HANGCHA X Series Operation And Maintenance Manual
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HANGCHA X Series Operation And Maintenance Manual

Electric forklift truck
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X Series
CPD10/15/18/20/25/30/35-XC4(-I)
CPD10/15/18/20/25/30/35-XD2(-I)
CPD40/45/50-XC4(-I) CPD20/25-XC4-JC(I)
CPD20-XXC4(-I) CPD25-XLC4(-I) CPD50-XXC4(-I)
CPD20-XXD24(-I) CPD25-XLD2(-I)
Electric Forklift Truck
OPERATION AND MAINTENANCE
MANUAL
Original Instruction
HANGCHA GROUP CO., LTD.
OM21-X01（08 / 2021）

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  • Page 1 X Series CPD10/15/18/20/25/30/35-XC4(-I) CPD10/15/18/20/25/30/35-XD2(-I) CPD40/45/50-XC4(-I) CPD20/25-XC4-JC(I) CPD20-XXC4(-I) CPD25-XLC4(-I) CPD50-XXC4(-I) CPD20-XXD24(-I) CPD25-XLD2(-I) Electric Forklift Truck OPERATION AND MAINTENANCE MANUAL Original Instruction HANGCHA GROUP CO., LTD. OM21-X01（08 / 2021）...
  • Page 2 FOREWORD Thanks for you purchasing our X series electric four-wheel forklift truck. X series electric four-wheel forklift truck is our company’s new product. It has the character of small turning radius, beautiful shape, small dimensions, low gravity, good stability, superior performance.

  • Page 3: Table Of Contents

    CONTENT 1.Specified purpose ....................1 General ......................... 1 Use as required ....................1 Allowed conditions of use ..................1 The obligations and responsibilities of the equipment user ........2 Attachment installation ..................2 2.Introduce ......................... 1 Main components ....................1 Displays and Controls...................
  • Page 4 Replace the key safe parts termly ..............106 Table for oil used in the truck ................107 Table for bolts tightening torque ............... 108 15.The use, Install and Safety Rules of attachment ........... 109 Attachment assy ....................109 Attachment use ....................109 Check and maintenance: ..................
  • Page 5 1.Specified purpose General Truck in this manual is only for lifting and transporting loads. It must be used, operated and maintained according to the information in this manual. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property.
  • Page 6 It is prohibited to travel crosswise or obliquely. When go uphill with loads, keep the forks forward; when go downhill, travel in reverse. Warning ·In extreme environments, especially when using the truck in an environment with severe dust or corrosion and rust, additional special equipment must be installed and approved by the manufacturer.

  • Page 7: Specified Purpose

    2.Introduce Main components Item Description Fork Load backrest Mast Rearview mirror Overhead guard Driver’s seat Counterweight cover Counterweight Towing pin Rear wheel Battery behind cover hood Front wheel...

  • Page 8: The Obligations And Responsibilities Of The Equipment User

    Displays and Controls...
  • Page 9 Item Control / Display Travel direction switch Multi-function display Horn Combination light switch Lifting lever Tilting lever Emergency disconnect switch Hand brake（non -E series forklift truck） Warning light switch Steering column positioning device Brake pedal Accelerator pedal Steering wheel Key switch Locker of battery cover hood Side door lock Air spring...

  • Page 10: Multi-Function Display

    Multi-function display The multi-function display shows the battery capacity, the service hours, the operating mode, the travel speed and fault code information. Graphic illustrations on the multi-function display act as warning indicators. Through the multi-function display on the right button can also check fault code and parameter setting.
  • Page 11 The setting mode is slow mode; when the meter is in the password interface, press ▼ to switch the user password or OEM password input setting; when the meter is in the menu interface, press ▼ to move the menu option down. The setting mode is power mode;...
  • Page 12 Main display interface Battery level display Left turn indication Travel speed display Right turn indication Operating mode display Turtle speed mode indication Traction controller running hours display Fault repair indication Vehicle running hours display Battery below 10%, lift lock indication Pump controller operating hours display Seat indication Vehicle steering angle display...
  • Page 13 Battery level display [A] Shows the remaining capacity of the battery. As shown in the above figure, when the battery power is less than 20%, the entire battery indicator will flash. At this time, please stop working and charge immediately. It is recommended to charge when two grids remain (the remaining battery is about 30%), otherwise the battery life will be greatly shortened.
  • Page 14 Traction controller running hours display [D] The hourglass icon indicates the hour meter function. Display the cumulative working time of the traction controller Vehicle running hours display [E] The hourglass icon indicates the hour meter function. When the vehicle key switch is turned on, the hour meter starts counting, and the minimum resolution is 0.1 hour.
  • Page 15 When there is 10% power, the indicator is on, and the mast lifting speed drops, to remind user to charge the battery as soon as possible. Seat switch indicator[M] When operator leaves the seat, the light will be on, and the truck will be unable to travel or lift. This function needs the seat to equip with seat switch.
  • Page 16 Enter the number "1" for the password. Enter the number "2" for the password. Enter the number "3" for the password. Enter the number "4" for the password. Switch user password/OEM password. Switch user password/OEM password. Switch user password/OEM password. Switch user password/OEM password.
  • Page 17 When the meter is in the fault interface, press again and the meter will return to the main interface display. Key function When the meter is in the main interface, you can enter the following 4 menu interfaces by pressing F1~F4.
  • Page 18 The multi-function display shows the battery capacity, the service hours, the operating mode, the travel speed and fault code information. Graphic illustrations on the multi-function display act as warning indicators. Through the multi-function display on the right button can also check fault code and parameter setting.
  • Page 19 Main display interface hour. Operating mode display[C] E S P E As the diagram shows, the pictures from the left to the right represent the mode of S mode→ P mode → E mode → SPE mode. S mode is super mode, thus the truck’s Battery capacity display[A] acceleration, deceleration rate, max climbing gradient and so on is much higher.
  • Page 20 Battery low capacity indicator[H](Red) power cutting every time, the work mode resets to mode E no matter which mode it is before power When there is only one line for the power, the cutting, but the switch key is still in indicator will be on to remind the user to the mode before turn off.
  • Page 21 Mode settings 、 In the main display interface, the button 、 、 , corresponding S mode、 P mode、E mode、SPE mode. For example: In the main display interface, (2) Language switch setting: This instrument supports two languages, Chinese and English, press the button , the screen shows as which will be adjusted to the language you need follows:...
  • Page 22 ⑥ Use the up key ( ) or down key ( ) to select the Chinese language. ⑦Refer to steps ⑤ ④ ③ ② ①, press the return key ( ) to return to the main interface. ④Select the "Language" option by moving up ) or down ( Press the menu key ( ) to enter the language...

  • Page 23: Controls

    stop ， then travel to the opposite Controls direction. Rearview mirror [4] WARNING Turning the key switch “on” does  not make the forklift truck move, if the travel direction switch is not in neutral position accelerator pedal is being pressed. In this case, the travel direction switch should be returned to neutral move...
  • Page 24  The turn signal switch does not the electricity is being shut down automatically return to the neutral even if the tilt lever is pushed position. Reset it by your hand. forwards. Lifting lever [17] Emergency disconnect switch [19] Switches power supply on and off. When happen emergency, presses down the emergency disconnect switch, and then the main power of the truck will be cut off, the truck...
  • Page 25 start the parking brake. CAUTION  Steering column positioning device [22] Loosen the accelerator pedal when truck is working, truck can make soft brake. WARNING  Before open the key switch to press the accelerator pedal, the more function digital indicator shall show alarm information.
  • Page 26 CAUTION CAUTION  Turning the key switch “on” does  When replace a new fuse, please not make the forklift truck move, if choose the same capacity fuse of the Direction switch lever is not in the old one. neutral position accelerator pedal is pushing.
  • Page 27 down. Brake fluid reservoir cup Change new fork: Firstly, make the fork dead The brake fluid reservoir cup is located at the against the truck and forklift’s mast to the meter board. bottom, then operate the truck traveling CAUTION forward, aim at the two gaps and beams, and ...
  • Page 28 Connector Battery Far light Position × × × CAUTION  This light does not relate to key switch position, so please don’t forget to turn off the rear big lamp when you leave the truck.
  • Page 29 Lift fingertip Fingertip operation（option） Armrest system is composed of armrest bracket, fingertip, emergency stop button, horn button and wire etc. Push the fingertip forward to lower the forks. Pull the fingertip back to raise the forks. The lifting lowering speed is controlled by the tilting angle that the lever is moved, the larger angle, the faster speed.
  • Page 30 Sideshifter fingertip Level shift handle Pull and push the fingertip can realize the left/right movement of the mast. Adjust horizontal position of armrest：Flip the Attachment fingertip picks up,release the armrest and move it to proper position;Flip the picks down,lock the armrest.

  • Page 31: Seat

    Seat Seat and seat adjustment lever In order to guarantee safety operation of the forklift, adjust the seat (2) according to driver’s need and fasten safety belt before operation. Incorrect seat adjustment may cause accident or endanger your health. To adjust the seat position, pull up on the adjustment lever and press it to slide the seat forward or backward to adjust the seat to a comfortable, easy-to-operate position.
  • Page 32 Adjust driver seat according to weight In order to get ideal damping effect, adjust the seat according to driver’s weight Procedures： – Pull out weight adjusting lever (56). – Elevate and press weight adjusting lever (56) to increase seat bearing weight. –...

  • Page 33: Safe Belt

    Safe belt Put on the seat belt④ each time before starting the truck. The belt protects against serious injury. Protect the belt from contamination and clean it regularly. Correct use the safe belt: – Sit correctly on the seat. – Check that seat belt is not twisted.
  • Page 34 How to act in unusual situations – Fasten seat belt, stay in seat. – Do not jump ! – Lean forward, hold on tight steering wheel, brace feet. – Lean your body away from impact. WARNING  If the truck is about to tip over, never undo the restraint belt and try to jump out. This will only increase the risk of serious injury or death !

  • Page 35: Nameplate And Safety Labels

    载货时，货物重量及尺寸应符合载荷曲线图规定，并使货物重心处于门架中心位置，切勿超载或偏位 载货行驶时，货叉离地300mm左右，门架最大后倾，使货物贴紧后壁，载货行驶中禁止急速制动和急转弯； 工作结束后，停好叉车，方向开关置"中档"，货叉下降着地，关闭电门开关，拉紧手制动，断开总电源插头 蓄电池电量不足时应及时充电，按说明书要求充电，避免过放电及过充电 叉车行驶时，如电控器失控，应立刻拉动总电源插头手柄及时断开总电源 吊装蓄电池箱时，箱体两侧的四个挂钩孔应同时挂钩起吊，严禁只用两只挂钩起吊，以免箱体变形挤伤蓄电池 Description Warning label：Do not step onto or beneath the load Hangcha fork Hoisting method Lift method Seat belt label Tethered point label Hangcha fork Hand brake label Warning label：No climbing Warning label：Risk of trapping with moving mast...
  • Page 36 Description Series and tonnage label Please abide by the operation instructions Warning label： Nameplate Rated capacities and load centers graph Nameplate:...

  • Page 37: Technical Specifications

    4.Technical Specifications Item CPD20-XC4 CPD25-XC4 Rated lifting capacity 2000 2500 Load center distance 3000 3000 lift height Free Mast Tilt angle (front/back) (° ) 6 / 10 6 / 10 Maximum travel speed(full km/h load/no load) Maximum lifting speed (full load/no load) Maximum grade...
  • Page 38 Item CPD30-XC4 CPD35-XC4 Rated lifting capacity 3000 3500 Load center distance 3000 3000 lift height Free Mast Tilt angle (front/back) (° ) 6 / 10 6 / 10 Maximum travel speed(full km/h 16.5 load/no load) Maximum lifting speed (full load/no load) Maximum grade ability...
  • Page 39 Item CPD25-XC4-JC CPD10-XC4 Rated lifting capacity 2500 1000 Load center distance 3000 3000 lift height Free Mast Tilt angle (front/back) (° ) 6 / 10 6 / 10 Maximum travel speed(full km/h 16.5 16.5 load/no load) Maximum lifting speed (full load/no load) Maximum grade...
  • Page 40 Item CPD35-XC4-I CPD30-XC4-I 3500 3000 Rated lifting capacity Load center distance 3000 3000 lift height Free 6/10 6/10 Mast Tilt angle (front/back) (° ) Maximum travel speed(full 16.5 km/h load/no load) Maximum lifting speed (full load/no load) Maximum grade ability (full load/no load) Minimum outside turning 2230...
  • Page 41 Item CPD25-XC4-I CPD20-XC4-I 2500 2000 Rated lifting capacity Load center distance 3000 3000 lift height Free 6/10 6/10 Mast Tilt angle (front/back) (° ) Maximum travel speed(full 16.5 km/h load/no load) Maximum lifting speed (full load/no load) Maximum grade ability (full load/no load) Minimum outside turning 2055...
  • Page 42 Item CPD18-XC4-I CPD15-XC4-I 1750 1500 Rated lifting capacity Load center distance 3000 3000 lift height Free 6/10 6/10 Mast Tilt angle (front/back) (° ) Maximum travel speed(full km/h load/no load) Maximum lifting speed (full load/no load) Maximum grade ability (full load/no load) Minimum outside turning 1860 1845...
  • Page 43 Item CPD10-XC4-I CPD20-XC4-JC 1000 2000 Rated lifting capacity Load center distance 3000 3000 lift height Free 6/10 6/10 Mast Tilt angle (front/back) (° ) Maximum travel speed(full 16.5 km/h load/no load) Maximum lifting speed (full load/no load) Maximum grade ability (full load/no load) Minimum outside turning 1845...
  • Page 44 Item CPD25-XC4-JCI CPD20-XC4-JCI 2500 2000 Rated lifting capacity Load center distance 3000 3000 lift height Free 6/10 6/10 Mast Tilt angle (front/back) (° ) Maximum travel speed(full 16.5 km/h load/no load) Maximum lifting speed (full load/no load) Maximum grade ability (full load/no load) Minimum outside turning 2055...
  • Page 45 Item CPD20-XXC4 CPD25-XLC4 2000 2500 Rated lifting capacity Load center distance 3000 3000 lift height Free 6 / 10 6 / 10 Mast Tilt angle (front/back) (° ) Maximum travel speed(full 16.5 km/h load/no load) Maximum lifting speed (full load/no load) Maximum grade ability...
  • Page 46 Item CPD20-XXC4-I CPD25-XLC4-I 2000 2500 Rated lifting capacity Load center distance 3000 3000 lift height Free 6 / 10 6 / 10 Mast Tilt angle (front/back) (° ) Maximum travel speed(full 16.5 km/h load/no load) Maximum lifting speed (full load/no load) Maximum grade ability...
  • Page 47 CPD50-XC4 CPD45-XC4 Item 5000 4500 Rated lifting capacity Load center distance 3000 3000 lift height Free 5/10 5/10 Mast Tilt angle (front/back) (° ) Maximum travel speed(full 13.5 km/h load/no load) Maximum lifting speed (full load/no load) Maximum grade ability (full load/no load) Minimum outside turning 2680...
  • Page 48 CPD40-XC4 CPD40-XC4-I Item 4000 4000 Rated lifting capacity Load center distance 3000 3000 lift height Free 5/10 5/10 Mast Tilt angle (front/back) (° ) Maximum travel speed(full 16.5 16.5 km/h load/no load) Maximum lifting speed (full load/no load) Maximum grade ability (full load/no load) Minimum outside turning...
  • Page 49 CPD50-XC4-I CPD45-XC4-I Item 4990 4500 Rated lifting capacity Load center distance 3000 3000 lift height Free 5/10 5/10 Mast Tilt angle (front/back) (° ) Maximum travel speed(full 15.5 km/h load/no load) Maximum lifting speed (full load/no load) Maximum grade ability (full load/no load) Minimum outside turning 2680...
  • Page 50 CPD50-XXC4 CPD50-XXC4-I Item 4990 4990 Rated lifting capacity Load center distance 3000 3000 lift height Free 5/10 5/10 Mast Tilt angle (front/back) (° ) Maximum travel speed(full km/h load/no load) Maximum lifting speed (full load/no load) Maximum grade ability (full load/no load) Minimum outside turning 2600 2620...
  • Page 51 CPD10-XD2 CPD15-XD2 Item 1000 1500 Rated lifting capacity Load center distance 3000 3000 lift height Free 6/10 6/10 Mast Tilt angle (front/back) (° ) Maximum travel speed(full 16.5 km/h load/no load) Maximum lifting speed (full load/no load) Maximum grade ability (full load/no load) Minimum outside turning 1845...
  • Page 52 CPD18-XD2 CPD20-XXD2 Item 1750 2000 Rated lifting capacity Load center distance 3000 3000 lift height Free 6/10 6/10 Mast Tilt angle (front/back) (° ) Maximum travel speed(full km/h load/no load) Maximum lifting speed (full load/no load) Maximum grade ability (full load/no load) Minimum outside turning 1845 1888...
  • Page 53 CPD20-XD2 CPD25-XD2 Item 2000 2500 Rated lifting capacity Load center distance 3000 3000 lift height Free 6/10 6/10 Mast Tilt angle (front/back) (° ) Maximum travel speed(full 16.5 km/h load/no load) Maximum lifting speed (full load/no load) Maximum grade ability (full load/no load) Minimum outside turning 1990...
  • Page 54 CPD25-XLD2 CPD30-XD2 Item 2500 3000 Rated lifting capacity Load center distance 3000 3000 lift height Free 6/10 6/10 Mast Tilt angle (front/back) (° ) Maximum travel speed(full 16.5 16.5 km/h load/no load) Maximum lifting speed (full load/no load) Maximum grade ability (full load/no load) Minimum outside turning...
  • Page 55 CPD35-XD2 CPD10-XD2-I Item 3500 1000 Rated lifting capacity Load center distance 3000 3000 lift height Free 6/10 6/10 Mast Tilt angle (front/back) (° ) Maximum travel speed(full 16.5 km/h load/no load) Maximum lifting speed (full load/no load) Maximum grade ability (full load/no load) Minimum outside turning 2230...
  • Page 56 CPD15-XD2-I CPD18-XD2-I Item 1500 1750 Rated lifting capacity Load center distance 3000 3000 lift height Free 6/10 6/10 Mast Tilt angle (front/back) (° ) Maximum travel speed(full 16.5 km/h load/no load) Maximum lifting speed (full load/no load) Maximum grade ability (full load/no load) Minimum outside turning 1845...
  • Page 57 CPD20-XXD2-I CPD20-XD2-I Item 2000 2000 Rated lifting capacity Load center distance 3000 3000 lift height Free 6/10 6/10 Mast Tilt angle (front/back) (° ) Maximum travel speed(full 16.5 km/h load/no load) Maximum lifting speed (full load/no load) Maximum grade ability (full load/no load) Minimum outside turning 1888...
  • Page 58 CPD25-XD2-I CPD25-XLD2-I Item 2500 2500 Rated lifting capacity Load center distance 3000 3000 lift height Free 6/10 6/10 Mast Tilt angle (front/back) (° ) Maximum travel speed(full 16.5 km/h load/no load) Maximum lifting speed (full load/no load) Maximum grade ability (full load/no load) Minimum outside turning 2055...
  • Page 59 CPD30-XD2-I CPD35-XD2-I Item 3000 3500 Rated lifting capacity Load center distance 3000 3000 lift height Free 6/10 6/10 Mast Tilt angle (front/back) (° ) Maximum travel speed(full km/h load/no load) Maximum lifting speed (full load/no load) Maximum grade ability (full load/no load) Minimum outside turning 2195 2230...

  • Page 60: Safety Instructions

    Safety Instructions Only trained and authorized operator shall be permitted to operate the truck. Inspect the truck at periodic intervals for oil or water leak, deformation, lousiness, etc. If neglected, short life of components will be caused and in the worst case a fatal accident would occur.
  • Page 61 – The considered climatic conditions when the forklift designs are: Temperature - 20℃-50℃; the wind speed does not surpass 5m/s; the air relative humidity is not bigger than 90% (temperature 20℃). – The forklift is not suitable in the flammable explosive working conditions. –...
  • Page 62 use of a hook or crane arm attachment. – Take care not to protrude the forks out of the load. The protruded fork tips may damage or turn over the adjacent load. 14. Know the rated capacity of your lift truck and its attachment, if any, and never exceed it. Do not use a man as an additional counterweight.
  • Page 63 21. It is forbidden to put your hands, arms or head stretch between the mast and safeguard. Once clamped, the life has danger. – It is forbidden to put your hands in inner and outer mast. 22. The goods is liable to drop turning or passing rough road when it departures the center. And the forklift may turn over more probably.
  • Page 64 above the ground or floor and the mast tilted backward) – Do not operate the side shift mechanism, if equipped, when the forks are raised and loaded, since this will cause the truck to be unbalanced. 26. Watch for branches, cables, doorways, or overhangs. Pay caution when working in congested areas.
  • Page 65 31. Never lift loads with the truck inclined. Avoid loading work on a grade. 32. Never permit anyone to stand or walk under upraised forks or other attachments if machine is so equipped. If unavoidable, use a safety stand or block to prevent a possibility of fork attachments falling down or moving unexpectedly.
  • Page 66 41. There are some chemical corrosive substances on the anti-corrosion truck surface, such as acid, alkali and salt etc. liquid, remove timely to avoid forklift corrosion. 42. In a corrosive environment, especially in heavy corrosion environment, such as acid, alkali, salt and other chemical etching medium, severe operation conditions as high temperature, humidity and dust etc., anti-corrosion truck cannot work continuously or park for a long time.

  • Page 67: Forklift Transport,Lifting﹠Towing

    6.Forklift Transport,Lifting﹠Towing Transport – The Fork Lift Truck is designed for material handling only, It is inappropriate for long-distance transportation. If needed, the Fork Lift Truck must be transported by ship, train or lorry, of 5T loading. Use a lifting pallet to hoist the truck. Use the steel wire ropes to tie the holes in the two side of the outside mast’s beam and the –...

  • Page 68: Towing

    Towing – The towing rod on the bottom of the counter balance is used to pull and drag the truck. – Turn off key and pull out power switch. – Loosen the brake lever. – Set switch lever to neutral position. WARNING ...

  • Page 69: The Structure And Stability Of Truck

    7.The Structure and Stability of Truck Prevent the forklift to turn over! It is very important for operator to know the truck’s structure and relationship between load and stability. Structure CAUTION The basic structure of the truck is mast (include mast and forks) and body (include tire).
  • Page 70 The max. load and load center CAUTION The load center distance is defined that: the distance between the load center and the fork carriage or the front of the fork carriage. The max. load means the maximum load the truck can charge at the normal load center distance.
  • Page 71 Capacity chart CAUTION The chart given shows the relation between the load center and the weight of loads. Before loading, make sure that the load and the load center distance in the range of capacity chart. If the load’s shape is complex, put the most weightily part on the middle of the forks, and close to the fork carriage.

  • Page 72: Running-In Of The New Truck

    8.Running-in of the new truck We recommended operating the machine under light load conditions for the first stage of operation to get the most from it. Especially the requirements given below should be observed while the machine is in a stage of 100 hours of operation. –...

  • Page 73: Daily Maintenance

    first, adjust the air pressure of the 9.Daily Maintenance compressor. Otherwise it will cause The earnest complete maintenance, can keep serious accident, since the forklift to be at the good status. And the maximum pressure of compressor safety of the truck is related with your job and higher than the pressure tire can your life.
  • Page 74 wooden block under each side of outer mast; ⑥ Tilt mast forward until front wheels are raised from surface Caution Do not loose nuts before the front wheels leave the ground. ⑦ Support truck by putting wooden blocks under both sides of the front truck frame. Stop the engine.
  • Page 75 Warning When removing tire from wheel rim, do not remove rim set bots and nuts before releasing air; Make sure that wooden blocks used to support lift truck are solid, one-piece units; c. Never get under forklift while it is supported only by wooden blocks.
  • Page 76 – The proper brake distance is 2.5m when level is between the scales. Add oil when lack. free load . – Adjust the height of pedal to 115～125mm . – Adjust brake booster push rod clearance to 1-3mm . – The brake lamp should be lighted when the brake pedal steps on 10-20mm .
  • Page 77 11.Check battery Adjust the lubricate schedule according to your – Check the battery whether be installed working condition. Add times when busy. firmly. To coordinate forklift's operation, grease – Check proportion of electrolyte. Refer to lubrication to the guide pulley and in outer “Battery”...
  • Page 78 properly by pull/push turn signal switch. Make sure that the sound of horn is properly by press the horn button Check the other lamp and back-up buzzer. 19. Battery maintenance Refer to battery section. 20. Other For instance, pay attention to abnormal noise.

  • Page 79: Driving And Operation

    Traveling 10.Driving and Operation Step the accelerate pedal slowly, the truck will WARNING travel forward or backward.  Before operating the truck, check all Decrease speed controls and warning devices for Loosen the accelerate pedal slowly, the proper operation. If any damage or truck will decelerate.

  • Page 80: Loading

    stop the truck. except when climbing grades. – Place the shift lever in neutral. – Pull up the parking brake lever. – Down the forks on the ground, tilt mast forwards fully. Place the key switch in “OFF” to shut off –...

  • Page 81: Un-Stacking Load

    – After making sure the forks leave the load, 10 cm and move backward 10 to 20 lower the forks to the basic position (15 to cm with the pallet on the forks, 20 cm off the ground). and then fall the pallet to the stack. ...

  • Page 82: Check After Operation

    brake coil is out of power, and the motor foreign body. – can not rotate; 4. When the seat switch is Check the wheel hub nut if it is loose. – ON, the direction signal input, the Check the height of electrolyte surface. If you haven’t lift the fork to the max.

  • Page 83: Deposit

    11.Deposit WARNING  The stow-wood must be single and Daily Depositing hard enough to support the truck. – Park your truck at the area appointed, and  Don’t use a stow-wood higher than block the wheels to prevent accidental 300mm（11.81 inch）. roll.

  • Page 84: Battery

    （8）Measures in winter: Maintain a good temperature, please contact the agent or charging environment. Do not park the truck Hangcha after-sales service. out in the cold or in the freezer for long time 1.1 Maintenance precautions especially after the battery is used, it is （1）Maintenance personnel must...
  • Page 85 1.2 Daily, weekly, monthly, long-term 2.1 Specific gravity detection storage maintenance （ 1 ） Use a thermometer to measure the Time Content temperature of the electrolyte. 1. After the battery is discharged, it （2）Vertically insert the flexible tube of a needs to be charged in time.
  • Page 86 splashguard level. 2.2 Specific gravity conversion Battery with hydrometer Convert electrolyte density at the standard temperature of 30 C based on the following Measure electrolyte level by reading the vent formula: cap hydrometer. ＝D ＋0.0007（t-30） ——electrolyte density at 30℃ Wherein：D ——measured electrolyte density at t℃.
  • Page 87 Battery with hydrometer 4.Battery charging Stop adding water when the red hydrometer float rises and a white line appears. Warning 1. The forklift should be charged as soon as possible after use. It must be charged in time before the battery is 20% left.
  • Page 88 1/7), that is, the current = (1/10 to 1/7) the manual. If it is not enough, add battery capacity. For example, the battery distilled water (filled with Hangcha pure capacity is 630Ah, the charger current = (1/10 distilled water).
  • Page 89 below the cut-off voltage; （2）The discharge current is frequently too high; （3）The battery is not charged in a timely manner after discharge is complete; （4）The battery frequently gets insufficient charge, or hasn't been used for a long time; 5.2 Battery weight and dimension 4.3.2 Equalizing charge method The battery replacement has the lightest and Please follow the instructions of the charger.
  • Page 90 CPD25-XC4 Model CPD25-XD2 Model CPD45/50-XC4 Battery CPD25-XC4-JC Battery CPD50-XXC4 Allowable 900 kg Allowable 1777 kg lightest lightest Length× Width 1028 ×571 ×784 Length× Width 1028 ×855 ×784 ×Height ×Height Model CPD30-XC4 Battery CPD30-XD2 Allowable 1170 kg lightest Length× Width 1028 ×711 ×784 ×Height...

  • Page 91: Lithium Battery

    13.Lithium battery 1 Safety warning 1.1 Electrodes short circuit is prohibited, do not heat the battery, or throw the battery into water; 1.2 Fully charge the new battery before use; 1.3 Do not mix different brands, different types, different capacities, and old and new batteries; 1.4 The battery combination should not be used in the case of inconsistent capacity saturation of each single cell to avoid overcharge and over discharge of the cell;...
  • Page 92 3. 1.6 Overcharge The state when the battery voltage is higher than the maximum charging voltage is usually regarded as the battery entering the overcharge state; 3.1.7 Overcurrent The battery's operation and charging current are higher than the maximum allowable operation of the manufacturer, and the state of charging current is usually considered as the battery entering the overcurrent state;...
  • Page 93 Overcharge protection voltage 3.75V Maximum charging current 200A Overcharge release voltage 3.67 V Undervoltage release voltage 2.8 V Undervoltage protection voltage 2.7 V parameter Over-discharge protection voltage 2.2 V configuration Over temperature protection 60℃ temperature Over discharge release voltage 2.6 V 4.
  • Page 94 wrenches, and screwdrivers used for installation operations; 4.6.3 Wear anti-smashing shoes and insulated gloves when installing. Do not wear watches, metal bracelets, necklaces, etc. 4.7 Daily maintenance 1） There should be professionals when charging, make sure the plug and socket is well contacted, charging facility work normally, and each battery connections are well contacted.
  • Page 95 5 Size and weight Long（L） Width（W） High（H） Item (mm) (mm) (mm) CPD1015/18-XC4-I CPD1015/18-XD2-I CPD20/25-XC4-I 1026 CPD20/25-XD2-I CPD30/35-XC4-I 1026 CPD30/35-XD2-I CPD20/25-XC4-JCI 1026 CPD20-XXC4-I CPD20-XXD2-I CPD25-XLC4-I 1026 CPD20-XLD2-I CPD40/45/50-XC4-I 1026 CPD50-XXC4-I Warning Weight and dimension of the battery has a great influence on the stability and bearing capacity of the truck travelling.
  • Page 96 6.Lithium battery charging This forklift truck is equipped with Titan can only charger. 3.0 t-5.0t and CPD25-XLC4-I with SLC-80200 smart charger，1.5t~2.5t with SLC-48200smart charger，1.0t with SLC-48100smart charger Touch screen display interface Start-up interface Main interface Click on the icon： , Enter the help description interface. Click on the icon：...
  • Page 97 Help interface. Click on the icon： , return to main interface. Click on the reservation icon to set the time for booking mode. The default password is 123456. Click on the icon： , enter the password input interface, enter the correct password into the factory parameter setting interface .
  • Page 98 Password entry interface (similar to operation password input interface) Enter the correct password in the password entry box. The default password is 888888. Click on the icon： , return to help description interface. Click on the icon：, enter the password modify interface. Click on the icon：...
  • Page 99 Click on the icon： , Return to the password entry interface. Parameter setting interface Click on the icon： , return to the help description interface. Parameter setting information: rated voltage, rated current and shunt range are related to machine hardware, and must not be arbitrarily modified after the factory. Consult the manufacturer if the above parameters need to be modified.
  • Page 100 Power module information display interface Click on the icon： , switch module information backward. Click on the icon：, return to the main interface. Click on the icon： , switch module information forward. Display single power module output voltage, output current, various operating conditions. Charging process explanation The charging step：...
  • Page 101 6. BMS charging complete, send charging termination command, charging motor end charging. 7. During the charging process, charging motor failure ("overheated "and" abnormal "lights of charging motor information are all charging motor failures), BMS charging or" charging allowed "in a prohibited state, and artificial charging control in a" stop "state, all will terminate the charging. * In appointment mode, the charging machine will only work when the appointment time is set.
  • Page 102 4.Connect the charging socket of the charger Charging procedures： 1.Stop the forklift to the charging pile and turn to the charging socket of the lithium battery, the charger will self-check and communicate off the key switch of the vehicle, that is, the with the lithium battery.

  • Page 103: Maintenance Summarization

    Inspection and maintenance are usually ignored; you’d better find the problems and solve it in – time. – Use the orthodoxy spare part of HANGCHA GROUP CO., LTD. Don’t use different oil when changing or adding oil. – Forbid to repair the fork lift truck if you haven’t been trained.
  • Page 104 The weight of the counterweight: Tonnage Weight(Kg） 650(+0~40) CPD20-XC4(-JC)、CPD20-XD2 CPD25-XC4(-JC)、CPD20-XC4-I 1000(+0~40) CPD25-XD2、CPD20-XD2-I CPD30-XC4、CPD25-XC4-I、CPD25-XLC4-I 1100(+0~40) CPD30-XD2、CPD25-XD2-I、CPD25-XLD2-I CPD35-XC4、CPD30-XC4-I 1430(+0~40) CPD35-XD2、CPD30-XD2-I CPD15-XC4、CPD10-XC4-I 530(+0~40) CPD15-XD2、CPD10-XD2-I CPD10-XC4、CPD10-XD2 340(+0~40) CPD18-XC4、CPD15-XC4-I 740(+0~40) CPD18-XD2、CPD15-XD2-I 1816(+0~40) CPD35-XC4-I、CPD35-XD2-I 740(+0~40) CPD18-XC4-I、CPD18-XD2-I CPD20-XXC4、CPD20-XXD2 915(+0~40) CPD25-XLC4、CPD20-XC4-JCI 650(+0~40) CPD25-XLD2 CPD25-XC4-JCI 1000(+0~40) CPD20-XXC4-I、CPD20-XXD2-I 1064(+0~40) CPD40-XC4、CPD40-XC4-I 1300(+0~40) CPD45-XC4 1460(+0~40)

  • Page 105: Preventive Maintenance Schedule

    Preventive maintenance schedule × — Replace 〇— Check, revise, adjust D—Daily；W—Weekly；M—Monthly；T—Trimonthly；S—Semiannually；Y—Yearly Battery Item Service required Tools (8 h) (40 h) (166 h) (500 h) (1000 h) (2000h) 〇 〇 〇 〇 〇 〇 Electrolyte level Eyeballing 〇 〇 〇 〇 〇...
  • Page 106 Motor Item Service required Tools (8 h) (40 h) (166 h) (500 h) (1000 h) (2000h) Clean the foreign body 〇 〇 〇 〇 on the motor Clean or replace the 〇 〇 bearing Check the carbon brush commutater 〇 〇...
  • Page 107 Steering System Item Service required Tools (8 h) (40 h) (166 h) (500 h) (1000 h) (2000h) 〇 〇 〇 〇 〇 〇 Check for clearance Check radial 〇 〇 〇 〇 〇 〇 looseness Check axial 〇 〇 〇 〇...
  • Page 108 Brake system Item Service required Tools (8 h) (40 h) (166 h) (500 h) (1000 h) (2000h) 〇 〇 〇 〇 〇 〇 Check for free travel Scale 〇 〇 〇 〇 〇 〇 Check for pedal travel 〇 〇 〇...
  • Page 109 Hydraulic system Item Service required Tools (8 h) (40 h) (166 h) (500 h) (1000 h) (2000h) Check level, 〇 〇 〇 〇 × × Change oil 〇 〇 Clean suction strainer 〇 〇 Clean foreign matter Check levers 〇 〇...
  • Page 110 Lifting system Item Service required Tools (8 h) (40 h) (166 h) (500 h) (1000 h) (2000h) Check chain 〇 〇 〇 〇 〇 〇 tension, damage or rust lubrication 〇 〇 〇 〇 chains Check connection of 〇 〇 〇...
  • Page 111 for looseness Check rollers, roller 〇 〇 〇 〇 pins and welded parts for cracks or damage Others Item Service required Tools (8 h) (40 h) (166 h) (500 h) (1000 h) (2000h) Check tight Test 〇 〇 〇 〇 〇...

  • Page 112: Replace The Key Safe Parts Termly

    Replace the key safe parts termly – Some parts should be checked periodically to detect the damage, for improving the safety, users should replace the parts periodically which are listed in the table as follows. – If the parts are abnormal before the replacing time is coming, it should be replaced immediately.
  • Page 113 Table for oil used in the truck Name Trademark, code name Capability Remark 35 L 1.0t~3.5t Normally: L- HM32 Hydraulic oil Cold environment :L-HV32 45 L 4.0t~5.0t 4.5 L 1.0t～1.8t GL-5 85W/90 （Cold environment Gear oil 2.0t～3.5t Cold storage forklift： GL-5 80W/90）...
  • Page 114 Table for bolts tightening torque Unit: N· m Grade Bolt’s diameter 4～5 5～7 6～8 9～12 10～12 12～15 14～18 22～29 20～25 25～31 29～39 44～58 35～44 44～54 49～64 76～107 54～69 69～88 83～98 121～162 88～108 108～137 127～157 189～252 118～147 147～186 176～216 260～347 167～206 206～265 245～314 369～492...

  • Page 115: The Use, Install And Safety Rules Of Attachment

    15.The use, Install 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 ect. Attachment assy  Untempered technology licence of our company, any refit at safety and capability to attachment is strict prohibit.

  • Page 116: Check And Maintenance

    avoid the suddenness except the driver position under overhead. – It is not allowed that an emergency brake in moving. Run slowly with load. – Prohibit outside force when attachment working. It couldn’t be use at malfeasance situation and overstep normal work range. –...

  • Page 117: Battery Automatic Filling Water System(Optional)

    16.Battery automatic filling water system(Optional) Makeup of the automatic filling watering system： – Automatic Watering Plug – End Plug – Floater – T-piece & L-piece – Flow Indicator（with filter） – 6mm, 8mm ,10mm watering pipe – Male & Female couplings (Kv10 and KV6, etc.) –...
  • Page 118 Application specification and installation During the period of development and long-term practical usage, the leak tightness of automatic watering system has received complete recognition. But when you use it, you need to keep the automatic watering system clean and there can’t be any filth on the surface.
  • Page 119 Automatic Watering System of Forklift Storage Battery-48V battery group Floater How to choose proper floaters correctly： According to different storage battery, we have five kinds of floaters for you to choose. In order to achieve our expected standard and completely reflect the effectiveness of the automatic watering system, the most important thing is to choose proper floaters.
  • Page 120 Watering pipe Our company offers watering pipes of different types and the clients can choose what they need according to the specification of the battery. The watering pipe must be perfectly sealed with T-piece and L-piece. Notes during the filling process: –...
  • Page 121 Characteristics of the automatic filling watering system – No need to water by hand, labor saving. – No malfunction factor leading to damage the battery. – Easy & safe operation. – Ensure a precise electrolyte level in every battery cell. –...

  • Page 122: Relevant Safety Command And Standard (Ce Models)

    17. Relevant safety command and standard (CE models) 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), EN ISO 12100:2010 (Safety of machinery —...
  • Page 123 Maintenance record Date Maintain content Maintainer...
  • Page 125 Revision Table Revision Version no. Date Note OM21-X01 08/2021 Original...
  • Page 126 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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