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1t-3.5t R Series Internal Combustion Counterbalanced Forklift Truck

1. eral mators lithium Complex Grease 2 Engine lubricating grease 4 Hyd 17 antifreeze label ANTIFREEZE 18 Hand cut risk label Ae DANGER 8S 19 noise label Expect W27 A498BT A498BT W27 engine engine Pi L 3 8 Ols hydraulic oil label oil label Ty 22 fang labels aft label show the hang position When hanging the rope should not touch the light and even destroy it sr HANGCHA 23 hang label show the hang method When hanging the rope should not touch the light and even destroy it LIFT METHOD U 24 CE label q 25 Tie down point label Tire Pressure Front Rear 0 7MPa 0 7MPa Dea 28a 26 Safe belt label Defend incline warn label Truck can Hold TIP OVER on Risk of serious m gm 1 did INHURY B DEATH _ WARNING Faste Seatblet Do Not Jum Feet From Impact 27 Hand brake label l or 28 Speaker label 55 lt C gt HANGCHA 29 Emergency stop label d SY a J i ay Pi 30 Tie down point labe 31 LPG label Only for LPG or double fuel truck Only for Europe or option MAXIMUM WEIGHT OF THE LPG TANK 52KG MAXIMU
2. 43 lt C gt HANGCHA Monthly Trimonthly Semiannually Annually 166hrs 500 hrs 1000 hrs 2000hrs Service required Tools 1 Check the valve clearance O O O clearance is correct gauge 2 Fan belt tension check O 0 0 3 Retighten cylinder head bolt 4 Clean the outface of radiator 1 5 Replace engine oil 1 6 Replace the oil cleaner diesel engine 1 7 Replace engine cooling fluid 8 Clean the air cleaner element gasoline engine Replace the air cleaner element diesel engine 9 Drain the water of oily water separator diesel engine 10 Clean or replace the filter element of air cleaner 11 Idling of engine tachometer 12 Ignition timing gasoline engine gt 13 Spark plug gasoline engine 14 Check distributor point cover and rotor gasoline engine 1 15 Lining of distributor CIC ignition system 1 16 Check fuel injector adjust pressure diesel engine 2 17 P C valve and pipe blocking or damage 18 Battery electrolyte check 44 sir HANGCHA Maintenance of chassis and body Checking Monthly Trimonthly Semiannually Annually Item Service required Tools eshrs 500 hrs 1000 hrs 2000hrs Check clutch pedal for free travel and clearance between pedal surface O O O O Clutch and floor
3. EE RR Te X Pa a i EN i li o j P a gt r C a o GN N i K Oo b oy ads The right box body removes hood DDODDDOD 0000000 red A DOOODOO EAR DOODDOD Si N ort Le o Le 21 1 typeface label 5 diesel label 9 danger label 13 operate label 2 2 danger label 6 gasoline label 10 danger label 14 load curve label 16 lubrication system label 18 fan cut hand amp strap 52 nip hand label label 3 tonnage label 7 lifting label 11 shift label 15 warning label 17 antifreeze label 4 fuse label 8 product nameplate 12 operate label 1 19 noise label 20 prohibit rinse label 23 Lift nameplate 24 CE nameplate 27 Brake label 28 Speaker label 30 Tie down point labe 31 LPG label 1 typeface label HANGCHA 2 danger label adhibit to the outside of mast No allowed to stand on or under the mast or it is dangerous to your life The word 30 means the rated load is 3 0 ton If the lifting height increases or adds attachment the rated load will decrease 4 fuse label USE SPECIFIED FUSES ONLY 5 diesel label show the position for adding oil at the left rear supporting leg of the cabane Not for gasoline and LPG trucks sr HANGCHA 21 hydraulic oil label 22 Lift nameplate
4. 4TNE92 HRJ Diesel Korea hydraulic transmission gearbox 1 500 1 5 500 1 8 500 2t 2 5t Model Engine Main transmission sir HANGCHA Rated capacity t Load center mm CPC20 25N RW9 W10 CPCD20 25N RW9 W10 CPCD20 25N RW9B CPCD20 25N RW10B C240PKJ 20 C240PKJ 30 Diesel ISUZU JDS25 Machinery transmission gear box YQXD25 Hydrodynamic power transmission gear box OKAMURA Hydrodynamic power transmission gear box CPQ20 25N RW7 CPQD20 25N RW7 Wan Feng BY491 gasoline JDS25 Machinery transmission gear box YQXD25H1 Hydrodynamic power transmission gear box CPCD20 25N RW27 A498BT1 1 Diesel YQXD25A Hydrodynamic power transmission gear box CPQ20 25N RW22 CPQD20 25N RW22 CPQD20 25N RW22A CPQD20 25N RW22B K25gasoline CNISSAN JDS25 Machinery transmission gear box YQXD25HHydrodynamic power transmission gear box NISSAN 2STF150 Hydrodynamic power transmission gear box OKAMURA Hydrodynamic power transmission gear box CPCD20 25N RW15A TD27AADiesel CNISSAN NISSAN 2STF150 Hydrodynamic power transmission gear box CPCD20 25N RW32 YANMAR 4TNE92 Diesel YQXD25 Hydrodynamic power transmission gear box CPCD20 25N RW33 CPCD20 25N RW33B CPCD20 25N RW33M 4TNE98 BQFLC diesel YQXD25 Hydrodynamic power transmission gear box OKAMUR Hydrodynamic power transm
5. 60 2t 3 5t Diesel Engine Oil Besides winter CD grade15W 40 Winter CD grade 10W 30 Or according to engine maintenance manual arctic alpine 5W 30 CD or according to engine maintenance manual 5 1t 1 8t 2t 3 5t Gasoline Engine Oil Up DE grade 15W 40 Or according to engine maintenance manual arctic alpine CALTEX API SAE 5W 30 1t 1 8t 2t 3 5t Hydraulic Oil L HM32 arctic alpine L HV32 1t 1 8t 2t 3 5t Hydrodynamic Power Transmission Oil DEXRON III Caltex See the table below Gear Oil GL 5 85W 90 1t 1 8t 2t 3 5t API GL 5 80W 90 Caltex exclusive use Brake Liquid Choice HZY3 brake liquid add when leaving factory or DOT3 brake liquid Except MS drive forklifts MobilDelvac advanced hydraulic oil SAE10W MS drive forklifts Antirust Antifreeze Liquid 35 car antifreeze add when leaving factory or FD 2 antifreeze Industrial Vaseline 2 Electrode of Storage battery Lubrication Grease Currency lithium group lubricate grease Remark the 1t 3 5 t trucks have been added antirust antifreeze liquid you need not discharge the liquid even at cold winter Add the liquid according to original requirement if need Replace the liquid every 2 years normally If the truck has not been added antirust antifreeze liquid users can add the liquid according to requirement T
6. 95 lt C gt HANGCHA 16 Related safety instruction and standard for trucks exporting to Europe or option The model by CE certification which according to the following instruction and standard DIRECTIVE 2006 42 EC OF THE EUROPEAN PAMENT AND OF THE COUNCIL DIRECTIVE 2000 14 EC OF THE EUROPEAN PAMENT AND OF THE COUNCIL EN1726 1 1998 Engineering Industry truck safety standardize EN12053 2001 EN1175 2 1998 EN13059 2002 coordinate standard Main safety factor will be according with DIRECTIVE 2006 42 EC OF THE EUROPEAN PAMENT AND OF THE COUNCIL and EN1726 1 1998 EN1175 2 1998 standard Noise will accord with EN12053 2001 and 2000 14 EC 96 Model The sound pressure level Sound radiation sound at operator position unit power level unit dB A dB A CPYD10N RW 85 2 102 8 CPYD15N RW 85 2 101 7 CPYD18N RW 85 7 101 9 CPYD20N RW 87 1 102 8 CPYD25N RW 87 1 102 9 CPYD30N RW 85 9 103 1 Fhe noise in Cpyp35N RW 85 5 103 4 the operator s position is in CPQD10N RW 85 2 101 9 pressure level 5QD15N RW 85 2 102 1 and radiated noise is in CPQD18N RW 85 7 102 5 power level Noise CPQD20N RW 87 1 103 0 pmissicn CPQD25N RW 86 5 103 3 according to EN12053 CPQD30N RW 85 6 103 4 CPCD10N RW 87 4 103 2 CPCD15N RW 87 8 103 2 CPCD18N RW 88 5 103 3 CPCD20N RW 88 1 103 1 CPCD25N RW 87 4 103 0 CPCD30N RW 88 7 103 2 CPCD35N RW 88 8 103 4
7. sir HANGCHA Vibration parameters will be accord with ISO5349 2 2001 EN13059 2002 Synthetic acceleration from Synthetic acceleration from Model the seat to the Model the seat to the operator body operator body unit m s unit m s CPYD10N RW 1 54 CPQD25N RW 1 54 CPYD15N RW 1 52 CPQD30N RW 1 48 CPYD18N RW 1 52 CPQD35N RW 1 52 CPYD20N RW 1 48 CPCD10N RW 1 54 CPYD25N RW 1 48 CPCD15N RW 1 53 CPYD30N RW 1 48 CPCD18N RW 1 54 CPYD35N RW 1 52 CPCD20N RW 1 48 CPQD10N RW 1 50 CPCD25N RW 1 50 CPQD15N RW 1 50 CPCD30N RW 1 46 CPQD18N RW 1 52 CPCD35N RW 1 50 CPQD20N RW 1 48 the requirement of 2004 108 EEC Engine emission is according to standard 97 68 EC and 2005 88 EC Electromagnetism compatible is measured according to EN12895 2000 and the result meets 97 lt C gt HANGCHA lt C gt WUC RIEL ER ZS Hd zw HANGCHA GROUP CO LTD hk PUNT AER 398 5 Hai 310022 Website http www zjhc cn Add 398 Shi Qiao Road Hangzhou 310022 E Mail sales zjhc cn Tel 86 571 88926666 Fax 86 571 88144682 EC DECLARATION OF CONFORMITY MANUFACTURE Name Zhejiang Hangcha Engineering Machinery Co Ltd Address 398 Shigiao Road Hangzhou 310022 P R China THE TECHNICAL DOCUMENTATION WAS COMPILED BY Name Address Post HEREBY DECLARES THAT THE PRODUCT DESCRIBED BELOW Description Industrial truck Counterbalanced Lift truck Model Seri
8. 25 Type pressure label 26 Safe belt label 29 Emergency stop label 6 gasoline label show the position for adding oil at the left rear supporting leg of the cabane Not for gasoline and LPG trucks 8 product nameplate INTERNAL COMBUSTIO JUNTERBALANCED FORKLIFT TRUCK MODEL TYPE I I ERIES N TM ERVICE WEIGHT w MINAL LOAD CENTE a mr ATED CAPACITY v k YEAR OF MANUFACTURE 1 MAX LIFT HEIGHT LOAD CENTE APACITY AT VAXLJI WITHOUT ATTACHMENT 1 mr m mr a k MTH ATTACHMENT K mr ii T HANGCHA GROU LT Licer 1S2510002 201 Add 398 ShiQiao Road Hangzhou China gt 9 danger label WARNING The inner and outer mast fork frame are all lifting slip parts The hands are not allowed to reach the place between the inner and outer mast If the part needs to be check or repaired the inspection and repair should be 53 sr HANGCHA carried out after shutting down the engine Nobody is allowed on the truck and the man outside the truck is not allowed to operate the truck preventing from accident caused by miss operating the mast handle 10 danger label N WARNING NO entering label Warning It is dangerous of your life If the body is clamped among the mast instrument frame and shield cabane your life will be dangerous If the part needs to be check or repaired
9. The radiator is located under the cover plate at the rear of the hood A Warning Do not open the radiator cap abruptly while waters temperature is higher than 70 C Turn the cap a little to the left to relieve the pressure in the pressure in the radiator and then remove the cap Do not wear glove when removing radiator cap The antifreeze fluid is dangerous for your health if touched to skin please wash clean by water Do not allow children access to antifreeze Fork stopper It s used to adjust fork spacing and to lock the forks in position Pull up fork stoppers turn 90 according to loads to handle the forks spacing Warning The forks should be set symmetrically to machine centerline and fork stoppers should always be set The lower beams of fork have a hatch to load or unload forks The fork is forbidden to fix on the location where the hatch locates Check the bolt at the middle of the fork bracket which is used to prevent load fork at the hatch sr HANGCHA Steering column adjustment tilting angle The tilting angle of the steering wheel is adjustable to suit individual operators The steering column is unlocked by pushing down the lever at the left side of turning rod then adjust the angle suit to the driver and pull up the lever to lock Caution a After stop the truck and pull on the parking brake lever then to adjust the tilting
10. CPCD30N RW33M CPCD35N RW33M Rated capacity kg 2000 2500 3000 3500 Load centre distance mm 500 500 500 500 Overall maximum lift height um 3000 3000 3000 3000 Free lift height mm 150 150 155 155 Maximum lift soeed with load 500 500 470 370 Tilt of the mast 6712 6712 6712 6 12 Max travel speed without load 19 19 20 20 Ground clearance Min outside turning radius Max negotiable gradient laden 20 20 20 20 Wheel base 1665 1665 1760 1760 Track F R 965 970 5 965 970 5 1005 973 5 1005 973 5 Service mass kg 3440 3765 4280 4555 Overall dimension L XxX WX H mm include forks 3615x1155x2120 3690x1155x2120 3820x1225x2150 3870x1225x2150 Tyre F R 28x9 15 12PR 2 6 50 10 10PR 2 7 00 12 12PR 2 6 00 9 10PR 2 28x9 15 12PR 2 6 50 10 10PR 2 7 00 12 12PR 2 6 00 9 10PR 2 Battery V capacity Ah 12 100 12 100 12 90 12 100 Model YANMAR 4TNE98 BQFLC Rated capacity 44 3 kW 2300r min Max torque rpm auibua jesaig 206N m 1700 r min Displacement L 76 3 319 sr HANGCHA Model CPCD20N RW26 Y CPCD25N RW26 Y CPCD30N RW26 Y CPCD35N RW26 Y Rated capacity kg 2000 2500 3000 3500 Load centre distance mm 500 500 500 500 Overall maximum lift height mm 3000 3000 3000 3000 Free lift height mm 150 150 155 155 Maximum lift s
11. Fill lubricate grease Check whether the junction plane between the nuts of wheel boss and the piston of hydro cylinder is loose and whether the surface of piston has been pulled Check whether the wheels of mast roll stably Lift the lifting cylinder to the top and fill it with oil In cold weather it needn t to discharge the antifreeze but the cold water should be removed completely 5 On the basic of the deposit you should do these checks and maintain additional Take down the battery and recharge it once a month place it in the shade 2 Brush antirust oil on those parts which is exposed such as piston rod and axle 3 Put a cloth on vent plug and air cleaner 4 Start the engine once a week If the water has already been let out add water in the radiator Then start the fork lightly In summer it is not recommendatory to park the fork on asphalt road 41 lt C gt HANGCHA Running after deposit for a long time 1 Get down the antirust oil from the exposed parts 2 Vent the gear oil of the crankcase driving axle transmission box clutch type hydraulic transmission box torque converter type clear it and add with new gear oil 3 Clean out dirty things and water in the hydraulic oil reservoir and fuel reservoir add with new hydraulic oil 4 Check the clearance of the valve gas valve cap and other parts on the engine 5 Adding antifreeze o
12. Name Address Post HEREBY DECLARES THAT THE PRODUCT DESCRIBED BELOW Description Industrial truck Counterbalanced Lift truck Model Serial number Net engine kW power Manufacturing year COMPLIES WITH THE PROVISIONS OF THE FOLLOWING EUROPEAN DIRECTIVES 2006 42 EC Machinery Directive 2004 108 EC EMC Directive 2000 14 EC amp 2005 88 EC Noise Directive Equipment according to the definition given by Annex I item 36 of Noise Directive Conformity assessment procedure followed Annex V of Noise Directive 2000 14 EC Holder of the technical documentation Name Address Measured sound power dB Guaranteed sound power dB level level COMPLIES WITH THE PROVISIONS OF THE FOLLOWING HARMONIZED STANDARDS EN1726 1 Safety of industrial trucks Self propelled trucks up to and including 10 000 kg capacity and industrial tractors with a drawbar pull up to and including 20 000 N Annex of Machinery Essential health and safety requirements relating to the design Directive 2006 42 EC and construction of machinery Done at Name of the place signatory On date Title Signature 99 lt C gt HANGCHA 17 Maintain record Date Item of maintenance Maintain personnel A SE HANGCHA GROUP CO LTD HANGCHA Address For OVERSEAS USERS Manufacturing Site 88 Donghuan Road LinAn Economic Development Zone Hangzhou P R of China m ZIP 311305 Registered
13. Take out the dipstick inspect fluid position If oil is not enough add oil to keep it between max and mix graduation 10 Check the filter and oil tuck if leakage 11 Flameout soleplate 2 CO engine install front 6 Air bleeding fuel system Diesel During add fuel or discharge water from sedimentor its also need to bleed air in the fuel system DLoosen the bleed plug 28 press the priming pump until fuel coming through the bleed plug contains no bubble Fasten the bleed plug 7 Water discharge from sedimentor W10 W15A W32 W33Diesel truck When the sedimentor indicator lamp lights up it means need water discharge Put a container under the fuel filter 2 Loosen away the drain bolt W15A then loosen the drain plug by turning 4 to 5 turns to dewater Fasten the drain bolt W15A and lug after the water was discharged 8 Exhaust gas check Normal complete Colorless f combustion Abnormal incomplete Black combustion Abnormal water come in White the burnt house Blue Abnormal oil burns Warning Don t start the lift truck in bad ventilation space There is carbon monoxide in the exhaust gas it is very dangerous Maintain semiannually 1000 hours Increase the below content base on maintain monthly 1 Brake oil fluid change 1 Let the truck at level ground play down the fork to floor inclined
14. 3 Keep the battery charge completely if the battery can not be removed down from truck 4 Make a general schedule charge every 30 45 days 92 sir HANGCHA 5 When the liquid level below the LOWER LEVEL please add pure water to the UPPER LEVEL do not add more otherwise vehicle and other components will be caused corrosion 3 Notice for usage Battery can produce explosive gas electrolyte has corrosive and the current can burn skin from battery producing please flush immediately when electrolyte touch skin or eyes then go to hospital if serious I Human body especially the head should be far away from battery and the protected glass must be wearing 1 Forbid battery emerging in naked fire or spark 2 Connect active and negative pole with electrical equipment correctly to avoid burning battery or electrical eduipment 3 To avoid short circuit of battery the electric things are forbidden to cover at battery 4 Check the battery Check the Maintenance free battery There is a little ball in battery capacity display this ball can change its color as density of electrolyte changing it is called electric eye The ball will be green when the capacity is normal density of electrolyte reaches the standard it will be white when capacity is not enough density of electrolyte does not reach the standard it will be red when the electrolyte is acute shortage the shell should be carefully examined whether there is rupt
15. 6 00 9 10PR 2 Battery V capacity Ah 12 90 12 90 12 90 12 90 Model ISUZU C240PKJ 30 Rated capacity 34 5 KW 2500r min Max torque rpm auibua jesaig 137 7N m 1800 r min Displacement L 2 369 Transmission F R OKAMURA 1 1 67 lt C gt HANGCHA Model CPCD20N RW15A CPCD25N RW15A CPCD30N RW15A CPCD35N RW15A Rated capacity kg 2000 2500 3000 3500 Load centre distance mm 500 500 500 500 Overall maximum lift height um 3000 3000 3000 3000 Free lift height mm 150 150 155 155 Maximum lift soeed with load 500 500 460 360 Tilt of the mast 6712 6712 6 12 e712 Max travel speed without load 18 18 18 18 Ground clearance Min outside turning radius Max negotiable gradient laden 25 25 25 25 Wheel base 1650 1650 1760 1760 Track F R 965 970 965 970 1005 975 1005 975 Service mass kg 3440 3765 4255 4555 Overall dimension L xX WX H mm include forks 360011502120 3675x1150x2120 3820x1225x2150 3870x1225x2150 Tyre F R 28x9 15 12PR 2 6 50 10 10PR 2 28x9 15 12PR 2 6 50 10 10PR 2 7 00 12 12PR 6 00 9 10PR 7 00 12 12PR 6 00 9 10PR Battery V capacity Ah 12 90 20h 12 90 20h 12 90 20h 12 90 20h Model TD27AA Rated capacity 38 5 kw 2500r min Max torque rpm auibua jesaig 160N m 2300 r min Displacement L Transmis
16. It may result in capsizal or sliding down of the load because of huge force to the front Centrifugal force will be formed during turning and its direction is from the turning center to the outer The force may result in the capsizal of truck Right and left stable zone is very small so the truck s speed must be reduced when turning to prevent capsizal If the truck conveys the load which is on the high location feasibility of capsizal is very big 36 6 Operation A Warning Before operating the truck check all controls and warning devices for proper operation If any damage of fault is found don t operate truck until corrected Star up Starting diesel engine Make sure that the shift lever s and loading levers are in neutral and hold position Turn the ignition switch to ON position after turning the ignition switch to START position sir HANGCHA Press down the accelerator pedal halfway and cold Crank the engine by turning the ignition key to START Release key when engine starts Caution Do not press down the accelerator pedal fully when starting warm engine This operation may harden the engine starting Pressing down the accelerator pedal several times will cause harder starting Caution The starting time should less than 5 seconds a time the interval between two starting should much than 2 minutes Caution If you can not start the eng
17. Maximum lift speed with load 560 560 560 Tilt of the mast 6YY12 6712 67 12 Max travel speed without load 15 15 15 Ground clearance mm 115 115 115 Min outside turning f mm radius Max negotiable gradient laden 20 20 20 Wheel base mm 1400 1400 1400 Track F R mm 890 897 5 890 897 5 890 897 5 Service mass kg 2500 2740 2930 Overall dimension LX WX H mm include forks 3145X 1080 X 1995 3185X 1080 X 2110 3222 X 1080 x 2110 Tyre F R 6 5 10 10PR 2 5 00 8 8PR 2 6 5 10 10PR 2 5 00 8 8PR 2 6 5 10 10PR 2 5 00 8 8PR 2 Battery V capacity Ah 12 60 12 60 12 60 Model YANMAR 4TNE92 HRu Diesel Rated capacity 32 8kW 2450r min Max torque rpm u u jesaig 149 AN m 1600 r min Displacement L 64 2 659 sir HANGCHA 2t 3 5t R series CPQ20N RW7 CPQ25N RW7 CPQ30N RW7 CPQ35N RW7 Model CPQD20N RW7 CPQD25N RW7 CPQD30N RW7 CPQD35N RW7 Rated capacity kg 2000 2500 3000 3500 Load centre distance mm 500 500 500 500 Overall maximum lift height mm 3000 3000 3000 3000 Free lift height mm 140 140 155 155 Maximum lift soeed with load 500 450 430 350 Tilt of the mast 6712 6712 6712 69712 Max travel speed without load 22 5 22 5 21 21 Ground clearance 105 105 Min outside tu
18. angle of steering column b After adjust the angle and pull the steering wheel to make sure tighten the lock rod Safety step and safety grip The safety steps are provided on both sides of the truck body The safety grip is provided on the front left pillar of the overhead guard Use the safety step and safety grip facing the truck when get on and get off the truck 12 Brake fluid reservoir The brake fluid reservoir is provided at the left of the cabinet Hydraulic fluid reservoir cap The hydraulic fluid reservoir cap is located at the right side in the hood Fill hydraulic fluid through this filler port The cap is provided with the dipstick After fill in clean hydraulic fluid lock the cap fi lg z T Fuel reservoir cap yS The fuel reservoir cap is located at the rear left side of the truck body The fuel reservoir cap has the breather inside it to allow air to enter the reservoir Check to see that the breather is in good condition every time addition of fuel is made Warning Fuel handling 1 Stop the truck shut down the engine and apply the parking brake securely Make sure that there is no naked flame near the area Never smoke The driver should not remain seated when adding fuel 2 After addition of fuel is finished securely close the reservoir cap A loose cap could cause fuel leak or fire hazard in the worst case 3 Before attempting to start the engine make
19. back the mast strain brake handle When transmission is at neutral position engine is cutoff Pick off the rubber dustproof cap of oil orifice install the both sides of preliminary clarity tube to oil orifice and waste oil collect bottle then use spanner loosen oil orifice bolt counterclockwise The other people step on the brake pedal repeat on the truck at same time Here the brake oil will burst forth from oil orifice note the fluid lever of brake oil tank Append new brake fluid when the lever fall Screw down the bolt of oil orifice when oil clear The people step on brake pedal repeat at culmination not loose the other people loose oil orifice bolt screw down it after brake oil gush completely Then inform the first people loose Repeat upwards operation till brake oil without air bladder Note the fluid lever of brake oil tank Append new brake fluid when the liquid drop 2 x de Note Transmission system forklift from Korea add brake fluid Brake oil pot is Mobil Delvac Hydraulic SAE10W Other model Caltex DOT3 or Choice HZY3 brake liquid note add after factory A Caution Prevent dust water into oil when add brake fluid The brake fluid is venomousness causticity touch in case and please wash clean sr HANGCHA 2 Steering wheel locked device lubricate Daub the lubricating grease on the steering wheel locked device 3 Hydraulic oil change Let the truck a
20. connect the connecting pipe with quick connector open outlet shutoff valve smear every joint with soap bubble to check whether the joint is leaking if there is leaking at joint eliminate the problem then fire forklift Please close outlet shutoff valve when the forklift is finishing working Notice during usage 1 When charging LPG assemble at first open inlet shutoff valve close outlet shutoff valve when charge is done close inlet shutoff valve 2 When take assembly to the truck it should be fixed and make the arrow direction upward and inlet shutoff valve closed Connecting inlet connector with assembly outlet port and then revolve to tighten open outlet shutoff valve make sure it no leak and convenient to use 3 It must check the cylinder assembly whether leak or not per charging and fixing it on truck 4 Please prevent dust to enter into the inlet and revolve dustproof cover after filling LPG out to protect the airproof of check valve 5 It is forbidden to change the pressure of safety valve 6 Call the qualified unit to check and maintain it is forbidden to repair by self And keep apart the abnormal cylinder 7 This assembly has 2 ways to fill LPG one is volume and the other is weight Weight make sure the cylinder stand vertically when filling LPG Volume make sure the cylinder lay horizontally when filling LPG and let the direction mark up 8 Please obey the gas cylinder safe supervise rule award
21. easily its usually installed on the safety frame rear supporting leg The operator should be familiar with position of the fire extinguisher and its application 45 Not allowed to carry small goods with fork should carry small goods with pallet 46 Markings on the machine describe warning and methods to operate the lift truck When operating the machine observe and follow all markings on the machine in addition to this operator s manual Replace damaged or missing decals and name plate sir HANGCHA sr HANGCHA 4 Maintenance More details for maintenance see Preventive maintenance schedule 8 hour daily or every shift check 1 Check leaks electrolyte hydraulic oil brake fluid coolant oil in hydraulic transmission gear box Check if the engine connector of hydraulic pipe radiator and driving system are leakage or not Do not use an open flame to check level or for leakage of fuel electrolyte or cooling water A Warning Don t attempt to operate the truck if leaked fuel is found through pre operational check Correct the leak before starting engine 2 Check appearance Check the lamps and meters are normal or not Check the tires air pressure and bolts are loose or not Check whether tires are damaged or pressure of tires is normal or not 3 Check fuel mass same Ka cap The fuel level gauge is provided on the indicator panel Check that fuel level is su
22. fixed pin to cylinder Cylinder fixed way Metal belt bracket The fixed way is opposite to disassemble way 87 lt C gt HANGCHA Buckle belt bracket a Hold strain device with right hand take buckle belt with left hand direct to the notch on ratchet wheel b Pass buckle belt through the notch on ratchet wheel c Pull buckle belt downward with left hand pull out the lock buckle with forefinger middle finger and third finger in right hand and push up to touch cylinder at the same time d Keep the buckle belt tensioning and keep the lock buckle out revolve strain device downward with right hand till touch cylinder e Keep it tensioning with left hand hold the strain device loose lock buckle and rotate strain device several times till it can not be pushed f Turn downward till touch cylinder 5 Make sure the inlet and outlet shutoff valve are on closed state 6 Connect the inlet connector with outlet valve and tighten 7 Open outlet shutoff valve slowly 8 Make sure there is no leaking before using if there is some leaking close outlet shutoff valve 88 in time turn on the forklift input connector 6 sir HANGCHA Darrow inlet shutoff valve outlet shutoff valve gas output valve forklift input port Notice after installing cylinder then
23. fully 5 Stop the engine after cool down fully still add cooling fluid to radiator up to way out and add cooling fluid to coolant reservoir MAX position 6 Check the drain cover if leakage A Warning When the water temperature of the engine higher than 70 degree please do not open the pressure cap of the radiator avoiding scald The engine cooling fluid is prevent rust and frostbite See lt lt Table for the oil used in the truck gt gt 2 Front wheel bear change lubricate grease Referrence lt lt Maintain manual gt gt drive wheel hub dismantle wheel hub 3 Front wheel bear change lubricate grease Referrence lt lt Maintain manual gt gt steering axle content sir HANGCHA 4 Change steering axle gear oil Let the truck at level ground At neutral engine flameout 1 Take out the oil plug put oil to a case Clean oil plug 2 Install oil plug 3 Take out breathe freely plug and oil fluid position plug Put the oil from orifice bend to steering axle shell until oil overflow from level plug See add mete anew 4 Press level and bend plug 5 Start up forklift Movement the engine let the steering wheel control handle at neutral 6 Take out level plug Keep oil level until overflow 31 sr HANGCHA Other 1 Fuse and relay The fuse box is at middle of instrument and nearside of steering wheel Before replace a new one fuse please find out the cause of problem
24. hospital e do not let children add antifreeze 6 Hydraulic oil level Check the oil level in the hydraulic oil tank The oil level should be in the place between two slots Brake fluid level check Check the fluid level in the brake fluid reservoir The level should be between the two seams of the reservoir When adding fluid due care should be taken prevent air entering the brake tube Caution When adding fluid due should be taken to prevent dirt or water from entering the reservoir Brake fluid is dangerous to health you should avoid touching it by skin sir HANGCHA Replacing of brake oil 1 Lay forklift truck at designated ground and lay it on level ground fall down fork to ground loosen park brake put transmission gear neutral position cut off engine 2 Remove rubber dustproof cap of oil drain port insert tube into oil drain port and wasted oil collection bottle and loosen oil drain screw at the same time the other person on truck press brake pedal again and again So the brake oil flows out from oil drain port watch the liquid level of brake fluid reservoir add new oil as the fallen liquid level until the oil from oil drain port is clean and then screw down screw of oil drain port 3 The person on truck press down brake pedal to the end and keep it at the same time the person at the oil drain port loosen oil drain port screw tell the person on truck to rel
25. pedal Torque converter type machines e Always stop the truck before reversing the direction of travel e Shift the shifting lever Slow down Clutch type machines Since the machine uses the synchromesh transmission it is not necessary to perform the double clutch operation Remove your foot from the accelerator pedal press the clutch pedal to the full place the speed shift lever into the first speed position and press the accelerator pedal while releasing the clutch pedal Torque converter type machines Release accelerator pedal depression a little and press the brake pedal if needed Steering Unlike general passenger cars the steer wheels are located at the rear of the truck These cause the rear of the truck to swing out when a turn is made Slow down the truck and move toward the side to which you are turning The steer hand wheel should be turned a bit earlier than as with the front wheel steering car Stopping or parking the truck 1 Slow down and press the brake pedal to stop the truck in the case of clutch type machine the clutch pedal is used 2 Place the shift lever in neutral 3 Apply the parking brake by pulling up on the parking brake lever 4 Down the forks on the ground and tilt the mast forward maximum 5 Place the key switch in OFF to shut down the engine In the case of the diesel truck pull out the engine stop button Remove the key
26. size Notice the load not drop from the load bracket for those trucks that overall maximum lift height is higher than 3 meters If necessary make some protective measure Travel with load as low as possible and tilt back the mast Before driving over a dock board or bridge plate be sure that it is properly secured and strong enough to sustain the weight Make sure that there is no naked flame near the area never smoke The driver should not remain seated when adding fuel The truck with attachments should be treated as a loaded truck When leave the truck you should let the fork down make the shift lever neutral shut down the engine and cut the power Parking on a grade make sure to tighten the brake lever If necessary use a block when parking on a grade for a long time If the truck suddenly get out of order or for leakage of electrolyte hydraulic oil or brake oil when lifting goods or grade climbing it needs to rush to repair and let the truck be in safe state then connect with maintainer or sales representative In the process of install and assemble it will be noise and libration Please choose the right tool and assembly method Depress the noise and libration as soon as possible to reduce the noise pollute to circumstance The work road surface for forklift should be stability and unknit cement blacktop or beton If there are snows ice water or other eyewinker bar Eliminate all and then work Otherwise the truck will b
27. the inspection and repair should be carried out after shutting down the engine Nobody is allowed on the truck and the man outside the truck is not allowed to operate the truck preventing from accident caused by miss operating the mast handle 11 shift label o 12 operate labels 1 Machinery truck EN CLUTCH BRAKE ACCELERATOR 13 operate labels 2 Hydraulic truck ee INCHING BRAKE ACCELERATOR 14 load curve label 54 It shows relation among the position of the load center max load and max lifting height If it has side moving and attachment the load decreases If the lifting height increases the load decreases Before loading check whether the load and the center distance of load are in the allowed range show in the diagram of load capacity If the shape of load is complicated make the most heavy part place in the center of the fork and approach the stop fork frame RATED CAPACITIES AND LOAD CENTRES GRAPH 1 __LiFting height 36n Ko A SES ze ree sae 255 Tn LHOISZM TvO1 Galva LOAD CENTRE POSITION Fi 15 warning label WAR N N 16 lubrication system label LUBRICATION SYSTEM CHART CO Smit Feplocment Ti jin tront pin Tit ein pin arin ial case Ditterenti
28. 25N RW22 CPQD30N RW22 CPQD35N RW22 Rated capacity kg 2000 2500 3000 3500 Load centre distance mm 500 500 500 500 Overall maximum lift height gi 3000 3000 3000 3000 Free lift height mm 140 150 140 155 140 Maximum lift speed with load mms 500 560 570 560 500 560 Tilt of the mast F B 6712 6 12 6 12 6712 Max 1 shift travel speed without load 2 shift mechanical km h hydraulic Ground clearance mm Min outside turning mm radius Max negotiable gradient laden ue 20 20 20 20 Wheel base mm 1650 1665 1760 1760 Track F R 965 970 965 970 1005 975 1005 975 Service mass kg 3440 3765 4255 4555 Overall dimension LX WX H mm include forks 3600x1155x2120 3675x1155x2120 3820x1225x2150 3870x1225x2150 Tyre F R 7 00 12 12PR 6 00 9 10PR 7 00 12 12PR 28x9 15 12PR 2 6 00 9 10PR 6 50 10 10PR 2 28x9 15 12PR 2 6 50 10 10PR 2 Battery V capacity Ah 12 60 12 60 12 60 12 60 Model K25 Rated capacity Max torque rpm 37 4 KW 2300r min 176 5N m 1600 r min aulbus suljosesy Displacement L 70 2 472 Model sr HANGCHA CPOD20N RW 22A CPQD25N RW22A CPQD30N RW22A CPQD35N RW22A Rated capacity kg 2000 2500 3000 3500 Load centre distance mm 500 500 500 500 Overall maximum lift height gii 3000 3000 3000 3000 Fr
29. 69 Model CPQD10N RW21 CPQD15N RW21 lt C gt HANGCHA CPQD18N RW21 Rated capacity 1000 1500 1750 Load centre distance 500 500 500 Overall maximum lift height 3000 3000 3000 Free lift height 155 155 155 Maximum lift speed with load 640 640 640 Tilt of the mast 6YY12 67 12 67 12 Max travel speed without load 15 15 15 Ground clearance mm 115 115 115 Min outside turning f mm radius Max negotiable gradient laden 20 20 20 Wheel base mm 1400 1400 1400 Track F R mm 890 897 5 890 897 5 890 897 5 Service mass kg 2420 2690 2880 Overall dimension LX WX H mm include forks 3145x1080x2110 3185x1080x2110 3220x1080x2110 Tyre F R 6 5 10 10PR 2 5 00 8 10PR 2 6 5 10 10PR 2 5 00 8 10PR 2 6 5 10 10PR 2 5 00 8 10PR 2 Battery V capacity Ah 12 60 12 60 12 60 Model NISSAN K21 Rated capacity 31 2 kw 2250 r min Max torque rpm u u jesaig 143 7N m 1600 r min Displacement L 1 982 63 lt C gt HANGCHA Model CPCD10N RW32 CPCD15N RW32 CPCD18N RW32 Rated capacity 1000 1500 1750 Load centre distance 500 500 500 Overall maximum lift height 3000 3000 3000 Free lift height 155 155 155
30. A He HANGCHA 1t 3 5t R Series Internal Combustion Counterbalanced Forklift Truck OPERATION AND MAINTENANCE MANUAL Original Instruction HANGCHA GROUP CO LTD Jun 2011 5 EDITION FOREWORD This operation manual is the explanations that how to use 1t 3 5t R series forklift truck correctly It will instruct you how to operate safety and precautionary maintenance To ensure safety and exert the truck s potential all the personnel that in charge of operation maintenance and management must read this manual thoroughly before starting work with the forklift Compared with 1t 3 5t N series internal combustion forklift truck 1t 3 5 t R series forklift truck has the following strengths enhancing the power improving the outline using buffer steering axle in addition besides the TCM and NISSAN main transmission are configured in our trucks we also configure Okamura main transmission in our trucks And there is different between masts of import and export trucks N series masts are used in the import trucks R series masts are used in export trucks This manual also applies to container forklift truck and forklift truck assembled attachments Our product design will update and perform better so the content in this manual may be not the same as the forklift you owned If you have any questions please keep touches with HANGCHA GROUP CO LTD sales department or let the agents know Jun 2011 5 EDITION HANGCHA GROUP CO L
31. Address 398 Shi Qiao Road Hangzhou P R of China m ZIP 310004 Fax 0086 571 88926789 0086 571 88132890 Web http www hcforklift com E mail sales hcforklift com sir HANGCHA
32. EE RE EE EA ER EE crt tt 39 Stacking load AA DEEDAT KA DEE EER AN OO AE ERA OE AE OE AL GN N wis KOOR ALS OER AO OE wees 39 Remove load EE tet eta Te EE EE EE EE 40 7 Deposit TLC EEC EE OE EE N EER EE N EO TILT OR ES OR EE EI OE OER ECE rir irri 41 8 Maintenance EE EE RE CECE OE CC EE EE EO NE REET 43 Preventive maintenance schedule ETE EE TE EE eden Dace TE TE TAAT 43 Maintenance of chassis and body TRE OE RENT RELATE TEC ERE RERT ETT OCC DNE RET rrr OE er kr 45 Table for bolt s tight moment AT T ene a WeSC beeen sein WeW nw ait enw EE RO PR EE ER 46 Periodic replacement of key safe parts TE RI OE OE OE EE TE 47 Table for the oil used in the truck EE RE DEE AO ER Dl N 48 Lubrication system drawing ER ER CODER IOC CRC EK EE CR EE RE AE EE 50 Environment protection ST ee T RET TORT CCE ERECT TPCT RET TT Creer ener Tree rn 50 Scutcheons aun wu mts LERE KEER EE NEER un RE N DER AO OE ARE OO RD ARE EDE NEER AEAEE 51 9 Truck s convey lifting towing EE EE E OE AA Ee EE EE 57 10 Type signification N OE OR EES DNE TERT EE ER ELE DERE EE DR OIE MERE OR EE DEEL rit 58 11 Performance parameters of R series IC forklift NOOO CO EE C CC CEC EE rIrr 61 12 Operation disassembly and installation of cab EE AE EE ES 79 13 Operation and notice about LPG forklift TEE RE EE AE EE KOLE EE DE MORE MELD NE 81 14 Operational method of lead acid battery TERR EE eee EE ee EE mre pert 92 15 Use installation and safety rules of attachment A TTT TETTA 94 16 Relat
33. Front whe Front wheel bearing Jifferentiol case Clutch brake Clute sha Inching brake an on Clutch type Stee smission Tor con type Steering axle 5 vlie tank Steering knuckle king pi 1 ankshat Rear wheel bearing C ering knuckle king pin Sering pin connecting ro 1 ear wheel Dearing T FOR Steering cylinder pm 1 1 reering pin connecting rod yes Steering axle support shatt Lr VAL Sfeering cylinder pin XS r O T Every 8 hours m Every 40 hours j Every 166 hours Ev hours S Every 2000 hours 1 General motors lithium Complex Grease 2 Engine lubricating grease Q Gear oil 4 Hydraulic oi Converferassy forque oil 6 Brake oil Notice 1 The detail of lubricating oil for different truck can refer to Table for the oil used in the truck 2 Lubrication for mast please see the 8 hour daily or every shift check Environment protection 1 Please do the clean and maintenance of the truck at the specified spot 2 Before remove the pipe connector and related parts please use the specified container to contain the disused liquid include antifreeze liquid engine oil hydraulic oil hydrodynamic power transmission oil gear oil brake liquid lubrication grease and disused battery 3 The disused liquid referred above should be disposed according to the local environment protection law rather than pouring at discretion to pollute the environment Safety note Th
34. M PRESSURE OF THE LPG TANK 22MPs MAXIMUM BEARING WEIGHT OF THE LPG SUPPORT 105KG j The label on the tank LPG tank most weight 52kg LPG tank most pressure 2 2MPa Bracket support most weight 105kg The print position of the series number of truck body Each truck has a unique truck body series number its print position is at the Right middle of the forklift truck body COn the hydraulic tank The print position of truck body series number DO JO PS Jjoo0 ODODDOOD A G DOODODOOUODOD O D00000 7 Jo 56 sir HANGCHA 9 Trucks convey lifting towing Hoist the truck e Use the steel wire ropes to tie the holes in the two side of the outside mast s beam and the hook of the counter balance then use the lifting device to hoist the truck Warning When hoist the truck don t coil the overhead guard with the steel wire The steel wire ropes and the lifting device must be very firm to support the truck because the truck is very heavy Don t lift the truck by hoist the overhead guard When lifting the truck don t take yourself below the truck Convey e The forklift truck is designed for material handling and short distance transportation only It is inappropriate for long distance transportation The Fork Lift Truck must be transported by ship train or lorry of 5T loading Tighten the brake leve
35. PR 2 5 00 8 10PR 2 Battery V capacity Ah 12 60 12 60 12 60 Model BaiYang BY491GP gasoline Rated capacity 41kW 2800r min aulbue auljosesy Max torque rpm 161N m 1800 2200 r min Displacement L 2 237 61 lt C gt HANGCHA Model CPCD10N RW10 CPCD15N RW10 CPCD18N RW10 Rated capacity 1000 1500 1750 Load centre distance 500 500 500 Overall maximum lift height 3000 3000 3000 Free lift height 155 155 155 Maximum lift speed with load 460 510 510 Tilt of the mast 6YY12 6YY12 6YY12 Max travel speed without load 14 5 14 5 14 5 Ground clearance mm 115 115 115 Min outside turning f mm radius 2005 2000 Max negotiable gradient laden 20 20 20 Wheel base mm 1400 1400 1400 Track F R mm 890 897 5 890 897 5 890 897 5 Service mass kg 2450 2740 2930 Overall dimension LX WX H mm include forks 3145x1080x2110 3185x1080x2110 3220x1080x2110 Tyre F R 6 5 10 10PR 2 5 00 8 8PR 2 6 5 10 10PR 2 5 00 8 10PR 2 6 5 10 10PR 2 5 00 8 8PR 2 Battery V capacity Ah 12 60 12 60 12 60 Model ISUZU C240PKJ 30 Rated capacity 34 5 KW 2500r min Max torque rpm u u jesaig 137 3N m 1800 r min Displacement L 62 2 3
36. Rated capacity 32 8 KW 2450r min Max torque rpm 149 4N m 1600 r min auibua jesaig Displacement L 2 659 74 Model sr HANGCHA CPCD20N RW33 CPCD25N RW33 CPCD30N RW33 CPCD35N RW33 CPCD20N RW33B CPCD25N RW33B CPCD30N RW33B CPCD35N RW33B Rated capacity kg 2000 2500 3000 3500 Load centre distance mm 500 500 500 500 Overall maximum lift height um 3000 3000 3000 3000 Free lift height mm 150 150 155 155 Maximum lift speed with load 580 580 460 360 Tilt of the mast 6712 6712 6712 e712 Max travel speed without load 20 20 18 20 18 5 20 Ground clearance Min outside turning radius Max negotiable gradient laden 20 20 20 20 Wheel base 1650 1650 1760 1760 Track F R 965 970 5 965 970 5 1005 973 5 1005 973 5 Service mass kg 3440 3765 4280 4555 Overall dimension L XxX WX H mm include forks 3600x1155x2120 3675x1155x2120 3820x1225x2150 3820x1225x2150 Tyre F R 28x9 15 12PR 2 6 50 10 10PR 2 7 00 12 12PR 2 6 00 9 10PR 2 28x9 15 12PR 2 6 50 10 10PR 2 7 00 12 12PR 2 6 00 9 10PR 2 Battery V capacity Ah 12 90 12 90 12 90 12 90 Model YANMAR 4TNE98 BQFLC Rated capacity 44 3 kW 2300r min Max torque rpm auibua jesaig 206N m 1700 r min Displacement L 3 319 75 lt C gt HANGCHA Model CPCD20N RW33M CPCD25N RW33M
37. TD Content Foreword 1 General Rules EE EE EE NE EE EE EE N RR IE OE N EIE N ER EN N 1 2 Name of main parts or component EE a NG EE 3 Instruments TEE TE ETE ET EE FEE EE EE ET EE ER EE ER EE EE GE EE ET EE EE ETE EER 3 Switches Sea ea da We We ee oa ed de We We ae Ee ed de Me Ee We dd Ee ed ee N ae ES Ee n Ee N Ee We ee ae Se ed ae ae 5 Controls BEE EE RE RE EE RE N EE EE EE EE EE N EE EE RE RE ee 6 Others RE EER EER EE DT OE OR ESE ORDES EO OE EE OON EET ORR OER RES 10 3 Safety instructions Ed EA BE HE EA BE DOSS OE OE EO MERE ET MOE OE nae en 14 4 Maintenance GEROER REELE GR TEES DEERE SR DER HE GR DEES HEG RE GR DE SR DER TESS TEER DES STEER DES ROER TOES DE SR EG RE GR OE SR RO 20 8 hour daily or every shift check EE IE OE TACT ECCT A OE ONE AE rere Corer iy 20 Weekly maintenance 40 hours EE ER Ee EE N RE EE EE RE AE EP EE EEN 23 Maintain monthly 1 66 hours ME OE RU SORSAN AV ANRT PARVENSA R ATRO RNAN AORO AVR TANAAN 27 Maintain semiannually 1 000 hours ET DE EO TITTET ITITI ITITI DI EE TT 29 Maintain annually 2000 hours TE EE EE ES ER ET EE ER EE AE OR EN 31 Other EE EE OE RE NE OE OE OR OE ON ER ONE IE ONE OO ONE OO AN ONE OE NE IE ONE NT 32 5 Structure and stability of truck EER wie Wa EE IE EA ORE OGE AE KOPER wie GER AE EE 35 6 Operation EE AA EE TE EE EE OE EE EA 37 Star up EE EE AE DEE DI EE OE N EA EE EI N EA OER N E EI ER EE DE NN N 37 Traveling EE EE EE AE EE HA EE AE EE EE EE EE EE 38 Pick up TE EE EE EE OE EE EE OE
38. The turn signal level does not automatically return to the neutral position unlike general passenger cars Reset it by hand lt C gt HANGCHA Light switch 6 Horn button 7 This light switch can be pulled out at Press the rubber cover at the center two steps of steering wheel to sound horn ight Near Far Clear Ed RONGI light light ance 0 x 1 st x x x pnd x x x x means connected Controls EESE giti Torque comverter type 8 Clutch pedal frictional clutch type 9 Inching pedal torque converter type 12 Forward reverse and Speed slect lever 10 Brake pedal 11 Accelerator peda frictional clutch type 13 Shift lever 14 Tilt lever 15 Lift lever 16 Steering hand wheel 17 Parking brake lever 18 Forward reverse lever Torque converter type Non electric switch 19 Choke 20 Forward reverse lever Torque converter type Switch 21 Guy head 22 Emergency Stop Label Pedal Clutch pedal 8 frictional clutch type Press the clutch pedal fully the operator can uncouple the engine and transmission When the clutch pedal released it allows power to flow through the clutch from the engine to transmission Caution Do not run the lift truck with the clutch in a half clutch condition as much as possible Inching pedal 9 Torque converter type As the inching pedal is pressed the oil pressure in the hydraulic clutch drops accordingly the need
39. al number Net engine kW power Manufacturing year COMPLIES WITH THE PROVISIONS OF THE FOLLOWING EUROPEAN DIRECTIVES 2006 42 EC Machinery Directive 2004 108 EC EMC Directive 97 68 EC Engine pollutant emission Directive 2000 14 EC amp 2005 88 EC Noise Directive Equipment according to the definition given by Annex I item 36 of Noise Directive Conformity assessment procedure followed Annex V of Noise Directive 2000 14 EC Holder of the technical documentation Name Address Measured sound power dB Guaranteed sound power dB level level COMPLIES WITH THE PROVISIONS OF THE FOLLOWING HARMONIZED STANDARDS EN 1726 1 Safety of industrial trucks Self propelled trucks up to and including 10 000 kg capacity and industrial tractors with a drawbar pull up to and including 20 000 N Annex of Machinery Essential health and safety requirements relating to the design Directive 2006 42 EC and construction of machinery Done at Name of the place signatory On date Title Signature 98 sr HANGCHA dT Art LARA BR Zs A zw HANGCHA GROUP CO LTD Hit SUNITA BRE 398 MA 310022 Website http Awww zjhc cn Add 398 Shi Qiao Road Hangzhou 310022 E Mail sales zjhc cn Tel 86 571 88926666 Fax 86 571 88144682 EC DECLARATION OF CONFORMITY MANUFACTURE Name Zhejiang Hangcha Engineering Machinery Co Ltd Address 398 Shigiao Road Hangzhou 310022 P R China THE TECHNICAL DOCUMENTATION WAS COMPILED BY
40. ance Min outside turning radius Max negotiable gradient laden 20 20 20 20 Wheel base 1665 1665 1760 1760 Track F R 965 970 5 965 970 5 1005 973 5 1005 973 5 Service mass kg 3440 3765 4255 4555 Overall dimension LX WX H mm include forks 3615x1155x2120 3690x1155x2120 3820x1225x2150 3870x1225x2150 Tyre F R 7 00 12 12PR 28x9 15 12PR 2 28x9 15 12PR 2 6 00 9 10PR 6 50 10 10PR 2 6 50 10 10PR 2 7 00 12 12PR 6 00 9 10PR Battery V capacity Ah 12 60 12 60 12 60 12 60 Model K25 Rated capacity 37 4 kW 2300r min Max torque rpm 176 5N m 1600 r min aulbua suljosey Displacement L 72 2472 Model sr HANGCHA CPCD20N RW27 CPCD25N RW27 CPCD30N RW27 CPCD35N RW27 Rated capacity kg 2000 2500 3000 3500 Load centre distance mm 500 500 500 500 Overall maximum lift height um 3000 3000 3000 3000 Free lift height mm 140 140 145 145 Maximum lift soeed with load 470 540 430 340 Tilt of the mast 6712 6712 6 12 e712 Max travel speed without load 20 5 20 5 19 19 Ground clearance 105 105 Min outside turning radius 2260 2320 Max negotiable gradient laden 20 20 15 Wheel base 1650 1650 1760 Track F R 965 970 5 965 970 5 1005 973 5 Service mass kg 3440 3440 4255 4555 Overall dimension L XxX WX H mm inc
41. and keep it Caution Don t dismount from the moving machine Never jump off the machine Pick up e The forks should be adjusted sidewise to maintain proper balance of load e Place the machine right in front of the load to be handled e The pallet should be evenly positioned across both forks e Insert forks into the pallet as far as possible e To raise loads from the ground First lift the forks 5cm to 10 cm off the ground or floor and make sure loads rest stable Then tilt the mast backwards fully and lift forks up to 15cm to 20 cm off ground then start running When handling bulky loads which restrict your vision operate the truck in reverse except when climbing grades sir HANGCHA 15 20cm 6 8in Stacking load e When approaching the deposit area slow down your truck e Once stop the truck right in front of the area where your load is to be deposited e Check the condition of the deposit position e Tilt the mast forward until forks become horizontal Raise forks until they are a little higher than the deposit position e Move forward to place the load directly over the desired area and stop the truck e Make sure your load is just over the desired area Slowly lower the load into position Make sure the load is securely stacked e Disengaged forks from the load by using necessary lift tilt operation and then back away e After making sure th
42. ange air cleaner on time 2 Fan belt tension check Stop the engine Use finger to press the belts at the midway between the water pump pulley and the generator pulley by 10kg press and check the drop distance if is up to standard Engine Drop distance mm TD27AA New 9 11 old 11 13 ISUZU C240 8 12 K21 K25 11 13 ples New 8 12 old 10 14 BY491GP New 5 7 old 7 8 23 lt C gt HANGCHA The latest parameters please see takes engine manual parameters shall prevail Warning If the belt has already been pulled long cut out or has no surplus it should be changed If the engine is still running it s not permitted to carry on this check avoiding fingers or sleeves being caught up in 3 Power shift transmission fluid level Open the inspections cover and remove the filler cap Inspect the lever gauge to make sure that the fluid level is on the upper mark of the gauge a O 4 Mast and forks Check the mast and forks to make sure There is no crack and bend on the forks and the forks are installed on the fork bracket strongly Check if there have leakage of oil cylinder and tubing 3 Check the rollers rotation Check the mast if there have crack and bend Operate the lever of lifting tilting and attachment check the mast if it s in good condition and pay attention to system operating sound 24 5 Lift chain t
43. anisation that accomplished the tasks sr HANGCHA 2 Name of main parts or component 1 Mast 2 Lifting cylinder 3 Backrest 4 Fork 5 Overhead guard 6 Steering wheel 7 Seat 8 Cover hood 9 Counterbalance weight 10 Rear wheel 11 Tilting cylinder 12 Front wheel Instruments lt C gt HANGCHA Hour meter 1 This meter measures working time of engine Use meter to schedule lubrication and maintenance periods Water temperature gauge 2 This gauge indicates the oil temperature in the torque converter transmission box In normal status the pointer is in green zone 60 C 115 C Caution If the pointer points red zone please stop the truck at once Decrease the engine speed to make the engine cool Check the cooling fluid if enough and the fan belt s elasticity if fit Fuel gauge 3 The gauge indicates the fuel level in the tank when the key is at ON position Charge A This lamp indicates the battery condition of charge The lamp comes on when the ignition switch is set at ON but it goes out as the engine starts and accelerator pedal is pressed Caution Glow indicator C Diesel truck Turn the key to ON position and the indicator light
44. at first Please replace the same capacity fuse See fuse and relay on page 16 2 The change of tyre A Warning When using an air compressor first adjust the air pressure of the compress or Failure to do so will Cause a serious accident since the compressor delivers the maximum pressure To make sure safe put the tyre in a defend casing when charge Front wheel 1 Place lift truck on level concrete 2 Start engine and raise carriage about 100mm height 32 3 Place chocks behind rear wheels to prevent movement of forklift 4 Loosen wheel nuts 1 2 turns each by turning them counter clockwise 5 Tilt mast fully backward and place a wooden block under each side of outer mast 6 Tilt mast forward until front tires are raised from surface Caution Do not allow loose nuts before the front wheels leave away from the ground 7 Support forklift truck by putting additional wooden blocks under each side of the front end frame as shown below Stop the engine 8 Take out the wheel nut and replace the front wheel tire Warning a When removing tire from wheel rim do not remove rim set bots and nuts before releasing air b 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 9 Retighten the wheel nut temporarily 10 Start the engi
45. be paid to the weight and the center of gravity of loads to maintain the stability of the truck There is difference because of the loads shape gravity such as box board and large roller It is very important to distinguish the difference and the gravity center of loads If the truck is going to turn over do not attempt to get out of the truck because the speed of overturn is much fast than you You should hold the steering wheel handle and this practice will let you in the Turn over steer wheel Tighten feet Don t jump seats Please tie safety belt Gravity and stability The combined center that is composed of the Pe able and the load center determine the stability Combined aa date di ai ift trucks When unloaded the barycenter does not change Truck gravity center When loaded the barycenter is determined by the J truck and the load s center The barycenter is also determined by the tilting and lifting of the mast The combined center is determined by these factors e Load s size weight and shape e The lifting height e The tilting angle e The pressure of the tire e The radius of turning e The road and grade s angle e The attachments 35 lt C gt HANGCHA the stability zone of the barycenter In order to make the truck stable the combined center must be in the triangle which is made up of tWO Stability zone points that the two front wheels attach ground and the midpoint of the back d
46. by hand 6 Install oil box top cover board and screw down bolt Take out respirator Clean by lotion and desiccation Install respirator 0 Startup the engine and operate hydraulic system let hydraulic oil in all system Check leakage 11 Close the engine retract all cylinder pole check the oil level of hydrualic oil box Add oil at graduation position 7 8 9 5 Change hydraulic transmission oil Refer to Change hydraulic transmission oi from Maintain monthly 6 Check clean change fuel filter Note In the dust and dirty work condition clean fuel filters per one month and changes per six months 1 Take out the fuel filter discreteness 2 Take out transducer form it 3 Before install new one install transducer discreteness existing put a little fuel on the filter airproof Note Before install prohibit add fuel to filter otherwise accelerate the abrasion of fuel system parts 4 Install new filter discreteness 5 Turn the new filter till the airproof mat adhibit to surface 6 Screw down 2 3 loops 30 Maintain annually 2000 hours Increase the below content base on maintain semiannually 1 Replace the engine cooling fluid 1 Open the radiator cover and loosen the drain cover let the oil flow out then wash the cooling system 2 Screw down the drain cover 3 Add cooling fluid to radiator up to way out 4 Let the engine run
47. certain that the fuel reservoir cap is securely tightened and that no fuel is split on or around the truck 4 For the purpose of fuel level inspection never use naked flame such as a match or lighter Rearview mirror There are two rearview mirrors on the safeguard for operator to see rear accident sir HANGCHA lt C gt HANGCHA 3 Safety instructions 1 Only trained and authorized operator shall be permitted to operate the truck 2 Inspect the truck at periodic intervals for oil or water leak deformation lousiness etc If neglected the life of the truck will be shortened and in the worst case a fatal accident would occur Make sure to replace the key safe parts at periodical inspection Wipe off oil grease or water from the floor board and foot and hand controls if any Shut down the engine before inspecting the engine and its allied components Especially use caution to the engine fan When inspecting the radiator or muffler exercise caution not to get burnt 3 Any time you find that the trucks are not functioning properly operation of the truck should be halted and the condition reported to the supervisor When doing maintenance in the high place such as mast front and rear lights should be care of slide and clamped If any warning lamp comes on move to a safe place and check or repair the trouble When doing maintenance take care of edges and corners to lacerate hand
48. curely If parking on a grade is unavoidable be sure to block the wheel Put the forks on the ground or floor and tilt a little forwards Shut down the engine and remove the key 11 Operate the controls smoothly don t jerk the steering wheel Avoid sudden stops starts or turns 12 Control speed and observe traffic signs A When traveling on public roads or streets obey all local traffic regulations 13 Pay attention to the route of the truck be sure to make a wide sight When reverse pay attention to driving direction 14 Never allow other person s to ride 14 Does not allow other people sitting on the forks pallets or on the truck 15 Before driving over a dock board or bridge plate be sure that it is properly secured and strong enough to sustain the weigh Check the ground or floor condition of working area in advance sr HANGCHA 16 Keep your mind on your work 17 Keep your head hands arms feet and legs within the cab Never let them out of cab for any reason 18 When handling bulky loads which restrict your vision operate the truck in reverse or have a guide 19 Slow down and sound horn at cross aisles and other locations where vision is restricted The speed should be Keep slower than 1 3 of max speed 20 Keep fluid cans row cotton paper or chemicals away from the truck during operation since there is a danger of their firing or exploding due to exhaust gas
49. curely and correctly grabbed and pull the loading control level to the full increase to relief pressure 39 Never lift loads with the truck inclined Avoid loading work on a grade 40 Don t stack loads on forks in such a way that the top of loads exceeds the load backrest height If unavoidable make the load stable securely When handling bulky loads that restrict your vision operate the truck in reverse or have a guide 41 Use minimum forward and reverse tilt when stacking and unloading loads Never tilt forward unless load is over stack or at low lift height When stacking loads on a high place once make the mast vertical at a height of 15cm to 20 cm above the ground and then lift the load farther Never attempt to tilt the mast beyond vertical when the load is raised high To unloading loads from a high place insert forks into the pallet and drive backwards then lower the load Tilt the mast back after lowering Never attempt to tilt the mast with the load raised high 42 Don t tow the truck that its engine is in trouble or steering system doesn t work correctly or its braking system has been disabled Obey the communication rules on the road when towing the truck 43 Dress the overalls or other protective uniforms suck as safety helmet safety shoes etc Don t dress necktie or other accouterments 44 The workplace should be equipped with fire extinguisher In order to get the fire extinguisher
50. d surface could cause an accident A Warning When using an air compressor first adjust the air pressure of the compress or Failure to do so will Cause a serious accident since the compressor delivers the maximum pressure A Warning All nuts and bolts should be properly installed and tighten before inflating tire and rim assembly An inflated tire contains potentially explosive energy Don t over inflate Tire pressure GB T2982 2001 Truck Driving wheels ee type Front wheel Rear wheal 1t 1 8t 790kPa 1000kPa 2t 2 5t 860kPa 860kPa 3t 3 5t 830kPa 790kPa Weekly maintenance 40 hours Increase the below content base on maintain daily 1 Air cleaner Please maintain the air cleaner when truck works 50 250 hours After six times please change air cleaner Note If the working condition is bad the cycle of maintain and change air cleaner need more frequency sir HANGCHA The badly work condition with dust the cycle of maintain and change air cleaner will be short Advice maintains one time between 8 50 hours change it between 100 300 hours Maintain method 1 Take apart the cover of air cleaner 2 Take out air cleaner 3 Clean the inside or outside of dust by compress air Caution 1 Please wear defend glass to avoid the dust fly up into your eyes 2 It will damage the engine if not maintain and ch
51. dangerous to travel with forks higher than appropriate position regardless of whether loaded or not Keep the good traveling posture When traveling the forks should be 15 to 30 cm above the ground or floor 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 A truck with attachments should be considered as with loads 26 Travel with load as low as possible and tilted back 27 Avoid braking too sharply or descending on a grade at a high speed There is danger of loads falling down or the truck turning over 28 Always brake to full stop before reversing direction of travel 29 Taking account of the shape and material of loads to be handled use a proper attachment and tools Avoid hoisting the load with wire rope hung on the forks or attachment since the wire rope may slide off If needed a qualified personnel for slinging operation should perform making use of a hook or crane arm attachment A Take care not to protrude the forks out of the load The protruded fork tips may damage or turn over the adjacent load 30 Know the rated capacity of your lift truck and its attachment if any and never exceed it sir HANGCHA Do not use a man as an additional counterweight It s quite dangerous 31 HANGCHA offers a variety of attachments such as forks bucket rotating roll clamp load grab or hinged fo
52. e antifreeze liquid engine oil hydraulic oil hydrodynamic power transmission oil and gear oil should be replaced under 70 C because the temperature will be high after long running no touching with skin or you will be scald or corroded 50 sr HANGCHA Scutcheons There are many scutcheons and labels on the different position of the truck Plug in mast chain view from D IE 710 Built in mast chain 2 al ks Ce Ja fo i PER tans 17 D SN Ak 7 I T Ag Py MT OP 7 eN A gi Lea ae Hy w TE l Oo ee view from B E Wo BAN 10 9 5 N we E 1 A a N et 7 d hi 1 view from A 7 SN view from C E a 2ls Q i 19 51 sr HANGCHA Fan Shroud 18 17 view from E
53. e fork tips leave 39 sr HANGCHA the load lower the forks to the basic position 15cm to 20 cm off the ground e Tilt the mast backwards Warning Never tilt the mast with loads upraised 2m or more Don t leave or dismount from the truck when the load is raising high Remove load e When approaching the area where the load is to be retrieved slow down your truck e Stop the truck in front of the load so that the distance between the load and fork tips is about 30 cm e Check the condition of the load e Tilt the mast forward until forks become horizontal Elevate forks up to the position of the pallet or skid e Make sure forks are positioned properly for the pallet Move forward slowly to insert forks into the pallet as far as possible and then stop the truck Caution If the forks are hard to be fully inserted use the following procedure move forward and insert 3 4 of the forks Raise the forks 5cm to 10 cm and move backward 10cm to 20 cm with the pallet or skid on the forks then lower the pallet or skid on the stack Move forward again to insert the forks fully e Raise the forks 5cm to 10 cm off the stack e Check all around the truck to insure that the path of travel is unobstructed and back away slowly e Lower forks to a height of 15cm to 20 cm above the ground Tilt the mast backward fully and move to the desired area 40 7 Deposit Deposit daily Park your t
54. e out of control and lead the safety accident Move the truck to the place which respects traffic when it anchors If the reason is brake or turn system move it by a suitable truck Reference the part of truck move Other reasons use a Suitable truck to traipse tie the cord outside of truck Please abide by the traffic regulations when traipse the truck on calzada After take down the hood water tank cover board overhead backrest of mast unallowed to operate the truck or load cargo There are enough light at truck work ground At night open the head lamp to 1 lt C gt HANGCHA collocate enough lamp house 24 Only in the event that the truck manufacturer is no longer in business and there is no successor in the interest to the business the user may arrange for a modification or alteration to a powered industrial truck provided however that the user shall a Arrange for the modification or alteration to be designed tested and implemented by an engineer s expert in industrial trucks and their safety b Maintain a permanent record of the design test s and implementation of the modification or alteration c Approve and make appropriate changes to the capacity plate s decals tags and instruction handbook d Affix a permanent and readily visible label to the truck stating the manner in which the truck has been modified or altered together with the date of the modification or alteration and the name and address of the org
55. e warming lamps are off After thoroughly warming up the engine operate the loading levers 2 to 3 times in their full stroke and check their working conditions 37 sr HANGCHA Traveling Hold the knob on the steering wheel with your left hand and get the right hand ready for loading working lightly putting it on the wheel Set the bottom of the fork 15 cm to 20 cm above the ground and fully tilt back the upright Check the safety around the machine and give a signal when starting the engine Clutch type e Depress the clutch pedal and engage the shift levers e Release the parking brake lever e Gradually release the clutch pedal while depressing the accelerator pedal to start the machine Caution Do not rest your foot on the clutch pedal while you are driving Torque converter type e Depress brake pedal and engage the forward reverse lever e Release the parking brake lever e Release brake pedal and depress the accelerator pedal to start the machine Gear shifting Clutch type machines e Always stop the truck before reversing the direction of travel e When gear shifting from high to low speed or vice versa once increase the engine speed and release accelerator pedal At the same time press the clutch pedal while shifting the shift lever into the desired position Then press 38 the accelerator pedal while releasing the clutch
56. ease brake pedal when the brake oil flows out and screw down oil drain port screw Repeat above operation several times till there is no bubble in the brake oil Watch the liquid level in brake oil reservoir add new brake oil as the liquid level is falling Notice The truck of Korea transmission system The brake oil in the brake oil can is MobilDelvac hydraulic oil SAE10W Other types choice HZY3 brake oil add when leaving the factory or DOT3 brake oil Head lamp check Make sure that the head lamp is lighting when the key is at ON position Turn signal check Make sure that the turn signal operates properly by moving the turn signal lever 21 sr HANGCHA Hand brake check Drive truck slowly 2 loosen hand brake lever stop the truck and truck has no deviation Back up lamp and buzzer check The back up lamp comes on and buzzer sounds when the shift lever or directional control lever is placed in reverse position Turning Operate the truck running slowly Turn the steering wheel to left and right 3 round respectively Check that the steering forces are equal in right and left Horn Press the horn button to make certain the horn sounds is normal or not Drivers seat adjustment Make sure the driver s seat is properly located If not properly shift the adjusting lever to back and move the driver s seat to a position which provides easy access to all foot and hand con
57. ed by the State Bureau of Quality and Technical Supervision when charging transporting depositing using and inspecting 9 When fixing and disassembling cylinder please do it lightly it is forbidden to hit other object Keep cylinder assembly intact and do not disassemble adjust and replace components 10 The LPG conform to GB11174 can be recharging the maximum volume is no more than 80 of cylinder 11 The LPG must be charging at the place awarded by qualified Quality and Technical Supervision Bureau it is forbidden to charging by self 12 Charging unit must vacuumize or displace with nitrogen when the new or recheck cylinder is using at the first time 89 lt C gt HANGCHA 13 Before reinstalling cylinder lay the cylinder horizontal perpendicular to installing sign close outlet shutoff valve open inlet shutoff valve see the finger of fluid indicator wether is lifting with the charging fluid when charging Stop charging when the limit charging valve is working in time and check whether the finger of fluid indicator is at the correct position Close inlet shutoff valve after charging out 14 Check the forklift truck fully ahead to ensure no leak of LPG then open the LPG outpouring valve on the LPG cylinder check more to ensure no leak of LPG fuel system before starting up 15 If there is LPG leak during operation shut off the LPG switch and the outpouring valve at once check every part and all connection to s
58. ed safety instruction and standard EER EE EE DEE EE TPT TT 96 17 Maintain record RATE OE EE rrr rman rrr 100 sr HANGCHA 1 General Rules oo a as 12 13 14 15 16 17 18 19 20 21 22 23 To make the truck and you safety operator should obey these rules below Only trained and authorized operator shall be permitted to operate the truck Before start truck you should check all control and alarm device if there are any damaged or objection you could not operate it until repaired it When carry the load the weight should not much overload The fork shall insert in the load entirely and well proportioned It is not permitted use only one fork to load You should operate the truck smoothly when start turning travel brake and parking On a slick or wet road you should decrease speed when turning Load travel should lower the goods down and tilt the mast backwards Be carefully when traveled on a grade If the slope angle is bigger than 10 travel forward up slope and backward down slope Never turn sideways and stack load on an incline Notice the foot passenger barrier pothole and the clearance upside It is prohibit picking up a man or standing on the fork No permitted to stand or walk under the fork No permitted to operate the truck or attachment on other position except the operator s seats Do not carry the load unpackaged Be carefully to carry these goods with large
59. ee if there is leak or loose and get rid of it in time Fuel by petrol before malfunction is removed 16 If there is 10 minutes halt you should shut off the LPG switch and the outpouring valve 17 Cylinder must be avoiding under the blazing sun for quite a long time and keep it far away from heat source and forbidden to heat cylinder with heat source which the temperature is more than 40 C 18 It should have no less than 0 5 the cylinder volume to remain 19 It is forbidden to modify cylinder mark and color sign 20 Cylinder must be taken to the special unit per 5 years to inspect the unit have qualification awarded by pressure vessel safety supervisor bureau 21 Observe the level indication frequently during operation if it is found that LPG consumption is not in proportion to working time you should stop to check where is leakage and shut off power the LPG valve and all valves concerned at once to take good measure in time 22 Park the truck at the shady and ventilated site close the valves on the LPG cylinder Never insolate the truck in the sun long 23 Shut off power and all valves after the truck is garaged Keep good ventilation and extinguishing measure in the garage 24 Never repair the LPG cylinder valves or pipes at garages or parking lots any smoke on the truck 90 sir HANGCHA Service amp maintenance 1 This truck has been taken pressure trial and performance test before leaving facto
60. ee lift height mm 150 150 155 155 Maximum lift speed with load 560 560 450 350 Tilt of the mast 6712 6712 6 12 6712 Max travel speed without load 19 5 19 5 19 5 19 5 Ground clearance 105 105 130 130 Min outside turning radius 2260 2260 2480 2480 Max negotiable gradient laden 20 20 20 15 Wheel base 1665 1665 1760 1760 Track F R 965 970 5 965 970 5 1005 973 5 1005 973 5 Service mass kg 3440 3765 4255 4555 Overall dimension LX WX H mm include forks 3600x1155x2120 3600x1155x2120 3870x1225x2150 3870x1225x2150 Tyre F R 28x9 15 12PR 2 6 50 10 10PR 2 28x9 15 12PR 2 6 50 10 10PR 2 7 00 12 12PR 2 6 00 9 10PR 2 7 00 12 12PR 2 6 00 9 10PR 2 Battery V capacity Ah 12 60 12 60 12 60 12 60 Model K25 Rated capacity 37 4 kW 2300r min Max torque rpm 176 5N m 1600 r min aulbus suljosey Displacement L 2 472 71 lt C gt HANGCHA Model CPQD20N RW22B CPQD25N RW22B CPQD30N RW22B CPQD35N RW22B Rated capacity kg 2000 2500 3000 3500 Load centre distance mm 500 500 500 500 Overall maximum lift height mm 3000 3000 3000 3000 Free lift height mm 150 150 155 155 Maximum lift soeed with load 560 560 450 350 Tilt of the mast 6712 6712 6 12 6712 Max travel speed without load 21 21 20 20 Ground clear
61. el base mm 1650 1650 1760 1760 Track F R mm 965 970 5 965 970 5 1005 973 5 1005 973 5 Service mass kg 3440 3765 4280 4555 Overall dimension LXWX 3600x1155x2120 3675x1155x2120 3820x1225x2150 3870x1225x2145 H mm include forks 7 00 12 12PR 2 7 00 12 12PR 2 28x9 15 12PR 2 28x9 15 12PR 2 Tyre FIR 6 00 9 10PR 2 6 00 9 10PR 2 6 50 10 10PR 2 6 50 10 10PR 2 Battery V capacity Ah 12 60 12 60 12 60 12 60 Model PSI GM3 0L RL LPGSingle fuel 5 O 3 Rated capacity 47 kw 2500r min 2 Max torque rpm 200N m 1600 r min 78 lt C gt HANGCHA 12 Operation disassembly and installation of cab 2 fastening bolt outside 2 fastening bolt inside rubber plug 79 sr HANGCHA lift hooks only for cab front glass rear door rear support leg and mounting bolt left door doorknob and key hole The operation of cab 1 Open left door with key enter into cab 2 Close door make sure left and right door close before working 3 The glass of left and right door can be moved by draw button on the glass 4 The rear door can be opened by loosing lock buckle Disassembling cab 1 Stop the truck on solid and smooth level ground close switch pull down hand brake 2 Remove 4 bolts from left front and right front legs To high position exhaust the fastening bolts should be removed 3 Pull out 4 rubber plugs from left rear and right rear legs remove 4 bo
62. el is changed from LPG to petrol 2 Change from petrol to LPG Shut off the petrol switch When petrol in the carburetor is about to be used up the engine runs slower switch on the LPG switch rapidly to fuel by LPG Outpouring limit valve Once the outpouring limit valve is opened see FIG A LPG is flowing to the LPG solenoid valve through the outlet When outpouring exceeds the stated value or the pipe is broken the outpouring device on the valve will be closed automatically If leaving the forklift unused for a long term you should close the limit outpouring valve 81 sr HANGCHA Adapter The adapter is to mix the vaporized LPG with air and to send them into the engine to meet kinds of working conditions according to the engine LPG cylinder 1 function It composed of safety valve LPG inlet quick fitting and other relevant accessories It supports and stores fuel and it is fixed at the back of truck The functions a shut off valve It control inlet and outlet line of the LPG b Charging limit valve open the charging limit valve to charge LPG till the charging device is automatically closed when 70 80 volume of the container is full c Level indication The digital shows percentage of the remainder volume d Outpouring limit valve When outpouring exceeds the stated value or the pipe is broken the outpouring device on the valve will be closed automatically e Safety valve Safety valve will open automatica
63. en range and have a check then If this light continues to stay lit or lights up during operation the pressure is lower than 0 05Mpa and should be checked immediately Switches sr HANGCHA Diesel engine Turn the key to ON position and the indicator lights up for a moment After the indicator goes out turn the key to Start position Caution Key 4 OFF O This is the position at which the key inserted or drawn out Gasoline engine and diesel engine stop at this position ON 1 The electric circuit is closed with the starter switch at ON After the engine is started the key is at this position START 2 As the key is placed in the START position the starter motor is engaged When removing hand off key it is automatically returned to the ON position by spring force 1 Do not keep the starter switch in the ON position while engine is shut down This result in a discharge battery 2 With the engine running do not turn the starter switch into the START position since there is a danger of the starter motor being damaged 3 Do not keep the starter engaged for more than 5 seconds at a time Wait about 120 seconds before trying again Turn signal lever 5 Use this lever which is at the right side of turning rod to indicate the turning direction of the truck R turn right N neutral L turn left
64. ension check DRaise the fork about 10cm 15 cm above the ground and make it vertical Press middle of the chain by thumb Make certain the tension for the right and left chains are even Adjust the tension Loosen the lock nut 1 screw the nut 2 and adjust the chain to make the equal tension turning the adjusting nut 1 of the chain anchor 6 Lubrication of mast Lubrication here on schedule refers to figure as below Mast Paint lubrication grease on the slide support Note a The periods of paint lubrication grease depend on the truck s work condition If works heavy please paint much more grease on mast Slide support b To assort with the truck s operation paint some lubrication grease on the surface where the idler pulley and inside and outside masts touchs A Caution Paint some lubrication grease put the truck stop on a smooth road engine flameout and tight hand brake Prevent hand or body is clamped and prevents falling off from high place Keep safe 7 Chain Lubrication Take one brush with engine oil paint two sides on chain 8 Lubrication grease to below parts the detail please see lt lt Lubrication system drawing gt gt 1 mast bear lubricate 2 Brake pedal clutch type lubricate Inching pedal tor con type lubricate Steering axle shaft lubricate Steering knuckle main bearing lubricate 6 Steering rod bar pin lubr
65. ents panel 1 the operation of double fuel switch Turn switch to LPG then fuel is becoming LPG 2 Turn switch to GAS then fuel is becoming gasoline Neutral position LPG and gasoline are both stopped 2 Starting up the engine 1 By gasoline Shut off LPG switch on the petrol switch for several seconds after petrol is flowing into the floater room of the carburetor turn the ignition key to start the motor the engine is started by petrol 2 By LPG a Starting up when there is no petrol in the carburetor if there is no petrol in the carburetor before starting up you could start up the engine directly by LPG that is to shut off the petrol switch but switch on the LPG switch for several seconds turn the ignition key to start the motor the engine is started by LPG b Starting up when there is petrol in the carburetor it is some difficult to start up when there is petrol in the carburetor you should switch the select switch to the neutral position start up the engine by petrol When petrol in the carburetor is about to be used up and the engine is running slower switch on the LPG switch to fuel by LPG Or after petrol in the carburetor is used up and the engine is halted switch on the LPG switch turn the ignition key to start the motor the engine is started 3 Change fuel during the engine runs 1 Change from LPG to petrol Directly switch the select switch from the LPG position to GAS position the engine fu
66. er repair 6 Check the drive of attachment timing or turn the component if fray or block change betimes 7 Check each element if in normal under load attachment is work in gear If not check the hydraulic pressure loop find out the broken part change air poof or whole loop part 94 sr HANGCHA 2 Attachment assembly Caution 1 Untempered technology licence of our company any refit at safety and capability to attachment is strict prohibit 2 Fact rating load capacity should be the least of rating load capacity the load capacity of attachment colligate load capacity of truck Generally speaking the colligate load capacity of truck is the least Attachment load capacity just a count value of attachment pressure 3 Assembly go to in reason credibility safety to avoid the attachment glide around carriage in using 4 After hang attachment embed the rise catch block to the gap of top beam let the offset of centre line of attachment and carriage is less than 50mm Otherwise it will be affect the landscape orientation stability of forklift 5 To these attachment with rotating function such as paper roll clamp bale clamp muti purpose clamp drum clamp it needs to weld chock block in the joint of carriage beam and attachment to prevent move from side to side in the operation 6 Assembly the attachment of below catch orientation it need to adjust the clearance between below catch and beam of carriage
67. fficient for the day s work The fuel filler port is provided at the rear left pillar of the overhead guard Engine oil level check Remove the dipstick clean the rod and reinstall Pull it out again and check the oil level The level should be within the mark on the dipstick H Normal 5 Check water level in the radiator Inspect the small reservoir tank to see the coolant level is between Min and Max position when the engine is cool If there is no coolant any more in the reservoir tank please add some coolant to radiator its freezing point is 35 C and add sub radiator to MAX position A Warning When the water temperature of the engine is higher than 70 degree please do not open the pressure cap of the radiator Loosen cap slowly to allow steam to escape After that tighten cap securely It is good practice to use thick waste cloth or the like when removing the cap Avoid putting on gloves since you may get burnt at your hand if hot water splashes on it Caution Caution When checking the engine oil should let the forklift truck on the level ground When check the engine oil it is exact when the engine is cool 20 Caution Adding clean water to radiator If you use antifreeze use the same brand of antifreeze Pay attention to water reservoir and cooling system in the hot season A warning e antifreeze is harmful to person if swallow disgorge at once and go to
68. 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 The Maintenance free batteries are all sealed besides 2 vent holes for overflowing a little air from battery at the side of Maintenance free battery Low maintenance lead acid batteries left plus liquid mouth in the battery cover 2 Storage and maintenance 1 Storage The place for storing battery should be clean dry airy and the battery should be charging every 3 months 2 Maintenance 2 If truck will be stored over 30 days the following should be done Maintenance free battery 1 Insure the green point visual in inner capacity display 2 Disconnecting negative earth wire to avoid discharging by additional current release 3 Keep the battery charge completely if the battery can not be removed down from truck 4 Make a general schedule charge every 30 45 days 5 Check battery when the green point of liquid densimeter at battery are invisible then charge or replace battery When that did not see a battery hydrometer on the green point the battery check charge or replace batteries Low Maintenance battery 1 Ensure that the battery electrolyte fluid level in the UPPER LEVEL 2 Disconnecting negative earth wire to avoid discharging by additional current release
69. for defective O O O O cracks or wear Check roller of mast and lifting bracket parts for O O O cracks or damage Table for bolt s tight moment unit Nem Bolt s diameter 8 8 6 9 12 8 22 29 Ts 44 58 12 76 107 14 121 162 16 189 252 18 260 347 20 369 492 22 502 669 24 638 850 27 933 1244 Note Use entirely 8 8 grade bolt in the important joint position Bolt s grade can be found in the head of the table if it can t be found the grade is 8 8 46 sr HANGCHA Periodic replacement of key safe parts Some parts can t be found damnification or mutilation though schedule maintenance In order to make sure the safety of truck please replace these parts termly listed in following table If there is any off normal happened on these parts before replacement time please replace it deservedly Name of key safe parts service life years Brake hose or hard tube I 2 Hydraulic rubber hose for lifting system Lifting chain High pressure rubber hose or tube for hydraulic system Grease cup for brake fluid Tube for fuel Sealing member rubber articles inside of hydraulic system 47 lt C gt HANGCHA Table for the oil used in the truck Description Shop sign Code name Capacity L Remark Gasoline 90 45 1t 1 8t 60 2t 3 5t Diesel O summer 10 35 winter 45 1t 1 8t
70. from the muffler lt C gt HANGCHA 21 Use head lights and required work light and clearance lights at night And travel at a low speed 22 The work surface should be solidity and flatness such as cement road surface bituminous macadam and beton road surface The climatic conditions that the trucks designed for are temperature is 20 C 50 C wind speed is lower than 5m s air relative humidity is less than 90 20 C Inspect the surface over which you will run Look for holes drop offs obstacles and look for rough spots Look for anything that might cause you to lose control bog down or upset Clear away trash and debris Pick up anything that might puncture a tire or let the load lose balance Slow down for wet and slippery roads Stay away from the edge of the road If unavoidable use extreme caution Rugged surface would cause vibration of truck and noise The high air pressure of tyres will cause vibration and noise too Do not operate the truck when the weather is execrable such as windy thunder storm snow and etc 23 When operating loaded truck have the rear end of your machine pointed downhill When operating unloaded truck have the rear end of your machine pointed upgrade 16 Never turn sideways on an incline There is danger of the truck turning over 24 When running down on a grade use engine idle speed At the same time use the brake pedal intermittently 25 It is
71. he cooling water must be discharged at winter if the truck has not been added antirust antifreeze liquid 48 sr HANGCHA Hydrodynamic power transmission oil Shop sign Description eripuo Code name Capacity L Remark CPQD10 15 18N RW7 CPQD20 25N RW7 CPQD30 355N RW7 CPCD10 15 18N RW10 CPCD20 25N RW10 CPCD30 35N RW10 CPQD10 15 18N RW21 CPQD20 25N RW22 CPQD30 35N RW22 CPCD20 25N RW27 CPCD30 35N RW27 CPCD10 15 18N RW32 CPCD20 25N RW32 CPCD20 25N RW33 CPCD30 35N RW33 CPCD20 25N RW15A Hydrodynamic CPCD30 35N RW15A_ power DEXRON ll CPQD20 25N RW22A transmission Caltex CPQD30 35N RW22A oil CPQD20 25 30 35N RW26 Y CPCD10 15 18N RW32M CPCD20 25N RW32M CPCD20 25N RW33M CPCD30 35N RW33M CPCD20 25N RW10B CPCD30 35N RW10B CPQD20 25N RW22B CPQD30 35N RW22B CPCD20 25N RW32B CPCD30 35N RW33B Okamura drive forklifts etc 49 lt C gt HANGCHA Lubrication system drawing Supplement teplacement rulindan rn 4 TIF cylinder tr CU Tilt cylinder pin 2 chain E Mast seat be 1 Mast seat bearing
72. icate 7 Steering cylinder pin lubricate 3 4 5 EE mT sir HANGCHA 9 Bolt nut tighten Referrence the lt lt Maintain cycle chart gt gt 10 Hub nut torque check Check hub nuts should be tightened to the specified torque securely Driving wheel front wheel Hub nut 2 Divided rim bolt only for 1ton 1 8 ton Drive shaft bolt Specified torque N m 1t 1 8t 2t 3 5t Hub nut 157 176 441 588 Turning wheel rear wheel 25 sr HANGCHA Rear hub nut Specified torque N m 1t 3 5t Hub nut 157 176 Divided rim bolt 11 Brake pedal inching pedal and clutch pedal check Press the brake pedal fully when the engine is running the distance between brake pedal and front soleplate should be more than 60 mm Check the inching pedal and clutch edal through the same method Height and the free clearance H Free Press height height 120 130 260 1 3 touching bolt of inching pedal brake pedal D0 9 3 4mm NRW15A QNR W22A 0 free clearance Brake pedal Inching 120 130 260 pedal 26 mmibesides NRW15A QN RW22A Clutch pedal 120 130 260 2 5 Notice QN RW22A is the shortening of CPQD20 25 30 35N RW22A RW15A is shorteningCPCD20 25 30 35N RW15A Maintain monthly 166 hours Increase the below conten
73. ice mass kg 3440 3765 4255 Overall dimension LX WX H mm include forks 360011552120 3675x1155x2120 3820x 1225x2150 Tyre F R 7 00 12 12PR 2 6 00 9 10PR 2 7 00 12 12PR 2 6 00 9 10PR 2 28x9 15 12PR 2 6 50 10 10PR 2 Battery V capacity Ah 12 90 12 90 12 90 Model ISUZU C240PKJ 30 Rated capacity 34 5 KW 2500r min Max torque rpm u u jeseig 137 3N m 1800 r min Displacement L 66 2 369 Model sir HANGCHA CPCD20N R10B CPCD25N RW10B CPCD30N RW10B CPCD35N RW10B Rated capacity kg 2000 2500 3000 3500 Load centre distance mm 500 500 500 500 Overall maximum lift height um 3000 3000 3000 3000 Free lift height mm 150 150 155 155 Maximum lift speed with load 410 540 380 340 Tilt of the mast 6712 6712 6 Tia 6e Max travel speed without load 20 5 20 5 19 19 5 Ground clearance 130 Min outside turning radius 2415 Max negotiable gradient laden 20 18 18 15 Wheel base 1665 1665 1760 1760 Track F R 965 970 5 965 970 5 1005 973 5 1005 973 5 Service mass kg 3440 3765 4255 4555 Overall dimension LX WX H mm include forks 3615x1155x2120 3690x1155x2120 3820x1225x2150 3870x1225x2160 Tyre F R 28x9 15 12PR 2 6 50 10 10PR 2 7 00 12 12PR 2 6 00 9 10PR 2 28x9 15 12PR 2 6 50 10 10PR 2 7 00 12 12PR 2
74. ine in 5 seconds should switch to OFF after 2 minutes then start it again If you can not start the engine 3 times continuously should check the truck to the core After engine has started Warm up the engine for about 5 minutes Check the rotation sound or gear of the engine Caution If the temperature is lower than 5 degree Turn the key to ON Y position and the indicator lights up for a moment After the indicator goes out turn the key to Start position Starting gasoline engine Make sure that the shift lever s and loading levers are in neutral and hold position Cold engine Pull out the choke button fully Depress the accelerator pedal to the floor two or three times and release it With your foot OFF the pedal crank the engine by turning the ignition key to START Release key when engine starts Warm engine Do not pull out the choke button Caution Diesel model After starring up the engine accelerate its speed to the arrange of 1800r min 2000r min and warm it without work Gas model After cranking the engine push in the choke button step by step observing the warm up condition and stability of speed of the engine Push in the choke button fully after making sure the engine is completely warmed up Check the combustion or misfiring sound Check the condition density of exhaust Make sure that all th
75. ission gear box Korea Hydraulic transmission gear box CPQD20 25N RW26 Y GMS3 OLPG single fuel engine YQXD25G1 Hydrodynamic power transmission gear box CPQD20 25N RW29 Y GM3 0 RL LPG single fuel engine YQXD25G1 Hydrodynamic power transmission gear box 2 500 2 5 500 59 lt C gt HANGCHA 3t 3 5t Rated capacity t Load center mm Model Engine Main transmission CPC30 35N RW9 JDS30 Machinery CPC30 35N RW 10 Co40PKJ 20 transmission gear box CPCD30 35N RW9 Vel CPCD30 35N RW10 C240PKJ 30 Hydrodynamic power Diesel transmission gear box ISUZU OKAMURA Hydrodynamic power transmission gear box JDS30 Machinery Wan Feng transmission gear box BY491 YQXD30H1 CPQD30 355N RW7 gasoline Hydrodynamic power transmission gear box YQXD30A Hydrodynamic power transmission gear box JDS30 Machinery transmission gear box YQXD30H CPQD30 35N RW22 Hydrodynamic power transmission gear box Peer NISSAN 2STF150 CPQD30 35N RW22A Hydrodynamic power transmission gear box OKAMURA CPQD30 35N RW22B Hydrodynamic power transmission gear box NISSAN 2STF150 CPCD30 35N RW15A Alge Diesel Hydrodynamic power transmission gear box YANMAR YQXD30 CPCD30N RW32 4TNE92 Hydrodynamic power Diesel transmission gear box YQXD30 CPCD30 35N RW33 Hydrodynamic power transmission gear box 4TNE98 BQFLC OKAMUR CPCD30 35N RW33B diesel Hydrodynamic power transmission gear box Korea Hydraulic transmissi
76. kwards will tilt the mast backwards and pushing it forwards will tilt the mast forwards sr HANGCHA The tilt speed can be controlled by tilt angle of the lever and accelerator pedal effort Caution The tilt lock mechanism built in the hydraulic control valve does not allow the mast to tilt forwards while the engine is being shut down even if the tilt level is pushed forwards Steering wheel 16 The steering hand wheel is operated in the conventional manner that is when the wheel is turn right the truck will turn to the right when the wheel is turned left the truck will turn the left The steer wheels are located at the rear of the truck These cause the rear of truck to swing out when a turn is made Warning This truck is provided with the power steering so heavy hand wheel operation is caused when the engine comes to a stall To put the power steering in operation again restart the engine without delay Parking brake lever 17 Loosen Tighten g Pull the parking brake lever backward to park push it forward to 8 release must pull the parking brake lever backward before driver leaving truck Forward reverse lever 18 Non electric switch F forward N neutral R backward Torque converter type truck have a forward shift and a backward shift When shift must stop the truck first Caution Do not fail to place the forward reverse lever in the neutral position before
77. le of the oil pressure gauge swings to the left allowing the operator to perform inching operation Use this pedal to inch the truck while operating the hoist system at a high speed When pressed to the full this inching pedal serves as a brake pedal also sir HANGCHA Forward reverse 12 Speed select lever 13 Machinery transmission Caution Do not use the inching pedal too much Long time use or use as rest would cause high temperature of transmission oil or result in slipping of clutch Accelerator pedal 11 Press down the accelerator pedal engine rotating speed increase traveling speed of truck increased On the contrary when loosen the pedal engine rotating speed and truck traveling speed will decrease 12 F front N neutral R backward 13 1 low N neutral 2 high Machinery gear box have four shifts tow are frontward and tow are backward Before gear shifting be sure to press the clutch pedal to the full Always brake to a full stop before reversing the direction of travel Shifting the level in reverse the back up lights turn on Lift lever 14 Control the forks up or down Pulling up Pushing down Lifting speed can be controlled by tit backwards angle of lever and accelerator pedal the lowering speed can be controlled by tilt forwards angle of the lever Tilt level 15 The mast can be tilted by operation of this tilt lever pulling on this lever bac
78. lly when pressure in cylinder is over the standard pressure 2 Main parameters Work temperature 40 C 60 C Work pressure 2 2MPa opening pressure of safety valve 2 5 MPa 0 2MPa Max capacity 80 of cylinder volume 3 Cylinder structure 1 Charge valve Cinlet port and dustproof cover 2 Installing mark 3 Outlet valve outlet connector 4 Fixed pin 5 Outlet shut off valve 6 Level indication 7 Inlet shut off valve 82 lt C gt HANGCHA 4 Cylinder replacement Paste safety operation procedures on cyliner 1 make the truck stay on flat and stability ground stop engine pull hand brake 2 remove cylinder a Close outlet shut off valve and remove outlet connector b Loosen cylinder fixed parts see followed Fig Metal band bracket 83 sr HANGCHA buckle belt bracket Buckle belt and tighten device 1 Right hand hold tighten device use forefinger middle finger and ring finger to pull lock buckle out ias 2 Keep 1 procedure and push up tighten device till touch cylinder 3 Keep the lock buckle out and pull downward the whole tighten device 4 Then buckle belt is loosened from tighten device 5 Remove the left tighten device from buckle belt by the same way 84 sr HANGCHA Remove cylinder and charge Notice 1 Please avoiding cyli
79. lts from left rear and right rear legs 4 Lift cab a little with crane 5 Remove switch connection of fan rain wiper alarm light etc remove wire from 4 support legs and slip into support legs 6 Put down cab slowly and lightly avoid pressing wire and keep wire intact Installing cab The installing procedure is opposite to removing procedure But remove the bolts which connect head frame and support legs after fastening support legs and truck body then fastening connected bolts connected head frame and support legs fastening torque of bolts connected support legs and truck body T 137N m 167 Nm bolts for connecting head frame and support legs T 110 N m 140 N m 80 sr HANGCHA 13 Operation and notice about LPG forklift More details refer to operation and maintenance manual and service Manual of 1 5t 3 5t R series LPG forklift American impco combustion system Italy BRC combustion system LPG fuel system consists of LPG cylinder petrol solenoid valve LPG solenoid valve with filter LPG vaporizer adapter LPG petrol select switch and level indication LPG comes from the LPG cylinder passing through the combination valve the high pressured pipe the filter and the solenoid valve in sequence enters the LPG vaporizer to vaporize then mix with air in certain proportion in the adapter and combust in the engine cylinder to drive the forklift truck to work There is double fuel switch at the top surface of instrum
80. lude forks 360011552120 3675x1155x2120 3820x1225x2150 3870x1225x2150 Tyre F R 28x9 15 12PR 2 6 50 10 10PR 2 28x9 15 12PR 2 6 50 10 10PR 2 7 00 12 12PR 2 6 00 9 10PR 2 7 00 12 12PR 2 6 00 9 10PR 2 Battery V capacity Ah 12 90 12 90 12 90 12 90 Model A498BT1 Rated capacity 36 8 KW 2400r min Max torgue rpm auibua jesaig 193N m 1800 r min Displacement L 3 168 73 lt C gt HANGCHA Model CPCD20N RW32 CPCD25N RW32 CPCD30N RW32 Rated capacity kg 2000 2500 3000 Load centre distance mm 500 500 500 Overall maximum lift height mn 3000 3000 3000 Free lift height mm 150 150 155 Maximum lift speed with load 535 535 430 Tilt of the mast 612 612 6712 Max travel speed without load 20 20 18 Ground clearance Min outside turning radius Max negotiable gradient laden 20 20 15 Wheel base 1650 1650 1760 Track F R mm 965 970 5 965 970 5 1005 973 5 Service mass kg 3440 3765 4280 Overall dimension LX WX H mm exclusive forks 360011551985 3675x1155x1985 3820 1225x2150 Tyre F R 7 00 12 12PR 2 6 00 9 10PR 2 7 00 12 12PR 2 6 00 9 10PR 2 28x9 15 12PR 2 6 50 10 10PR 2 Battery V capacity Ah 12 90 12 90 12 90 Model YANMAR 4TNE92 HRJ
81. nder hit counterpoise when taking it down form truck 2 Make sure the outlet shut off valve closed 3 When charging the place must have charging license which is awarded by Quality and Technical Supervision Bureau It is forbidden to charge by self and the component must accord with table 1 Notice a 1 may use more than 20 C b 2 may use more than 10 C c 3 may use more than0 C inlet input port safety valve inlet shutoff inlet input amin port cylinder direction MAER outlet shutoff output valve value 85 lt C gt HANGCHA Table 1 technique parameter of LPG special for vehicle Item component com Quality parameter position 1 2 3 wa 0 TERE F eo oe En lt 1430 890 1430 660 1340 GB T 6602 propane gt 85 gt 65 85 40 65 QO 3 Butane and utane an S advanced SH T 0614 5 Pentane and lt 2 lt 2 L advanced alkene lt 10 lt lt Butadiene 1 3butadiene aia ce oe g 100ml remainder F after lt 0 05 lt 0 05 lt 0 05 evaporation ml oe OD 5 Observe soiled oil pass pass pass density 20 C kg m actually actually actually SH T0221 measure measure measure Sheet copper corrosion lt 1 lt 1 lt 1 SH T 0232 Total sulfur content d mg m lt 270 lt 270 lt 270 SH T 0222 sulphuretted hydrogen zero zero zero SH T 0125 free water zero zero zero Eyeballing 1 gaseity content total sulf
82. ne and take out the wooden block 11 Tilting backward the mast and lower down the mast slowly then take out the wooden block under the outer mast and rear wheel 12 Retighten the wheel nut with right tightens torque 13 Inflation tyre again to right air pressure Rear wheel 1 Place lifts truck on level concrete 2 Pull the parking brake lever and place chocks before front wheels to prevent movement of forklift 3 Put the lifting jack under the counterweight Caution Make sure the jack capacity is bigger than 2 3 of service weight of forklift sr HANGCHA 4 Loosen wheel nuts 1 2 turns each by turning them counter clockwise AN Warning Do not move wheel nuts until rear tires are raised from ground 5 Raised the forklift by swing the rod of jack until it out of ground Support forklift truck by putting additional wooden blocks under each side of the front end frame as shown below 6 Take out the wheel nut of rear wheel and then replace the wheel AN Warning a When removing tire from wheel rim do not remove rim set bots and nuts before releasing air b 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 7 Retighten the nut on consequence as figure show below 8 Remove the wooden block under chassis body Let down the forklift slo
83. oeed with load mm s 540 540 430 340 Tilt of the mast F B 6712 67 12 67 12 67 12 Max travel speed without load km h 20 20 18 5 18 5 Ground clearance mm 105 105 130 130 Min outside turning rm 2260 2320 2480 2520 radius Max negotiable K gradient laden ig 20 ao 20 20 Wheel base mm 1650 1650 1760 1760 Track F R mm 965 970 5 965 970 5 1005 973 5 1005 973 5 Service mass kg 3440 3765 4280 4555 Overall dimension L XxX WX H mm include forks 3600x1155x2120 3675x1155x2120 3820x1225x2150 3870x1225x2145 7 00 12 12PR 2 7 00 12 12PR 2 28x9 15 12PR 2 28x9 15 12PR 2 Tear 6 00 9 10PR 2 6 00 9 10PR 2 6 50 10 10PR 2 6 50 10 10PR 2 Battery V capacity Ah 12 60 12 60 12 60 12 60 Model IMPCO GM3 0L LPGSingle fuel Q 3 Rated capacity 50 kw 2500r min 3 a Max torque rpm 189N m 1600 r min 77 lt C gt HANGCHA Model CPCD20N RW29 Y CPCD25N RW29 Y CPCD30N RW29 Y CPCD35N RW29 Y Rated capacity kg 2000 2500 3000 3500 Load centre distance mm 500 500 500 500 Overall maximum lift height mm 3000 3000 3000 3000 Free lift height mm 150 150 155 155 Maximum lift soeed with load mm s 540 540 430 340 Tilt of the mast F B 6712 67 12 67 12 67 12 Max travel speed without load km h 20 20 18 5 18 5 Ground clearance mm 105 105 130 130 Min outside turning mm 2260 2320 2480 2520 radius Max negotiable gradient laden is a a9 ag a Whe
84. of transmission It is first time Let the truck at level ground play down the fork to floor inclined back the mast strain brake handle when transmission is at neutral position engine is cut off A Caution Hot hydraulic oil and part will hurt Body Do not touch the hot hydraulic oil and part 1 Dismantle rubber mat and front soleplate 27 lt C gt HANGCHA 2 Dismantle filter deal with located statute 3 Clean pedestal of filter confirm that the old gasket of pedestal have be cleaned 4 Plus less hydraulic oil on the new filter gasket 5 Install filter by hand When the filter get to pedestal screw down 1 2 3 4 laps 5 Change hydraulic transmission oil first time then semiannually Let the truck at level ground play down the fork to floor inclined back the mast strain brake handle When transmission is at neutral position engine is cutoff A Caution Hot hydraulic oil and part will hurt Body Do not touch the hot hydraulic oil and part 1 Put one case cubage is over 20 litre under the transmission 2 Dismantle oil tuck put oil in it 3 Clean oil tuck then install 4 Take out the dipstick Add hydraulic oil See lt lt Table for the oil used in the truck gt gt 5 Startup engine Step on the brake pedal operate the engine let the transmission at state of go forward and backpedal so that the oil is in clutch 7 Let the transmission at neutral strain hand brake
85. on gear box GM3 0LPG YQXD30G1Hydrodynamic CPQD30 35N RW26 Y single fuel power transmission gear engine box GM3 0 RLLPG YQXD30G1Hydrodynamic CPQD30 35N RW29 Y single fuel power transmission engine gear box CPCD30 35N RW9B CPCD30 35N RW10B CPQ30 35N RW7 A498BT 1 1 CPCD30 35N RW27 Diesel CPQ30 35N RW22 CPCD30 35N RW33M 60 11 Performance parameters of R series IC forklift 1t 1 8t R series Model CPQD10N RW7 CPQD15N RW7 sir HANGCHA CPQD18N RW7 Rated capacity 1000 1500 1750 Load centre distance 500 500 500 Overall maximum lift height 3000 3000 3000 Free lift height 155 155 155 Maximum lift speed with load 490 480 540 530 540 530 Tilt of the mast 612 6712 6712 Max travel speed without load 15 5 15 5 15 5 Ground clearance mm 115 115 115 Min outside turning radius mm Max negotiable gradient laden 20 20 20 Wheel base mm 1400 1400 1400 Track F R mm 890 897 5 890 897 5 890 897 5 Service mass kg 2450 2740 2930 Overall dimension LX WX H mm include forks 3145 1080 X 1995 3185 x 1080 x 2110 3222 X 1080 x 2110 Tyre F R 6 5 10 10PR 2 5 00 8 10PR 2 6 5 10 10PR 2 5 00 8 10PR 2 6 5 10 10
86. perate one functional then do another one 4 Prohibit the cargo at a high position when truck move with attachment If the size of cargo is too big prohibit the truck move on Transport the cargo make sure that the distance of bottom of cargo and ground is less than 300mm and mast incline back 5 The weight of cargo couldn t exceed the limited value of combination carrying capacity of forklift and attachment It is not allowed that partial load at high position It is a short time work for attachment with side shifter Partial load is around 100mm Above 5 ton including 5 ton the side shifter movable within 300mm 6 In the range of the projection forth 2m of the lower of attachment and cargo prohibit stand to avoid the suddenness except the driver position under overhead 7 It is not allowed that an emergency brake in moving Run slowly with load 8 Prohibit outside force when attachment working 9 It couldn t be use at malfeasance situation and overstep normal work range 10 When the attachment failure prohibit use without check Check and maintenance 1 Check the clearance of carriage beam and below catch of attachment if accord the attachment manual 2 Check the rise catch is right on the flute of fork carriage 3 Use the auto currency lithic grease per 500 hours to bearing surface 4 If the tighten firmware become flexible 5 Check the tie in of hydraulic pressure loop if tube attaint Prohibit use aft
87. r take woods to block the front ad tear wheels and bind the truck body with enough strong rope to avoid slippage during transportation Towing The towing rod on the bottom of the counter balance is used to pull and drag the truck For installing the rod first remove the towing rod and then install the ropes After that loose the rod Note Loosen the brake lever Warning a Don t tie the steel wire ropes on the unfixed position b Don t carry a load to steel wire ropes suddenly 57 lt C gt HANGCHA 10 Type signification 1t 1 8t Main transmission Rated capacity t Load center mm CPQ10 15 18N RW7 CPQD10 15 18N RW7 Wan feng WF491 Gasoline JDS18 Machinery transmission gear box YQXD18H1 Hydrodynamic power transmission gear box CPC10 15 18N RW9 CPCD10 15 18N RW9 C240PKJ 20 Diesel ISUZU JDS18HA Machinery transmission gear box YQXD18E Hydrodynamic power transmission gear box CPC10 15 18N RW10 CPCD10 15 18N RW10 ISUZU C240PKJ 30 Diesel JDS18HA Machinery transmission gear box YQXD18E Hydrodynamic power transmission gear box CPQ10 15 18N RW21 CPOD10 15 18N RW21 K21 Gasoline NISSAND JDS18HA Machinery transmission gear box YQXD18HB Hydrodynamic power transmission gear box CPCD10 15 18N RW32 YANMAR ATNE92 Diesel YQXD18E Hydrodynamic power transmission gear box CPCD10 15 18N RW32M 58
88. r water to the required scale 6 Recharge the battery then install on the truck 7 Check others carefully such as start running turning lifting etc 8 Warm up your truck 42 sr HANGCHA 8 Maintenance Preventive maintenance schedule O Check revise adjust x Replace Note 1 If the working place has much duty or other pollutions the times of maintenance should be increased 2 If the parts are abnormal such as engine power descends emit black smoke or noise increase before the replacing time is coming it should be check Sometime it needs to adjust diesel nozzle pressure and fuel atomization Note 1 The fork lift truck needs inspection and maintenance termly make it in good working condition 2 Inspection and maintenance are usually ignored you must find the problems and solve it in time 3 Use the orthodoxy spare part of HANGZHOU fork lift truck general plant 4 Don t use different oil when changing or adding oil 5 Don t throw away the waste oil or electrolyte liquid as you wish Should deal with it depend on the local environmental protection laws and regulations require 6 Maintenance on schedule 7 After you make maintenance you d better make a record 8 Forbid to repair the fork lift truck if you haven t been trained Counterbalance weight unit kg Model of truck it 1 5t 1 8t 2t 2 5t 3 0t 3 5t Counterbalance weight 550 770 925 1192 1534 1780 2100
89. riving axle If the combined center is in the front driving axle the two front wheels become two fulcrums the truck will overturn If the combined center departures the triangle the trucks shall overturn in the corresponding direction the max load The distance between the load center and the front surface of forklift or load bracket select the min on the forklift is called LOAD CENTER DISTANCE The max gravity that the truck can load is called MAX LOAD on condition that the load is on the load center distance The relationship of MAX LOAD and LOAD CENTER DISTANCE is specified on the load capability chart If the load center is moved near the front of forklift the load should be cut down the load capability chart F F This chart shows the relationship of MAX LOAD 0 S E a And the location of LOAD CENTER DISTANCE Check AS costo moar whether the load and load center distance is in the range referred by the chart Put the most important parts near the load bracket if the shape of goods is complex LOAD CENTRE POSITION Caution speed and acceleration A static object keep its static station which is not affected by outside force one dynamic object moves with the same speed which is not affected by outside force this is inertia Because of inertia one force affected backward when the truck is moving one force affected forward when the truck is stopping It is very dangerous to press the brake suddenly
90. rks Don t use such attachments and special equipment for applications other than specified 32 Safeguard is used to prevent us from hitting of the higher goods Load bracket is used to ensure loading stable The forklift truck without two items is forbidden to be used 33 Never permit anyone to stand or walk under upraised forks or other attachments if machine is so equipped Never permit anyone to stand on the forks 34 Don t put your head or body into the interspace of mast and safeguard what may cause life risk Don t put your hand into the interspace of inner mast and outer mast sr HANGCHA WARNING 35 When load is to be retrieved from a pile enter the area squarely Engage forks into the pallet carefully 36 the goods is liable to drop turning or passing rough road when it departures the center And the forklift may turn over more probably 37 Don t enter into loads at a high speed Always make certain that your load is stable before lifting the forks Be sure to once stop in front of the load to be lifted and make certain that there is no obstacle then engage the load by driving forwards 18 38 Make certain that your load is well stacked and evenly positioned across both forks Don t attempt to lift a load with only one fork On the truck with an attachment such as a load grab make certain that the load is se
91. rning radius 2260 2320 Max negotiable gradient laden 20 20 20 20 Wheel base 1650 1650 1760 1760 Track F R 965 970 5 965 970 5 1005 973 5 1005 973 5 Service mass kg 3600 3675 4255 4555 Overall dimension LX WX H mm include forks 3600x1155x2120 3675x1155x2120 3820x1225x2150 3870x1225x2150 7 00 12 12PR 2 7 00 12 12PR 2 28x9 15 12PR 2 28x9 15 12PR 2 Tyre FR 6 00 9 10PR 2 6 00 9 10PR 2 6 50 10 10PR 2 6 50 10 10PR 2 Battery V capacity Ah 12 60 12 60 12 90 12 90 Model BaiYang BY491GP_ gasoline Rated capacity 41kW 2800r min Max torgue rpm 161N m 1800 2200 r min aulbue auljosesy Displacement L 2 237 65 lt C gt HANGCHA Model CPC20N RW10 CPCD20N RW10 CPC25N RW10 CPCD25N RW10 CPC30N RW10 CPCD30N RW10 Rated capacity kg 2000 2500 3000 Load centre distance mm 500 500 500 Overall maximum lift height my 3000 3000 3000 Free lift height mm 140 140 145 Maximum lift speed with load ie 430 480 380 Tilt of the mast F B 6YY12 67 12 67 12 Max travel 1 shift speed without load 2 shift mechanical km h hydraulic Ground clearance Min outside turning radius Max negotiable gradient laden 20 18 18 Wheel base 1650 1650 1760 Track F R 965 970 5 965 970 5 1005 973 5 Serv
92. ruck on a level ground preferably in a wide area If parking on a slope is unavoidable position the truck so that it cross the slope and block the wheels to prevent accidental roll Make sure the shift level on neutral position Pull the hand brake Shut down the engine and control the lift and tilt level several times so that the inner pressure in the hydraulic tube will decreased Take down the key and deposit it in a safe position sir HANGCHA Deposit the truck for a long time Deposit the truck for a long time fill up the truck body and counter weight with block to reduce the load of the two rear wheels Warning You should tell the manager if you find any failure about the truck then repair it immediately A Warning a The block must be single and hard enough to support the truck b Don t use a block with high than 300 mm 11 81 inch c Lift the truck to height of placing on the bearing block d Place two same size blocks under the left and right sides of the truck e After supporting the truck with block swing the truck forward backward left and right check its safety Do the following things Clean the oil and grease with cloth and water on the truck body 2 Check the whole situation of truck especially the tyres 8 Fill the oil tank with destined fuel 4 Check whether the hydraulic oil the engine oil fuel and the cooling liquid are leakage
93. ry If there is performance failure strictly forbid repairing without permission 2 Close the valves on the LPG cylinder before disassembly and maintenance of the LPG device 3 Suitably adjust the measure valve for LPG consumption is changing with season 4 Check and clean often the air cleaner and the LPG filter replace it with a new one in time if there is any damaged 5 After finishing the LPG forklift debugging and one day well run or a full container of LPG is used up you should adjust the LPG vaporizer again to ensure proper ratio of fuel to air 6 Check the electric system after every three months have elapsed if any switch connection peg is oxidized or rusted and get rid of it in time 7 Take a routine care for the whole LPG fuel system after every one year working that is clean the vaporizer check airproof capacity of each tie in in the high pressurized pipes and the low pressurized pipes YDROSTATIC RELIEF VALVE a LI CYLINDER ASSEMBLY __ FILTERLOCK BULKHEAD FITTING AIR CLEANER MIXER REGULATOR NISSAN ENGINE IMPCO single fuel system 91 lt C gt HANGCHA 14 Operational method of lead acid battery 1 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
94. s head and other parts of body The sign of defect should be put on the defecting forklift truck 4 Don t use an open flame to check level or for leakage of fuel electrolyte or cooling water Never smoke while inspecting the battery handling fuel or working on the fuel system There is a danger of explosion At working place fire extinguisher should be prepared 14 Never fill the fuel tank with the engine running 5 Warm up the temperature of water to 70 C before operation and cool down the temperature of water to lower than 70 C after work If the temperature of the water tank is higher than 70 C never open the tank cap 6 When using your truck in an enclosed space make sure there is enough ventilation If needed use a ventilation fan Don t work in a closed working space because of the tail gas of truck is dangerous to health It s forbidden to use truck under a circumstance of flammability and easy to blast 7 Never mount or dismount the moving truck Use the safety step s and safety grip facing the truck when mounting or dismounting the truck 8 Never attempt to work the controls unless properly seated Before staring adjusting the seat so you can get easy access to all hands and foot controls 9 Before staring make sure no one is under on and close to the truck The forward reverse lever is in neutral 10 Park the truck on a level surface and apply the parking brake se
95. s up for a moment After the indicator goes out turn the key to Start position Sedimentor indicator D Use in W9 W13 W15A diesel truck In normal state once the starter is set to ON position this lamp lights up After the engine is started up it goes out This lamp lights up when water in sedimentor reaches to a certain level while the engine is running If this lamp continues to stay lit or lights up during the engine running stopping the engine and discharge water immediately Caution Fuel injection pump will be damaged if continue working when the light is up If the light continues to stay lit or lights up during operation the charging rate is low and should be checked immediately Engine coolant temperature E In normal state once the starter is set to ON position this lamp lights up After the engine is started up it goes out During work time if the oil temperature exceed the normal rang 60 C 120 C the indicator light on Oil pressure alert lamp B This lamp indicates the pressure condition of engine lube oil Although it lights up when the engine switch is set at ON once the engine starts up and the accelerator pedal is pressed this lamp goes out Caution Caution If the pointer enters the red range stop the operation instantly and slow down engine speed to cool the coolant and wait until the pointer goes into the gre
96. sion F R 68 2 663 NISSAN 1 1 Model sr HANGCHA CPQ20N RW22 CPQ25N RW22 CPQ30N RW22 CPQ35N RW22 CPQD20N RW22 CPQD25N RW22 CPQD30N RW22 CPQD35N RW22 Rated capacity kg 2000 2500 3000 3500 Load centre distance mm 500 500 500 500 Overall maximum lift height gi 3000 3000 3000 3000 Free lift height mm 140 150 140 155 140 Maximum lift speed with load mmng 500 560 570 560 500 560 Tilt of the mast F B 6712 6 12 6 12 6712 Max 1 shift travel speed without load 2 shift mechanical km h hydraulic Ground clearance mm Min outside turning mm radius Max negotiable gradient laden ue 20 20 20 20 Wheel base mm 1650 1665 1760 1760 Track F R 965 970 965 970 1005 975 1005 975 Service mass kg 3440 3765 4255 4555 Overall dimension LX WX H mm include forks 3600x1155x2120 3675x1155x2120 3820x1225x2150 3870x1225x2150 Tyre F R 7 00 12 12PR 6 00 9 10PR 7 00 12 12PR 28x9 15 12PR 2 6 00 9 10PR 6 50 10 10PR 2 28x9 15 12PR 2 6 50 10 10PR 2 Battery V capacity Ah 12 60 12 60 12 60 12 60 Model K25 Rated capacity Max torque rpm 37 4 KW 2300r min 176 5N m 1600 r min aulbue auljoses Displacement L 2 472 69 lt C gt HANGCHA Model CPQ20N RW22 CPQ25N RW22 CPQ30N RW22 CPQ35N RW22 CPQD20N RW22 CPQD
97. sition which is comfortable for you and provides easy access to all hand and foot controls The seat is unlocked by moving the adjusting lever to the right Before proceeding with work adjust operator s seat and make sure that it is securely locked Warning a Before adjusting the lever you d better turn off the key switch b Must stop the truck to adjust the seat TIN TEI Al Ed 7 NaN Fa at Hh f 7 SEN PP Pi H j TN e LIHI ve UIT J ro Wf IE B des Al Seat weight support adjusting Use spanner to adjust the bolt which is at the back of seat or adjust the knob for supporting the weight on seat at the lift side of seat adjust the 10 hanging s weight basing on person s weight It s better to sit on the seat when adjusting Seat switch While you are on the vehicle and wearing the Safety belt at the same time your back and waist should close to the seat as much as possible Check whether the bolts which fixed seat belt were loose frequently It is forbidden to use the Safety belt when the belt was tie a knot Do not let the belt press on the hard or fragile objects And also do not make friction with the sharp edge to avoid damaging the belt Do not let the seat back tilted too much otherwise the safety belt will not be able to correctly elongation The components which are on the safety belt can not be removed randomly If the safety belt used frequently you should alwa
98. starting the engine Forward neutral BA Two shift type Backward BET et One shift type Choke line 19 To pull out the choke line the engine will stop Some of the model forklift has no choke line When turn off the key switch the engine will stop Forward reverse lever 20 Electrical Switch The forward reverse lever of truck installed with electronic reserving is set on the left of turning rod Forward Forward N neutral After allocation backward Caution Do not forget to place the forward reverse lever in the neutral position before starting the engine Guy head 21 Hood and snap close To avoid opening the hood at discretion a snap close is set here Open the snap close first then the hood can be open Guy head To avoid opening the hood at discretion the hood only can be opened by specified tools The guy head is the specified tool guy head snap close guy Emergency stop switch 22 Switch is located below the steering wheel on the right Pressing the switch will cut off the power of electric element from battery if you want to restart the truck you have to pull up the switch sr HANGCHA lt C gt HANGCHA Others Load bracket Load bracket can ensure stabilization when loading the goods It s forbidden to use the forklift truck without the load bracket Seat and seat adjusting lever Adjust operator s seat to po
99. t base on maintain per week 1 Change engine oil and oil filter 1 Start the engine warm up enough then flameout 2 Take out the oil cover and bottom shell to plug release the oil A Caution Be careful about the hot oil Milky oil shows there is some cooling fluid in it find out the reason and revise Oil is very rare show that the oil contains gasoline 3 Wipe up and fit tuck and gasket Screws down moment of oil tuck 29 N m 39 N m 4 Dismantle the oil filter by tool 5 Use cloth clean the surface of oil filter 6 Lay on little oil on the rubber ring of new oil filter 7 Install new oil filter by hand not spanner 8 Referrence lt lt Table for the oil used in the truck gt gt oil preferred sir HANGCHA 9 Start the engine check leak oil around oil tuck and filter If leak obviously this part is wrong install 7 Warm up engine enough then flameout check oil level later fil if need Check the oil fluid surface put the truck at ground flatly 2 Plus lubricate to front and rear of pin roll of Tilt cylinder Clean the plus place pile out the past oil 3 Check the gear oil of drive Axle housing If there is more dust at work place after 200 hours use it need consider that change the gear oil of drive axle housing 4 Change transmission oil filter Check the hydraulic transmission oil fluid if more dust change the hydraulic oil
100. t level ground play down the fork to floor inclined back the mast strain brake handle When transmission is at neutral position engine is cutoff A Caution Hot hydraulic oil and part will hurt body Do not touch the hot hydraulic oil and part 1 Put one case cubage is over 60 litre under the hydrualic oil box Dismantle the oil tuck let the hydrualic to case 2 Dismantle hydrualic dipstick and fuel box cover discreteness 3 Take out the magnet from oil box to clean and rinse the oil orifice of box bottom by hydrualic oil 4 Clean and install the oil plug 5 Fill hydrulic oil box Referrence lt lt Table for the oil used in the truck gt gt 6 Startup the engine and operate multiple valve joy stick and turn system fill hydrualic oil in all system 7 Check each hydrualic component and pipeline if leakage oil 8 Close the engine retract all cylinder pole check the oil level of hydrualic oil box Add oil at graduation position 4 Check clean and change hydraulic return oil filter respirator and strainer Let the truck at level ground play down the fork to floor inclined back the mast strain brake handle When transmission is at neutral position engine is cutoff 1 Loose the bolt of hydraulic oil box cover board discreteness 2 Take out return oil filter from top cover broad 3 Install new filter by hand 29 sr HANGCHA 4 Take out the strainer from oil box 5 Install new filter
101. trols Shift lever s check Check the shift lever s for looseness and operation for smooth Lifting lever tilting lever and attachment lever check Check the loading levers for lift tilt and optional attachment for looseness and smooth operation Increase the rotate speed of engine make certain that the lifting lever tilting lever and attachment lever in good work condition Instruments and sensors Make sure that hour meter water temperature indicator oil temperature indicator transmission fluid sensor and fuel sensor etc properly 22 7 Brake pedal inching pedal and clutch pedal check Drive truck slowly press down brake pedal and brake lamp lights Drive truck slowly press down inching pedal the speed of truck becoming decrease and press downward more truck will be braked and stop Check function of clutch pedal see Page 6 Controls Pedal lt clutch pedal Tire pressure Turn the tire valve cap counter clock wise and move it Using a tire pressure gauge measure the inflation pressure and adjusting it to the specified pressure if needed After making sure there is no sir leakage from the tire valve reinstall the cap Check that each tire does not get damaged at the tread surface or side face or bending at the rim A Warning Since the forklift truck needs tires that have a high inflation pressure to carry heavy loads even a small bending of rims or damage at the trea
102. ur content is at 0 C 101 35kPa 2 can measure sample whether it exists free water by eyeballing when measuring density a evaporation pressure can be evaluated by GB T 12576 6602 when arbitration measured by GB T b component can be measured by SH T 0230 but measure by SH T 0614 when arbitration c density can be measured by GB T 12576 but measured by SH T 0221 when arbitration d Total sulfur content 0222 when arbitration canbe measured by SY T 7508 but measured by SH T From PRC STANDARD 86 LPG IN VEHICLE GB 19159 2003 sr HANGCHA Procedure of replacing LPG cylinder 1 Take canvas glove to avoid the leaking gas to frostbite finger when gas changing 2 Make sure the place is clear and the air is ventilating when charging LPG it is forbidden to smoke keep away from other naked flame 3 Fill LPG as following Lay the LPG cylinder flat and set the charging limit valve upward then screw off the dust cap on the charging valve plug the filling connector open the inlet shutoff valve to charge LPG till 80 rated volume of the container is full the charging device is automatically closed when 80 rated volume of the container is full take out the filling connector screw down the dust cap and the charging limit valve Check all parts and make sure they are all at intact condition 4 Lift the cylinder up to truck and fix it let the arrow be upward then insert the
103. ure leakage or battery failure Check the Low Maintenance battery As the forklift is used in a high temperature ambient and the battery easily consumes water you should do pay attention to the liguid level when using the forklift There is an aperture for adding liquid in the cover of the battery Please add enough water up to the UPPER LEVEL when the liquid level is below the LOWER LEVEL and be sure the water is not so much that can spill out to erode your forklift When lacking of the electrolyte please check whether the surface is damaged or leaky or the battery is conking out 93 lt C gt HANGCHA 15 Use installation and safety rules of attachment HANGCHA will choose attachment that according with International standard ISO2328 Forklift pothook fork and install size of carriage such as clamp rotator paper roll clamp carrying ram side shifter etc 1 Attachment use 1 Know well the content of nameplate on attachment read the instruction manual before Usage Especially the manual from attachment company Before operate the attachment the people should be trained and obtain the qualification 2 It should be understand the basic capability and operate methods of attachment Especially the admit load lift height size of cargo and adapt range of attachment 3 Operate the multi functional attachment such as with side shifter clamp or rotator it is not allowed that two action at one time O
104. when clutch is unlocked Release bearing lubricate O O Mechanical Check oil level and O O O Transmission replace it if needs Torque Clean oil filter element O O Converter First Transmission Replace oil 1 mex x x Check differential oil and O x Driving axle replace it if needs front axle Check connection and O O retighten moment Check and adjust brake pedal for free travel and O O O O clearance Brake and Replace brake fluid x x inching Check for proper brake system operation O O O O Check and inching brake pedal for free travel and O O O O clearance Check for oil level Change oil 1 dj Clean oil return suction strainer 1 Proper work of the hydraulic oil pump H l a Proper work of control valve Check for oil leaks looseness collapse O O O O deformation and damage Clean the hydraulic oil reservoir 2 o 45 lt C gt HANGCHA Checking Monthly Trimonthly Semiannually Annually Item Service required Tools e6hrs 500 hrs 1000 hrs 2000hrs Check chain for tension O O O O Lubrication of chains O O O O Check chain and bearing for damage or deformation a amp 3 Check lifting cylinders for proper operation and O O O O i connection E Check tilting cylinders for proper operation and O O O O connection Check for forks and stopper pins for damage O O O O or wear Check fork base and hook welding
105. wly Then take away the chocks before the front wheel 9 Retighten the wheel nut with right tightens torgue 10 Inflation tyre again to right air ressure 33 sr HANGCHA 5 The operation of engine too hot If the engine is too hot do not stop it at once do it as follow Movement engine low speed Open the engine cover to airiness Stop when water temperature fall Check the cooling fluid add water if need 3 The measure for cold and hot Base on the temperature choose the suitable viscosity oil 4 Clean the radiator and radiation fin Caution The dust may fly to your eyes so you d better wear your glasses to protect your eyes If the radiation fin is build up it will lead over hot so use compress air vapour or water Caution Clean the radiation fin by compress air or vapour put the muzzle to radiator a right angle 34 sir HANGCHA 5 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 The basic structure of the truck is mast include mast and forks and body include tire The lift truck keeps the balance of weight between the truck body and the load on the forks with the center of the front wheels as a fulcrum when the rated capacity load is placed in position Due care should
106. ys do exterior inspection when found something abnormal please immediately replace new belt The belt can be used for 3 to 5 years when found something abnormal it should be scrapped early Overhead guard The overhead guard used is strong enough to meet safety standard and protects the operator from falling materials It s forbidden to use forklift without overhead guard Hood The hood can be swung up fully to provide easy maintenance service You can lift up the hood with little effort with an aid of hood damper To lock the hood push down on the front of hood until it covers Caution Before open the hood the handle of the snap close should be pulled out first Use caution not to catch your fingers in the hood when closing it Caution While maintaining under the cover hood the engine must be flameout to avoid hands or other parts of the body being clamped by running assembly The engine can be no flameout only when human body does not touch parts under cover hood and to examine where the fault is by hearing Radiator cover hood Must use special tools socket spanner to open radiator cover hood You can open the radiator cover hood even close the engine hood so to inspect the coolant fluid f f f fi Radiator cove Caution Retighten the bolt on the cover hood Radiator cap and coolant reservoir sir HANGCHA The reservoir is located inside the hood

1t-3.5t R Series Internal Combustion Counterbalanced Forklift Truck

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