HANGCHA XF Series Operational And Maintenance Manual
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HANGCHA XF Series Operational And Maintenance Manual

HANGCHA XF Series Operational And Maintenance Manual

Internal combustion counterbalanced forklift truck
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XF series
OPERATION MANUAL
series Internal Combustion
1.0t-X5.5T XF
Counterbalanced Forklift Truck
Operational and
Maintenance Manual
Original Instruction
HANGCHA GROUP CO., LTD
04/2018

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Summary of Contents for HANGCHA XF Series

  • Page 1 XF series OPERATION MANUAL series Internal Combustion 1.0t-X5.5T XF Counterbalanced Forklift Truck Operational and Maintenance Manual Original Instruction HANGCHA GROUP CO., LTD 04/2018...
  • Page 2 Foreword 1-x5T XF series internal combustion forklift is a new developed forklift of Hangcha Group, it owns characteristics as energy conservation and environment protection, novel structure and superior performance. This manual introduces safety, operation, transportation, lubrication, brief structure and maintenance method of trucks.

  • Page 3: Table Of Contents

    Content I. General rules · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1 II.
  • Page 4 XV. Operational method of lead acid battery · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 125 XVI.

  • Page 5: General Rules

    I. General rules To keep the truck and you safe, obey these rules below: Only trained and authorized operators shall be permitted to operate the truck. Before starting truck you should check all control and alarm devices; if any are damaged, DO NOT operate until it is repaired.
  • Page 6 This includes changes affecting, for example, braking, steering, visibility and the addition of removable attachments. When the manufacturer or his successor approves a modification or alteration, the manufacturer or successor shall also make and approve appropriate changes to the capacity plate, decals, tags and operation and maintenance handbooks. 28.

  • Page 7: Name Of Main Parts Or Component

    II. Name of main parts or component 1. Fork 2. Load backrest 3. Tilt cylinder 4.Mast 5.Lift cylinder 6. Steering wheel 7. Overhead guard 8. Seat 9. Cover hood 10. Counterbalance weight 11. Rear wheel 12. Truck frame 13. Front wheel...

  • Page 8: Instruments

    1. Instruments 1.0t-3.5t forklift (Except W43)instrument LCD 4.0t-x5.5t W34,W35 forklift instrument LCD A.Water temperature gauge B.Fuel gauge C.Timer E. Neutral position start-up D.Accumulator warning indicator F. OPS indicator indicator G.Transmission oil temperature H. Parking indicator I. Preheat indicator light warning light J.
  • Page 9 4.0t-x5.5t W58 forklift instrument LCD 4.0t-x5.5t W57,W24,W68 forklift instrument LCD A. Water temperature gauge B.Fuel gauge C.Timer E. Neutral position start-up G. Transmission oil temperature indicator warning light H. Parking indicator I. Preheat indicator light K. Engine oil pressure warning light L.
  • Page 10 Instrument of the state shown in Figure Fuel gauge [B] The gauge indicates the fuel level in the tank when the key is at ┃(ON) position. Suggest filling up the fuel tank after work every day. Water temperature gauge [A] This gauge indicates the oil temperature in the torque converter transmission box when the key is at ┃(ON) position.
  • Page 11 Hour meter [C] pointer goes into the green range, and have a check then. Parking indicator [H] This meter measures working time of engine when the key is at ┃(ON) position. The meter increase one number every working hour. Use meter to schedule lubrication and Parking indicator shows on means brake is maintenance periods.
  • Page 12 Engine oil pressure alert lamp（K） Engine fault indicator [P] [Electronic-controlled engine] This lamp indicates the pressure condition of engine lube oil. Although it lights up when the 1.0t-3.5t(Except W43 Cummins engine): This engine switch is set at ―ON‖, once the engine indicator does not work.

  • Page 13: Controls And Switches

    2. Controls and switches 1.0t~x5.5t forklift Controls and switches graph 1.Steering wheel 2.Horn 3.Combination switch 4.Key switch 5. Lift control lever 6. Tilt control lever 7. Cup holder 8.Instrument 9. Rocker switch 10. Accelerator pedal 11. Brake pedal 12. Inching pedal 15.
  • Page 14 Steering wheel Turn on the headlamp and small lamp, turn this switch, and aim the position line on the Turn right Turn left switch knob to the relevant marking on the switch subject. Key switch[4] It controls the movement direction of truck. Rotate counterclockwise, the truck moves to the left;...
  • Page 15 Lift lever [5] Side shift control lever Used for left shifting and right shifting of the Controls the forks‘ up or down side shift bracket. Push forward——lowered Push forward-move to the left Pull backward——lifting Pull backward-move to the right Lifting speed is controlled by tilting backwards Side shifting speed depends on the tilting angle of lever and accelerator pedal.
  • Page 16 Pedal Emergency disconnect switch [14] Press the emergency disconnect switch, [10] Accelerator pedal disconnect electrical appliance with battery. Re-start the truck, pull up the switch. After shut down, turn off the switch in 30 seconds. Parking brake lever [15] Depress accelerator pedal to increase speed. Release pedal to decrease speed.
  • Page 17 Reversing lever [17] through R1. It‘s installed on the left of the steering column. These series forklift trucks are electronic Caution reversing, push or pull this lever to realize the Only place the lever in neutral can you following functions： start the engine Forward 1.5~3.5t...

  • Page 18: Truck Body And Others

    3. Truck body and others Warning Load backrest  Turn off the key before adjusting the The load backrest improves stabilization seat. when loading goods. Never use forklift truck  It‘s prohibited to adjust the position of without the load backrest. the seat only when the truck stops.
  • Page 19 extended correctly. Hood Prohibit use the belt knotted or twisted. The hood can be swung up fully to provide To tie the belt in the daily operation will easy maintenance service. You can lift up the protect you when the truck turn over and hood with little effort with an aid of hood WARNING reduce the harm.
  • Page 20 cover hood can be removed to check cooling liquid. Caution Reinstall the radiator cover hood and tighten the bolt by hand. Fix up this part by inner hexagon bolts for Warning truck exported to Europe. Use socket forks should spanner to loose before remove; reinstall and symmetrically to machine centerline and tighten the bolt by socket spanner.
  • Page 21 Fuel reservoir cap cylinder when opening the rear windor, so you need to turn over the cylinder, after pushing away the rear window, resume the cylinder to original position. Fuel reservoir cap without lock Cylinder bracket（LPG truck） Cylinder bracket is back-rotated（Only for 1.0t-3.5t）.
  • Page 22 Head lamp Disassembly and assembly of the head lamp 1. Dismantle the decorative frame; 2. Screw the four bolts at the back of the lamp housing and open the lamp housing; 3. Cut the lead wire, loosen the lock button, remove the lamp, change a new lamp and install;...

  • Page 23: Safety Rules

    III. Safety rules 1. Only trained and authorized operators 7. Never mount or dismount a moving truck. should operate the truck. Use the safety step(s) and safety grip when 2. Inspect the truck at periodic intervals for oil mounting or dismounting the truck. or water leaks, deformation, defects, etc.
  • Page 24 19. Slow down and sound horn at cross aisles and other locations where vision is restricted. The speed should be kept 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 weight of the truck/load.
  • Page 25 loaded, since this will cause the truck to Warning become unbalanced. DO NOT operate the truck when the weather truck with attachments should is inclement, such as wind storms, thunder considered the same as a loaded truck. storms, snow and etc. 26.
  • Page 26 30. Know the rated capacity of your lift truck and its attachment, if any, and never exceed it. people additional counterweights. It is quite dangerous. WARNING 34. When driver‘s ear noise is bigger than 80dB, please adopt hearing protective measures. Caution Rough or uneven road surface and tyre deformation may largen noise value.
  • Page 27 47. HANGCHA provides various attachments to the user, like rotating clamp, side shifter, jib and so on, which are for special use. If attachment configuration needed, it must be admitted by the factory.

  • Page 28: Maintenance

    IV. Maintenance See Preventive maintenance schedule for further information. 1. Daily maintenance（8hours） It is also used as check before operation. ： 1. Check leaks electrolyte, hydraulic oil, brake fluid, coolant, and oil in hydraulic 5. Check engine coolant transmission gear box. Inspect the small reservoir tank to see if the coolant level is between Min and Max Warning...
  • Page 29 6. Hydraulic oil level check Check the oil level in the hydraulic oil tank. The oil level should be in the place between two limits. The 1-3.5t square oil dipstick has three surfaces with marks, and the figure inside the round at the top of dipstick means the truck model applied for(see figure)：...
  • Page 30 4.0t~5.5t W35、W57、W23、W68 Forklift Brake oil fluid change See ― Every half year maintenance (1000 Truck: ○ hours)‖ symbol means its value of mark can be applied for 4t～x5t truck(except W58) 7. Head lamp check When the mast is in the lowest place： Make sure that the head lamp is lighting when The truck with standard mast demands filling the key is at ―ON‖...
  • Page 31 Drive truck slowly, step down brake pedal, and brake lamp lights. Drive truck slowly, step down inching pedal, and check the inching pedal condition. 18. Tire inspection and Tire pressure Check the tires for damage, and whether the rims are deformation. Turn tire valve cap counter clock-wise and remove it.

  • Page 32: Weekly Maintenance（40Hours

    advance. 2. Weekly maintenance（40hours） Increase the following content based on daily With air filter Service indicator models: maintenance. 1. Air cleaner maintenance General condition： Perform maintenance on the air cleaner after 50-250 hours of operation. Replace air cleaner after maintaining for six times.
  • Page 33 2. Fan belt Stop the engine. Use finger to press the belt at the midway point between the water pump pulley and the generator pulley by 10kg press, and check the drop distance if it is up to standard. Engine Drop distance（mm）...
  • Page 34 Install belt tensionmeter(1) to the center of the 4. Mast and forks longest free length and check tension. Correct Check the mast and forks to make sure: tension of new belt is 535N. It the tension is ① There is no crack and bend on the forks, lower than 250N, adjust the belt to 535N.
  • Page 35 7. Chain Lubrication Take one brush with engine oil paint both sides on chain 8. Lubrication grease to below parts, the detail please see Lubrication system drawing ① Mast bearing lubricate ② Inching pedal lubricate ③ Steering axle shaft lubricate ④...
  • Page 36 Rear wheel 1.0t-1.8t Height and the free clearance Height mm Free clearance mm Brake 135±5 pedal touching bolt Inching – inching pedal 135±5 pedal brake pedal：0 mm ④ ； Rear hub nut 2.0t-3.5t Height and the free clearance Height Tightening torque N.m： Free clearance mm 1.0t-1.8t 2.0t-3.5t...
  • Page 37 13.Cylinder bracket check（only for LPG truck） Pull the cylinder, check if the bracket is firm,restore the normal position and check if stable.

  • Page 38: Monthly Maintenance（166Hours

    3.Monthly maintenance（166hours） Increase the below content based upon weekly maintenance 1. Change engine oil and oil filter （ only for the first time, then per 500hours） ① Start the engine, warm-up enough, then shut off. ② Remove oil cover and bottom shell to ⑨...
  • Page 39 ④Be sure to prime the diesel fuel system position, and shut off engine. when you are done. Warning Cummins Diesel： Hot hydraulic oil and parts will cause injury. DO NOT touch the hot hydraulic oil and parts ① Put one case (volume is over 20 liters) under the transmission.
  • Page 40 Normal: complete Colorless combustion Abnormal: incomplete Black combustion Blue Abnormal: oil burns Abnormal: water in White combustion chamber Warning Don‘t start the lift truck in bad ventilation space. There is carbon monoxide in the exhaust gas, it is very dangerous 9.

  • Page 41: Every Half Year Maintenance (1000 Hours)

    Park the truck on level ground, lay-down the 4.Every half year maintenance forks on the floor, incline the mast back, and (1000 hours) apply parking brake. Put transmission in neutral position, shut off the engine. Increase the following content based on monthly maintenance.
  • Page 42 5. Change hydraulic transmission oil Refer to ‗Change hydraulic transmission oil‘ from ‗Monthly Maintenance‘. 6. Check, clean, change fuel filter Caution In the dust and dirty work condition, clean fuel filters per one month and replace every six months. ① Remove out the fuel filter.

  • Page 43: Annual Maintenance (2000 Hours)

    ② Install oil plug. 5.Annual maintenance (2000 hours) ③ Remove breather plug and oil fluid position Increase the following content based on plug. Put the oil from orifice bend to steering semiannual maintenance. axle housing until oil overflows from level plug. See ―Re-add amount‖.

  • Page 44: Others

    ① Park forklift truck on level concrete; 6.Others ② Start engine and raise mast about 1. Fuse, relay 100mm height. ① Please first find out the reason before ③ Place chocks behind rear wheels to replace damaged fuse or relay. ②Replace with regulated standard fuse prevent movement of forklift;...
  • Page 45 ④ Loosen wheel nuts 1-2 turns by turning them counter-clockwise. Warning Do not remove wheel nuts until rear tires are raised from ground. ⑤ Raise the forklift with jack until rear wheels off the ground. Support forklift truck by putting additional wooden blocks under both sides of the front truck frame as shown below.
  • Page 46 Caution Clean the radiator fins by using compressed air or vapor, place the muzzle to radiator a right angle. 5. The operation of too hot engine If the engine is too hot, DO NOT stop it at once, do as follows: ①...

  • Page 47: Structure And Stability Of Truck

    V. Structure and stability of truck It is very important for operator to know the truck‘s structure and relationship between load and stability. The structure of the truck Caution The basic structure of the truck is mast (include mast and forks) and body (include tire).
  • Page 48 Caution the stability zone of the barycenter In order to make the truck stable, the combined center must be within the triangle which is made up of the two points where the two front wheels touch the ground and the midpoint of the back driving axle.

  • Page 49: Operation

    VI. Operation Caution Warning The time to start should be less than 5 Before operating the truck, check all seconds each attempt, and the interval controls and warning devices for proper between attempts should be at least 2 operation. If any damage of fault is found, don‘t operate truck until corrected.

  • Page 50: Pick Up

    · · Release hand brake The pallet should be evenly positioned · across both forks Release brake pedal, step · Insert forks into the pallet as far as accelerator pedal, and then the vehicle moves. possible. ： Gear shift · To raise loads from the ground Hydraulic drive forklift ①...

  • Page 51: Remove Load

    · Make sure your load is just over the desired area. Slowly lower the load into position. Make sure the load is securely stacked. · Disengage forks from the load by using necessary lift-tilt operation and then back away. · After making sure the fork tips leave the load, lower the forks to the basic position (15 to 20 cm off the ground).

  • Page 52: Parking

    VII. Parking Warning 1. Parking daily The block must be single and hard ① Park your truck to desired place and enough to support the truck. Don‘t use blocks higher than block the wheels. ② Make sure the shift level is in the 300 mm（11.81 inch）.

  • Page 53: Running After Storing For A Long Time

    ⑧ 3. Running after storing for a long Warm-up your truck. time ① Remove the antirust oil from the exposed parts. ② Drain the gear oil of the crankcase, driving axle, hydraulic transmission box (torque converter type) clear it and add with new gear oil.

  • Page 54: Maintenance

    ⑧ Follow the maintenance schedule. ⑨ After performing maintenance, keep a record. ⑩ Only use Hangcha parts 1. Preventive maintenance schedule ○——Check, revise, adjust ×——Replace Caution：（1）If the work place has a lot of dirt or other pollutants, time between maintenance intervals should be decreased.
  • Page 55 Check Daily Monthly 3months Semi-annual Annual Tool Service required (8 hrs) (166hrs) (500hrs) (1000hrs) (2000hrs) Item Check crankcase and ○ ○ ○ clean dirt First time Check valve Plug ○ ○ ○ ○ clearance is correct gauge First time Tighten cylinder head Torque ○...
  • Page 56 Check Daily Monthly 3months Semi-annual Annual Tool Service required (8 hrs) (166hrs) (500hrs) (1000hrs) (2000hrs) Item Check for the oil ○ ○ ○ ○ ○ leakage of engine Check oil capacity and ○ ○ ○ ○ ○ Lubricat cleanness First time system Replace engine oil ×...
  • Page 57 Drive system periodical maintenance schedule Check Daily Monthly 3months Semi-annual Annual Service required Tools item (8 hrs) (166hrs) (500hrs) (1000hrs) (2000hrs) × Replace oil absorption First time × × filter (200h) ○ ○ ○ ○ ○ Leakage condition × Check oil quantity and ○...
  • Page 58 Wheel（front, rear wheel）periodical maintenance schedule Check Daily Monthly 3months Semi-annual Annual Service required Tools item (8 hrs) (166hrs) (500hrs) (1000hrs) (2000hrs) ○ ○ ○ ○ ○ Charge pressure Barometer Abrasion, crack or ○ ○ ○ ○ ○ damage If there is nail, stone or ○...
  • Page 59 Brake system periodical maintenance schedule Check Daily Monthly 3months Semi-annual Annual Service required Tools item (8 hrs) (166hrs) (500hrs) (1000hrs) (2000hrs) Dividing ○ ○ ○ ○ ○ Idle stroke scale ○ ○ ○ ○ ○ Pedal travel Brake pedal ○ ○...
  • Page 60 Brake drum abrasion, ○ damage condition Check if baseboard ○ deforms Flaw Brake ○ Check if crack baseboard detection Check if loosen during Test ○ installation hammer Hydraulic system periodical maintenance schedule Check Daily Monthly 3months Semi-annual Annual Service required Tools item (8 hrs)
  • Page 61 Circuit joint looseness ○ ○ ○ condition Steering Work and installation ○ ○ ○ ○ ○ indicator condition light Work and installation ○ ○ ○ ○ ○ Horn condition Light and Work and installation ○ ○ ○ ○ ○ bulb condition Reversing Work and installation...
  • Page 62 Fork root hook welded ○ ○ ○ ○ part crack wear condition. welded part between Inner and outer ○ ○ ○ ○ mast and beam has crack or damage. welded part between mast and tilting ○ ○ ○ ○ cylinder welding, crack damage.

  • Page 63: Torque Specifications

    chassis ○ beam damage or Truck crack body If rivet or bolt ○ loosen Check chassis lubrication ○ ○ ○ ○ condition after lubricate clean grease or change oil Check oil in the ○ oil tank Operator Working ○ ○ ○...

  • Page 64: Periodic Replacement Of Key Safe Parts

    3. Periodic replacement of key safe parts Some parts are not checked during routine maintenance. Please refer to the table below for the average service life of these parts Replace them when their service life has expired, sooner if they damaged. Name of key safe part service life (years) Brake hose or hard tube...
  • Page 65 4. Table for the oil used in the truck 1.0t~3.5t Forklift used oil Description Shop sign, Code name Capacity(L) Remark 1t∽1.8t Gasoline 93# or 97# 2t∽3.5t 1t∽1.8t 0#（Summer） Diesel -10#∽-35#（Winter） 2t∽3.5t General season：CH-4 grade 15W／40 winter：CH-4 grade 10W／30 (arctic-alpine: CF-4 grade Diesel engine oil 5.2∽7.5 Diesel engine...
  • Page 66 Description Shop sign, Code name Capacity(L) Remark SAE10W Delvac advanced Only for South Korean drive hydraulic oil axle(M truck model) Antirust -35# motor antifreeze liquid （add when leaving factory） antifreeze liquid 10∽11 1t∽3.5t (Radiator) or FD-2 antifreeze Industrial Battery terminal vaseline 3# Automobile general lithium Lubrication...
  • Page 67 4.0t~x5.5t Forklift used oil Capacit Description Shop sign，Code name Remark 100L 4.0t∽4.5t 93# or 97# Gasoline 116L 5.0~5.5t 100L 4.0t∽4.5t 0#（winter）(w58 sulphur content＜15pmm) Diesel -10#∽-35#（winter） 116L 5.0~5.5t General season：CH-4 grade 15W／40(add Diesel W34, when leaving factory)winter：CH-4 grade 10W／ engine oil 30 or refer to engine manual(arctic-alpine: CH-4 grade 5W/30，or refer to engine manual SF grade 15W/40(add when leaving factory) or...
  • Page 68 model: truck with the last letter M Recommendatory diesel engine oil viscosity under different temperature Note： The capability and quality of diesel engine oil should be in accordance with API class or SAE J183 CD grade or above CD grade, GB11122-1997CD grade and above CD-grade. Fill oil to diesel engine before leaving factory：CD grade SAE 15W／40.

  • Page 69: Lubrication System Drawing

    5. Lubrication system drawing 1. General motor lithium complex grease 2. Engine lubricating grease 3. Gear oil 4. Hydraulic oil 5. Torque converter oil 6. Brake oil Note： 1. The details of lubricating oil for different trucks are listed in the Table for the oil used in the truck.

  • Page 70: Labels：stick Various Nameplate And Mark At Different Position Of The Truck

    IX. Labels：Stick various nameplate and mark at different position of the truck Take 1-3.5t truck for example, and 4-x5.5t truck is similar： warning Tire Pressure Front Rear...
  • Page 71 view from"A" Stick emergency stop button Overhead view from"B" guard warning inboard view from"C" view from"D" The right box body (removes hood) Overhead guard Right flank kneading board Truck can Hold TIP OVER! Risk of serious Tight INHURY WARNING or DEATH! Brace Lean Away Faste Seatblet...
  • Page 72 Diesel label Gasoline label Hang label Operate label Lubrication Nameplate label Load curve label Warning label system label 18. Hand injury risk 15. No washing label 16. Danger label 17. Danger label label Hydraulic 19. Antifreeze label 20. Character label 22.
  • Page 73 LIFT METHOD SUBTRACT 200kg WITH SIDESHIFTER LOAD CENTRE POSITION Operate label Hydraulic truck Warning label W A R N I N G 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.
  • Page 74 21. Hydraulic oil label 16. Danger label The inner and outer mast, fork frame are all lifting slip parts. The hands are not allowed to reach in between the inner and outer masts. If a part needs to be check or repaired, the inspection and repair should be carried out after shutting down the engine.
  • Page 75 27. Tire pressure label TIRE PRESSURE REAR FRONT 1.5t~1.8t 10bar 7.9bar 145psi 115psi TIRE PRESSURE REAR FRONT 2.0t~2.5t 8.6bar 8.6bar Stick this label on the cylinder： 125psi 125psi Marked：Max. LPG weight is 52kg. Max. LPG pressure 2.2MPa TIRE PRESSURE Max. support bearing weight 105kg REAR FRONT 30.

  • Page 76: Truck Transporting, Lifting, Towing

    X. Truck transporting, lifting, towing Hoist the truck Use steel wire ropes through the holes in the two sides of the outside mast‘s beam and the hook of the counter balance, then use the lifting device to hoist the truck. Warning •...

  • Page 77: Model Meaning

    XI. Model meaning 1t-1.8t Hydraulic Rated capacity(t)/ Model Engine transmission Load center(mm) C240PKJ-30 1/500、 CPCD10/15/18-XW10F XF150-120000-G00 Diesel engine 1.5/500、1.75/500 CPQD10/15/18-XW21F XF150-120000-G00 GK21 1/500、1.5/500 CPQD10/15/18-XW21B Gasoline engine Y43160X / Y48130X 1.75/500 GCT(NISSAN) Gasoline CPQD10/15/18-XW21M XM150-130000-G00 CPYD15/18-XW21F XF150-120000-G00 GK21 1.5/500、1.75/500, CPYD15/18-XW21B Gasoline engine Y43160X / Y48130X IMPCO LPG single GCT(NISSAN)
  • Page 78 2t-2.5t Hydraulic Rated capacity(t)/ Model Engine transmission Load center(mm) CPCD20/25-XW10F XF250-130000-G00 2/500、2.5/500 C240PKJ-30 Diesel engine CPCD25-XW10B Y43160X / Y48140X 2.5/500 2/500、2.5/500 CPQD20/25-XW21F Gasoline 2/500、2.5/500, GK21 CPYD20/25-XW21F IMPCO LPG gasoline engine XF250-130000-G00 single fuel system GCT(NISSAN) 2/500、2.5/500, CPQYD20/25-XW21F IMPCO dual fuel system CPQD20/25-XW22F XF250-130000-G00 2/500、2.5/500...
  • Page 79 Rated Hydraulic capacity(t)/ Model Engine transmission Load center(mm) A498BT1-20 CPCD20/25-XW27F XF250-130000-G00 2/500、 2.5/500 Diesel engine CPCD20/25-XW32F XF250-130000-G00 2/500、 2.5/500 4TNE92-HRJ CPCD25-XW32B Y43160X / Y48140X 2.5/500 Diesel engine CPCD25-XW32M RM322-130000-G00 2.5/500 CPCD20/25-XW33F XF250-130000-G00 4TNE98-BQFLC CPCD20/25-XW33B Y43160X / Y48140X 2/500、 2.5/500 Diesel engine CPCD20/25-XW33M RM322-130000-G00 Cummins...
  • Page 80 3t-3.5t Rated Hydraulic Model Engine capacity(t)/ transmission Load C240PKJ-30 CPCD30/35-XW10F XF300-120000-G00 3/500、3.5/500 Diesel engine center(mm) CPQD30/35-XW22F XF300-120000-G00 GK25 gasoline 3/500、3.5/500 CPQD30/35-XW22B engine Y43160X / Y48150X Gasoline GCT(NISSAN) CPQD30/35-XW22M RM622-130000-G00 CPYD30/35-XW22F XF300-120000-G00 GK25 gasoline 3/500、3.5/500 CPYD30/35-XW22B engine Y43160X / Y48150X single IMPCO GCT(NISSAN) fuel system...
  • Page 81 Rated Hydraulic Model Engine capacity(t)/ transmission Load 4TNV94L-BXPHZ Y43160X / Y48150X CPCD30/35-XW56B Diesel engine center(mm) RM622-130000-G00 CPCD30/35-XW56M...
  • Page 82 4t-5t Hydraulic Rated capacity(t)/ Model Engine transmission Load center(mm) CPCD40/45-XW35B 4.0/500，4.5/500 1104D-44 XB450-130000-G02 （PERKINS） CPCD50/55-XXW35B 5.0/500,5.5/500 CPCD40/45-XW34B 4.0/500，4.5/500 1104D-44T XB450-130000-G02 （PERKINS） CPCD50/55-XXW34B 5.0/500,5.5/500 CPCD40/45-XW58B 4.0/500，4.5/500 QSF2.8 T4F XB450-130000-G01 (CUMMINS) CPCD50/55-XXW58B 5.0/500,5.5/500 CPYD40/45-XW57B 4/500、4.5/500 CPYD50/55-XXW57B 5.0/500, 5.5/500 GM4.3L LX XB450-130000-G01 Dual fule engine CPQYD40/45-XW57B 4/500、4.5/500 CPQYD50/55-XXW57B...

  • Page 83: Main Technical Performance Parameter

    XII. Main technical performance parameter 1t—1.8t Model CPCD10-XW10F CPCD15-XW10F CPCD18-XW10F Rated capacity 1000 1500 1750 Load centre distance Overall maximum 3000 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6°...
  • Page 84 Model CPQD10-XW21 CPQD15-XW21 CPQD18-XW21 Rated capacity 1000 1500 1750 Load centre distance Overall maximum 3000 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6° /12° 6° /12° Max travel speed km/h (without load) Ground clearance mm...
  • Page 85 Model CPYD15-XW21 CPYD18-XW21 Rated capacity 1500 1750 Load centre distance Overall maximum 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6° /12° Max travel speed km/h (without load) Ground clearance mm Min outside turning 1990 2015...
  • Page 86 Model CPQYD15-XW21 CPQYD18-XW21 Rated capacity 1500 1750 Load centre distance Overall maximum 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6° /12° Max travel speed km/h (without load) Ground clearance mm Min outside turning 1990 2015...
  • Page 87 Model CPYD15-XW51 CPYD18-XW51 Rated capacity 1500 1750 Load centre distance Overall maximum 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6° /12° Max travel speed km/h (without load) Ground clearance mm Min outside turning 1990 2015...
  • Page 88 Model CPYD15-XW87B CPYD18-XW87B Rated capacity 1500 1800 Load centre distance Overall maximum 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6° /12° Max travel speed km/h (without load) Ground clearance mm Min outside turning 1990 2015...
  • Page 89 CPCD10-XW32F CPCD15-XW32F CPCD18-XW32F Model CPCD10-XW32B CPCD15-XW32B CPCD18-XW32B CPCD10-XW32M CPCD15-XW32M CPCD18-XW32M Rated capacity 1000 1500 1750 Load centre distance Overall maximum 3000 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6°...
  • Page 90 2-3.5t CPCD25-XW10F Model CPCD20-XW10F CPCD30-XW10F CPCD35-XW10F CPCD25-XW10B Rated capacity 2000 2500 3000 3500 Load centre distance Overall maximum 3000 3000 3000 3000 lift height Free lift height Maximum lift mm/s 650/620 speed (with load) Tilt of the mast 6° /12° 6°...
  • Page 91 Model CPQD20-XW21F CPQD25-XW21F Rated capacity 2000 2500 Load centre distance Overall maximum 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6° /12° Max travel speed km/h 18.2 18.2 (without load) Ground clearance mm Min outside turning 2180...
  • Page 92 Model CPYD20-XW21F CPYD25-XW21F Rated capacity 2000 2500 Load centre distance Overall maximum 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6° /12° Max travel speed km/h 18.2 18.2 (without load) Ground clearance mm Min outside turning 2180...
  • Page 93 Model CPQYD20-XW21F CPQYD25-XW21F Rated capacity 2000 2500 Load centre distance Overall maximum 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6° /12° Max travel speed km/h 18.2 18.2 (without load) Ground clearance mm Min outside turning 2180...
  • Page 94 CPQD25-XW22F CPQD20-XW22F CPQD30-XW22F CPQD35-XW22F Model CPQD25-XW22B CPQD20-XW22M CPQD30-XW22M CPQD35-XW22M CPQD25-XW22M Rated capacity 2000 2500 3000 3500 Load centre distance Overall maximum 3000 3000 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6°...
  • Page 95 CPYD20-XW22F CPYD25-XW22F CPYD30-XW22F CPYD35-XW22F Model CPYD20-XW22B CPYD25-XW22B CPYD30-XW22B CPYD35-XW22B CPYD20-XW22M CPYD25-XW22M CPYD30-XW22M CPYD35-XW22M Rated capacity 2000 2500 3000 3500 Load centre distance Overall maximum 3000 3000 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6°...
  • Page 96 CPQYD20-XW22F CPQYD25-XW22F CPQYD30-XW22F CPQYD35-XW22F Model CPQYD20-XW22B CPQYD25-XW22B CPQYD30-XW22B CPQYD35-XW22B CPQYD20-XW22M CPQYD25-XW22M CPQYD30-XW22M CPQYD35-XW22M Rated capacity 2000 2500 3000 3500 Load centre distance Overall maximum 3000 3000 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6°...
  • Page 97 Model CPYD20-XW51F CPYD25-XW51F Rated capacity 2000 2500 Load centre distance Overall maximum 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6° /12° Max travel speed km/h 18.2 18.2 (without load) Ground clearance mm Min outside turning 2180...
  • Page 98 CPYD20-XW52F CPYD25-XW52F CPYD30-XW52F CPYD35-XW52F Model CPYD20-XW52B CPYD25-XW52B CPYD30-XW52B CPYD35-XW52B CPYD20-XW52M CPYD25-XW52M CPYD30-XW52M CPYD35-XW52M Rated capacity 2000 2500 3000 3500 Load centre distance Overall maximum 3000 3000 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6°...
  • Page 99 Model CPYD20-XW77B CPYD25-XW77B CPYD30-XW77B CPYD35-XW77B Rated capacity 2000 2500 3000 3500 Load centre distance Overall maximum 3000 3000 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6° /12° 6° /12° 6°...
  • Page 100 Model CPCD20-XW27F CPCD25-XW27F CPCD30-XW27F CPCD35-XW27F Rated capacity 2000 2500 3000 3500 Load centre distance Overall maximum 3000 3000 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6° /12° 6° /12° 6°...
  • Page 101 CPCD25-XW32F Model CPCD20-XW32F CPCD25-XW32B CPCD25-XW32M Rated capacity 2000 2500 Load centre distance Overall maximum 3000 3000 lift height Free lift height Maximum lift mm/s 600 /620/620 speed (with load) Tilt of the mast 6° /12° 6° /12° Max travel speed km/h 19.4 19.4/18.6/17.9...
  • Page 102 Model CPCD20-XW33 CPCD25-XW33 CPCD30-XW33 CPCD35-XW33 Rated capacity 2000 2500 3000 3500 Load centre distance Overall maximum 3000 3000 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6° /12° 6° /12° 6°...
  • Page 103 Model CPCD20-XW43 CPCD25-XW43 CPCD30-XW43 CPCD35-XW43 Rated capacity 2000 2500 3000 3500 Load centre distance Overall maximum 3000 3000 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6° /12° 6° /12° 6°...
  • Page 104 Model CPCD20-XW55 CPCD25-XW55 CPCD30-XW55 CPCD35-XW55 Rated capacity 2000 2500 3000 3500 Load centre distance Overall maximum 3000 3000 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6° /12° 6° /12° 6°...
  • Page 105 Model CPCD20-XW56 CPCD25-XW56 CPCD30-XW56 CPCD35-XW56 Rated capacity 2000 2500 3000 3500 Load centre distance Overall maximum 3000 3000 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6° /12° 6° /12° 6°...
  • Page 106 Model CPCD40-XW34B CPCD45-XW34B CPCD50-XXW34B CPCD55-XXW34B Rated capacity 4000 4500 5000 5500 Load centre distance Overall maximum 3000 3000 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6° /12° 6° /12° 6°...
  • Page 107 Model CPCD40-XW35B CPCD45-XW35B CPCD50-XXW35B CPCD55-XXW35B Rated capacity 4000 4500 5000 5500 Load centre distance Overall maximum 3000 3000 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6° /12° 6° /12° 6°...
  • Page 108 Model CPYD40-XW57B CPYD45-XW57B CPYD50-XXW57B CPYD55-XXW57B Rated capacity 4000 4500 5000 5500 Load centre distance Overall maximum 3000 3000 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6° /12° 6° /12° 6°...
  • Page 109 Model CPQYD40-XW57B CPQYD45-XW57B CPQYD50-XXW57B CPQYD55-XXW57B Rated capacity 4000 4500 5000 5500 Load centre distance Overall maximum 3000 3000 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6° /12° 6° /12° 6°...
  • Page 110 Model CPCD40-XW58B CPCD45-XW58B CPCD50-XXW58B CPCD55-XXW58B Rated capacity 4000 4500 5000 5500 Load centre distance Overall maximum 3000 3000 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6° /12° 6° /12° 6°...
  • Page 111 Model CPYD40-XW24B CPYD45-XW24B CPYD50-XXW24B CPYD55-XXW24B Rated capacity 4000 4500 5000 5500 Load centre distance Overall maximum 3000 3000 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6° /12° 6° /12° 6°...
  • Page 112 Model CPYD40-XW68B CPYD45-XW68B CPYD50-XXW68B CPYD55-XXW68B Rated capacity 4000 4500 5000 5500 Load centre distance Overall maximum 3000 3000 3000 3000 lift height Free lift height Maximum lift mm/s speed (with load) Tilt of the mast 6° /12° 6° /12° 6° /12° 6°...

  • Page 113: Cab And Overhead Guard

    XIII. Cab and overhead guard The structure of cabin: New type design, it is consist of left support leg, rear support leg, front glass, left door, right door, rear door. The operation of cab: 1. Open left door with key, enter into cab. 2.
  • Page 114 4. Dismantle the left, middle and right protect cover which conjoint with instrument frame. 3.bolt discreteness 1.Instrument frame 4.rear protect 2.left protect cover （5pcs） discreteness cover 8、bolt 7.right protect 5.bolt discreteness 6.bracket discreteness cover M5×16（3pcs） 9.front protect 10.bolt 11.bolt 12.switch rear cover discreteness discreteness...
  • Page 115 M4×16（2pcs） 13.switch rear cover 14.bolt discreteness M6×16（5pcs） 5. Remove switch connection of fan, rain wiper, alarm light etc 6. Remove 4 bolts from left front and right front legs. 7. Open the hood. 8. Remove 2 bolts inside left rear legs.(hand spanner) 9.
  • Page 116 Disassemble overhead: 1.rearview 2.cabane 3.clearstory 4.cover board 5.bolt M5×12 mirror board 6.right support 7.glue pipe 8.pipe hoop 9.gasket 14 10.gasket 14 assembly (8 pcs) (8 pcs) 12.left support 14.gasket 16 15.gasket 11.bolt M14× 13.bolt M16×...
  • Page 117 （8pcs) （8pcs) assembly 1.5×45(8 pcs) 1.5×45（8 pcs) 17.gasket 6 18.gasket 6 19.right rubber 20.left rubber 16.bolt M6×12 (6 pcs) (6 pcs) （6 pcs) 1. Stop the truck on solid and smooth level ground; close switch, pull down hand brake, engine flameout, ensure the door could open. 2.

  • Page 118: Operation And Notice About Lpg Forklift

    XIV. Operation and notice about LPG forklift 1.5-3.5t LPG Forklift for more details refer to 《R & XF Series 1.0t-3.5t LPG Forklift Operation and maintenance manual)》. Equipped with American GM4.3 LX Dual fuel engine 4.0t-x5.5t CPYD40-XW57、CPYD45-XW57、CPYD50-XXW57、CPYD55-XXW57 CPQYD40-XW57、CPQYD45-XW57、CPQYD50-XXW57、CPQYD55-XXW57 LPG fuel system consists of cylinder, filter, press reducing regulator, mixer, etc.. LPG is from cylinder to combination valve and high pressure pipeline, then pass filter and last into reducer.
  • Page 119 （2） By LPG ①Carburetor without gasoline：If you know the carburetor without any gasoline before start, use LPG directness. Close the gasoline switch, open LPG switch a few seconds, then open key to start motor, the engine move; ②Carburetor with gasoline：start engine is not easy by LPG, close the LPG and Gasoline switch(choose to middle position), start by gasoline.
  • Page 120 7. Mixer（ （K21 LPG\K25LPG\4.0-7.0t engine equip with） Mixer is based on the engine running condition, send the vaporized LPG and air together into engine to meet requirement of engine under different work conditions. 8. C ylinder （1）Function It is composed of safety valve, LPG inlet, quick fitting and other relevant accessories. It supports and stores fuel, and it is located at the back of truck.
  • Page 121 Buckle belt bracket 1. Hold tightening device with right hand, use forefinger, middle finger, and ring finger to Buckle belt and tightening device pull lock buckle out. 3．Keep the lock buckle out and pull 2. Keep holding lock buckle up, and push up downward the whole tightening device tightening device until it touches cylinder.
  • Page 122 Remove cylinder and charge Caution Avoid banging cylinder against truck when removing. Make sure the outlet shut off valve is closed. Only take empty cylinder to authorized charging place. Not allow charge privately, and the LPG ingredient should meet table 1 Truck Used LPG Technical Requirement.
  • Page 123 Item Quality index Test method Sulphuretted hydrogen None None None SH/T 0125 Free water None None None Eyeballing Note 1：Gaseity content, total sulfur content is at 0℃, 101.35kPa. Note 2： It can be measured whether it exists free water by eyeballing when measuring density.
  • Page 124 （5） （4,8） Make sure the inlet and outlet shutoff valve are closed. （6） （10） （9） Connect the inlet connector with outlet valve , and tighten （7） （8） Open outlet shutoff valve slowly. （8） （8） Make sure there is no leakage before using, if there is leakage, close outlet shutoff valve （3）...
  • Page 125 Pull buckle belt downward with left hand, Keep the buckle belt tensioning and keep pull out the lock buckle with fore finger, the lock buckle out, revolve restraint middle finger and third finger in right hand, downward with right hand until touch and push up to touch cylinder at the same cylinder.
  • Page 126 (10) The LPG conform to GB11174 can be recharging; the maximum volume is no more than 80% of cylinder. (11) The LPG must be charging at the place awarded by qualified Quality and Technical Supervision Bureau, do not fill by self. (12) Charging unit must vacuumize or displace with nitrogen when the new or recheck cylinder is used at the first time.
  • Page 127 pipes. IMPCO single fuel system...
  • Page 128 LPG system drawing...

  • Page 129: Operational Method Of Lead Acid Battery

    XV. Operational method of lead acid battery I. Lead acid battery and its application 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 130 3.2 Maintenance-free battery with battery display：Users need to add a little water and electrolyte in the use. 3.2.1. Battery check When the battery volume status is normal and electrolyte density reaches the standard, the small ball is in green; when the battery volume is insufficient and electrolyte density drops, the color is white;...
  • Page 131 Check and make sure the electrolyte is between "UPPER LEVEL" "LOWER LEVEL" 1: "UPPER LEVEL" 2: "LOWER LEVEL" If the electrolyte is or lower than ―Lower Level‖, please add distilled water. When lacking of the electrolyte, please check whether the surface is damaged or leaky, or the battery is conking out.
  • Page 132 Ⅴ. Notice for usage Battery can produce explosive gas, electrolyte is corrosive, and the current can burn skin from ： battery producing. When handle battery or work near it, comply with the following cautions Caution  When working near battery, one must wear safety inspection. ...

  • Page 133: Use, Installation And Safety Rules Of Attachment

    XVI. Use, installation and safety rules of attachment The attachment is in accordance to International standard ISO2328 Hook-on type fork arms and carriages - mounting dimensions, such as clamp, rotator, paper roll clamp, carrying ram, side-shifter etc. Sideshifter Fork positioner Rotator Push/pull Coil boom...
  • Page 134 2. Attachment assembly Warning Any change to safety or capability of attachment without authorization is strictly prohibited Actual load capacity should be the least of rated load capacity, attachment load capacity, combined load capacity of truck and attachment, combined load capacity of truck. Generally speaking, the combined load capacity of truck is the least.

  • Page 135: Description Of Ops System

    XVII. Description of OPS System OPS System（For hydraulic electronic shifting truck only） The OPS (Operator Presence Sensing) System is developed to assure the safety and prevent the operators from travelling or handling operation when the operator is not seated or not in the proper position, helping to decrease or prevent the accidents due to the maloperation.
  • Page 136 If it happens to encounter the following situations, please park the forklift truck in a safe place and contact the local agency of Hangcha forklift for inspection. a) Shift the gear switch to first gear of forward or reverse, but the neutral indicator light flashes when ready to start.

  • Page 137: Relevant Safety Command And Standard

    XVIII. Relevant safety command and standard The model with CE certification which accords to the following directive and standard: Machinery Directive 2006/42/EC (The European Council of the Laws of the Member States concerning Machinery), Noise Directive 2000/14/EC (Directive of the Laws of the Member States concerning Outdoor Equipment Noise Radiation), EN1726-1:1999+A1:2003(Safety Standards for Machinery Industrial Vehicles), EN12053:2001, ISO 3691-1:2015, EN16307-1:2013+A1:2015 EN1175-2:1998+A1:2010,...
  • Page 138 CPYD50-XXW24 1.06 85.1 104.5 CPYD55-XXW24 1.08 85.1 104.5 CPYD40-XW68 1.02 103.8 CPYD45-XW68 1.15 103.8 CPYD50-XXW68 1.17 103.7 CPYD55-XXW68 1.16 103.7  Electromagnetism compatibility is measured according to EN12895:2000, and meet with 2004/108/EE Directive.  Static test coefficient for lifting attachment is 1.33. Declaration example：...
  • Page 139 88 DONGHUAN ROAD,LIN‘AN ECONOMIC DEVELOPMENT ZONE,ZHEJIANG,CHINA Add： 311305 E-Mail：sales@zjhc.cn Tel：+86-571-88926666 Fax： +86-571-88144682 EC DECLARATION OF CONFORMITY MANUFACTURE： NAME: HANGCHA GROUP CO., LTD. ECONOMIC DEVELOPMENT ADDRESS: 88 DONGHUAN ROAD,LIN‘AN ZONE,ZHEJIANG,CHINA PERSON AUTHORISED TO COMPILE THE TECHNICAL DOCUMENTATION IN EU： NAME: ADDRESS: HEREBY DECLARES THAT THE PRODUCT DESCRIBED BELOW：...
  • Page 140 DECLARATION OF CONFORMITY EG-KONFORMITÄTSERKLÄRUNG Business name of the manufacturer: Hangcha Group Co., Ltd. Firmenbezeichnung des Herstellers: Full address of the manufacturer: 88 Donghuan Road, Lin’an Economic Development Zone, Zhejiang 311305, P. R. China Vollstä ndige Adresse des Herstellers: Name and address of the person (established in the Community) compiled the technical file: Name und Adresse der Person (innerhalb der Gemeinschaft), die das technische Datenblatt erstellt hat Saamuk Lift Truck Ltd.

  • Page 141: Xvi.maintenance Record

    XVI.Maintenance record Date Item of maintenance Signature Remark...
  • Page 142 HANGCHA GROUP CO. , LTD. ■ Address For: OVERSEAS USERS ■ Address: 666 Xiangfu Road, Hangzhou, Zhejiang, China ■ Fax: 0086-571-88926789 0086-571-88132890 ■ ZIP:311305 ■ Web: http://www.hcforklift.com ■ E-mail: sales@hcforklift.com...

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