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HANGCHA CPCD15 Operation And Maintenance Manual
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HANGCHA CPCD15 Operation And Maintenance Manual

HANGCHA CPCD15 Operation And Maintenance Manual

1.5t -3.5t roughterrainforklift
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1.5t -3.5t ROUGH TERRAIN FORKLIFT
OPERATION AND
MAINTENANCE MANUAL
Original Instruction
HANGCHA GROUP CO., LTD.
OM22-RT03(08/2022)

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  • Page 1 1.5t -3.5t ROUGH TERRAIN FORKLIFT OPERATION AND MAINTENANCE MANUAL Original Instruction HANGCHA GROUP CO., LTD. OM22-RT03(08/2022)
  • Page 2 This manual is also applicable to forklift trucks equipped with attachments. For any query, please contact the sales company or agent of HANGCHA GROUP CO., LTD. Standard configuration model Load center distance mm (in) 500(19.7)
  • Page 3 Model Engine Main Transmission CPCD30/35-XW43E-RT RTE350-120000-G01 Cummins CPCD25-XW43E-RT RTE250-120000-G01 QSF2.8T3NA49 CPCD30/35-XW43C-RT4 Diesel engine RTC350-120000-G01 CPCD25-XW43C-RT4 RTC350-120000-G01 CPCD30/35-XW33E-RT RTE350-120000-G01 CPCD25-XW33E-RT RTE250-120000-G01 Yanmar CPCD30/35-XW33C-RT4 RTC350-120000-G01 4TNE98-BQFLC CPCD25-XW33C-RT4 RTC350-120000-G01 Diesel engine CPCD30/35-X2W33E-RT2 RTE356-120000-G00 CPCD25-X2W33E-RT2 RTE356-120000-G00 CPCD30/35-XW98C-RT4 RTE350-120000-G01 CPCD30/35-XW98E-RT2 RTE250-120000-G01 CPCD30/35-X2W98E-RT2 RTE356-120000-G00 Kubota V2607-CR-T CPCD25-XW98C-RT4 RTC350-120000-G01 Diesel engine...
  • Page 4 Main Transmission CPCD30/35-XG92C-RT4 RTC350-120000-G01 CPCD25-XG92C-RT4 RTC350-120000-G01 CPCD15/18-XW97C-RT4 RTC180-120000-G00 Kubota diesel engine V2607-CR-E5B CPCD15/18-XW97E-RT2 RTE180-120000-G00 Yanmar CPCD15/18-XW33C-RT4 RTC180-120000-G00 4TNE98-BQFLC Diesel engine Load center CPCD15/18-XW33E-RT2 RTE180-120000-G00 distance Xinchai CPCD15/18-XG98C-RT4 RTC180-120000-G00 4D29X41-034 Diesel engine CPCD15/18-XG98E-RT2 RTE180-120000-G00 © August 2022, HANGCHA GROUP CO., LTD.
  • Page 5 Contents I. Instructions for use ..........................1 II. Forklift truck component names ......................4 1、 Instrument ..........................5 2. Controls and switches ........................25 3. Body and other parts ........................32 III. Safety regulations ..........................37 IV. Maintenance ............................43 1. Daily maintenance (8 hours) ......................43 2.
  • Page 6 XV. Relevant safety directives and standards ..................139 XVI. Forklift daily check and maintenance sheet ................... 141...
  • Page 7 I. Instructions for use In order to ensure personal and equipment safety, the driver should follow the following precautions: 1. Only drivers with proper training and a valid license should operate the vehicle; 2. Check each control and alarm device before driving, if any damage or defects are found they should be repaired before operation;...
  • Page 8 equipment as well as loading and unloading of containers in wharf yards. 21. In the event of a breakdown, the truck should be first moved to a place where it does not obstruct traffic. If the breakdown is caused by the brake system or steering system, the truck should be carried away with a suitable vehicle (see the vehicle handling content);...
  • Page 9 the exhaust system or the truck. Do not regenerate in gas stations, dusty places or other flammable and explosive areas. 36. When the regeneration is carried out while parked, a warning sign indicating high temperature and danger should be placed near the exhaust. 37.
  • Page 10 II. Forklift truck component names 1. Fork 2. Backrest 3. Tilt cylinder 4. mast 5. Lifting hydraulic 6. Steering wheel 7. Overhead guard 8. Driver’s seat cylinder 9. Hood 10. Counterweight 11. Rear wheel 12. Frame 13. Front wheel...
  • Page 11 1、 Instrument CPCD25/30/35-XW33E-RT CPCD25/30/35-XW43E-RT D. Accumulator alarm A. Water temperature gauge B. Fuel gauge C. Stopwatch indicator light E. Neutral start indicator G. Gearbox oil temperature F. OPS indicator light H. Parking indicator light light alarm light J. Oil-water separator K.
  • Page 12 Instrument Status Display Fuel gauge [B] When the ignition key switch is in the ┃ (open) position, the fuel gauge will display the approximate fuel quantity in the fuel tank. It is recommended to fill up the fuel tank everyday after work. Water temperature gauge [A] When the ignition key switch is in the ┃...
  • Page 13 Stopwatch [C] the starting switch is in the (Start) position. It turns off when the engine is started. When the engine is running and the gearbox oil When the ignition key switch is in the ┃ (open) temperature exceeds the normal range (60℃ position, the stopwatch will start running.
  • Page 14 indicator light [N] when the engine is started. The light turns on when the water precipitation reaches a certain level while the is engine Left steering Right steering running. indicator light indicator light If the light continues to turn on or flash when Before the truck turns left, the combination switch lever should be pushed forward, the front the is engine running, the engine should be shut...
  • Page 15 Applicable truck models:CPCD25/30/35-XW33C-RT4,CPCD25/30/35-XW43C-RT4, CPCD25/30/35-XG72E-RT2,CPCD25/30/35-XG72C-RT4,CPCD25/30/35-X2W33E-RT2, CPCD25/30/35-X2G72E-RT2,CPCD15/18-XW33C-RT4,CPCD15/18-XW33E-RT2 Water temperature gauge everyday after work . Stopwatch When the ignition key switch is in the ┃ (open) When the ignition key switch is in the ┃ (open) position, the water temperature gauge is active, position, the stopwatch will start running.
  • Page 16 The light displays the battery charge status, switch is in the (start) position, and turns off turns on when the starting switch is in the ┃ when the engine is started. (open) position, and turns off when the engine The light turns on after the water precipitation is started.
  • Page 17 immediately and the fault must be addressed released, the light turns off. based on the engine fault code table. Maintenance personnel can diagnose the faults Caution based on the fault indicator light (flashing code) Driving the truck when the light is on ...
  • Page 18 Instruments of China-IV forklift trucks (G92 and G98) 1. Homepage display ① Instrument self-test: When the instrument is powered on, the system starts the self-test. ② Fault code warning display: Displays the fault code. ③ DPF indicating display: Displays DPF-related indicator lights (without this function).
  • Page 19 Water temperature gauge Caution After the cumulative hours reaches the  first 100h and 350h and a certain period, the “wrench” icon will flash for When the ignition key switch is in the ┃ (open) 1 hour, this indicates that the forklift position, the water temperature gauge is active, truck needs to be serviced.
  • Page 20 Preheat indicator light [diesel forklift truck] -120℃), the alarm light will turn on. Caution The light turns on for a short period after the If the alarm light turns on, please stop  switch is moved to the ┃ (open) position, operation immediately reduce...
  • Page 21 When the light turns on, it indicates that the filter of the air intake system is blocked and the truck must be stopped to clean the filter. Seat safety belt alarm indicator light (optional Vehicle-mounted terminal fault indicator light: configuration) the light “！...
  • Page 22 to small, then press “Key 1”, the cursor jumps to the next number; press “Key 2” together with “Key 1” to set the pulse number and alarm speed as required, then press “Key 3” 2. Operating instructions for instrument when finished. This completes the speed keys：...
  • Page 23 CAN Bus Instrument (W98/W97) Key 4 Key 3 Key 2 Key 1 Kubota Engine Homepage 1. Instrument indicator lights Water temperature gauge everyday after work . Stopwatch When the ignition key switch is in the ┃ (open) When the ignition key switch is in the ┃...
  • Page 24 Charging indicator light brake lever) should be released; when the lever is released, the light turns off. Warning The light displays the battery charge status, Driving the truck when the light is on  ┃ turns on when the starting switch is in the may cause damage to the engine, drive (open) position, and turns off when the engine system and other components.
  • Page 25 with an electronically controlled engine] When the light turns on, it indicates that there is a fault and the forklift must be stopped When the engine is running and the gearbox immediately. oil temperature exceeds the normal range (60 Maintenance personnel can press the right key ℃-120℃), the alarm light will turn on.
  • Page 26 In the second case, it prompts that the parking After confirmed that  regen should be started. surrounding environment around the forklift truck is safe, regen can be Parking regen conditions: restarted, which generally should not The forklift truck should be parked on exceed 40 min.
  • Page 27 fault light should turn on at the same time. Inhibit indicator light When the light turns on, it indicates that the regen status of the engine is restricted and driving regen or parking regen is inhibited. Caution When working in an environment that is ...
  • Page 28 2. Operating instructions for instrument keys 2.1 Engine fault information display page (1) Kubota diesel engine No faults Fault present ① Enter the engine fault information display page: Homepage=》Key 4 ② Fault query page selection: Press key 2 or key 3 again for page selection (the page selection key is not displayed when there are no faults) ③...
  • Page 29 2.3 Setting page (1) Operations on the setting page Setting 高级设置 保养提醒 Back 返回 Enter the setting page: Homepage=》Key 1  Enter the maintenance page: Homepage=》 Key 1=》 Key 2, to enter the maintenance repair  page Enter the emissions system setting page: Homepage= 》 Key 1= 》 Key 3, to enter the ...
  • Page 30 (3) Maintenance repair page a. Remaining hours query page Reset 重置 返回 Back The remaining hours can be observed on the page Reset: Press Key 2 to be redirected to the maintenance hour reset page, and reset the remaining hours to the set initial value (maintenance cycle interval). Back to the setting page: Press Key 1 b.
  • Page 31 2. Controls and switches 1. Control and Switch Diagram of the 1.5t-3.5t Forklift Truck 1. Steering wheel 2. Horn 3. Combination light switch 4. Ignition key switch 5. Lifting lever 6. Tilt lever 7. Cup holder 8. Instrument 9. Rocker switch 10.
  • Page 32 Steering wheel [1] To turn on the headlights and the front signal light, turn this switch to align the position Turn right Turn left marker on the switch handle with the corresponding symbol on the switch body. Controls the driving direction of the truck Anticlockwise rotation Ignition key switch [4] turns the truck to the left;...
  • Page 33 continuously rotate for more than 5s and the Move to the interval between consecutive starts should be left Tilt 120s. Lifting lever [5] Move to the right Lower This lever is used to move the sideshift frame to the left or right. Lift Push forward –...
  • Page 34 1. Alarm light switch: normal driving will cause serious When pressing down, the alarm light will flash; damage to the tires, drive shafts and when pressing up, the alarm light will turn off. other components. Therefore, please 2. Rear headlight switch: push the differential lock switch upward When pressing down, the rear headlight will when driving normally.
  • Page 35 The differential lock is a mechanism installed on the center differential and used for 4WDforklift trucks. Its function is to improve the traction of forklift trucks in poor road conditions or extreme conditions, when one wheel of forklift truck is slipping the differential lock can quickly lock the differential, so that the left and right wheels become rigidly coupled.
  • Page 36 disconnect the electric appliances from the Adjust the steering wheel tilt angle only  battery. after the forklift truck has stopped and If the forklift truck needs to be restarted, the the hand brake is engaged. emergency power-off switch should Forcibly move the steering wheel up ...
  • Page 37 the lever is in the neutral position. Gear I should be used for starting the  forklift truck. (4WD rough terrain forklift truck) Gear I Gear II Gear III Step on the brake pedal to fully stop the truck before changing the driving direction; push the lever forward to engage gear I and then rotate backward to gear II from gear I;...
  • Page 38 3. Body and other parts when the forklift truck has stopped. For safety reasons, do not adjust the Load-backrest  driver's seat when driving. The load-backrest ensures the stable loading of cargo. The forklift truck must not be operated For front and rear adjustment and ...
  • Page 39 daily operation to protect yourself and reduce permission, the truck is fitted with a locking injury if the forklift rolls over. hood; in order to open the internal ·Unfasten the safety belt combustion engine hood, the lock handle should be pulled. The internal combustion engine hood can then be released.
  • Page 40 released with a socket spanner; the bolt should be tightened with a socket spanner Warning during reinstallation The engine must be shut down during  maintenance and repairs are carried out Water tank lid and additional water tank under the internal combustion engine The additional water tank is under the internal hood.
  • Page 41 There is an opening on the lower beam  Caution of the fork arm carrier for loading and When refuelling, the forklift truck must unloading forks.  be stopped, the engine must be shut Do not use the fork in the open position ...
  • Page 42 lock, remove the headlight, replace the bulb with a new one and then fit the cover. 4、 Loosen the two fixing screws of the LED width light, remove it to check for any damage; if it is damaged, cut the lead wire near the soldering point, replace the panel with a new one, re-solder it to its original position and replace it.
  • Page 43 III. Safety regulations increased if necessary. Caution 1. Only trained and approved operators can The forklift may not be used underground. operate the forklift truck. It may not be used in flammable and Oil/water leakage, deformation explosive environments. looseness should regularly checked;...
  • Page 44 19. Slow down and sound the horn when passing through intersections other junctions with poor visibility; limit the speed to 1/3 of the maximum driving speed of the truck. 14. Other people must not sit on the fork, pallet or forklift truck. 20.
  • Page 45 from losing balance. cause vehicle vibration and noise. Attachments on forklift should Warning considered as vehicle loads. Do not use the forklift truck in sand, snow, lightning, rain, wind and other bad weather conditions. 26. The mast should tilt backward and the height of cargo should be lowered as much as possible when the truck is operated under load.
  • Page 46 Caution Be careful not to let the forks touch the road surface, to avoid damaging the fork tip and road surface. 30. Know the load curves of the forklift truck and accessories, and do not overload. It is very Do not place your hands between the inner dangerous artificial additional...
  • Page 47 41. Reduce the forward tilt angle as much as 37. Do not lift cargo at high speed. Cargo possible when stacking for unloading; when should be fixed securely before lifting the fork. the height of the cargo is slightly higher or Pause before lifting cargo and only lift after lower than that of the stacking layer, the cargo confirming there are no obstacles.
  • Page 48 damaged or missing labels, signs and marks. and property due to improper operation. 47. Various accessories provided for the user, 54. When working in an environment that is such as rotating clamps, flat holding clamps, not suitable for DPF regeneration, turn on the sideshift forks, and booms are to be used exclusively.
  • Page 49 IV. Maintenance Caution For more detailed maintenance information, ·The forklift truck must be placed on a flat please refer to the Regular Maintenance and surface to conduct the oil level check. Lubrication Cycle Table. · When the engine is cool, the fuel level can 1.
  • Page 50 the human body. If you swallow it by 1.5t-1.8t: accident, you should induce vomiting The scale line “L” marks the lower limit of the immediately and go to hospital. hydraulic oil level, and the hydraulic oil level · Keep children away from the antifreeze. must be higher than this scale line for trucks with an mast no greater than 4 m.
  • Page 51 16. Lift lever, tilt lever and accessory lever Check the brake fluid reservoir. Check whether Check that the lift lever, tilt lever and accessory the brake fluid quantity is within the scale; if lever are secure and they return properly. the liquid quantity is insufficient, please top it Increase engine...
  • Page 52 should be adjusted first, see the following table for tire pressures; over pressurising may cause a serious accident. In order to ensure safety, the tire should  be placed in a protective frame during air inflation. Tire pressures should adopt the new standard GB/T2982-2014: 4WD: Driving wheel...
  • Page 53 2. Weekly maintenance (40 hours) Add the following maintenance items in addition to daily maintenance. 1. Air filter maintenance Generally: Please maintain the filter after the truck has Remove the end cover of the air filter. been operated for 50-250 hours. Remove the main filter element and the Please replace the filter after six maintenance safety filter element and then separate them.
  • Page 54 ④ Check the mast for cracks and Engine Deflection (mm) deformation. 4TNE92 New 8-12(＜5min) 4TNE98 Old 10-14(≥5min) ⑤ Manipulate the lifting, tilting, and metal V2607-CR-T handle to check whether the mast works 10-12 V2607-CR-E5B normally and whether there are any 4D32XG30-004 10-15 abnormal noises.
  • Page 55 maintenance lubrication cycle, Use a brush dipped in engine oil to lubricate following parts should be lubricated regularly. the chains on the left and right sides. ① The lubrication cycle should be adjusted 8. For the lubrication of the following parts, see according to the operating conditions.
  • Page 56 Brake 145±5 pedal Inchin Inching pedal contact 145±5 bolt - brake pedal: 2-2.5 pedal 12. Hand brake Make sure the hand brake handle acts normally ④ Rear wheel nut; after it is tightened and then loosened to its Tightening torque N.m.: original position.
  • Page 57 ⑧ Refer to the Forklift Oil List and fill with 3. Every one and a half months the recommended oil. maintenance (250 hours) Add the following maintenance items in addition to the weekly maintenance. 1. Replace the engine oil and oil filter (the first 100h and then every 250 hours thereafter.) ①...
  • Page 58 ③ Clean the oil drain plug and install it. 4. Replace the gear box oil filter (only for the ④ Take out the oil dipstick, fill with ATF (see first time, and then every six months the Forklift Oil List) and then replace the thereafter) dipstick.
  • Page 59 Cummins diesel engine: 8. Exhaust check Complete combustion - Colorless normal Incomplete combustion - Black abnormal Blue Engine oil burning - abnormal Water in combustion chamber White - abnormal Warning Tanked type: Do not run the engine in places with poor ...
  • Page 60 locking device. 4. Bi-annual maintenance (1000 hours) 3. Check, clean and replace the hydraulic Add the following maintenance items in addition to the monthly maintenance. return oil filter, breathing apparatus and filter screen Add the following maintenance items in Park the forklift truck on a horizontal road, addition to the monthly maintenance.
  • Page 61 ① Remove the oil drain plug and drain the oil Caution into a container. Clean the oil drain plug. Do not refill the filter with fuel before  ② Install the oil drain plug. installation. Otherwise, it will accelerate ③ Remove the air vent plug and oil level plug. wear fuel system...
  • Page 62 Refer to the drive axle hub content in the 5. Annual maintenance (2,000 hours) Maintenance Manual, disassemble the wheel 1. Change hydraulic oil bearing, and then change the grease. Park the forklift truck on a horizontal road, 3. Change rear wheel bearing lubricating lower the forks to the ground, tilt the mast grease back, pull the hand brake handle firmly, put the...
  • Page 63 6. Maintenance every two years (4,000 hours) Add the following maintenance items in addition to the semi-annual maintenance. 1. Change the engine coolant ① Open the radiator cover and drain plug to drain the coolant, then flush the cooling system. ②...
  • Page 64 7. Others 1.Fuses and relays ① Before replacing any defective fuse or relay, please investigate the cause of failure. ② Replace the fuse with a new one of the specified rating. The forklift control unit is installed on the left Front tires side of the engine inside the internal a）Park the forklift on level and solid ground.
  • Page 65 diagram and lock them temporarily. j ） Start the engine and remove the wooden blocks from the forklift frame. k）Tilt the forklift frame backward so that the forklift is slowly lowered, and then take out the wooden blocks under the forklift frame and at the rear wheels.
  • Page 66 to support the forklift are solid and sufficiently strong. When the forklift is supported with  wooden blocks only, do not lie underneath it. g） Put on the nuts in sequence as shown in the diagram and lock them temporarily. h）...
  • Page 67 If there is an alarm or every 6000 working hours, it is necessary to contact the after-sales service to clean the DPF with a professional ash cleaning device. For the service mentioned above, please contact the sales company or agent of HANGCHA GROUP CO., LTD.
  • Page 68 V. Forklift truck structure and stability Be aware that the structure and stability of the forklift truck are very important to safe operation. Forklift truck structure Caution The basic components of the forklift truck are the lifting device (forks and mast) and the forklift truck itself at the rear (with tires).
  • Page 69 Center of gravity and stability Caution The center of gravity of the forklift truck depends on the combined center of gravity of the forklift truck. When the forklift truck is unloaded, the center of gravity remains unchanged; when it is loaded, the center of gravity is formed by the combined center of gravity of the forklift truck and the load.
  • Page 70 Bearing Capacity Chart Caution The chart shows the relationship between the location of the load center distance and the maximum load. Check whether the load and the SUBTRACT 200kg WITH SIDESHIFTER load center distance are within the allowable range of the Bearing Capacity Chart before loading. If the load shape is complicated, the heaviest part should be placed in the center of the fork and close to the LOAD CENTRE POSITION...
  • Page 71 VI. Operation Caution Diesel engine Caution Step on the accelerator to make it run at  If the forklift truck has any damage or  intermediate speed after the diesel faults, it should not be started before engine is started; preheat the engine repairing.
  • Page 72 start moving. Gear shift a）Stop the truck before shifting gear. b）Toggle the shift lever. Slowing down Slightly release the accelerator pedal, and step on the brake pedal, if necessary. 3. Loading Steering a ） Adjust the fork spacing to keep cargo The forklift truck is different from ordinary balanced.
  • Page 73 i）Tilt the mast backwards Caution Do not tilt the mast when the load is lifted  above 2m. Do not get off the truck or leave the truck  when the load is at a high level. 5. Unstacking a） Slow down when the forklift truck approaches the place to pick up the cargo.
  • Page 74 VII. Storage emptied. 2. Long-term storage 1. Daily storage When the forklift is parked for a long time, use a）Park the forklift at the designated place and wooden blocks for support under the vehicle use wedge blocks to support the wheels. body and counterweight to reduce the load on b）Pull the shift lever into the neutral position.
  • Page 75 b ） Apply anti-rusting oil to exposed parts that may start to rust such as the piston rod and shaft. c）Parts such as vent plugs and air filters should be covered to protect them from moisture. d ） Start the forklift truck once a week. If the cooling water is drained out, it should be refilled with cooling water.
  • Page 76 Develop a comprehensive maintenance and repair plan. Complete records should be made after maintenance and repair. Use the spare parts from Hangcha.
  • Page 77 1. Regular maintenance schedule ○——Check, correction, adjustment ×——Replacement Note: When operating in dusty or polluted environments, it is necessary to increase the frequency of maintenance. If the engine power drops, there is any black smoke or the engine noise becomes louder before maintenance is due, inspections and checks should be carried out and the opening pressure of the diesel nozzle and fuel atomization state should be adjusted if necessary.
  • Page 78 Mainten Every month Trimonthl Semi-annua Daily Annually ance Maintenance Content Tool and a half (8h) (2,000h) Item (250h) (500h) (1,000h) Check camshaft ○ ○ ○ sensor and its line Check the crankshaft ○ ○ ○ sensor and its line Fill with specified fuel ○...
  • Page 79 Mainten Every month Trimonthl Semi-annua Daily Annually ance Maintenance Content Tool and a half (8h) (2,000h) Item (250h) (500h) (1,000h) Leakage ○ ○ ○ ○ ○ System Change engine × coolant Check the fan belt tension and check for ○ ○...
  • Page 80 Every Maint Semi-annua Daily month and Trimonthly Annually enanc Maintenance Content Tool (8h) a half (500h) (2,000h) (1,000h) Item (250h) × Clean and refill the First time × lubricating oil (100h) Check for leakages ○ ○ ○ ○ ○ Check the axle body for any deformation, ○...
  • Page 81 Regular Maintenance Schedule for the Steering System Maint Every Semi-annua enanc Daily month and Trimonthly Annually Maintenance Content Tool (8h) a half (500h) (2,000h) (1,000h) Item (250h) Check the clearance ○ ○ ○ ○ ○ Check for looseness in Steerin ○...
  • Page 82 Regular Maintenance Schedule for the Brake System Maint Every month Semi-annu enanc Daily Trimonthly Annually Maintenance Content Tool and a half ally (8h) (500h) (2,000h) (250h) (1,000h) Item Calibrat Idle running ○ ○ ○ ○ ○ ed scale Brake Pedal travel ○...
  • Page 83 Maint Every month Semi-annu enanc Daily Trimonthly Annually and a half ally Maintenance Content Tool (8h) (500h) (2,000h) (250h) (1,000h) Item hammer Brake Vernier Friction lining wear ○ shoe caliper Operating condition of ○ the brake shoe Check the fixed pin for ○...
  • Page 84 Regular Maintenance Schedule for the Hydraulic System Maint Every Semi-annua enanc Daily month and Trimonthly Annually Maintenance Content Tool (8h) a half (500h) (2,000h) (1,000h) Item (250h) Check the oil level or ○ ○ ○ ○ × replace it (1) Clean ○...
  • Page 85 Regular Maintenance Schedule for the Electrical System Maint Every Semi-annua enanc Daily month and Trimonthly Annually Maintenance Content Tool (8h) a half (500h) (2,000h) (1,000h) Item (250h) Starti Gear engagement ○ ○ ○ motor Electrolyte amount Stora ○ ○ ○ ○...
  • Page 86 Regular Maintenance Schedule for the Lifting System Maint Every month Trimonthl Semi-annu enanc Daily Annually Maintenance Content Tool and a half ally (8h) (2,000h) (250h) (500h) (1,000h) Item Check the tension of the chain and check for any ○ ○ ○...
  • Page 87 Maint Every month Trimonthl Semi-annu enanc Daily Annually and a half ally Maintenance Content Tool (8h) (2,000h) (250h) (500h) (1,000h) Item Check the welding between the inner/outer mast and ○ ○ ○ ○ beam for any cracks or damage Check the welding between the tilt cylinder frame and ○...
  • Page 88 Every Mainten Semi-annua Maintenance Daily month and Trimonthly Annually ance Tool Content (8h) a half (500h) (2,000h) Item (1,000h) (250h) Inspectio Overhea backrest ○ ○ ○ ○ ○ hammer guard Check deformation, cracks ○ ○ ○ ○ ○ load- or damage Check for any dirt or ○...
  • Page 89 Nominal Strength Grade Diameter 9-12 10-12 12-15 17-23 22-30 20-25 25-32 33-45 45-59 36-45 45-55 58-78 78-104 55-70 70-90 93-124 124-165 90-110 110-140 145-193 193-257 120-150 150-190 199-264 264-354 170-210 210-270 282-376 376-502 230-290 290-350 384-512 512-683 300-377 370-450 488-650 651-868 450-530 550-700...
  • Page 90 Name Model/Code Volume (L) Remarks 0# (Summer) 1.5t-1.8t -10# to -35# (Winter) Diesel (Sulfur content of diesel used in 2.5t-3.5t Kubota engines <15pmm) Normal weather : CH-4,15W／ Winter: CH-4, 10W／30 (severely cold environments: 5.2-7.5 W33 diesel engine CF-4, 5W/30) or refer to the Engine Maintenance Manual Normal weather: CH-4, 15W/ 40 Winter: CH-4, 10W/30...
  • Page 91 antifreeze Industrial vaseline Battery electrode pole No.3 general purpose Each lubrication point Grease automotive lithium grease (each lubrication Suitable for high-temperature point) HP-R grease (polyurea-based) resistant lubrication points Recommended viscosity of diesel engine oil at different ambient temperatures...
  • Page 92 5. Lubricating System Diagram Note: Please add the specific lubrication oil for the specific forklift model based on the Forklift Oil List. Refer to the Weekly Maintenance (40h) for the lubrication of the mast and chain. Environmental protection: Clean, maintain and repair the vehicle at the designated place. Before dismantling the pipeline, joints or related parts, special containers should be used to receive used fluids (including coolant, engine oil, hydraulic oil, transmission oil, ATF, brake fluid, grease, etc.) and used batteries.
  • Page 93 IX. Various signs/labels: various signs or labels are affixed to different parts of the forklift truck. 两驱/四驱切换开关 驱动桥差速锁开关 注意 两驱/四驱切换开关:车辆正常运行请选择两驱模式;当驱动桥动力 输出不足时,可使用四驱模式； 驱动桥差速器锁开关:车辆正常运行请关闭,避免转弯时损坏差速器 和存在翻车隐患;当驱动桥轮胎打滑时,可使用驱动桥差速器锁功能; 其他情况下,请操作者按需使用。 起吊方法 排放控制诊断系统 载 荷 曲 线 图 门架型号 属具型号 最大起升高度A 产品编号 工业用途，依据标准GB/T 26949.2-2013 越野用途，依据标准GB/T 26949.13-2017 实 际...
  • Page 94 1. Hazard label: Stuck on the outer mast 5. Safety belt label and its (anti tilting warning Do not stand on or under the fork arm carrier; label) otherwise, your safety will be at risk. Truck can Hold TIP OVER! Risk of serious Tight INHURY...
  • Page 95 8. Fan cutting and clamping labels 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 96 If an attachm ent is installed the actual capacity at m axim um lifting height ， refer to the m odel plate of the attachm ent or the rated capacities and load centers graph. HANGCHA GRO UP CO .,LTD. Add: 666 Xiangfu Road, Hangzhou,Zhejiang,China(311305) Non-CE:...
  • Page 97 22. Hazard label (Label for keep clear of mast) Warning: Danger to your life. If you become T he pri nt posi t i on trapped between the mast and instrument of t ruck body seri se num ber stand or overhead guard, you will be at risk of serious injury.
  • Page 98 2WD: normally, it indicates that the forklift is in the regen active status. At that time, manual D IFFEREN TIAL LO CKER SW ITCH O F D RIVE AXLE intervention is not required and normal working status can be maintained. When the indicator light automatically turns off, it indicates that the particulate treatment is completed.
  • Page 99 The driver should pay attention to safety,  Em i ssi ons should not leave the site, and should monitor the engine conditions during regen. The driver should not stop the engine  1. Press "Regen" to turn on parking regen. during regen;...
  • Page 100 28、Noise label W33/W98: W97: 29、China IV emission label (G92/G98 engine only) 30、Emission control diagnosis system label (G92/G98 engine only) 31、Euro 5 emission label (W97/W98 engine only)
  • Page 101 X. Lifting, handling and towing of the forklift truck Lift the forklift truck •Tie the steel rope on the lifting hole and counterweight lifting hook at both ends of the beam of outer mast firmly and lift the forklift truck with the lifting device. Caution Do not wind the steel rope around the overhead guard when lifting the forklift truck.
  • Page 102 Caution • Do not tow trucks with defective steering systems or damaged brake systems. • Obey traffic rules when towing a truck on the highway. Warning • Only attach the steel rope to the specified position. • Do not suddenly apply load on the steel rope.
  • Page 103 XI. Main technical performance parameters Model CPCD30-XW43E-RT CPCD35-XW43E-RT Rated load lifting 3000 3500 capacity kg Load center distance Max. lift height mm 3000 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° 10°/12° forward/backward Max.
  • Page 104 Model CPCD25-XW43E-RT Rated load lifting 2500 capacity kg Load center distance Max. lift height mm 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° forward/backward Max. running speed, no load km/h Min. ground clearance, mm Min.
  • Page 105 Model CPCD30-XW33E-RT CPCD35-XW33E-RT Rated load lifting 3000 3500 capacity kg Load center distance Max. lift height mm 3000 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° 10°/12° forward/backward Max. running speed, no load km/h Min.
  • Page 106 Model CPCD25-XW33E-RT Rated load lifting 2500 capacity kg Load center distance Max. lift height mm 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° forward/backward Max. running speed, no load km/h Min. ground clearance, mm Min.
  • Page 107 Model CPCD35-XW43C-RT4 CPCD30-XW43C-RT4 Rated load lifting 3500 3000 capacity kg Load center distance Max. lift height mm 3000 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° 10°/12° forward/backward Max. running speed, no load km/h Min.
  • Page 108 Model CPCD25-XW43C-RT4 Rated load lifting 2500 capacity kg Load center distance Max. lift height mm 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° forward/backward Max. running speed, no load km/h Min. ground clearance, mm Min.
  • Page 109 Model CPCD35-XW33C-RT4 CPCD30-XW33C-RT4 Rated load lifting 3500 3000 capacity kg Load center distance Max. lift height mm 3000 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° 10°/12° forward/backward Max. running speed, no load km/h Min.
  • Page 110 Model CPCD25-XW33C-RT4 Rated load lifting 2500 capacity kg Load center distance Max. lift height mm 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° forward/backward Max. running speed, no load km/h Min. ground clearance, mm Min.
  • Page 111 Model CPCD30-XW98C-RT4 CPCD35-XW98C-RT4 Rated load lifting 3000 3500 capacity kg Load center 1100 1100 distance 3000 (3m mast) 3000 (3m mast) Max. lift height mm 6000 (6m mast) 6000 (6m mast) 3000 (3m 2750 (3m 1940 (3m 3500 (3m 3200 (3m 2260 (3m mast) mast)
  • Page 112 Model CPCD30-XW98E-RT2 CPCD35-XW98E-RT2 Rated load lifting 3000 3500 capacity kg Load center 1100 1100 distance 3000 (3m mast) 3000 (3m mast) Max. lift height mm 6000 (6m mast) 6000 (6m mast) 3000 (3m 2750 (3m 1940 (3m 3500 (3m 3200 (3m 2260 (3m mast) mast)
  • Page 113 Model CPCD25-XW98C-RT4 Rated load lifting 2500 capacity kg Load center distance 1100 3000 (3m mast) Max. lift height mm 6000 (6m mast) 2500 (3m mast) 2280 (3m mast) 1600 (3m mast) Max. lift weight, kg 600 (6m mast) 540 (6m mast) 380 (6m mast) Free lift height mm Max.
  • Page 114 Model CPCD25-XW98E-RT2 Rated load lifting 2500 capacity kg Load center distance 1100 3000 (3m mast) Max. lift height mm 6000 (6m mast) 2500 (3m mast) 2280 (3m mast) 1600 (3m mast) Max. lift weight, kg 600 (6m mast) 540 (6m mast) 380 (6m mast) Free lift height mm Max.
  • Page 115 Model CPCD30-XG72E-RT2 CPCD35-XG72E-RT2 Rated load lifting 3000 3500 capacity kg Load center distance Max. lift height mm 3000 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° 10°/12° forward/backward Max. running speed, no load km/h Min.
  • Page 116 Model CPCD25-XG72E-RT2 Rated load lifting 2500 capacity kg Load center distance Max. lift height mm 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° forward/backward Max. running speed, no load km/h Min. ground clearance, mm Min.
  • Page 117 Model CPCD30-XG72C-RT4 CPCD35-XG72C-RT4 Rated load lifting 3000 3500 capacity kg Load center distance Max. lift height mm 3000 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° 10°/12° forward/backward Max. running speed, no load km/h Min.
  • Page 118 Model CPCD25-XG72C-RT4 Rated load lifting 2500 capacity kg Load center distance Max. lift height mm 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° forward/backward Max. running speed, no load km/h Min. ground clearance, mm Min.
  • Page 119 Model CPCD30-XG92E-RT2 CPCD35-XG92E-RT2 Rated load lifting 3000 3500 capacity kg Load center distance Max. lift height mm 3000 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° 10°/12° forward/backward Max. running speed, no load km/h Min.
  • Page 120 Model CPCD25-XG92E-RT2 Rated load lifting 2500 capacity kg Load center distance Max. lift height mm 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° forward/backward Max. running speed, no load km/h Min. ground clearance, mm Min.
  • Page 121 Model CPCD30-XG92C-RT4 CPCD35-XG92C-RT4 Rated load lifting 3000 3500 capacity kg Load center distance Max. lift height mm 3000 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° 10°/12° forward/backward Max. running speed, no load km/h Min.
  • Page 122 Model CPCD25-XG92C-RT4 Rated load lifting 2500 capacity kg Load center distance Max. lift height mm 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° forward/backward Max. running speed, no load km/h Min. ground clearance, mm Min.
  • Page 123 Model CPCD15-XW97E-RT2 CPCD18-XW97E-RT2 Rated load lifting 1500 1800 capacity kg Load center distance Max. lift height mm 3000 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° 10°/12° forward/backward Max. running speed, no load km/h Min.
  • Page 124 Model CPCD15-XW97C-RT4 CPCD18-XW97C-RT4 Rated load lifting 1500 1800 capacity kg Load center distance Max. lift height mm 3000 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° 10°/12° forward/backward Max. running speed, no load km/h Min.
  • Page 125 Model CPCD30-X2W33E-RT2 CPCD35-X2W33E-RT2 Rated load lifting 3000 3500 capacity kg Load center distance Max. lift height mm 3000 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° 10°/12° forward/backward Max. running speed, no load km/h Min.
  • Page 126 Model CPCD25-X2W33E-RT2 Rated load lifting 2500 capacity kg Load center distance Max. lift height mm 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° forward/backward Max. running speed, no load km/h Min. ground clearance, mm Min.
  • Page 127 Model CPCD30-X2W98E-RT2 CPCD35-X2W98E-RT2 Rated load lifting 3000 3500 capacity kg Load center distance Max. lift height mm 3000 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° 10°/12° forward/backward Max. running speed, no load km/h Min.
  • Page 128 Model CPCD25-X2W98E-RT2 Rated load lifting 2500 capacity kg Load center distance Max. lift height mm 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° forward/backward Max. running speed, no load km/h Min. ground clearance, mm Min.
  • Page 129 Model CPCD30-X2G72E-RT2 CPCD35-X2G72E-RT2 Rated load lifting 3000 3500 capacity kg Load center distance Max. lift height mm 3000 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° 10°/12° forward/backward Max. running speed, no load km/h Min.
  • Page 130 Model CPCD25-X2G72E-RT2 Rated load lifting 2500 capacity kg Load center distance Max. lift height mm 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° forward/backward Max. running speed, no load km/h Min. ground clearance, mm Min.
  • Page 131 Model CPCD30-X2G92E-RT2 CPCD35-X2G92E-RT2 Rated load lifting 3000 3500 capacity kg Load center distance Max. lift height mm 3000 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° 10°/12° forward/backward Max. running speed, no load km/h Min.
  • Page 132 Model CPCD25-X2G92E-RT2 Rated load lifting 2500 capacity kg Load center distance Max. lift height mm 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° forward/backward Max. running speed, no load km/h Min. ground clearance, mm Min.
  • Page 133 Model CPCD15-XW33E-RT2 CPCD18-XW33E-RT2 Rated load lifting 1500 1800 capacity kg Load center distance Max. lift height mm 3000 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° 10°/12° forward/backward Max. running speed, no load km/h Min.
  • Page 134 Model CPCD15-XW33C-RT4 CPCD18-XW33C-RT4 Rated load lifting 1500 1800 capacity kg Load center distance Max. lift height mm 3000 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° 10°/12° forward/backward Max. running speed, no load km/h Min.
  • Page 135 Model CPCD15-XG98E-RT2 CPCD18-XG98E-RT2 Rated load lifting 1500 1800 capacity kg Load center distance Max. lift height mm 3000 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° 10°/12° forward/backward Max. running speed, no load km/h Min.
  • Page 136 Model CPCD15-XG98C-RT4 CPCD18-XG98C-RT4 Rated load lifting 1500 1800 capacity kg Load center distance Max. lift height mm 3000 3000 Free lift height mm Max. lift speed, full load mm/s Dip angle of mast, 10°/12° 10°/12° forward/backward Max. running speed, no load km/h Min.
  • Page 137 XII. Usage and maintenance methods for the lead-acid battery 1. Lead-acid battery and use The battery is used as the power source to start the engine, and it is used to replace the power supply of the voltage regulator and overload generators. Light weight, low failure rate, easy to use and maintain.
  • Page 138 4) A regular schedule should be formulated and batteries should be charged once every 30-45 days. 5) When the observation window does not display green, the battery should be checked and charged or replaced. Inspection of low-maintenance battery As the ambient temperature around the forklift truck is high, batteries consume water; please keep an eye on the liquid level during use;...
  • Page 139 During recharging, the hydrogen produced by batteries is flammable and explosive. Therefore, pay attention to the following matters before operation: · If batteries that are still installed on the truck are recharged, the ground cable has to be disconnected. · When connecting and disconnecting battery charger cables, the power switch on the charger should be off.
  • Page 140 XIII. Use, installation and safety rules for accessories Hangcha selects accessories, such as the flat clamp, rotating clamp, roll clamp, string rod, side shifter and others in accordance with ISO2328 Fork Lift Trucks-Hook-on Type Fork Arms and Fork Carriers- Mounting Dimensions.
  • Page 141 accessories; (10) When accessories are faulty, they should not be used until the fault has been eliminated. The following inspection and maintenance should be carried out frequently (1) Check whether the spacing between the lower beams of the forks of the forklift truck and the lower hooks of accessories conform to the requirements of the accessory manual.
  • Page 142 XIV. OPS (Operator Presence Sensing) system instruction OPS system (only limited to electric reversing hydraulic trucks) The OPS (Operator Presence Sensing) system is mainly used for safety, when the operator is not in the correct driving position, the forklift cannot be driven and transported, thereby reducing accidents caused by misuse.
  • Page 143 In the event of the following conditions, the forklift truck should be stopped in a safe place and Hangcha agency should be contacted for inspection. When you are ready to start the forklift truck, and you pull the shift switch to forward gear 1 or backward gear 1, the neutral indicator light will flash.
  • Page 144  Some models are not equipped with an “ ”OPS indicator light on the instrument panel.
  • Page 145 CPCD30-XW98C-RT4 1.18 (whole body) CPCD30-XW98E-RT2 1.19 (whole body) CPCD35-XW98C-RT4 1.15 (whole body) CPCD35-XW98E-RT2 1.16 (whole body) CPCD15-XW97E-RT2 1.3 (whole body) CPCD18-XW97E-RT2 1.4 (whole body) CPCD15-XW97C-RT4 1.3 (whole body) CPCD18-XW97C-RT4 1.4 (whole body) Static test coefficient for lifting attachment is 1.33.
  • Page 146 DECLARATION OF CONFORMITY EG-KONFORMITÄTSERKLÄRUNG Business name of the manufacturer: Hangcha Group Co., Ltd. Firmenbezeichnung des Herstellers: Full address manufacturer:666 Xiangfu Road, Lin'an,Hangzhou, Zhejiang 311305, P. R. China Vollständige Adresse des Herstellers: Name and address of the person (established in the Community) compiled the technical file:...
  • Page 147 Unterschrift des Ausstellers XVI. Forklift daily check and maintenance sheet Date Check and Maintenance Item Operator...
  • Page 148 Revision Table Revision Version no. Date Note OM22-RT01 04/2022 Original OM22-RT02 05/2022 OM22-RT03 08/2022...
  • Page 149 HANGCHA GROUP CO., LTD. ■Address: 666Xiangfu Road, Hangzhou,Zhejiang, China ■Fax: 0086-571-889267890086-571-88132890■ ZIP:311305 ■Web: http://www.hcforklift.com■E-mail: sales@hcforklift.com...

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