HANGCHA R Series Operation And Maintenance Manual
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HANGCHA R Series Operation And Maintenance Manual

1-3.5t internal combustion counterbalanced forklift truck
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1-3.5t R Series Internal Combustion
Counterbalanced Forklift Truck
Operation AND MAINTENANCE MANUAL
Original Instruction
ZHEJIANG HANGCHA ENGINEERING MACHINERY CO., LTD.
th
DEC.2009
4
EDITION

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  • Page 1 1-3.5t R Series Internal Combustion Counterbalanced Forklift Truck OPERATION AND MAINTENANCE MANUAL Original Instruction ZHEJIANG HANGCHA ENGINEERING MACHINERY CO., LTD. DEC.2009 EDITION...
  • Page 2 Okamura main transmission in our trucks. And there is different between masts of import and export trucks, N series masts are used in the import trucks, R series masts are used in export trucks.
  • Page 3 Table for the oil used in the truck ..................46 Lubrication system drawing....................48 Environment protection......................49 Scutcheons ..........................50 9. TRUCK’S CONVEY, LIFTING, TOWING ................58 10. TYPE SIGNIFICATION ......................59 11. PERFORMANCE PARAMETERS OF R SERIES IC FORKLIFT ........62 12. OPERATION, DISASSEMBLY AND INSTALLATION OF CAB........81...
  • Page 4 13. OPERATION AND NOTICE ABOUT LPG FORKLIFT ...........83 14. OPERATIONAL METHOD OF MAINTENANCE FREE LEAD ACID BATTERY ..95 15. USE, INSTALLATION AND SAFETY RULES OF ATTACHMENT .......97 16. RELATED SAFETY INSTRUCTION AND STANDARD (FOR TRUCKS EXPORTING TO EUROPE OR OPTION) ......................99 17.
  • Page 5 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.
  • Page 6 choose the right tool and assembly method. Depress the noise and libration as soon as possible to reduce the noise pollute to circumstance. 20. The work road surface for forklift should be stability and unknit, cement, blacktop or beton. If there are snows, ice, water or other eyewinker, bar. Eliminate all, and then work.
  • Page 7 2. NAME OF MAIN PARTS OR COMPONENT Mast Backrest Fork Overhead guard 2. Lifting cylinder Steering wheel Seat Cover hood Counterbalance weight Rear wheel Tilting cylinder Front wheel Instruments...
  • Page 8 Hour meter [1] Caution This meter measures working time If this light continues to stay lit or of engine. Use meter to schedule lights up during operation, the pressure lubrication and maintenance periods. is lower than 0.05Mpa and should be checked immediately.
  • Page 9 Switches position by spring force. Diesel engine Turn the key to “ON” position and the indicator lights up for a moment. After the indicator goes out, turn the key to “Start” position. Caution 1.Do not keep the starter switch in the ┃...
  • Page 10 Light switch [6] Horn button [7] Press the rubber cover at the center This light switch can be pulled out of steering wheel to sound horn. at two steps. Controls Light Near Clear Power Stage light light -ance × × ×...
  • Page 11 Clutch pedal [8] (frictional clutch Forward-reverse [12] type) Speed-select lever [13] Press the clutch pedal fully, the operator can uncouple the engine and transmission. When the clutch pedal released, it allows power to flow through the clutch from the engine to transmission. Caution: Do not run the lift truck with the clutch in a half-clutch condition as much...
  • Page 12 Warning This truck is provided with the power steering, so heavy hand-wheel operation is caused when the engine comes to a stall. To put the power steering in operation again, restart the engine without delay. Parking brake lever [17] Lift lever [15] Control the forks’...
  • Page 13 forklift has no choke line. When turn off Warning! the key switch, the engine will stop. a. Before adjusting the lever, you’d better turn off the key switch. Forward-reverse lever [20] b. Must stop the truck to adjust the [Electrical Switch] seat .
  • Page 14 △ should always do exterior inspection, Caution when found something abnormal, please While maintaining under the cover hood, the immediately replace new belt. The belt engine must be flameout to avoid hands or can be used for 3 to 5 years, when found other parts of the body being clamped by something abnormal, it should be running assembly.
  • Page 15 Radiator cap and coolant reservoir Steering column tilting angle The reservoir is located inside the adjustment hood. The radiator is located under the cover plate at the rear of the hood. Warning! Do not open the radiator cap abruptly while water’s temperature is higher than 70℃.
  • Page 16 Brake fluid reservoir 2.After addition of fuel is finished, brake fluid reservoir securely close the reservoir cap. A provided at the left of the cabinet. loose cap could cause fuel leak or fire hazard in the worst case. Hydraulic fluid reservoir cap 3.Before attempting to start the engine, The hydraulic fluid reservoir cap is make certain that the fuel reservoir cap...
  • Page 17 should be prepared. 3. Safety instructions Never fill the fuel tank with the Only trained and authorized engine running. operator shall be permitted to operate 5. Warm up the temperature of water the truck. to 70℃ before operation; and cool down Inspect the truck at periodic the temperature of water to lower than intervals...
  • Page 18 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.
  • Page 19 21. Use head lights and required work 23. When operating loaded truck, have light and clearance lights at night. And the rear end of your machine pointed travel at a low speed. downhill. When operating unloaded The work surface should be truck, have the rear end of your machine solidity and flatness such as cement road pointed upgrade.
  • Page 20 Do not use a man as an additional counterweight. It’s quite dangerous. 27. Avoid braking too sharply or ZHEJIANG HANGCHA descending on a grade at a high speed. ENGINEERING MACHINEARY CO., There is danger of loads falling down or LTD. offers a variety of attachments, the truck turning over.
  • Page 21 34. Don’t put your head or body into the interspace of mast and safeguard, what may cause life risk Don’t put your hand into the interspace of inner mast and outer mast 37. Make certain that your load is well stacked and evenly positioned across both forks.
  • Page 22 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.
  • Page 23 4） Engine oil level check 4. Maintenance Caution More details for maintenance see When checking the engine oil, 《Preventive maintenance schedule》. should let the forklift truck on the level 8 hour (daily or every shift) check ground. 1). Check leaks: electrolyte, hydraulic When check the engine oil, it is exact oil, brake fluid, coolant, oil in hydraulic when the engine is cool.
  • Page 24 Caution Caution Adding clean water to radiator. If When adding fluid, due should be you use antifreeze, use the same brand of taken to prevent dirt or water from antifreeze. entering the reservoir. Brake fluid is dangerous to health, Pay attention to water reservoir and you should avoid touching it by skin.
  • Page 25 when leaving the factory) or DOT3 condition. brake oil. Instruments and sensors Make sure that hour meter, water temperature indicator, oil temperature Head lamp check indicator, transmission fluid sensor and Make sure that the head lamp is fuel sensor etc., properly. lighting when the key is at “ON”...
  • Page 26 △ Please maintain the air cleaner when truck Warning! works 50-250 hours. After six times, please change air cleaner. When using an air compressor, first Note：If the working condition is bad, adjust pressure the cycle of maintain and change air compress-or.
  • Page 27 ② Check if there have leakage of oil Drop distance Engine cylinder and tubing. （mm） ③ Check the rollers’ rotation. A498BT1-1 10-15 ④ Check the mast if there have crack and bend. K21，K25 11-13 ⑤ Operate the lever of lifting, tilting and attachment, check the mast if it’s in WF491GP 汽油机...
  • Page 28 8) Lubrication grease to below parts, the detail please see <<Lubrication system drawing >> (1) mast bear lubricate (2) Brake pedal(clutch type) lubricate (3) Inching pedal(tor-con type) lubricate (4) Steering axle shaft lubricate (5) Steering knuckle main bearing lubricate Mast (6) Steering rod bar pin lubricate Paint lubrication grease on the slide (7) Steering cylinder pin lubricate...
  • Page 29 Height and the free clearance H: Turning wheel（rear wheel） Free Press free clearance height height Brake 120-130 ≥60 pedal touching bolt of inching pedal – brake pedal: D. Rear hub nut ①0.9-3.4mm Inching Specified torque N.m 120-130 ≥60 (NRW15A,QNR pedal 1-3.5t W22A) ②0 mm(besides...
  • Page 30 4) Dismantle the oil filter by tool. housing. 4. Change transmission oil filter Check the hydraulic transmission oil fluid, if more dust, change the hydraulic oil of transmission. It is first time. Let the truck at level ground, play-down the fork to floor, inclined back 5) Use cloth clean the surface of oil the mast, strain brake handle, when filter.
  • Page 31 3) Clean oil tuck then install. 4) Take out the dipstick.Add hydraulic oil.See <<Table for the oil used in the truck>>. 5) Startup engine. 6) Step on the brake pedal,operate the engine,let the transmission at state of go forward and backpedal so that the oil is in clutch.
  • Page 32 △ waste oil collect bottle, then use spanner Caution loosen oil orifice bolt counterclockwise. The other people step on the brake pedal Hot hydraulic oil and part will hurt repeat on the truck at same time. Here body. Do not touch the hot hydraulic the brake oil will burst forth from oil oil and part.
  • Page 33 11) Close the engine,retract all cylinder 4）. Let the engine run fully. pole,check the oil level of hydrualic 5） . Stop the engine, after cool down fully, oil box.Add oil at graduation still add cooling fluid to radiator up to position.
  • Page 34 100mm height. Other 1. Fuse and relay 3) Place chocks behind rear wheels to prevent movement of forklift. The fuse box is at middle of instrument and nearside of steering wheel. Before 4) Loosen wheel nuts 1-2 turns each by turning them counter-clockwise.
  • Page 35 turning them counter-clockwise. △ Warning! Do not move wheel nuts until rear tires are raised from ground. 5) Raised the forklift by swing the rod of jack until it out of ground. Support forklift truck by putting additional wooden blocks under each side of the front-end frame as shown below.
  • Page 36 5. The operation of engine too hot If the engine is too hot, do not stop it at once, do it as follow: ① Movement engine low speed； ② Open the engine cover to airiness ③ Stop when water temperature fall；...
  • Page 37 5. Structure and stability of truck It is very important for operator to know the truck’s structure and relationship between load and stability. Caution The structure of the truck The basic structure of the truck is mast (include mast and forks) and body (include tire).
  • Page 38 Caution the stability zone of the barycenter In order to make the truck stable, the combined center must be in the triangle which is made up of two points that the two front wheels attach ground and the midpoint of the back driving axle.
  • Page 39 “START”. Release key when engine 6. Operation starts. △ Warm engine Warning! Do not pull out the choke button. Press down accelerator pedal Before operating the truck, check all halfway and cold. Crank the engine by controls and warning devices for proper turning the ignition key to “START”.
  • Page 40 exhaust. ·Always stop the truck before reversing ·Make sure that all the warming lamps are the direction of travel. off. ·When gear shifting from high to low ·After thoroughly warming up the speed or vice versa, once increase the engine, operate the loading levers 2 to engine speed and release accelerator 3 times in their full stroke and check pedal.
  • Page 41 clutch type machine, the clutch pedal is used). 2. Place the shift lever in neutral. 3. Apply the parking brake by pulling up on the parking brake lever. 4. Down the forks on the ground, and tilt the mast forward maximum. 5.
  • Page 42 • After making sure the fork tips leave the load, lower the forks to the basic position (15 to 20 cm off the ground). • Tilt the mast backwards. Warning! Never tilt the mast with loads upraised 2m or more. Don’t leave or dismount from the truck when the load is raising high.
  • Page 43 In cold weather, it needn’t to discharge 7. Deposit the antifreeze, but the cold water should Deposit daily be removed completely. Park your truck level Deposit the truck for a long time ground-preferably in a wide area. If Deposit the truck for a long time, parking on a slope is unavoidable, position fill up the truck body and counter weight with block to reduce the load of...
  • Page 44 4.Start the engine once a week. If the water has already been let out, add water in the radiator. Then start the fork lightly. 5.In summer, it is not recommendatory to park the fork on asphalt road. Running after deposit for a long time 1.
  • Page 45 8. Maintenance Preventive maintenance schedule ○ — Check, revise, adjust × — Replace Note: (1) If the working place has much duty or other pollutions, the times of maintenance should be increased. (2) If the parts are abnormal such as engine power descends, emit black smoke or noise increase before the replacing time is coming, it should be check.
  • Page 46 Checki Monthly Trimonthly Semiannually Annually Service required Tools ng Item (500 hrs) (1000 hrs) (2000hrs) (180-200hrs 1. Check the valve clearance ○ ○ ○ ○ clearance is correct gauge 2. Fan belt tension ○ ○ ○ ○ check 3. Retighten cylinder ○...
  • Page 47 Maintenance of chassis and body Checking Monthly Trimonthly Semiannually Annually Service required Tools Item (500 hrs) (1000 hrs) (2000hrs) (180-200hrs) Check clutch pedal for free travel and clearance between ○ ○ ○ ○ pedal surface and floor when Clutch clutch is unlocked Release bearing lubricate ○...
  • Page 48 Checking Monthly Trimonthly Semiannually Annually Service required Tools Item (500 hrs) (1000 hrs) (2000hrs) (180-200hrs ○ ○ ○ ○ Check chain for tension ○ ○ ○ ○ Lubrication of chains Check chain and bearing for ○ ○ ○ ○ damage or deformation Check lifting cylinders for ○...
  • Page 49 Periodic replacement of key safe parts · Some parts can’t be found damnification or mutilation though schedule maintenance. In order to make sure the safety of truck, please replace these parts termly listed in following table. If there is any off-normal happened on these parts before replacement time, please replace it deservedly.
  • Page 50 Table for the oil used in the truck Description Shop sign，Code name Capacity(L) Remark 1∽1.8t Gasoline 2∽3.5t 1∽1.8t 0#（summer ） Diesel -10#∽-35#（winter） 2∽3.5t Besides winter ： CD grade15W／40， 1∽1.8t Winter ：CD grade 10W／30 Diesel engine Or according to engine maintenance arctic-alpine manual( :5W/30 CD or...
  • Page 51 Hydrodynamic power transmission oil Shop sign， Description Capacity(L) Remark Code name CPQD10/15/18N-RW7， CPQD20/25N-RW7 CPQD30/355N-RW7， CPCD10/15/18N-RW10， CPCD20/25N-RW10， CPCD30/35N –RW10； CPQD10/15/18N-RW21， CPQD20/25N-RW22 CPQD30/35N-RW22， CPCD20/25N-RW27， CPCD30/35N-RW27， CPCD10/15/18N-RW32， CPCD20/25N-RW32， CPCD20/25N-RW33， CPCD30/35N-RW33， Hydrodynamic CPCD20/25N-RW15A power DEXRON—III （Caltex） CPCD30/35N-RW15A， transmission CPQD20/25N-RW22A CPQD30/35N-RW22A, CPQD20/25/30/35N-RW26-Y CPCD10/15/18N-RW32M CPCD20/25N-RW32M CPCD20/25N-RW33M CPCD30/35N-RW33M CPCD20/25N-RW10B CPCD30/35N –RW10B...
  • Page 52 Lubrication system drawing fill replace front axis pin of tilt cylinder tilt cylinder axis pin chain chain mast seat bearing mast seat bearing front-wheel drive bearing front-wheel drive bearing brake oil cup differential shell clutch brake pedal(clutch type) transmission shaft fine motioin brake pedal(hydraulic type) mechanical gear-box (clutch) steering wheel lock device...
  • Page 53 Notice: 1. The detail of lubricating oil for different truck can refer to “Table for the oil used in the truck” 2. Lubrication for mast, please see the 8 hour (daily or every shift) check . Environment protection 1. Please do the clean and maintenance of the truck at the specified spot. 2.
  • Page 54 Scutcheons There are many scutcheons and labels on the different position of the truck.
  • Page 55 1. typeface label 2. danger label 3.fuse label 4. diesel label 5.gasoline label 6. Tonnage label 7. Danger label 8. Danger label 9. Product nameplate 11. Safety belt label 12. Shift label 13. Operate label 14. Operate label 15. Hand brake label 16.
  • Page 56 1、typeface label 2、danger label：adhibit to the outside of mast No allowed to stand on or down the mast, or it is dangerous to your life. 3、fuse label USE SPECIFIED FUSES ONLY 4、diesel label: show the position for adding oil, at the left rear supporting leg of the cabane.
  • Page 57 7、danger label The inner and outer mast, fork frame are all lifting slip parts. The hands are not allowed to reach the place between the inner and outer mast. If the part needs to be check or repaired, the inspection and repair should be carried out after shutting down the engine.
  • Page 58 13、14 operate labels Hydraulic truck INCHING BRAKE ACCELERATOR Mechanism truck CLUTCH BRAKE ACCELERATOR 15、hand brake label Forward, release hand brake; backward, strain hand brake. 16、load curve scutcheon It shows relation among the position of the load center, max. load and max. lifting height.
  • Page 59 19、warning label SERIOUS OR FATAL INJURY MAY RESULT TO YOURSELF OR OTHERS IF NOT FOLLOWED This lift truck should not be operated by anyone who is not authorized and properly trained. Read the Operators Manual and all warnings carefully,and make yourself familiar with your lift truck. Operator's Manual and Service Manual are supplied with this truck or available from our forklift truck dealers.
  • Page 60 26、CE label 27、No water flushing label: at the right safety supporting leg where is the channel for engine air. No water is allowed to enter into the transom window, no water can be entered into when washing truck. 28、antifreeze label 29、lubrication system label fill replace...
  • Page 61 32、horn label 33、LPG label（only for LPG trucks and double fuel trucks） There is a label with the word on the cylinder: the max. weight of the LPG cylinder 52kg the max. pressure of the LPG 2.2 M Pa the max. weight the bracket can support 105kg The print position of the series number of truck body Each truck has a unique truck body series number, its print position is at the right front side of the truck body.
  • Page 62 9. Truck’s convey, lifting, towing Hoist the truck • Use the steel wire ropes to tie the holes in the two side of the outside mast’s beam and the hook of the counter balance, then use the lifting device to hoist the truck. Warning •...
  • Page 63 10. Type signification 1-1.8t Rated capacity(t)/ Model Engine Main transmission Load center(mm) YQXD18H1Hydrodynamic Wan feng WF491 CPQD10/15/18N-RW7 power transmission gear Gasoline YQXD18EHydrodynamic ISUZU C240PKJ-30 CPCD10/15/18N-RW10 power transmission gear Diesel 1/500、 YQXD18HBHydrodynamic K21 Gasoline 1.5/500、 CPQD10/15/18N-RW21 power transmission gear （NISSAN） 1.8/500 YQXD18EHydrodynamic CPCD10/15/18N-RW32 YANMAR4TNE92Diesel...
  • Page 64 2-2.5t Rated capacity(t)/ Model Engine Main transmission Load center(mm) YQXD25Hydrodynamic CPCD20/25N-RW10 power transmission gear box ISUZU C240PKJ-30 Diesel （ISUZU） CPCD20/25N-RW10B OKAMUR transmission Wan Feng WF491 YQXD25H1Hydrodynamic CPQD20/25N-RW7 gasoline power transmission gear box YQXD25AHydrodynamic CPCD20/25N-RW27 A498BT1-1 Diesel power transmission gear box 2/500、...
  • Page 65 3-3.5t Rated capacity(t)/ Model Engine Main transmission Load center(mm) YQXD30Hydrodynamic power CPCD30/35N –RW10 C240PKJ-30 transmission gear box Diesel （ISUZU） CPCD30/35N –RW10B OKAMUR transmission WanFengWF491 YQXD30H1Hydrodynamic CPQD30/355N-RW7 power transmission gear box gasoline YQXD25AHydrodynamic power A498BT1-1Diesel CPCD30/35N-RW27 transmission gear box YQXD25H Hydrodynamic power CPQD20/25N-RW22 transmission gear box K25gasoline...
  • Page 66 11. Performance parameters of R series IC forklift 1—1.8t R series Model CPQD10N-RW7 CPQD15N-RW7 CPQD18N-RW7 Rated capacity Kg 1000 1500 1800 Load center mm Max. lifting height mm 3000 3000 3000 Free lifting height mm Max lifting speed mm/s，full load Tilting angle F/B 6°/12°...
  • Page 67 Model CPCD10N-RW32 CPCD15N-RW32 CPCD18N-RW32 Rated capacity 1000 1500 1800 Load center Max. lifting height mm 3000 3000 3000 Free lifting height mm Max lifting speed mm/s，full load Tilting angle F/B 6°/12° 6°/12° 6°/12° Max traveling speed Km/h Ground clearance mm Min turning radius 1925 1970...
  • Page 68 Model CPQD10N-RW21 CPQD15N-RW21 CPQD18N-RW21 Rated capacity Kg 1000 1500 1800 Load center mm Max. lifting height mm 3000 3000 3000 Free lifting height mm Max lifting speed mm/s Tilting angle F/B 6°/12° 6°/12° 6°/12° Max traveling speed Km/h 14.5 14.5 14.5 Ground clearance mm Min turning radius...
  • Page 69 Model CPCD10N-RW10 CPCD15N-RW10 CPCD18N-RW10 1000 1500 1800 Rated capacity Kg Load center mm Max. lifting height mm 3000 3000 3000 Free lifting height mm Max lifting speed mm/s Tilting angle F/B 6°/12° 6°/12° 6°/12° mechanical Max traveling speed Km/h hydraulic 14.5 14.5 14.5...
  • Page 70 2-3.5t R series Model CPCD20N-RW15A CPCD25N-RW15A CPCD30N-RW15A CPCD35N-RW15A Rated capacity Kg 2000 2500 3000 3500 Load center mm Max. lifting height 3000 3000 3000 3000 Free lifting height Max lifting speed mm/s Mast tilt angle F/R 6°/12° 6°/12° 6°/12° 6°/12°...
  • Page 71 Model CPQD20N-RW22A CPQD25N-RW22A CPQD30N-RW22A CPQD35N-RW22A Rated capacity Kg 2000 2500 3000 3500 Load center mm Max. lifting height 3000 3000 3000 3000 Free lifting height mm Max lifting speed mm/s Tilting angle F/B 6°/12° 6°/12° 6°/12° 6°/12° Max traveling speed 19.5 19.5 19.5...
  • Page 72 Model CPCD20N-RW10 CPCD25N-RW10 CPCD30N-RW10 Rated capacity Kg 2000 2500 3000 Load center mm Max. lifting height mm 3000 3000 3000 Free lifting height mm Max lifting speed mm/s Tilting angle F/B 6°/12° 6°/12° 6°/12° Max traveling speed Km/h hydraulic 20．5 20．5 Ground clearance mm Min turning radius...
  • Page 73 Model CPQD20N-RW22 CPQD25N-RW22 CPQD30N-RW22 CPQD35N-RW22 Rated capacity Kg 2000 2500 3000 3500 Load center mm Max. lifting height mm 3000 3000 3000 3000 Free lifting height mm Max lifting speed mm/s Tilting angle F/B 6°/12° 6°/12° 6°/12° 6°/12° traveling speed hydraulic 18.5 18.5...
  • Page 74 CPCD25N- CPCD35N- CPCD30N- Model CPCD20N-RW10B RW10B RW10B RW10B Rated capacity Kg 2000 2500 3000 3500 Load center mm Max. lifting height mm 3000 3000 3000 3000 Free lifting height mm Max lifting speed mm/s Tilting angle F/B 6°/12° 6°/12° 6°/12° 6°/12°...
  • Page 75 Model CPQD20N-RW22B CPQD25N-RW22B CPQD30N-RW22B CPQD35N-RW22B Rated capacity Kg 2000 2500 3000 3500 Load center mm Max. lifting height 3000 3000 3000 3000 Free lifting height Max lifting speed mm/s Tilting angle F/B 6°/12° 6°/12° 6°/12° 6°/12° Max traveling speed 21.5 21.5 Km/h Ground clearance...
  • Page 76 Model CPQD20N-RW7 CPQD25N-RW7 Rated capacity Kg 2000 2500 Load center mm Max. lifting height mm 3000 Free lifting height mm Max lifting speed mm/s，full load Tilting angle F/B 6°/12° Max traveling speed Km/h hydraulic 22.5 Ground clearance mm Min turning radius mm 2175 2235 Grade full load...
  • Page 77 Model CPCD20N-RW27 CPCD25N-RW27 Rated capacity Kg 2000 2500 Load center mm Max. lifting height mm 3000 Free lifting height mm Max lifting speed mm/s，full load Tilting angle F/B 6°/12° Max traveling speed Km/h hydraulic 20.5 Ground clearance mm Min turning radius mm 2175 2235 Grade full load...
  • Page 78 CPCD25N-RW33 CPCD20N-RW33 Model CPCD20N-RW32 CPCD25N-RW32 CPCD25N-RW33 CPCD20N-RW33B Rated capacity Kg 2000 2500 2000 2500 Load center mm Max. lifting height mm 3000 3000 Free lifting height mm Max lifting speed mm/s，full load Tilting angle F/B 6°/12° 6°/12° mechanica Max traveling speed Km/h hydraulic Ground clearance mm...
  • Page 79 Model CPCD20N-RW33M CPCD25N-RW33M Rated capacity Kg 2000 2500 Load center mm Max. lifting height mm 3000 Free lifting height mm Max lifting speed mm/s，full load Tilting angle F/B 6°/12° mechanical traveling speed Km/h hydraulic Ground clearance mm Min turning 2175 2235 radius Grade full...
  • Page 80 Model CPQD30N-RW7 CPQD35N-RW7 Rated capacity Kg 3000 3500 Load center mm Max. lifting height mm 3000 Free lifting height mm Max lifting speed mm/s，full load Tilting angle F/B 6°/12° mechanical Max traveling speed Km/h hydraulic Ground clearance mm Min turning radius 2375 2415 Grade full load...
  • Page 81 Model CPCD30N-RW27 CPCD35N-RW27 Rated capacity Kg 3000 3500 Load center mm Max. lifting height mm 3000 Free lifting height mm Max lifting speed mm/s，full load Tilting angle F/B 6°/12° Max traveling speed Km/h hydraulic Ground clearance mm Min turning radius mm 2375 2415 Grade full load...
  • Page 82 CPCD30N-RW33 CPCD35N-RW33 Model CPCD30N-RW32 CPCD30N-RW33B CPCD35N-RW33B Rated capacity Kg 3000 3500 3000 Load center mm Max. lifting height mm 3000 3000 Free lifting height mm Max lifting speed mm/s， full load Tilting angle F/B 6°/12° 6°/12° mechanical traveling speed hydraulic Km/h Ground clearance mm Min turning radius...
  • Page 83 Model CPCD30N-RW33M CPCD35N-RW33M Rated capacity Kg 3000 3500 Load center mm Max. lifting height mm 3000 Free lifting height mm Max lifting speed mm/s，full load Tilting angle F/B 6°/12° mechanica traveling speed Km/h hydraulic Ground clearance mm Min turning radius 2375 2415 Grade full...
  • Page 84 CPCD20N CPCD25N CPCD30N CPCD35N Model -RW26-Y -RW26-Y -RW26-Y -RW26-Y Rated capacity Kg 2000 2500 3000 3500 Load center mm Max. lifting height mm 3000 3000 3000 3000 Free lifting height mm Max lifting speed mm/s Tilting angle F/B 6°/12° 6°/12° 6°/12°...
  • Page 85 12. Operation, disassembly and installation of cab...
  • Page 86 The operation of cab: 1. Open left door with key, enter into cab. 2. Close door, make sure left and right door close before working. 3. The glass of left and right door can be moved by draw button on the glass. 4.
  • Page 87 13. Operation and notice about LPG forklift More details refer to 《OPERATION AND MAINTENANCE MANUAL and SERVICE MANUAL of 1-3.5t R series LPG forklift (American IMPCO combustion system)(Italy BRC combustion system)》. LPG fuel system consists of LPG cylinder, petrol solenoid valve, LPG solenoid valve with filter, LPG vaporizer, adapter, LPG-petrol select switch and level indication.
  • Page 88 2．Change from petrol to LPG: Shut off the petrol switch, When petrol in the carburetor is about to be used up, the engine runs slower, switch on the LPG switch rapidly to fuel by LPG. Outpouring limit valve Once the outpouring limit valve is opened (see FIG A), LPG is flowing to the LPG solenoid valve through the outlet When outpouring exceeds the stated value, or the pipe is broken, the outpouring device on the valve will be closed automatically.
  • Page 89 3．Cylinder structure 1．Charge valve（inlet port and dustproof cover） 2. Installing mark 3.Outlet valve（outlet connector） 4. Fixed pin 5. Outlet shut off valve 6.Level indication 7. Inlet shut off valve 4．Cylinder replacement Paste safety operation procedures on cyliner (1) make the truck stay on flat and stability ground, stop engine, pull hand brake;...
  • Page 90 Metal band bracket buckle belt bracket 1. Right hand hold tighten device, use Buckle belt and tighten device forefinger,middle finger, and ring finger to pull lock buckle out. 3 ． 2 . Keep 1 procedure， and push up tighten device till touch cylinder.
  • Page 91 Remove cylinder and charge Notice : 1. Please avoiding cylinder hit counterpoise when taking it down form truck. 2. Make sure the outlet shut off valve closed. When charging the place must have charging license which is awarded by Quality and Technical Supervision Bureau . It is forbidden to charge by self and the component must accord with table 1.
  • Page 92 Table 1 technique parameter of LPG special for vehicle Quality parameter Item component com Trial position 37.8℃ vapour (indication) ≤1430 890～1430 660～1340 GB/T 6602 k Pa ＞65～85 ＞85 propane 40～65 ≤2.5 Butane and advanced — — ≤2.0 ≤2.0 Pentane and advanced SH/T 0614 —...
  • Page 93 Procedure of replacing LPG cylinder （1）Take canvas glove to avoid the leaking gas to frostbite finger when gas changing. （2）Make sure the place is clear and the air is ventilating when charging LPG, it is forbidden to smoke ,keep away from other naked flame （3）...
  • Page 94 Buckle belt bracket a. Hold strain device with right hand, take buckle belt with left hand, direct to the notch on ratchet b. Pass buckle belt through the notch on ratchet wheel wheel. c. Pull buckle belt downward with left hand, pull d.
  • Page 95 Notice ：after installing cylinder, then connect the connecting pipe with quick ○ 3 ,smear every joint with soap bubble to check connector, open outlet shutoff valve whether the joint is leaking, if there is leaking at joint, eliminate the problem, then fire ○...
  • Page 96 (9) When fixing and disassembling cylinder please do it lightly, it is forbidden to hit other object. Keep cylinder assembly intact and do not disassemble, adjust and replace components. (10) The LPG conform to GB11174 can be recharging; the maximum volume is no more than 80% of cylinder.
  • Page 97 （22）Park the truck at the shady and ventilated site; close the valves on the LPG cylinder. Never insolate the truck in the sun long. （23）Shut off power and all valves after the truck is garaged. Keep good ventilation and extinguishing measure in the garage. （24）Never repair the LPG cylinder, valves or pipes at garages or parking lots, any smoke on the truck.
  • Page 98 Service & maintenance 1．This truck has been taken pressure trial and performance test before leaving factory. If there is performance failure, strictly forbid repairing without permission. 2．Close the valves on the LPG cylinder before disassembly and maintenance of the LPG device. 3．Suitably adjust the measure valve, for LPG consumption is changing with season.
  • Page 99 14. Operational method of maintenance free lead acid battery 1. Maintenance free lead acid battery and its application Maintenance free lead acid battery is used for power start engine ,and it can be for voltage regulation and overload generator substitute power ,it has following strengths: low internal resistance, stable end voltage, large support current, low water cost, huge capacity, nice starting performance at low temperature, light pole corrosion , light mass, low fault rate, convenient maintenance.
  • Page 100 4)To avoid short circuit of battery, the electric things are forbidden to cover at battery. 4.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;...
  • Page 101 15. Use, installation and safety rules of attachment HANGCHA will choose attachment that according with International standard ISO2328《Forklift pothook fork and install size of carriage》,such as clamp, rotator, paper roll clamp, carrying ram, side-shifter etc. 1、Attachment use. （1） Know well the content of nameplate on attachment, read the instruction manual before Usage.(Especially the manual from attachment company)Before operate the...
  • Page 102 repair. （6） Check the drive of attachment timing or turn the component if fray or block, change betimes. （7）Check each element if in normal under load attachment is work in gear. If not, check the hydraulic pressure loop, find out the broken part, change air poof or whole loop part.
  • Page 103 16. Related safety instruction and standard (for trucks exporting to Europe or option) The model by CE certification which according to the following instruction and standard: DIRECTIVE 2006/42/EC OF THE EUROPEAN PAMENT AND OF THE COUNCIL, DIRECTIVE 2000/14/EC OF THE EUROPEAN PAMENT AND OF THE COUNCIL, EN1726-1:1998(Engineering Industry truck safety standardize), EN12053:2001, EN1175-2:1998, EN13059:2002 coordinate standard.
  • Page 104 Vibration parameters will be accord with ISO5349-2:2001、EN13059:2002. Synthetic acceleration Synthetic acceleration from the seat to the from the seat to the Model Model operator body operator body unit： m/s unit： m/s CPYD10N-RW 1.54 CPQD25N-RW 1.54 CPYD15N-RW 1.52 CPQD30N-RW 1.48 CPYD18N-RW 1.52 CPQD35N-RW 1.52...
  • Page 105 Add：398 Shi Qiao Road, Hangzhou 310022 E-Mail：sales@zjhc.cn Tel：+86-571-88926666 Fax： +86-571-88144682 EC DECLARATION OF CONFORMITY MANUFACTURE Name: Zhejiang Hangcha Engineering Machinery Co., Ltd. Address: 398 Shiqiao Road, Hangzhou 310022, P. R. China THE TECHNICAL DOCUMENTATION WAS COMPILED BY: Name: Address: Post:...
  • Page 106 Add：398 Shi Qiao Road, Hangzhou 310022 E-Mail：sales@zjhc.cn Tel：+86-571-88926666 Fax： +86-571-88144682 EC DECLARATION OF CONFORMITY MANUFACTURE Name: Zhejiang Hangcha Engineering Machinery Co., Ltd. Address: 398 Shiqiao Road, Hangzhou 310022, P. R. China THE TECHNICAL DOCUMENTATION WAS COMPILED BY: Name: Address: Post:...
  • Page 107 17. Maintain record Maintain Date Item of maintenance personnel...
  • Page 108 ZHEJIANG HANGCHA ENGINEERING MACHINERY CO., LTD Manufacturing site: 88 Donghuan Road, LinAn Economic Development zone, Zhejiang, P.R.China ZIP:311305 Registered Address 398 Shi Qiao Road, Hangzhou, P.R. China) ZIP :310004 Fax: 0086-571-88132890 0086-571-88926789 Web: http://www.hcforklift.com E-mail: sales@hcforklift.com...

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