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HELI green Series Operator's Manual

1.6-1.8t electric narrow alise reach truck
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1.6-1.8t
Electric Narrow Aisle
Reach Truck
OPERATOR'S
MANUAL

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  • Page 1 1.6-1.8t Electric Narrow Aisle Reach Truck OPERATOR’S MANUAL...
  • Page 2 The manual is based on truck with standard equipments, other kinds of truck is explained only in different parts. If you have any questions during using, please contact with HELI specified sale point for service. This manual content might not correspond with the actual truck because of the improving of our products and using method.

  • Page 3: Table Of Contents

    CONTENTS I. About use method…………………………………………………………………1 1. Main use of reach truck……………………………………………………..1 2. Working plan and environment………………………………………………2 3. Travelling road……………………………………………………………….6 4. Selecting driver………………………………………………………………6 5. Truck and load………………………………………………………………..8 6. Inspection…………………………………………………………………….10 7. Transporting…………………………………………………………………11 8. What vehicle the reach truck is……………………………………………..11 9. Driving…………………………………………………………………….. .15 10.Lifting………………………………………………………………………22 11.

  • Page 4: About Use Method

    I. About use method 1. Main use of reach truck The main use of reach truck is handle and stack the loads that on the pallets. It is prohibited to use it in prohibitive applications. The prohibitive applications refer to travel with human riding on, lift human up, tow other vehicles and so on.

  • Page 5: Working Plan And Environment

     Push the loads or other trucks with forks  Open or close the doors of other trucks with forks 2. Working plan and environment (1) Set down working plan and discuss the plan well You must decide the travel route and the method of working before start and discuss the safe problem well.
  • Page 6 (4) Point out travel area of reach truck and clean up the load Point out travel area of reach truck and clean up the road in the travel area in order to avoid obstacle. (5) Prohibit 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.
  • Page 7 Clean up working area, keep good condition of road surface and wipe off oil and grease on the road. (8) Lighting for operation area is needed for 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.
  • Page 8 (10) Affirm contact method in emergent condition Affirm contact method in emergent condition in order to deal with fire, accident and other unpredictable things properly. (11) Set and affirm fire extinguisher Set fire extinguisher to avoid fire hazard, accident and other unpredictable thing. Use the fire extinguisher according to its operating rules.

  • Page 9: Travelling Road

    power and direction of the wind outside, so do no work in strong wind to make sure people and truck safety. 3. Travelling road (1) Prohibit travel on public road Reach truck is the special vehicle for indoor use. It is different to go through ramp and rough road for its small and compact structure.
  • Page 10 Goods stacking is for storage, it is not to put goods on platform, but stack goods together. If goods are not stacked accurately, goods will collapse and it will threaten driver and other people. It is necessary to make safety education for the people carrying out stacking operation.

  • Page 11: Truck And Load

    5. Truck and load (1) Do not use the reach truck when its overhead guard is dismantled. (2) Modifications shall not be carried out by user at will. Modifications on truck or attachments that affect performance, safe construct and strength shall not be performed. For example, modifications that enhance the weight of counterbalance shall not be performed without the written approval of our company.
  • Page 12 The pallet must endure the weight of load. Worn-out pallet must be repaired in time. (6) Make sure to load and unload the goods in stable and safe condition. Avoid off-center loads or falling loads. Make sure to load and unload the goods in stable and safe condition.

  • Page 13: Inspection

    Operator should inspect the truck before operation and if there is any fault, report to administrative person. (2) Inspect regularly and make a record. Inspect monthly and annual, repair it immediately if there is any fault. the inspection should be carry out by professionals because special technique and equipments are needed.

  • Page 14: Transporting

    7. Transporting Load and unload the goods on flat and solid surface. Besides, take care of connecting plate length, width and strength and make sure it is reliable and safe. In rainy days, use anti-slip connecting plate or stop working. When handling goods from or to the truck, it is very safe to use the truck assembled with jack and winch.
  • Page 15 Load wheel supporting point load weight (2) Be sure the center of the goods’ gravity The goods can be boxlike, board like, stick and all other kinds of shape. To estimate the stability, it is important to well-known the center of gravity of all kinds of the goods shape.
  • Page 16  The size, the weight and the form if the loading  The height of the loading  The tilt angle of the wheel  The material of the wheel  The acceleration, deceleration and the rolling radius of the truck ...
  • Page 17 (4) The max loading weight (the loading weight and its center) The horizontal distance from the center of gravity of the loading to the bottom of the fork arm (in front of the load backrest) called the load center distance. The maximum weight that can load in the just load center called the maximum loading capacity.

  • Page 18: Driving

    9. Driving (1) Read this manual before driving Prior to operation, read this carefully to ensure safety and efficient material handling by proper driving and maintenance, This manual should be kept by operator and read it carefully. (2) Attention before the start When you start the truck, please obey the following rules: ...
  • Page 19 travelling in order to lower the center of gravity. (6) It is prohibited to lift or tilt sharply when loaded. Do not lift or tilt the mast sharply when it is loaded. If so, the truck may have a danger of overturn. (7) Rude operation such as sudden start, sudden stop, sudden steering and so on are prohibited.
  • Page 20  When down a slope, make full use of brake system.  When travelling on a slope, do not make engine power off. (9) Do not drive into a weak road shoulder. Do not drive into a weak road shoulder because it has a danger of collapse. Keep a safe distance with the road shoulder in narrow road so as to avoid truck falling.
  • Page 21  Slow down and take care of the connecting plate safety.  Take care of the passersby.  Inform the lorry driver not to operate the lorry until the operation is finished.  Fix the connecting plate to avoid slipping. (11) It is prohibited to use people as a balance weight or operate with two drivers.
  • Page 22 (13) When travelling backward with high goods, assign a guider. When the goods are high, the driver has poor front view. Face backward and travel after check. Assign a guider for the safety of goods and around. (14) It is prohibited o operate the truck until checks are all finished. It is prohibited o operate the truck until checks are all finished.
  • Page 23 (18) Check the safety around before start. Check the safety around before start. Sound the horn and then travel forward. (19) Do not shut down the engine during travelling. The powered steering unit can not work when the flame is out. (20) Safety during travelling ...
  • Page 24 (21) It is prohibited to travel with working device reaching out.  It is prohibited to travel with mast reaching out. It has a danger of overturn when braking under this condition.  Travel with working device drawn back. (22) It is prohibited to travel on ground with ponding or wet floor. When travelling, avoid ground with ponding, wet floor or hallow.

  • Page 25: Lifting

    (28) Please take care if rear part rotation because it is different from the automobile. The rear part will rotate to the outside greatly when travelling forward. Be sure to keep a safe distance from the wall. (29) Take adequate brake into account and brake a little earlier. The wet road had longer brake distance than normal road.
  • Page 26  Do not stand on the forks. Do not lift or lower the truck with people stand on. It has a danger of falling down and people may get injured.  It is prohibited to put hand and foot into mast or between the mast and truck, or it has a danger of hurt.
  • Page 27 (7) It is prohibited to lift, reach forward and travel with mast tilt forward. (8) It is prohibited to load and unload when the truck is leaning. (9) Loosen chains When the chains are loosen, there is a danger of catching loads and rack by forks or falling of loads and overturning of truck.
  • Page 28 falling down. (14) Make sure lift chains are equivalent in tension Make sure lift chains are equivalent in tension. If lift chains are not equivalent, there is a danger of falling of loads and overturning of truck. (15) Be care of the tip of forks, and do not hurt person or goods. The fork tip is sharp and it has a danger of hurting someone.
  • Page 29 It is not allow to unload the goods at high height position of forks by other trucks. When the loads is off center, it could lead to overturn the truck and falling loads. Do not hold down the loads by hands. There is a danger of load’s falling. (23) Do not press the goods by people sitting on the goods.

  • Page 30: Parking

    is reasonable. Please drive and steer slowly and carefully when hanging up loads with steel wire or rope. It could lead to overturning of truck when loads shake severe. Please lower the loads as possible. 11. Parking (1) Obey the following working orders before leaving the truck: ...

  • Page 31: Inspection And Repair

    except normal parking orders. (7) Parking of fault truck When the forks could not be lowered by fault, place a large mark at the front part of forks in order not to be hit by other truck or walkers. Park the truck off road or at a place which does not disturb traffic.
  • Page 32 Please wipe off split oil and grease at once, and wipe off hydraulic oil as soon as excluding. Otherwise, it is hard to find crack when covered with dust. (8) Prohibition of fire especially when using a clothto clean oil, grease and fuel. It is easy to cause a fire.
  • Page 33 (19) Carefully inspection of battery and its pipeline The pipelines of battery are easy to burst. It is dangerous. Please check it by appointed factory. (20) Please consult a physician immediately when spilled on the skin or splashed in eye by the high pressure hydraulic oil. (21) Be sure to disconnect the battery plug when inspecting the electrical system Do not touch the electric conductor of the battery when inspecting high voltage equipments.
  • Page 34  Use crane or travelling crane when hanging up the truck.  Hook the wire at appointed position when hanging up the truck.  Use wire rope which has sufficient strength and no damage when hanging up the truck. (23) Precaution of battery using ...

  • Page 35: Plates

    explosion and a fire. Keep away from a fire. (26) Charge the battery at a temperature lower than 35℃。 Hydrogen gas is occurred during charging lead acid battery. The battery is heated for chemical reaction. Please charge the battery when its temperature is lower than 35℃.
  • Page 36 once. Some plates examples are followed. 1. Reach truck plate 2. Safe plate...
  • Page 38 3. Lubricating chart...
  • Page 39 4. Sling plate 5. Caution plate 6. No entry into the space behind the mast...
  • Page 40 7. Routine battery use 8. Routain battery maintenance 9. Load capacity...
  • Page 41 10. General information when operating 11. Oil adding plate...

  • Page 42: Operating Device

    II. Operating device 1. Name of parts (1) support wheel (2) front 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...

  • Page 43: Operating Device And Using Method

    2 Operating devices and using method 1) Crystal displayer (1) Fork height indicator (optional) It is used to display the current fork height and the unit is mm. (2) Heating in cold environment indicator (optional) When the electric heating is started in cold storage, the indicator shows. (3) Hour meter When the hour glass symbol flickers, it means it is recording time.
  • Page 44 It shows lifting is locked. (8) Fault code indicator It shows the fault node and fault code. (9) Electricity quantity indicator It shows the current electricity quantity. Meter usage instruction (1) Turn on the key switch and the meter system carries out self checking after it gets electricity.
  • Page 45 2) Key switch OFF----the switch is off and at this time the key can be taken out or inserted. ON----The electric control return circuit is open and the running preparation is finished after the liquid crystal display flicker four times. ...
  • Page 46 When travelling, operate through grasping the steering wheel handle with left hand. When travelling, grasp the steering wheel handle all the time. CAUTION:  Electric powered steering is installed on the truck. it begins working when powered steering rotates steering wheel when the key switch is ON. CAUTION: Pay attention to the following when lifting and lowering, tilting , front reaching and side shifting:...
  • Page 47 6) Front reaching thumb switch 3 There is front reaching button 3 on integrated knob. Pull it along the axis obliquely upward and the fork will reach out; pull it along the axis obliquely downward and the fork will retract back. Proper operation speed will be realized with certain tilting angle of knob.
  • Page 48 may occur. 11) Fork stopper CAUTION:  According to the principle that the center of the object’s gravity must be consistent with the truck’s center, so the fork arm should be adjusted to have equal space. After is it adjusted, be sure that the fork arm stopper is fixed to avoid the fork arm moved.
  • Page 49 completely and the mast seat is retracted. If the oil level is under the min. mark, add hydraulic oil. 1. Oil draining plug 2. Magnet 3. Return oil filter 4. Oil tank install plate 5. Box 6. Line card 7. Oil suction pipe 8.
  • Page 50 press the emergency button.  When connecting the battery plug, make sure the key switch is on OFF position.

  • Page 51: Operation Of The Truck

    III. Operation of the truck To keep the truck in good performance, use safely and working economically, please follow the notes below. 1. Notes on new truck usage Though the truck has experienced thoroughly adjust and test before delivery, the truck need moderate operation in the first month (200 hours) until all parts of the truck have full running-in time.

  • Page 52: Load Center And Load Chart

    3. Load center and load chart CAUTION:  When handling load, lift the load 5-10cm higher than the truck. Draw back the fork and tilt back completely. The distance between the fork arm roots and the goods center is load center. For example, the figure above shows the relationship between the load center and load capacity of 1.6t truck and 1.8t truck.

  • Page 53: Transporting Of The Truck

    mast to the max. position.  When driving with load, refer to capacity chart. Lift the fork 30cm above the ground and tilt the fork to the max. position. 5. Transporting of the truck CAUTION: When transporting with lorry:  Wedge the four wheels and fix the truck with rope to prevent the truck from moving.

  • Page 54: Operation Of The Truck

     All rope should have enough strength.  The knock-down parts of the truck have its appointed sling position also. 7. Operation of the truck (1) Start the truck CAUTION:  When starting the truck (turn on the key switch), stand rightly in the cab. ...
  • Page 55 The truck is different from automobile and its steering wheel is rear wheel, so when steering, the rear part of the truck rotates to the outside greatly. Slow down when steering and steer a little earlier than automobile. a) Hold the steering wheel knob with left hand; b) Operate the lifting system lever with right hand.
  • Page 56  Get out of the truck from the direction facing to the truck direction. (5) Ground condition CAUTION:  Be careful when travelling on uneven road.  When get across a railway, park for a while to be sure its safety. ...

  • Page 57: Battery Usage

    8. Battery usage (1) Usage notes CAUTION:  Select proper battery charger and do according to BATTERY SERVICE MANUAL.  When changing a battery, do according to the following orders: a) Disconnect the battery plug. b) Move out the battery. c) Be care not to hit the truck body when slinging the battery out.
  • Page 58 disassemble the battery; do not repair the battery unless authorized.  Do not over discharge. Do not use the truck until it can not move again or it will reduce the battery service lift. The battery should be charged when the battery indicator gives an alarm.
  • Page 59  For battery compartment without liquid leakage hole, check if there is hydrops inside of compartment every month. If there is electrolyte spillage caused by improper adding of distilled water, please clean the hydrops in the compartment with sucker in time. Do not charge the battery which had the following conditions: a) the electrode of plug is damaged;...

  • Page 60: Loading And Unloading

    NOTE:  If the electrolyte temperature is higher than 40℃ when beginning charging, stop charging for a while.  During charging, when the electrolyte temperature exceeds 50℃, it is bad for battery service life.  Do not charge the battery in low temperature for example, charging outside housed in the cold areas or in the refrigerator warehoused will shorten the battery service life.
  • Page 61 (1) Loading a) The distance between two forks should be as wide as possible so that the truck has a better transverse stability. b) When the forks are inserted into pallet. The center of the load should be in the middle of the two forks.
  • Page 62 i) Make sure the tips of the forks are off the load and pallet, and lower the forks to the position for running (15-20cm above the floor). i) Tilt the fork backward. CAUTION:  When the goods are lifted high, never tilt the mast forward except when at the beginning of stacking.

  • Page 63: Vehicle Storing

    load to its destination. 10. Vehicle storing (1) Before storing CAUTION The small troubles are the causes of serious accident. Even there is a little abnormity, report to supervisor. Do not operate it before finishing the repair. Before storing, clean it thoroughly and perform inspection according to the following procedures.
  • Page 64 DAILY STORING.  Park the truck at a higher and hard ground taking the rainy season into consideration.  Dismount the battery.  Even though the truck is parked indoors, if the place is hot and humid, the battery should be kept in a dry, cool place. Change the battery once a month. ...

  • Page 65: Inspection

    This is forbidden by law. (1) Notes when inspecting a) When replacing parts, use HELI pure parts. b) Please use HELI pure oil and grease. c) When adding oil or grease, clean the oil adding mouth with brush or cloth.
  • Page 66 The status of the truck Check if it inclines to one side. When inclining, the tyres or chassis may have some fault, contact HELI specified service point. c) Check the parking ground Check if there is leaked oil on the parking ground. If there is any fault, contact with HELI specified service point.
  • Page 67 g) Inspection of front wheel(supporting wheel) Check if the front wheels are wear, crack and damaged. h) Inspection of pipelines and cylinders Check if pipelines and cylinders (lift cylinder, tilt cylinder , reach cylinder) leak. i) Inspection of driving wheel Check if driving wheels are wear, crack and damaged.

  • Page 68: Periodic Inspection

    Except simple inspections before operation such as oil adding, clean filter and so on, please carry out complicated inspection in HELI specified service point because professional knowledge and special tools and equipment are needed. Or serious accident may occur.
  • Page 69 Hours shown below are based on 200 hour operation per month. CAUTION:  Please read the contents descript in this chapter before inspection. (1) Replace the safety parts regularly It is very important to make precautionary maintenance for operating safety. Especially the following safety parts must be replaced periodically because they are related to truck and operator safety.
  • Page 70 electricity and explosion, please do not clean it with a wet cloth. b) Adding grease to the reaching fork bracket Add a thin-layer grease to the center of both left and right reaching fork bracket groove’s inside surface. (3) Monthly inspection (200h) Inspect the following items in addition to the inspection prior to operation and weekly inspection: ...
  • Page 71 The monthly inspection needs more technology 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.
  • Page 72  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.
  • Page 73  Tighten the connecting bolts between the frame and mast ;  Tighten the main bolts of the frame and mast. Inspection, adjusting and replacement should be done by HELI specified service point according to HELI periodic inspection service contact.
  • Page 74 a) Electric device Check before Every Weekly Monthly Semiannually Annually operation three-month Item Content 200h 600h 1200h 2400h ○ ○ ○ ○ ○ Surface cleanness Clean ○ ○ ○ ○ ○ ○ Electrolyte quantity Check and replenish ○ ○ ○ ○...
  • Page 75 ○ ○ ○ Abnormal noise Inspect ○ ○ Unstable current (drive motor) Measure and adjust ○ ○ ○ Insulation condition Measure ○ ○ cleanness Clean ○ ○ ○ ○ ○ ○ Wires, Loose Inspect and tighten binding Spring condition of contacting Inspect ○...
  • Page 76 b) Brake, steering and travelling device Check before Every Weekly Monthly Semiannually Annually operation three-month Item Content 200h 600h 1200h 2400h ○ ○ ○ ○ ○ ○ Brake effect Inspect ○ ○ ○ ○ ○ ○ Brake Brake clearance Inspect and adjust ●...
  • Page 77 c) Lifting system Check before Every Weekly Monthly Semiannually Annually operation three-month Item Content 200h 600h 1200h 2400h ○ ○ ○ ○ ● ● Oil level and cleanness Change and inspect Hydraulic ○ ○ oil tank Oil suction filter Clean ○...
  • Page 78 Operating lever work condition , Inspect ○ ○ ○ ○ ○ ○ jolt and damage condition Inching switch work condition , Inspect ○ ○ ○ ○ jolt and damage condition Leakage, jolt, loose, deformation Tighten ○ ○ ○ ○ ○ ○...
  • Page 79 ○ ○ ○ ○ ○ ○ Work condition, leakage Inspect All oil Piston rod, screwed part and end Inspect ○ ○ ○ ○ ○ ○ cylinders are damaged ○ Natural decline distance Measure ○ R part crack condition Color filter ○...
  • Page 80 d) Truck body and others Items Check Every Weekly Monthly Semiannually Annually before three-month Content operation 200h 600h 1200h 2400h ○ ○ ○ ○ ○ ○ Overhead Crack, deform condition Inspect ○ ○ ○ ○ ○ ○ guard Fixing bolt loose Inspect and tighten ○...
  • Page 81 Working Work condition, leakage, damage Inspect ○ ○ ○ ○ device and deform condition ○ ○ ○ ○ Installation condition Inspect Pin axle connecting inner and Inspect, change ● ● ● ● ○ ○ outer fork plates and lubricate Bearing of tilting cylinder pivot Inspect, change ●...
  • Page 82 ADD:NO.668 Fangxing Street,Economical Development Zone,Hefei ,P.R.China FREE SERVICE HOTLINE TEL:(86 551)63689000 FAX:(86 551)63689666 4001 600 761 400 SERVICE: 4001-600761 WEBSITE:http://www.helichina.com S274-3:2020 heli copyright...

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