the fork bracket strongly.

6) Lubrication of mast

Lubrication here on schedule, refers

to figure as below:

Mast

Paint lubrication grease on the slide support.

Note:

a). The periods of paint lubrication grease depend on the truck’s work condition. If works heavy, please paint much more grease on mast.

b). To assort with the truck’s operation, paint some lubrication grease on the surface where the idler pulley and inside and outside masts touchs.

8) Lubrication grease to below parts,

the detail please see <<Lubrication system drawing >>

(1) mast bear lubricate (2) Brake pedal(clutch type) lubricate (3) Inching pedal(tor-con type) lubricate (4) Steering axle shaft lubricate (5) Steering knuckle main bearing

lubricate

(6) Steering rod bar pin lubricate (7) Steering cylinder pin lubricate

9) Bolt, nut tighten

Referrence the <<Maintain cycle chart>>

10) Hub nut torque check

Check hub nuts should be tightened

to the specified torque securely.

Driving wheel （front wheel）

! Caution

△

Paint some lubrication grease; put the truck stop on a smooth road, engine flameout and tight hand brake. Prevent hand or body is clamped, and prevents falling off from high place. Keep safe.

7) Chain Lubrication

Take one brush with engine oil paint two sides on chain.

A. Hub nut B. Divided rim bolt (only for 1-1.8 ton) C. Drive shaft bolt

Specified torque N.m 1-1.8t 2-3.5t Hub nut 157-176 441-588

–

Turning wheel（rear wheel）

D. Rear hub nut

Specified torque N.m 1-3.5t Hub nut 157-176

E. Divided rim bolt

11) Brake pedal, inching pedal and

clutch pedal check

Press the brake pedal fully when the engine is running, the distance between brake pedal and front soleplate should be more than 60 mm.

Check the inching pedal and clutch pedal through the same method.

Height and the free clearance H:

Brake

pedal

Inching

pedal

Clutch

pedal

Notice :QN-RW22A is the shortening of CPQD20/25/30/35N-RW22A、RW15A is shorteningCPCD20/25/30/35N-RW15A.

Maintain monthly (180-200 hours)

maintain per week.

1. Change engine oil and oil filter

1) Start the engine, warm-up enough, then flameout.

2) Take out the oil cover and bottom shell to plug, release the oil.

△

cooling fluid in it, find out the reason and revise.

contains gasoline.

3) Wipe up and fit tuck and gasket. Screws down moment of oil tuck: 29～39 N·m

Free

height

120-130 ≥60 1-3

120-130 ≥60

120-130 ≥60 2-5

Increase the below content base on

! Caution

Be careful about the hot oil.

·Milky oil shows there is some

·Oil is very rare show that the oil

Press

height

free clearance

touching bolt of inching pedal brake pedal: ①0.9-3.4mm (NRW15A,QNR

W22A)

②0 mm(besides

NRW15A,QNR W22A)

4) Dismantle the oil filter by tool.

5) Use cloth clean the surface of oil filter.

6) Lay on little oil on the rubber ring of new oil filter.

7) Install new oil filter by hand,not spanner.

8)Referrence <<Table for the oil used in the truck>>,oil preferred.

9)Start the engine,check leak oil around oil tuck and filter. If leak obviously,this part is wrong install.

10) Warm-up engine enough,then

flameout,check oil level later.fill if

need. Check the oil fluid surface,put the truck at ground flatly.

2.Plus lubricate to front and rear of pin roll of Tilt cylinder

Clean the plus place,pile out the past oil.

3.Check the gear oil of drive Axle

housing If there is more dust at work place, after 200 hours use, it need consider that change the gear oil of drive axle

housing.

4. Change transmission oil filter Check the hydraulic transmission oil fluid, if more dust, change the hydraulic oil of transmission. It is first time.

Let the truck at level ground, play-down the fork to floor, inclined back the mast, strain brake handle, when transmission is at neutral position, engine is cut off.

! Caution

△

Hot hydraulic oil and part will hurt Body. Do not touch the hot hydraulic oil and part.

1) Dismantle rubber mat and front

soleplate.

2) Dismantle filter, deal with

located statute.

3) Clean pedestal of filter, confirm

that the old gasket of pedestal have be cleaned.

4) Plus less hydraulic oil on the new

filter gasket.

5) Install filter by hand. When the

filter get to pedestal, screw down 1/2-3/4 laps.

5.Change hydraulic transmission oil(first time, then semiannually)

Let the truck at level ground, play-down the fork to floor, inclined back the mast, strain brake handle. When transmission is at neutral position, engine is cutoff.

! Caution

△

Hot hydraulic oil and part will hurt Body. Do not touch the hot hydraulic oil and part.

1) Put one case(cubage is over 20 litre) under the transmission.

2) Dismantle oil tuck,put oil in it.

+ 78 hidden pages

Hangcha 1-3.5t R Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Hour meter [1]

Water temperature gauge [2]

Caution

Fuel gauge [3]

Charge (A)

Caution

Oil pressure alert lamp (B)

Glow indicator (C) [Diesel truck]

Engine coolant temperature [E]

START ( )

Diesel engine

Caution

Turn signal lever [5]

Light switch [6]

Horn button [7]

Clutch pedal [8] (frictional clutch type)

Inching pedal [9] (Torque converter type)

Accelerator pedal [11]

Tilt level [14]

Caution

Lift lever [15]

Steering wheel [16]

Warning

Parking brake lever [17]

Choke line [19]

3. Safety instructions

4. Maintenance

8 hour (daily or every shift) check

2) Check appearance

4） Engine oil level check Caution

5) Check water level in the radiator

6) Hydraulic oil level

7) Brake fluid level check

8) Head lamp check

9) Turn signal check

10) Hand brake check

11) Back-up lamp and buzzer check

12) Turning

13) Horn

14) Drivers seat adjustment

15) Shift lever(s) check

17) Instruments and sensors

19) Tire pressure

Weekly maintenance (40 hours)

1) Air cleaner

2) Fan belt tension check

5） Lift chain tension check ①Raise the fork about 10-15 cm above

3) Power shift transmission fluid level

4) Mast and forks

6) Lubrication of mast

9) Bolt, nut tighten

10) Hub nut torque check

7) Chain Lubrication