HELI green Series, Operator'S Manual

Page 1: ...1 6 1 8t Electric Narrow Aisle Reach Truck OPERATOR S MANUAL ...

Page 2: ...mined and monitor by us in user actual operation For the operation inspection and service not listed in the manual please take into consideration by yourself for safety reason Symbols are corresponding meanings used in the manual and truck plates are followed Symbol Meaning DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury You must obser...

Page 3: ...s 32 II Operating device 39 1 Name of parts 39 2 Operating device and using method 40 III Operation of the truck 48 1 Notes on new truck usage 48 2 Relationship between load and stability of truck 48 3 Load center and load chart 49 4 Truck stability 49 5 Transporting of the truck 50 6 Note on get onto or get out of the lorry 50 7 Operation of the truck 51 8 Battery usage 54 9 Loading and unloading...

Page 4: ...plications The prohibitive applications refer to travel with human riding on lift human up tow other vehicles and so on The truck can not be used in the prohibitive applications Examples of prohibitive applications Lift with people standing on fork or pallet Stand on the fork to press the goods Hoist the goods with steel wire hang on the forks directly Tow other trucks ...

Page 5: ... discuss the plan well You must decide the travel route and the method of working before start and discuss the safe problem well 2 Regulate limit speed You must regulate limit speed in working environment and set striking plate in order to show clearly 3 Avoid dropping Set protector on sideways or platform s edges in order to avoid reach truck dropping ...

Page 6: ...ohibit passerby to come into working area Prohibit passerby to come into working area and prohibit the guider of the truck to contact with reach truck 6 Prohibit the reach truck without license to come into working area Prohibit the reach truck without license to come into working area and set a clear sign 7 Keep good condition of road surface and wipe off oil and grease ...

Page 7: ... safety working It is difficult to find passerby and obstacle on dark way and it is very dangerous Keep brightness and full of full of sunshine on way and working area 9 Arrange a guider when working in narrow area Arrange a guider when working in narrow area or working with other works and other truck Do working according to the guider s lead ...

Page 8: ...void fire hazard accident and other unpredictable thing Use the fire extinguisher according to its operating rules 12 Safety precautions in danger Set a clear sign in dangerous place in order to alarm the truck to keep away from assisted 13 As a motor vehicle the truck should only be used in the following condition a Temperature 25 to 40 b Relative humidity 90 c Altitude 1200m 14 The stability of ...

Page 9: ...ll block the travel of other vehicle and person s pas for its low speed If the wheel is out of round or the status of the road surface is not good it will raise the running noise Prohibit travel on public road Only use indoor 4 Selecting driver 1 Wear safety clothes Please wear proper safety clothes when driving Improper clothes may be caught by operating levers or pedal which may cause truck mis ...

Page 10: ... every five year Structure of vehicle will change and rule of law will change for technique renovation Make safety education when operation method and equipment using method have important change Because the fast development of truck structure application of microcomputer and automatic devices and changes of law it is necessary to receive the courses from expert 4 Do not let someone operate the re...

Page 11: ... modifications that enhance the weight of counterbalance shall not be performed without the written approval of our company 3 Decal must be put on obvious position You must paste new plate when it damaged or lost Check the plate in periodic checking 4 Do not over trust overhead guard The overhead guard is used to protect the driver when goods are falling from the top of head But it does not mean i...

Page 12: ...falling loads Make sure to load and unload the goods in stable and safe condition 7 Be careful of the capacity of ground The reach truck is heavy 80 90 of reach truck weight is center on front wheel when the reach truck is loaded You must investigate the ground of warehouse and enhance the quality of ground if necessary 6 Inspection 1 When operation have a good habit of inspection ...

Page 13: ...ularly Name of safety parts Term 1 Pipe for lifting system 1 2 2 Chain s of lifting 2 4 The items listed above must be replaced for a fixed period because they are very important for safety 4 It is strictly prohibited to operate fault truck Before driving you should check truck carefully If there is any fault hang a warning plate on the truck and then remove the key and report to the administrativ...

Page 14: ...truck assembled with jack and winch 8 What vehicle the reach truck is 1 Keep the balance of the truck The reach truck is equipped with the fork in the lifting system that can move forward and backward The supporting point of the reach truck is its front wheels which balance the truck s center of gravity with the goods For this reason the center of gravity of the truck together with the goods are i...

Page 15: ...he center of its gravity The combine barycenter of the truck itself and the loading determined the truck s stability While unloading the combine barycenter is the truck s center gravity itself While loading goods the barycenter combined the truck s barycenter with the loading goods The barycenter changed while the mast tilt forward or backward or lift the fork arm Tor this reason it changed the co...

Page 16: ...hment To level off the truck the combined center of gravity shall be located in the interior of triangle composed by the ground contacting points of left front wheel right front wheel and drive wheel If the combined center of gravity exceeds the position of front wheel and tipping forward with the front wheel as supporting point will be resulted If the combined center of gravity exceeds the right ...

Page 17: ...on and the rolling radius of the truck A quiescent object will be keeping its state if out of outside force And it is applicable to the moving object also This is called inertia The inertia is of the same direction when the truck moving forward The inertia will increase with the increasing of speed While braking the inertia will make the truck overturn to the forward It is dangerous while braking ...

Page 18: ...n after ensuing the safety around WARNING Operate the truck on designated operating position Prohibition of reach lever operating when your body is between the mast and chassis or this will lead to a dangerous condition unexpectedly Operate the mast on the designated operating position 3 Change the direction after the truck is stopped Sharp direction changing is very dangerous 4 Do not drive or ma...

Page 19: ...teering please slow down The truck will have a danger of overturn when making a sharp steering without load because the rear of the truck is very heavy 8 Driving on a slope Do not make a turn and travel horizontally on a slope or truck may have a danger of overturn Take care of the road height when there is a sharp slope so as to avoid fork or pallet contacting with ground When traveling on a slop...

Page 20: ...ad so as to avoid truck falling 10 when operating in a container It is prohibited to travel on the platform edge because it has a danger of falling down which may even cause death Check the connecting plate capacity and its safety It is prohibited to use improper connecting plate Apply the hand brake of the lorry and wedge the four wheels to prevent it from slipping Lift the truck with jack to pre...

Page 21: ...finished Fix the connecting plate to avoid slipping 11 It is prohibited to use people as a balance weight or operate with two drivers It is prohibited to use people as a balance weight or ride any people except driver 12 When travelling backward it is dangerous to depend on back view mirror only Face backward and travel after a direct check of the backward ...

Page 22: ...ers with oil or water it has a danger of out of control 16 It is prohibited to get on or out of truck quickly It is prohibited to get on or out of truck quickly It is very dangerous When getting on or out of the truck step on the pedal to support your body when the truck is stopped completely Besides keep the pedal clean and at good condition If it is damaged repair it at once 17 It is prohibited ...

Page 23: ...uring travelling concentrate on front view or serious accident may be caused Slow down when giving pass to other trucks and keep a proper distance with other truck When a limited speed is regulated please keep to it It is prohibited to overtake other trucks in places with poor view such as turn cross and so on Stop and sound the horn to ensure the safety in narrow aisle or places with poor view St...

Page 24: ...stacles Do not run over bumps and obstacles If has to please take care 25 Do not travel on slipped road 26 Pay attention to the ground loading limit When operating in a building or elevator pay attention to the ground loading limit and it is prohibited to overload 27 Notes when travelling in places with limit When travelling in the places with height or width limit pay attention to the following n...

Page 25: ...ng 31 Practice operating truck carefully and be familiar with the truck Before operating truck practice carefully and be familiar with the truck Please drive the truck carefully even you are familiar with the truck 32 When operating more than one truck When operating more than one truck which even have the same performance the brake accelerator and lifting device may be different 10 Lifting WARNIN...

Page 26: ...slide to the operator s side and the operator may be hurt 3 It is prohibited to unload and load when goods are unstable It is prohibited to load and unload when goods are unstable Fix the unstable goods before travelling 4 Take care of the stability when making a double stack When making a double stack handling fasten the loads with rope to protect falling of loads 5 It is prohibited to load the g...

Page 27: ... it to push other trucks Do not lift the truck with steel rope directly hooked at the fork Do not tow other trucks Do not pull or push goods and goods has a danger of falling down and be broken Never tilt the mast with loads upraised 150cm or more otherwise there is a danger of overturning 11 Adjust the fork space to proper position Adjust the fork space to proper position according to goods size ...

Page 28: ...n it is loading and unloading 18 Please follow the director when working together The driver should follow the guider to work 19 Use pallet with enough strength Use pallet with enough strength Goods may fall down when damaged pallet is used 20 Take care when handling goods with large size Careful driving should be taken when handling long or wide loads Lift or lower the goods slowly to take care n...

Page 29: ...ads by the movement of truck it leads to damage of loads or overturning of truck 25 Prohibition of reaching movement when the goods approach the floor Do not reach forward or backward when the loads approach the floor 26 Do not push or pull the goods with reach movement Do not push or pull the goods with the cylinder force 27 Do not lift goods with steel wire directly hooked on the fork It is very...

Page 30: ... on the ground Press parking brake switch Place directional switch lever in neutral Place the key switch in OFF and turn off the key switch Remove the key 2 Park at reserved place 3 Parking place should be hard enough 4 Park a place which does not disturb traffic Please park the truck at a place which does not disturb traffic and do not park the truck at a place close to exit ladder and the place ...

Page 31: ...or people 12 Inspection and repair WARNING inspecting the truck prior to operation should be done for safety operation and keep good condition of the truck this is duty in law Only trained and authorized serviceman shall be permitted to service the truck improper inspection and repair is bad for truck and it is dangerous 1 Inspection on the truck should be done on a flat floor Inspecting and servi...

Page 32: ...ut supporting block under mast in case of fork and mast falling down 14 When working together assign a guider and follow his command 15 Please use proper tools Please use proper tools which are suitable for inspection and serving it is dangerous to use improper tools 16 Do not use tools out if its function 17 Take care of spurting of hydraulic oil which is at high temperature After truck s operati...

Page 33: ...en being struck by a high voltage shock consult a physician immediately 22 Do not use a mast assembly instead of a ladder Do not use a mast assembly and a bracket instead of a ladder to climb and work It is dangerous when the mast and the backrest fall suddenly It could lead to snipping your hands or feet And there is a danger of falling down from the mast WARNING When the truck is jacked up do no...

Page 34: ...r treatment in time There is danger of explosive because battery produces hydrogen gas so do not use lighter or other objects with fire near the battery Do not disconnect the plug during charging Do not make short circuit between both terminals by bolt or tool When the terminals are loosen there is danger of explosion because of poor connection Make sure the terminals are fixed firmly When reassem...

Page 35: ...When servicing the battery such as refilling electrolyte and adjusting the specific gravity of all cells please wear goggles rubber gloves and boots 29 Be care of static electricity when clean the battery Do not use a dry cloth a chemical fiber cloth for cleaning the battery surface And do not cover the battery by a vinyl sheet It causes a ignite explosion by a static electricity 30 Be care of a s...

Page 36: ...33 once Some plates examples are followed 1 Reach truck plate 2 Safe plate ...

Page 37: ...34 ...

Page 38: ...35 3 Lubricating chart ...

Page 39: ...36 4 Sling plate 5 Caution plate 6 No entry into the space behind the mast ...

Page 40: ...37 7 Routine battery use 8 Routain battery maintenance 9 Load capacity ...

Page 41: ...38 10 General information when operating 11 Oil adding plate ...

Page 42: ... straddle leg 3 fork 4 fork bracket 5 backrest 6 mast 7 battery 8 auxiliary wheel 9 overhead guard 10 power off switch 11 integrated knob 12 hand mad 13 brake pedal 14 steering wheel 15 accessories 16 pedal 17 brake pedal 18 drive wheel 19 dashboard 20 key switch ...

Page 43: ...rage the indicator shows 3 Hour meter When the hour glass symbol flickers it means it is recording time The number shows the current working hours 4 Wheel angle indicator It shows the current wheel angle and direction There are 12 arrows and only on arrows is highlighted 5 Working mode indicator It shows current working mode The working mode has 1 4 and soft gears 6 Speed display It shows current ...

Page 44: ...on the safety pedal the truck can travel and the is off Press the button and light on the meter is on At this time the truck is under brake condition and the traction system of the truck can not work press the button again the light on the meter is off At this time the truck is stand by and traction system works 3 Battery electricity quantity display there are 10 LED lights to shown the battery el...

Page 45: ... work under such condition Carry out reset methods a When the key is ON forward and backward switch are operated Operate in other gears except neutral gear b When the key is ON disconnect or connect battery plug Reset methods For a Put gears shifting switch in neutral position and switch the key to ON position after switch it to OFF position For b turn the key to OFF position and disconnect the pl...

Page 46: ...es steering wheel when the key switch is ON CAUTION Pay attention to the following when lifting and lowering tilting front reaching and side shifting Operate in operating position Make sure of the safety around 5 Lifting thumb switch 2 There is lifting operation button 2 on integrated knob Pull it upward and the fork will lift up push it downward and the fork will lower down Proper operation speed...

Page 47: ...d with certain tilting angle of knob 8 Side shifting thumb switch 4 Pull the switch back and the fork shifts to left push the switch forward the fork shifts to right Proper working speed can be achieved through adjusting the tilting angle of operating lever 9 Emergency button 5 Press the emergency button and electric control system is power off WARNNING It is very dangerous to touch electric parts...

Page 48: ...ork arm stopper is fixed to avoid the fork arm moved Lean against the load backrest when adjusting the fork arm with foot Never adjust with hand After loosing the fork arm stopper the fork arm can be adjusted We should adjust it according to the object size 12 Hydraulic oil tank There is oil adding port oil draining port and oil return port Besides there is hydraulic dipstick in oil adding cover C...

Page 49: ...bined washer 13 Cover gasket 13 Battery plug CAUTION It is dangerous when touch the inner electric parts so you must disconnect the battery plug The main electric loop can bear pressure even if the switch key is on off position Never disconnect the battery plug unless it is necessary Or you can not steering The battery plug is used to connect or disconnect the battery with the electric equipment N...

Page 50: ...47 press the emergency button When connecting the battery plug make sure the key switch is on OFF position ...

Page 51: ...ruck is heavy loaded or travelling with high speed The operation shall be smooth avoiding emergency gear shifting emergency braking sharp turning and sudden acceleration During the running in period or after replacing the new brake friction plate the friction plate shall be fully run in to achieve the best braking effect 2 Relationship between load and stability of truck The truck balances the rea...

Page 52: ...ease refer the one on the truck 4 Truck stability The state standard ordered the stability of the truck When it reaches the condition it is stable But it can not keep stable on any condition The following list reasonable condition a The work ground is smoothness and firmness b Driving in standard load or unload state c Make the fork arm be horizontal when picking up or unload goods Do not tilt for...

Page 53: ...t out of the lorry CAUTION Never steering or move transverse in connecting board to prevent any dangerous Use connecting board with enough width length and intensity Apply the parking brake of the lorry and wedge up its wheels Be sure the connecting board fixed in the center of the lorry Make sure there is no grease on the connecting board Keep the right and left side of the connecting board at th...

Page 54: ... the working device backward 2 Travelling CAUTION Ensure the safety around with eye and sound the horn before driving Slow down in the following condition a in sharp turning b in narrow road c on bad road d when near the goods or obstacle When travelling backward it is dangerous to depend on back view mirror only Face backward and travel after a direct check of the backward Operate on the forward ...

Page 55: ...rd c Lower the fork to the ground d Turn off the key switch and keep it well e Take care to get off the truck CAUTION Safety parking The parking place should be as wide and flat possible When unloaded truck has to park on a slope the mast side should face downward Wedge the wheels When parking at a safe place or appointed place pay attention to the signs and signals Park at a solid ground and take...

Page 56: ... list 6 Move out the battery and place it well Note Install or move out the battery on level ground and surface without barriers Lower the fork to 100 300mm and make sure there is no goods on the fork Turn off the key lower the fork disconnect the battery when check maintain or change the battery When installing the battery make sure the cables are not distorted or clamped Turn off the key switch ...

Page 57: ...d for a cycle and the power of the battery is exhausted replace the battery with a fully charged battery Charge the battery in time 2 Notes when handling battery CAUTION Proper connection during charging or operation connect the positive pole and negative pole properly or over high temperature burn smoke and explosion may occur It is prohibited to put metal object on battery because short circuit ...

Page 58: ...attery Eyesight may be loosed or burnt Dealing with abandoned battery Contact with our sale department when dealing with abandoned battery Abnormal phenomena of the battery when the battery is smelly the electrolyte is dirty the temperature of the battery is over high the electrolyte decrement is too fast contact with our sale department 3 Maintain or service the battery CAUTION Keep the electroly...

Page 59: ...aged contact with sale department of our company and replace them When disconnecting the charging of battery operate it according to the OPERATION AND SERVICE MANUAL of the charger Do not pull out the plug when charging the battery or spark may be caused 4 Notes when charging CAUTION When charging the battery hydrogen gas is occurred and it is very dangerous No smoking Charge the battery where is ...

Page 60: ...it If accidents occur go to hospital after taking urgent measures If not you will injury and even lose eyesight When electrolyte is splashed on your skin wash then by a great deal of water When electrolyte is splashed into your eyes wash then by a great deal of clean water for 15 minutes When electrolyte is drunk by mistake wash your mouth with a great deal of water and then drink egg white with m...

Page 61: ... position of the pallet is high and the front view is poor drive backward 2 Stacking a Slow down the travel speed when approaching the stacking area b Stop the truck in front of stacking area c Check for safety around the stacking area d Tilt the mast and make the fork horizontal and lift the forks above the stacking position e Check the stacking position and move forward and stop slowly at the pr...

Page 62: ...lift up to the position of pallet of carriage hole e Check the proper position of inserting the forks and move forward slowly stop the truck at a proper position f Through operating the mast forward and backward inset the forks fully to the pallet When it is different to insert the forks fully into the pallet through operating the mast forward and backward insert the forks by its 3 4 length and li...

Page 63: ...ter if needed Check the body of the truck if there are some abnormity concave or protruding chap and etc Check if there is leakage Apply grease where needed Check for looseness of hub nut cylinder piston rod joint Check the working of mast roller Prime oil into the lift cylinders by actuating the lift cylinders at the full stroke 2 Daily storage Park the truck at a specified place and block the wh...

Page 64: ...mponents such as the breather and air cleaner which may be caught with humidity The truck should be operated at least once a week and moved slightly forward and backward Avoid parking on soft grounds such as phalt ground in summer 4 Operate the truck after long term storage Remove the humility proof cover Remove antirust from the exposed parts Discharge the gear oil of the transmission box Change ...

Page 65: ...om falling down using the wood to support between the inner mast and the ground When checking front reach put pallet between mast and frame to prevent from being caught Dealing with the waste oil improperly drain into the sewer soil and ignition will pollute the soil and atmosphere This is forbidden by law 1 Notes when inspecting a When replacing parts use HELI pure parts b Please use HELI pure oi...

Page 66: ...e is completely repaired b Inspection of electric wires Check if battery wire charge wire other wire and battery plug are loose and damaged c Inspection of electrolyte level Check if the electrolyte level is at the prescriptive position d Inspection of battery lock device Check if the battery is locked by the hook on the truck if it is not hooked the battery will shake e Inspection of backrest CAU...

Page 67: ...dipstick with clean cloth and insert into oil tank again check the oil level it should stay between H and L NOTE Check the oil level on flat ground l Inspection of brake pedal Press and depress the brake pedal to check if the return of brake pedal is normal m Inspection on steering clearance Turn the steering wheel clockwise and anti clockwise slightly and check if there is enough steering clearan...

Page 68: ... s Inspection of steering wheel Turn the steering clockwise and anti clockwise lightly and check to see if there is abnormal 2 Periodic inspection It is very necessary to do periodic inspection in order to operate truck safely in good condition Using a fault will cause serious accident Inspection and maintenance are ignored usually Finding the fault early and solving it timely will do good to deve...

Page 69: ... NOTE The safety parts periodic replacement is different from remedy of the trouble Safety parts name Year High pressure oil pipe for lifting 1 2 Lifting chain 2 4 2 Weekly inspection 50h Inspect the following items in addition to the inspection prior to operation Cleaning battery Measuring and adjusting of battery electrolyte gravity and temperature Adding grease to the reaching fork bracket The ...

Page 70: ...heck whether the braking pedal is loose Check the steering clearance operating state and whether it jolt when steering Check the steering chain s tension and adding grease Adding grease Check the drive device oil quantity and cleanness Check the drive wheel and support wheel wear and damage condition Check the wheel fix nut and bolts Check whether the hub bearing shakes or has abnormal noise Add g...

Page 71: ...ogy and special tools and the adjusting and replacement are complex Inspection adjusting and replacement should be done by HELI specified service point according to HELI periodic inspection service contact a Lubricate the lifting chain Lubricate lifting chain with engine oil Pay attention to the following item in order to fully lubricate pin and link joint Add oil when the chain is loosing Lift an...

Page 72: ...the voltage Check the electric timing of the charger s operation and adjust the time Check the clearance between the brake disc and fiction disc Inspection adjusting and replacement should be done by HELI specified service point according to HELI periodic inspection service contact 5 Semiannually 1200h inspection Inspect the following items in addition to the inspection prior to operation weekly i...

Page 73: ...nspection Measure the natural downfall distance of the lift cylinder Check if the friction disc of the brake is worn and shakes Check if the R area of the fork is cracked Color filter inspection The annually inspection must be carried out as mentioned above In addition this inspection must be carried out by the approved service and please accomplish inspection at the HELI specified service point 7...

Page 74: ...ery Surface cleanness Clean Electrolyte quantity Check and replenish Gravity Measure and adjust Equal charging Insulation status Measure Controller Surface cleanness Clean Electric contact erode Inspect Electric contact clearance Inspect and adjust Insulation status Measure The joint loosing Clean Motor Operation condition Inspect and adjust ...

Page 75: ...ires binding post plugs and sockets Loose Inspect and tighten Spring condition of contacting piece of the battery socket Inspect Damage Inspect Color Inspect Battery socket contact surface erode Inspect Others Accelerator condition Inspect and adjust Horn sound Inspect clean and change Attachments lights function Inspect ...

Page 76: ...ke Brake effect Inspect Brake clearance Inspect and adjust Friction disc wear Change Steering Abnormal noise Inspect Approaching switch clearance Inspect and adjust Wheel Abnormal wear Abnormal wear Installation condition Inspect and tighten Wheel bearing lubrication Inspect and change Gear box Leakage Inspect Oil level Inspect and change Abnormal noise Inspect ...

Page 77: ...and cleanness Change and inspect Oil suction filter Clean Lifting chain Tension Inspect and adjust Lubrication condition Add oil Chain replacement Change 2 4years Hydraulic pump Work condition leakage damage and installation condition Inspect Control valve Work condition leakage damage and installation condition Inspect Overflow valve work condition Measure pressure ...

Page 78: ...eline Leakage jolt loose deformation and damage condition Tighten High pressure pipeline replacement Change 1 2year Mast Working condition crack curve or jolt Inspect Chain wheel work condition crack jolt Inspect and tighten Roller work condition jolt damage or loosing Inspect tighten and change Fork bracket condition jolt crack or curve Inspect ...

Page 79: ...e damaged Inspect Natural decline distance Measure Fork R part crack condition Color filter Curve crack and wear condition Inspect Fix pin curve crack wear and damage condition Inspect Backrest optional Crack deform damage condition Inspect Fixing bolt loose condition Inspect and tighten ...

Page 80: ...n Inspect Fixing bolt loose Inspect and tighten Support plate Crack damage deform condition Inspect Oil adding condition Add oil Truck body Bolts loose Inspect and tighten initial time Crack damage deform condition Inspect Adjustment of clearance between the two articulated sides of drive axle Inspect and adjust Bearing connecting the drive axle pivot Inspect change and lubricate ...

Page 81: ...pect Pin axle connecting inner and outer fork plates Inspect change and lubricate Bearing of tilting cylinder pivot Inspect change and lubricate Pivot of front reaching cylinder Inspect change and lubricate Guide rail of attachment steel channel Inspect change and lubricate Others Abnormal before Inspect ...

Page 82: ...ERVICE HOTLINE 4001 600 761 S274 3 2020 ADD NO 668 Fangxing Street Economical Development Zone Hefei P R China TEL 86 551 63689000 FAX 86 551 63689666 400 SERVICE 4001 600761 WEBSITE http www helichina com heli copyright ...