Hangcha 5t-10t R Service Manual
5t-10t R Series
Internal Combustion Counterbanlance Forklift Truck
OPERATION AND MAINTENANCE MANUAL
CPCD50/60/70/80/100-RW28
CPYD50/60/70-RW17（CPQD50/60/70-RW17-Y）
CPCD50/60/70-RW38
Original Instruction
HANGCHA GROUP CO., LTD.
Jan.2011 5
th
EDITION
1
Foreword
Thanks for your purchasing our forklift truck.
The R series IC forklift trucks for 5t-10t ,these trucks adopt a new type coppery radiator with
tube and belt, and modified heat emission channels. The load security control and the engines all
achieve EU Ⅱand EPA Ⅱexhaustion standard.
This operation manual is the explanations that how to use 5t-10t R-series forklift truck
correctly. It will instruct you how to operate safety and precautionary maintenance. All that in
charge of operation, maintenance and management must read and comprehend this manual well.
Only in this way it can exert the forklift truck’s potential and it will protect your safety.
This manual is also applicable to other types of container forklift truck.
If you have any questions please keep touches with HANGCHA GROUP CO., LTD. sales
department or let the agents know.
C Jan.2011 5th EDITION
○
HANGCHA GROUP CO., LTD.
2
Contents
1. GENERAL RULES ................................................................................................................................................................ 3
2. NAME OF MAIN PARTS OR COMPONENT ...................................................................................................................... 5
Instruments .............................................................................................................................................. 5
Controls ................................................................................................................................................... 9
3. SAFETY INSTRUCTIONS ................................................................................................................................................. 18
4. 8 HOUR (DAILY OR EVERY SHIFT) CHECK ................................................................................................................. 24
5. STRUCTURE AND STABILITY OF TRUCK .................................................................................................................... 33
6.OPERATION......................................................................................................................................................................... 32
Star-up ................................................................................................................................................... 32
Traveling ............................................................................................................................................... 33
Load....................................................................................................................................................... 34
Stacking load ......................................................................................................................................... 34
Remove load .......................................................................................................................................... 35
Measures against cold and hot weathers Oil ........................................................................................ 35
7. DEPOSIT ............................................................................................................................................................................. 37
8. MAINTENANCE................................................................................................................................................................. 39
Preventive maintenance schedule .......................................................................................................... 39
Maintenance of chassis and body .......................................................................................................... 41
Table for bolt’s tight moment ................................................................................................................. 42
Periodic replacement of key safe parts.................................................................................................. 43
Table for the oil used in the truck .......................................................................................................... 44
Lubrication system drawing .................................................................................................................. 46
Different scutcheon in different position................................................................................................ 48
9. TRUCK’S CONVEY, LIFTING, TOWING ......................................................................................................................... 57
10. TYPE SIGNIFICATION .................................................................................................................................................... 58
11.TRUCK SPECIFICATION.................................................................................................................................................. 59
12.CABIN USE,DISMANTLES AND INSTALL ................................................................................................................... 63
13.NOTE THE USE OF LPG FORKLIFTS ............................................................................................................................ 65
14.OPERATIONAL METHOD OF LEAD ACID BATTERY ................................................................................................. 75
15.ATTACHMENT USE,ASSEMBLY AND SAFETY RULE ................................................................................................ 77
16.RELATED SAFETY INSTRUCION AND STANDARD ................................................................................................... 79
ZHEJIANG HANGCHA ENGINEERING MACHINERY CO.,LTD.
ZHEJIANG HANGCHA ENGINEERING MACHINERY CO.,LTD.
17.MAINTENANCE RECORD............................................................................................................................................... 82
....................................................................................... 80
....................................................................................... 81
3
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. Handle with automatic pitch fork of the forklift when the load must not make lateral
operation, so as not to lose balance and forklift components of the damage caused
18. 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.
4
19.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.
20.In the process of install and assemble,it will be noise and libration.Pls choose the right
tool and assembly method.Depress the noise and libration as soon as possible to reduce the
noise pollute to circumstance.
21.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.
22. Move the truck to the place which respect traffic when it anchor.If the reason is brake or
turn system,move it by a suitable truck(Reference the part of truck move);Other reason,use a
suitable truck to traipse,tie the cord outside of truck.Pls abide by the traffice regulations when
traipse the truck on calzada.
23. After take-down the hood,water tank cover board,overhead,backrest of mast,unallowed
operate the truck or load cargo.
24. There are enough light at truck work ground.At night,open the head lamp to collocate
enough lamp-house.
25. 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
2. Name of main parts or component
0
0
0
0
0
1/10h
1. Fork 2.Fork F 3. Backrest 4. Tilting cylinder 5. Steering wheel
6. Mast 7.Mast 8. Overhead guard 9. Seat 10. Counterbalance
weight 11. Cover hood 12.Frame 13. Rear wheel 14. Front wheel
Instruments
W17
6
W28、W38
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 if fit.
Caution
If the light continues to stay lit or lights up
during operation, the charging rate is low
and should be checked immediately.
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.
0
0
1/10h
0
0
0
Hourmeter[1]
as the engine starts and accelerator pedal is
When the Key Switch on the
position┃(ON) ， Hourmeter begin to
work.When work an hour, Hourmeter will
increase a number.
Hourmeter display the hours of the truck
works.
Water temperature gauge [2]
Whern the Key Switch on the
position┃(ON),Water temperature begin to
work. This gauge indicates the temperature of
Engine Cooling Water.normally, the pointer at
range of 60℃-115℃.
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
pressed.
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.
Glow indicator (C)
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)
In normal state, once the starter is
set to ―ON‖ position, this lamp lights up.
After the engine is started up, it goes out.
7
This lamp lights up when water in
Caution
If this light continues to stay lit or
lights up during operation,.Fuel injection
pump may be broken.
Caution
If warning lamp stay lit,please stop
the truck at once, Decrease the engine
speed to make the engine
cool.Otherwize,check the oil quantity or
check others.
△
! Caution
Before maintain the brake and hydraulic
system of 8-10t,the truck should be
flameout,press the brake pedal 5-10 times to
release the power.Otherwise,it is dangerous
about service people.
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.
Torque Converter 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.C) the
indicator light on.
2、 Aften engine flameout,there are limited
times for brake(3-5 times for different
model). Release the accumulator
power,the truck without any brake.In
case of dangerous,don’t jump from
truck,strain hand brake,let the truck slow
stop.
3 、Unallowed that the truck coast on the
ramp in flameout.Strain the hand brake,then
start the engine.If the engine couldn’t be
start,don’t start by slide.It about your safely.
Brake pressure lower warning indicator
light（H）(only for 8-10ton)
It indicator the all hydraulic brake
accumulator pressure.After start the
engine,the brake pressure of truck will be
based.After start the engine,press the pedal
a few times so that increase the pressure till
the light off.Then move the truck.This light is
bright, means less pressure.It should be
check the hydraulic system oil route.
! Caution
△
1、 After start the engine,press the pedal a
Warning indicator（I）（ J）（ only W28、
W38）
（I）Red guiding light，（J）Yello guiding
light.Any light lit,express the malfunction of
engine, you must stop to examine, remove
the trouble base on the showing malfunction
yard. If there are mult-malfunction,check
them on the other pages.
Engine malfunction detect switch（only
W28、W38）
few times so that increase the pressure .
8
When the engine has something wrong，
put the Key Switch at the position┃（ON）,
―Engine detect‖switch at ―ON‖ 位 ，（ J ）
Indictator continous lit（I）Indictator display
malfunction yard by various frequency,
remove the trouble base on the showing
malfunction yard.
If there are muti-malfunction ,you can
watch the other malfunctions by using
―Engine detect flp‖.After removed the
malfunctions,（I）（ J）indictator get out.Put
―Engine detect‖switch ―OF‖,Key switch o
（OF）and only After 30seconds can start the
engine.
left turn indicator（F）
When the vehicle turns left, you should
allocate the turning guiding lights in the front
shift to an earlier date, now the light is bright.
right turn indicator（G）
When the vehicle turns right, you should
allocate the turning guiding lights in the back
shift to an earlier date, now the light is bright.
9
Controls
4．Key Switch
5.Combination Switch（Turn lamp、Head lamp、Side lamp switch）
6.Horn-pull
button
7. Forward reverse gear switch[electrical change
8. Micro-pedal
9. Brake pedal
10. Accelerator
pedal
11. Chock line [RW28、RW38 None]
12. Lift lever
13. Tilt lever
14．Steering hand wheel
15. Parking brake lever
16. Engine hood fastener switch
17．Steering wheel regulating handle
21．Lift fork side shift lever(Only 8-10t）
22．Right fork side shift lever(Only 8-10t）
23. Engine idle speed control button[RW28、RW38 None]
24. Emergency power switch（optional）
10
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.
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.
Turn the key to ―┃‖ position and the
indicator lights up for a moment. After the
indicator goes out, turn the key to
―Start‖ position.
Engine start process [Only RW28、RW38]
Turn the key to ―┃‖
position,(I),(J)indictator,Oil
temperature ,Preheat indicator lighs
up,Engine come into selttes state.If there are
no malfunction,the lights get out one by
one.Otherwize,（I）（ J）indictator continue to
stay lit.After solve the problem,start the
engine.
Combination switch[5] （ Turn signal
switch,Head lamp,Side lamp switch ）
（Except RW18A、RW19A）
Combination switch lies right of the
steering column， include Turn signal,Head
lamp and side lamp switch.
When truck turning,turn this switch forward
and back,so it is the turn signal switch.R-Right
turn lamp，N-Neutral，L- Lift turn lamp.
The turn signal level does not
automatically return to the neutral position.
Reset it by hand.
When turn the switch on the top,it is the
switch of Head and side lamp.It has three
positions.
Turn to first position—Side lamp lights up；
Turn to second position—Head and Side
lamp lights up；
off ——Pull off.
Horn-pull button[6]
Press the rubber cover at the center of
steering wheel to sound horn.
Forward and Reverse switch[17]
Before change the direction，pressedthe
brake pedal to stop the truce,then change
the electrical direction switch correspond to
the request direction.
Turn forward——Froward；
Turn back————Reverse；
Middle————Neutral.
Only at the Neutral ,can start the truck.
Pedal.
11
The ico of tortoise and rabbit on the
tortoise
rabbit
Front
first geal
second geal
Rear
first geal
second geal
Note：
1、 Start the truck when the handle
at middle position.
2、 The truck step,climb slope,turn
to tortoise position.
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.
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
Handle.
Brake pedal[9]
As the Brake pedal pressed, Truck
Front revolve(tortoise）-- first geal（slow
geal）
Rear revolve(rabbit） -- second geal
（quick geal）
traveling speed decrease or stop.The brake
lamp lights up at the same time.
Accelerator pedal [10]
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.
RW28、RW38 is electrical throttle。
Lift lever [12]
To control the forks raise or low.
Pulling-raise, Pushing-low.
Lifting speed can be controlled by tilt
backwards angle of lever and accelerator
pedal effort while the lowering speed can be
controlled by tilt forwards angle of the lever.
Inching pedal [8]
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.
Tilt level [13]
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.
12
Caution：The forklift with automatic
changing distance on load,please
do not operate the side shift
lever.Avoid losing blance and being
broken elements.
△
! 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.
Lift fork side shift lever(Only 8-10t）
[21]
Lift side fork can shift by pushing the
handle,Push the handle forward,the lift side
fork will shift to right; Push the handle
backward it will shift to lift.
5-7t,No this lever.
Right fork side shift lever(Only
8-10t）[22]
Right side fork can also shift by pushing the
handle,Push the handle forward,the right
side fork will shift to liftt; Push the handle
backward it will shift to right.
5-7t,No this lever.
Parking brake lever [15]
Move the lever back，Tighen；move the
lever forward ,Release。Before you leave the
truce,Move the lever back.
Caution ： When the truck’s brake
system out of control or some
emergency hapend,you can tighen this
lever,brake the truck.
Engine hood fastener switch [16]
To avoid opening the engine hood
fastener limitless, Do that may heart
you.so we set the engine hood
fastener.To open the engine hood,you
must pull out the fastener,and the hood
5-7t，No this lever.
Steering wheel [14]
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
will raise slowly by the spring force.If you
wang to close the hood,please press
down the hood.
Engine idle speed control button [23]
（None W28、W38）
13
The button could adjust engine idle
△
! Warning!
a. Before adjusting the lever, you’d
better turn of the key switch.
b. Stop the truck to adjust the seat.
speed.Clockwise rotation, the speed
increase;contrarotate, the speed down.
Start the engine,release the accelerator
pedal slowly.Then circumvolve Clockwise
rotation until engine move placidity.
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.when loading big goods, make the
goods back rely on the Load bracket as
much as possible.
Seat
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.
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, to adjust the hanging’s weight basing
on person’s weight.The weight adjustment
range is 55-110kg.
It’s better to sit on the seat when
adjusting.
Safety belt
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 Saftey belt will not be able to
correctly elongation.
14
The components which on the Safety belt
Note:
a.Before open the hood,the handle of the
snap close should be pulled out first
b.Use caution not to catch your fingers in
the hood when closed.
△! Warning
Maintenance the hood after engine
flameout to avoid body or other part
hurt.But when the body donot touch with
part,it allow that engine is not flameout and
the hood is open for find the failure through
ears.
can not be removed arbitratly. 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 3-5years,
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 permitted 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.
Tension wire clamp
To avoid opening the hood at discretion,a
special tool is there. Tension wire clamp is
special tool.
Radiator cover hood (Only for Europe
especial or option)
Open the radiator cover hood,it should be
special use tool(SOCKET spanner).
You can open the radiator cover hood
even close the engine hood, so to inspect
the coolant fluid.
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.
15
Caution:
Retighten the bolt on the cover hood.
△
! 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.
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 remove the radiator cap abruptly
while water’s temperature is higher 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.
Fork stopper（5t-7t）
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
Fork replacement
When the right or left fork have become
deformed gravely or the rift appears,they
should be I twinning replacement.
Changing method：
5t-7t
1).The vehicle is parked in solid level road；
2).The mast comes down till the fork is away
from a field five to ten millimeter, moving the
fork in centre, make lower part aim at
breach；
3).Make the mast face forward inclination,
make the vehicle retreat slowly, the fork
come off；
4).The new fork twinning field is put in the
floor stably. pull up the locating pin, The
carry-scraper centre line alignment fork
works slowly, make the mast face forward
inclination when Will get in touch with them；
5). When the fork hang to enter a crossbeam,
make the mast face backward inclination till
perpendicularity；
6).Adjust fork spacing to the location
needing, Relax the locating pin.
8t-10t
1).The vehicle is parked in solid level road；
2).Operate the lift and right side fork
lever,make the two forks move to center;
16
③Remove the cylinder of changing distance
Warning
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.
between two forks;
④Hoist the two forks;
⑤Pull lower portion of fork to remove its
lower jaw and lift it out.
Assembly is opposite to remove.
Caution: Be careful when removing and
installing the forks, as they are heavy
Steering column tilting angle
adjustment
safety grip facing the truck when mounting
and dismounting the truck. hydraulic fluid,
lock the cap.
Brake grease nipple
Brake grease nipple lies under the lower
left bottom
Hydraulic oil tank cap
The cap lie in the engine hood,on the
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.
right side of truck bracket. open the hood to
injecgt the oil,inject the clean hydraulic oil
through oil filling port.Oil inject over,close
the cap.
Fuel reservoir cap
The safety steps are provided on both
side of the truck body. The safety grip is
provided on the front left pillar of the
overhead guard. Use the safety step and
Safety step and safety grip
17
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.
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.
Rearview mirror
There are two rearview mirror on the
safeguard for operator to see rear accident.
18
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, short life of components will
be caused 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.
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 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 water to lower 70℃ after work.
If the temperature of the water tank
higher than 70 degree, never open the tank
cap.
6. When using your truck 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.
8. Never attempt to work the controls
unless properly seated.
Before staring, adjusting the seat so you
can get easy access to all hand 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. Observe speed and traffic control
signs.
When traveling on public roads or streets,
19
obey all local traffic regulations
13. 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.
14、Never allow other person(s) to ride
on the forks, pallets or on the truck.
18. When handling bulky loads, which
restrict your vision, operate the machine
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.
16. Keep your mind on your work.
17. Keep your head, hands, arms, feet
and legs within the confines of the operator’s
compartment. Never reach into upright for
any reason.
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%(25℃).
Inspect the surface over which you will
run. Look for holes, drop-offs, obstacles, and
20
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
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.
upgrade.
Never turn sideways on an incline. There
is danger of the truck turning over.
26. Travel with load as low as possible
and tilted back.
21
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
!
△
30. Know the rated capacity of your lift
truck and its attachment, if any, and never
exceed it.
attachments if machine is so equipped.
Never permit anyone to stand on the
forks.
34. Don’t put your head or body into
22
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.
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.
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
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
23
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. Workplace shoud be have fire
extingnishers. Operator shuod know the
place of fire extingnishers and the use of fire
extinguishers.
44. Before Maintaining the brake and
hydraulic system of 8-10ton, first of all, you
should flameout the vehicle. And press the
brake padel for 5-10 times to release the
energy in the accumulator.
45. You should use the Safety belt
correctly, it should be level, can not be
distorted. You’d better tie the belt inthe hip
but not at waist line. If a vehicle overturned
in the accident, the driver first to do is
flameout the vehicles, in order to avoid
burning vehicles or explosion. When
flameout, open your legs, then used your
hands to seize the steering wheel in your
room or fixed roof-care, shoring body firmly
in the seats, to facilitate the lifting of seat
belts.
46. 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.
24
4. 8 hour (daily or every shift) check
△
! Warning!
Don’t attempt to operate the truck if leaked
fuel is found through pre-operational
check. Correct the leak before starting
engine
△! Warning!
When the water temperature of the
engine higher than 70 degree, please do
not open the pressure cap of the radiator.
Loosen cap slowly to allow steam to
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.
△! Warning！
When the water temperature of the
engine higher than 70 degree, please do
not open the pressure cap of the radiator
avoiding scald.
1.Check leaks of oil, fuel or water
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.
2. 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.
Otherwise it may damage to engine.
3. Replace the engine cooling fluid
1）.Open the radiator cover and loosen the
drain cover, let the oil flow out, then wash the
cooling system.
2）. Screw the drain cover tighten.
3）. Add cooling fluid to radiator up to way
out.
4）. Let the engine run fully.
5）. Stop the engine, after cool down fully, still
add cooling fluid to radiator up to way out,
and add cooling fluid to coolant reservoir
―MAX‖ position.
6）.Check the drain cover if leakage.
25
4. Fuel lever check
Caution
When check 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.
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.
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
5. Engine oil level check
7.Battery electrolyte check
There is a little ball in battery capacity
display, this ball can change its color as
density of electrolyte changing, it is called
electric eye. The ball will be green when the
capacity is normal ,density of electrolyte
reaches the standard; it will be white when
capacity is not enough, density of electrolyte
does not reach the standard; it will be red
when the electrolyte is acute shortage ,look
over whether the shell is broken, leaking or
the battery has fault. SEE<Operational
method of maintenance free lead acid
battery>
8.Power shift transmission fluid
level
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.
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.
6. 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.
9.Hydraulic oil level
Check the oil level in the hydraulic oil
tank.
The oil level should be in the place
between two slots,
26
Free
height
Free play
Brake
pedal
140±5
0
1-3
Inchin
g
pedal
140±5
0
touching bolt of
inching pedal – brake
pedal:
0.9-3.4mm
10.Brake pedal, inching pedal
Press the brake pedal fully when the
engine is running, the distance between
brake pedal and front soleplate should be
more than 60mm.
Check the inching pedal through the
same method.
Height and the clearance H(mm):
11. Parking brake lever
Make sure that the parking brake lever
return back is in good condition after
securely applied.
The force on this lever should be
100-300N.
12. 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 a press, and check
the drop distance if is up to standard.
QSB4.5、QSB3.3 Engine have auto
tension round, fan belt don’t need adjust.
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