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1. I X35mm GI I X35mm d ees s0 S X Bottery lev DC ABA 40A 1 X4 Ommi p lt lt 001 t lt lt t ABA Alternator lt S5 R GS FI C ue 009 mesi d F1 50A 004 008 p 003 E MI 007 005 a EXAV Storter gt EE 150A Mali E JILL 1 X35mm OG 013 F2 03 60 RI zs 2 50A 006 GAE Glow plug og 5o rJ 0 MN 015 AGS H9 ee C9 AMETK Preheot indicator lamp F8 10A on 1 C9 REHBM Charge indicator lamp Y H 6 S10 AESSK UIL pressure indicator lamp ANS 46A 12 017 1x0 85mr l QF S104 a XXE DI water separator indicator lamp H13 018 69 5109
2. Fig 10 CPCD20 25 30 35N RW33 HJEL 190 S R 150A St 1 X35mm Gl 1x35mme ees a u Bottery lev DC AR 40A 1 x4 0mnf i Kj lt i 001 t IS lt t RBA Alternator lt lt S5 R GS FT ZS 009 EH Ki F1 504 004 002 aa 003 as MI 007 005 0 d REM Starter Vs Anto 150 H ndi AURI 150A 1 X35mrf Q 013 M 03 60 RI F2 50A 006 T W ME Glow plug 02 ar 014 oi 40 TE 4 KERRE Water temperature sensor QGS a HW MM H 1 ar sk THEHR Timer Solenoid er Q AMETK Preheot indicator lamp 8 10A we 1 C9 AUERK Chonrge indicator lamp bi SS 4 H Gi 6 S10 wERB Oil pressure indicator lamp AES 6A 12 017 1X0 85mmi 4 Q S104 a HADERBT Oil woter separator indicator lamp H13 018 y TC i 69 t 103 3 WERZA
3. ui Bye 150 E 1 EE Iu 001 GI cece 0 fX Bottery lev DC lt lt lt s RBA Alternator Dame Head lamp amp signal lamp switch GS net 5 m Leu Ge Posto 113 4 2 erate of X Un p X X X Led X XIX dabat 15A K1 002 Fao 003 7 004 pH SS M 005 i D Ed J 0K 007 re heat amp start suteh Ait 150A nt 1X35mmt d xy BL Be Acc C RI RO VW RAV Storter SC RE reneg F2 50 FF X X 4 1 j 1 Run X X X E02 E01 gt H Start X X X X X 1 F3 2 ad Oo S pns XEE Spark plug m c a L E uo t Number Sign Instruction SES m mite Fuse AG 6A F8 10A lees 9 ad o c AI ESE Banked batter 4 G9 REHOM Charge indicator lamp l De 013 S101 WIESEX DIU pressure indicator lamp 3 ME Relay i lg 014 WERZA temperature indicator lamp 4 nm Normally open switch S Re 3A
4. s kk 150A UE Q 1X35mm 001 Gl l HM TAS I B kl EI egen unn lt lt 1 X4 0mm S FT S4 L B Ge MV SAKT ISA Kl F1 50A mM UU c o us dit de M 005 4 007 At 150 SE WE Wr F2 S0An S C 4 SE C0 E01 gt LA 7 mm Fo ON gt e M O o Be decem 011 dd K l VV 009 O LU AX 6A F8 10A OA Ue 013 lg SIU 008 lg 014 4 S MET CIA i p 019 KA Vater temperature gauge V 102 J F7 10A 1x0 85mm he 019 b104 7 HEI amp Ke SH Sl g 56 Moy O 7 018 Q 1 V 3 4 6 4 D 69 3 021 gy 5 4 Sd 4 3 me F6 10A cog Kl eg Sl 023 Be gt l emm a ree HH 6A 024 Q LA l 1X0 85mri 5 Q 3 P 4 026 GO 8 4 AS AA FS 10A 1X0Bomm nos SP 027 gp 6 3 F10 204 l el RUE Ho cover fuse F9 10A DRM DG ever fuse F4 104 HOL i 028 d 33 FER AA 029 1x1 25mre Gi UMS S6 ig S T Gi EE 16 031 6 3 196 MES 1 D EN O HO 030 m Jal Q Q
5. 1 X35mm 1 X35mm WS 001 de de 9 W x Bottery 12V DC 8 e i RAY Alternator HHK GAOA 1X4 Omm E GS FT S4 L Bg Ge VVV swem lt 15A K1 F1 50A SE 002 ap FI M 005 l 007 AER 150A side RWV Storter F2 50 UG E E3 1 E02 EOL ER EE sg ES be OO Gg F3 3 X4 X Spork plug D ad 3 4 om d i O va a t Corburetor AER COA FEAA x085mm 9 009 og AR AAM Charge indicator lamp l lg 013 S101 WESREAH UIL pressure indicator lamp 008 dere daf Lg 014 e S104 WERZA temperature indicator lamp soak dk 015 4 4 Water temperature gauge WZ EERE F 7 104 P 5108 AKinkkRe Water temperature sensor p 1 0 85mm ex 016 ER Fvel quantity gauge 013 RIA x uel tit 4 TT ED 5103 WEE Fuel quantity sensor 03 4 Wht Timer es K2 6 KZ SS SI o 2 5 017 JL NHE HAA Forward solenoid valve O E 018 BER Reverse solenoid valve n Q E EREI L ett reversing lamp T Q ot ABEX Right reversing lamp e SE
6. VAANSc 0FG8l SEP VING 8I 8T VANS S IG TI DANE w7 00 270 S KEN C MNSS A BON A1930SO ICH SHEER HY X Uo S6 5 x 2 05 amp OdW86 0 94nssa4c nu 5 EVO eae cx eo 70 BA Sung s Ge CdN86 0 KINK o E CO I qi KE a 1d0 IK B OodMW0g eansseaad cog US ED 019 Bunn sano N e EE OdWOE YHHH E d aA OA 4030jh884 mot Dan We SS ge e En DE 2170 Mee VANG I EM 3 5 E O 7 8 GG F cl jd d N OdWwe eunsseud ke a D 0 VEER AINE ER i Q D ol le B Ny so eil ON l li J W x d E ACIAIC c 2y0 VAWS 8 Sief emos 104 194 Y det i 3 TERE SCH id AP SEH Us pe 2 d V EEN 3 570 ie 8e g y 670 S H e VANDE SUNSSSUA odW0g eansseaud 2 2 e JE IVO Bun sano Sun sana D D Ge T Iv CANOE reser OANOE EDE 9 amp o 270 89 8g 840 p xig em Sy N SdlUOre Anse ede VANDSauNSSaAd DI ae U o ae Sun sano men ES IE soe ER BEE n oj 0 5 Gut i Zy OdINOS respi EE G IxOI 6170 202 E Yapundd Buuaa EE 3 Eed S RE cl cog HZ ole gt odW0S 94nssead 96 99 ES D Odwagevnssevd Sun suna GIZO 91Z0 DUIT SUNG OdWOS t spia m ONO YEAR ps 8A 0 JO3uO OA MO2UO2 Mi LL o TAO n IVO
7. Fig 7 7 Schematic figure of hydraulic system ADUMd uaa s Wou8 vip onnoapKu epiAp pinjj SeMaS s 4C KUNG A Lt ai Dm Sut HANGCHA 58 sr HANGCHA VI Lifting system 1 Assemble debugging data Debugging data Double mast and triple mast standard type and m e l Lifting height Lifting height Mast type lifting height of 2 4 sd ee gt 5 6 meter meter Mast tilt ew e 1 angle Backward o amo 2 EE EE Lom NEAN roller and MEN roller if rated capacity is less than 3 5t Inspection and adjustment Place Assembly clearance Repair clearance mm mm Inner mast to carriage 0 1 0 6 KEN side roller 0 5 1 0 1 5 Lift chain deflection 25 30 mm Tightening torque Model or Lifting capacity 1 1 8t 193 257 M16 Lift chain lock nut 2 3 El 245 314 M20 1 1 8t 124 165 M14 Mast support cap blot 2 3 El 176 216 M18 1 1 8t Tilt cylinder lock nut 53 Bi 89 118 M14 Lift cylinder bolt top ME 76 107 M12 1 1 8t Lift cylinder bolt bottom 235 22 30 M8 Lift cylinder fixing 1 1 8t bolt cylinder light bolt D 3 Bt 76 107 M12 Basic model mast weight 59 sr HANGCHA 2 Trouble diagnoses and corrections 1 Tilt cylinder and ring abraded Replace piston ring tilt Fork arm carrier or mast tilt excessively cylinder by itself 2 The hydrau
8. Bn Pre hent amp start switch Head lamp amp signal lamp switch Positio 4 ES off X i X X X Iip X XIX Pre neat amp stort switch Uk xo B1 BE Acc C RI R2 Preheat X X X Fry XX Run X X X SEO VAA JA X Number Sign Instruction 1 Rie Fuse E JE et Bonked battery 3 Fi 468 Relay 4 BA Normally open switch 3 ME Normally closed switch 6 e 1 WM rope double tron se SG Ate Flasher 8 fe p Solenoid 9 id n Horn 0 ra PRS Sensor GO m Bulb 2 YY Ga Buzzer 3 vr t Resistance 4 HA fk Glow plug 5 BL AE Diode 6 D HAARA Pointer gauge i amp 8 Control box a TE 1x35mm 1x35mm p lee eel Sp Battery 12V DC KRL lt 40A lt _ ki 1x5mm B E 001 M lt lt KBA Alternator lt lt IG FT L G DEEN K1 F1 504 003 1x3mm SEH 004 002 Te 009 027 M HER lt 40A LP 1x4mm JA Starter age lt 150A 1x35mm MA l S7 F2 50A 006 ms ESN mm E R2 O4 Lent F 4 1 Te WAB Glow plug EE gar 2 E01 036 9 029 ese OA DT amp Reo Preheat indicator lamp 0 als F8 10A Re amp er Charge indicator lamp e US 4 1 amp Eel FI ER N Dil pressure indicator lamp GO ne t A gt MERZI temperature indicator lamp X amp amp Water t t 0 S102 ee ee P 033 x am xXAi amp K Water temperature sensor 3E amp F uel tit 0 F7 10A ASA d EE 63 034 f
9. At 150A Gl z 1 x35mm po 135mm eos A E tib Battery 12V DC ET t Ki B E 001 T t lt lt s RBI Alternator N sive yal CAOA ace 1 x5 0mm R FT S8 id G MES 1 AR 15A K1 F1 50A 003 1 X3 0mm 004 002 Y o 5 a dp 009 027 Cl MI ASI 304 x4 mm 4 KBB RL 1504 po DaSmm 4 NW RWV Starter Fe 50A 006 0 F04 04 0 60 F 7 SE 005 HGME Glow plug har Zeg 038 A 4 037 m VE 29 AEFK Preheot indicator lamp 0 130 Gen KRKAH Charge indicator lamp o a Gong KER 6A Q 031 ran WEREN LIl pressure indicator lamp SS Ke REES 3 ap 032 ES TEM 4 1 Gi a 7 m WARREN DL uo ter separation indicator lamp d Q 033 at 3 WERSAL temperature indicator lamp Ai Voter tenperat T SME d m EE 034 A KERRE Water temperature sensor ver wex Fuel quantity gauge 035 c S10 7 10 AU YT AA 623 I wefeee Fuel quantity sensor y 1 x0 85mm 028 P EET 4 63 HHR Timer 036 T 7 B rel shut off switch 024 6 i T Mb ME e 5 5 5 7 A Hit HA F orword solenoid valve HO OD Ka 1 H 7 SC fERAK Reverse solenoid valve 025 3 4 T GI Z HN Left reversing lamp 29 4 69 1 ABIEX Right reversing lamp H02 i xt f t amp S Reverse warner Q i ARREN Left turn indicator lamp e Q 2 AWRAM Left turn signal lamp Front F6 10A 020 Se 021 ie o Gi a Zkkwk Left turn signal lamp Rear kans M S Q Bre 4 amp WEWX RIght turn signal lamp Front 1 x0 85mm 023 5
10. we Horn a WARIX Instrument panel lamp WHW DI Instrument panel lamp AR RX Rear left width lamp I FE R Rear right width lamp AKA Left head lamp d amp AN Right head lamp AWAREN Front left width lamp EE 120 7 1 X35mm G1 1 X35mm eee e ASI lt 40A 1 x4 0mm lt lt k 001 Lei Lei 4 lt SO R FT ca T Ue mc T F1 S04 004 00d 8 003 M1 007 005 0 A TT il 1504 1X35mm 5 9 013 F eZ50A 006 03 60 R1 o2 ar 014 SC 015 QGS H9 Q 021 vie H10 F8 10A C9 l 011 11 016 r Gi S10 ART 65 12 017 1x0 85mr Q S104 Den 018 _ Com AE Water temperature gauge 019 V 4 P 10 wea Fuel quantity gauge 020 Ed 5103 5j F7 10A 012 p 4 PJ ART quy 1x0 85mm Ke Ka 4 K7 039 ES 022 5 6 S1 Q 2 I 7 E 0 d ue 1 A 023 3 4 S6 a l 0244 amp 5 5 54 4 69 E s H02 12 Korg RA CEA GE F6 108 1x9 85mm Ku x SL o 4087 Q 4 a 4 O 3 023 028 7 F5 10A ARR AA 92 SH C 1x0 85mm 029 030 Q 6 3 F107204 53 4 lmus Resever fuse C9 Come o EAR H Resever fuse C AM lt 4A 4 108 eg nor S4 032 033 7 N S9 E ZS F3 15A SET BA 1 61 War EN Nu 033 Q 034 E peres gt O o o K3 og 1 3 4 5 Q 3 03
11. WARNING To avoid the danger of being scalded never attempt to change the coolant when the engine is hot When using anti freeze coolant mix the anti freeze coolant with water 2 2 6 Cleaning Radiator Outside Clean outside of radiator with dry compressed alr 2 2 7 Checking cooling System Hoses and Connections Check hoses and fittings for Lose connections or deterioration Retighten or replace if necessary sir HANGCHA Ac HANGCHA 2 2 8 Checking Compression Pressure 1 Warm up engine sufficiently then stop engine 2 Remove all spark plugs 3 Properly attach a compression tester to spark plug hole in cylinder being tested 4 Set carburetor throttle valve at fully open position 5 Crank engine and red gauge indication Run engine at about 250r min Engine compression measurement should be made as quickly as Engine possible Compression pressure K21 K25 1 23kPa 1 27kPa Standard 6 Cylinder compression in cylinders should not be less than 80 of the highest reading If cylinder compression in one or more cylinders is low pour a small quantity of engine oil into cylinders through the spark plug holes and retest compression If adding oil helps the compression pressure piston rings may be worn or damaged If pressure stays low valve may be sticking or seating improperly If cylinder compression in any two adjacent cylinders is low and if adding oil does
12. re heat amp start switch Uk iwi BL BE Acc C R1 R2 Preheat X X X Saak Run X X X Stary XIX X X X Number Sign Instruction ite Fuse e JE ng Bonked batter 3 EE 1488 Relay 4 Wm Normally open switch 9 Is EE Normally closed switch 6 e ME hopie dwie ror itc 7 SG Ate Flasher 8 fl UM Solenoid 9 id n Horn 0 R Sensor CO Bulb SY Wie Buzzer 3 vv B L Resistance 4 DS Glow plug 3 BE RE Diode 6 7 itil Pointer gauge 7 d EE Control box 8 TAE Preheat start switch 19 DY HAGE Time relay PI 2 ON RWORAR M 1 EE 001 1 kel b A K lt FT Ka Ge S8 EE
13. 7 Noticing debugging 1 Adjust Forward and BackWard of the mast Place fork lift truck on the level ground operate control lever to realize that proceeding of 19 Ac HANGCHA mast inclined forward or backWard extremely As assembly debugging data required adjust combined screw thread length till according with data of BackWard Then lock earring ring close please see foregoing table if you want know tightening torque of M10 bolt 2 Adjust installation position of left and right lifting jack again a Adjust washer in the middle of piston rod and inner mast bracket if one lifting jack is not synchronization with the others when rising or falling and if one lifting jack is different height from the others b Loose two nuts on the U bolt Mast is not rise and lower until relative position of U bolt and lifting jack is suitable Then screw down nuts and tightening screw on the U bolt Thus lifting jack can be used longer and wear of piston rod can be reduced 3 Please see foregoing table if you want know tightening force of bolt or screw Please refer to common bolt tightening torque prescribed in our company if you want know other tightening force of bolt or screw refer to OPERATION AND MAINTAIN MANUAL backing boardched with it 76 sr HANGCHA IX Electrical system N WARNING Before starting to work on any parts of electrical system remove rings and jewelry to prevent an accidental short
14. 6 To install reverse disassembly procedures Meter shell Fastening bolt of front protect hood Front protect Meter board Meter plate Fastening bolt of meter board Key start switch 1 Remove combination meter 2 Disconnect connector of wring 3 Remove nuts washers spacers and instrument plate 4 To install reverse removal procedures Adjust ledge of switch to proper length when installing Inspect Use multimeter with ohm to check key switch wether it is on at each position 82 lt HC gt HANGCHA ee on een gt Location of switch REVERSE BUZZER 1 Remove the wiring terminal then Left rear pillar safeguard unscrew the bolt 2 To install reverse removal procedure Backup buzzer HORN securing bolt REMOVAL AND INSTALLATION 1 Disconnect horn harness connector 2 Remove bolt and horn 3 To install reverse removal procedure er Horn securing bolt 83 Abt 1904 AP 1904
15. 1 1 8 turning 2 3 5 N163 220020 00 angle i thickness mm 0 Tyre pressure pees Kingpin wheel hub bearing Kingpin axial play mm Less than Tighten steering spindle op pray 0 20 nut until drive wheel hub Pre tighten no longer rotates with Kingpin adjusting washer one hand Then loose 1 8 1 6 rotations Or wheel hub bolt force 0 10 0 30 0 70 N163 220012 000 Axial Less than 0 10 play mm 2 Trouble diagnoses corrections condition Probable cause Corrective action tighten adjust adjust refer to turning system section loose wheel nut Unstable wheel bearing out of adjustment driving Improperly adjusted shims faulty steering system insufficient lubrication loose bolts and nut Apply calcium grease Improperly adjusting shim for axle tighten end Shaft adjust damaged joint bearing at two ends of replace rod Noises 36 P1soped pue uun oo 1E aspain 994 1ojno Jo Zurieaq 19402 qni ynu 4220 1JEUS ah Ze GE We Jaysea Surrag 4 gt L9 LEL QD ig ez d B6 82D 18 4 4 11 09 TOUR sSuruuny A H C gt HANGCHA paeoq 3UTUJE aiA dryrunaud um Td 1349 SSO iaqiosqe yooys 2oo q iaqqni lotsEA 207 A Pas again ERA Za I e 0S4 0 Oh 1199 Loo LC e LZ SSOUMITUL d DA 1 Tas oie trie as ase AC AN Bas aspald slee E Autaeaq appaau m ao Bas srar as KN onbior un run Wra aayy Sula eiseped pue uun oo 1 1 O
16. EKSK NL temperature indicator lamp Kiss Water temperature gauge 019 V l s EH 10 KERRE Water temperature sensor wea Fuel quantity gauge ea 020 4 d he i S T o WEKRYV F uel quantity sensor d 4 P3 NR Timer Saal ery 1x0 85mn Ke 022 se K SL 2 e y WAtA Forward solenoid valve O 7 o 0 l ii V AFERA Reverse solenoid valve 023 3 4 Og MAUERA Fuel shut off solenoid switch 6 4 a AAL 0249 Gi ABEX Left reversing lamp d G9 2 4 AflEN Right reversing lamp H02 de TE AR Reverse warner GS ZUWA Left turn signal lamp Front AXI 464 EE Gi a Z ibzi urn left indicator lamp F610 gf 1085mm Kl oog ot amp gt 5 ZhKWN Left turn signal lamp Rear 1 025 SG p hee Q GHRAX Right turn signal lamp Front amp UNS ARTA Turn right indicator lamp EE F5 10A E So SES GE ABRAM Right turn signal lamp Rear d 0294 KSE T ZWEK Left brake lamp F10 204 53 4 e HERA Resever fuse m G9 AsK Right brake lamp F9 10A Wornl l HERE Z Resever fuse 3 di Se AST 44 4 108 XL asm lt HO S4 ET EE 7 RUP Horn SS G9 T a WRHXI Instrument panel lamp 35A EWER BA 4 Gi SCH a WHUDX Instrument panel lamp LSM u A oo BREM Rear left width lamp s O O a MEM e Oo o K3 GI 1 RKH Rear right width lamp 3 4 5 amp 3 v EAW Left head lamp 021 3r 03A Q 4 4 amp AW Right head lamp EA Q Ll AWREN Front left width lamp cl EWOEM Front right width lamp C9 Fig 9 CPCD10 15 18 20 25 30
17. Used 1 Dustproof ring 3 Protect ring 6 Compound bushing 8 Bolt 9 Piston rod 11 WR Wearing ring in fig 10 4 7 O ring 2 Cylinder cover 4 ISI ring 5 0 ring 10 Gylinder 12 Piston A H C gt HANGCHA l CU MI UIT D r 100 ON mm mm an d EF 12 J E d dE A um amm amr amr AP mm em am P am AP MV ARE SEA III bal 67 4 O ring epo EE IEEE E AG SVS a AF EF FF AF UV EE N ag Kr EL nn NG S AS es OK ASAT KKK KKK IR ks slk KE x FF UP AF FF FF ELEC FF FF ELE a MELLE OW Z Fig 8 8 free lifting cylinder left Fig 8 7 Lifting cylinder used in 8 2 8 3 1 Dustproof ring 2 Cylinder cover 4 Guide sleeve 3 used in fig 8 2 8 2 Cylinder cover 4 O ring 6 Plunger rod assembly 8 Piston 10 Cylinder 1 dustproof ring 3 Guide sleeve 5 Stop piece 7 Support ring 9 Check ring 5 O ring 6 seal ring 7 O ring 8 deflation plug 9 Piston rod 10 cylinder 11 Support ring 11 ISI ring More than or equal to 3t cylinder sr HANGCHA A KE N O0 KXXXi een e EE A Fig 8 9 Lifting cylinder left used in fig 10 2 10 3 1 Cylinder cover 2 dustproof ring 3 Adjusting washer 4 Guide sleeve 6 O ring 7 compound sleeve b ISI ri
18. sr HANGCHA II Hydrodynamic transmission torque converter Hydrodynamic transmission torque converter for CPCD20 25 30 35N RW15A CPQD20 25 30 35N RW22A see import NISSAN MOTOR CO LTD SERVICE MANUAL FOR THREE MAIN COMPONENT CPCD20 25 30 35N RW1B CPCD20 25 30 35N RW6B CPCD20 25 30 35N RW9B CPCD20 25 30 35N RW13B CPQD20 25 30 35N RW22B CPCD20 25 30 35N RW33B see import OKAMURA Japan MOTOR CO LTD SERVICE MANUAL FOR TRANSMISSION 3 CPCD20 25 30 35N RWE33M see 2 3 5 TON TRANSMISSION AND DRIVE AXLE The others see as follows 1 Summary YQX18 YQX25 YQX30 model hydrodynamic transmission gear box consists of hydrodynamic torque converter and power shift which has two shifts forward reverse transmission box Fig 2 3 It has virtues as follows 1 Hydrodynamic transmission gear box has automatic adaptability for hydrodynamic transmission output it can change it s output torque and rotation speed according to the external load 2 It can absorb and remove the impact liberation that the engine and external load brings to the transmission system 3 Inching valve cushion valvecan make the truck to move a little when the engine in either low speed or high speed make the operation easy convenient steady starting reduce the labor intension of operators 17 HANGCHA 2 Data men vos Ya Single stage Two phrase Three element Max torque converter Hydrodynamic ratio Ko torque Diamete
19. Positio E MISERE off A iib X X X 1 ead np X X X Pre neat amp start switch OK xi B1 BE cc C R1 R2 Preheat X X X FF XIX Run X X X Start XIX X X X Nunber Sign Instruction iit Fuse C C FEL Banked battery 3 CG we Relay 4 SR Nom ly open switch 9 gt RI Normally closed switch 6 e HR mie dotle tror sic 7 SG WX Flasher 8 m EAA Solenoid 9 c S Horn 0 Fr AE Sensor GO Wk Bulb C Hx wis Buzzer 3 vr H Resistance 4 WA Glow plug 5 4f Dode 6 P Pointer gauge 7 d WE Control box 8 EI Fig 6 CPQD10 15 18N RW21 Y3 CPQD20 25 30 35N RW22 Y3 electrical system schematic diagram 89
20. and the steering action will be realized manually by turning the steering wheel to move valve spool valve guide coupling block and to actuate he rotor to feed oil into steering cylinder in this case rotor and stator act as a hand pump making manual steering possible 3 ase mein Bj HE OD 1 2 4 ja 5 6 7 g 9 10 11 12 TE UY Wi jd EE am EET ir p fy Lee Ee P FALSE h PA He I er ee NT TS Kei eas E E E SR Ta ar areas SES i SSC hi ura ap oa um m A RH cT E 21 Br d JD AS SSS i k DC J DU MS o PI E Pe GE TIT Fig 5 2cycloidal rotor full hydrostatic power steering gear 1 Connected block inner spline connection none 2 Front cover 3 Screw 4 Spring 5 O ring 6 X ring 7 Stop ring 8 Thrust bearing 9 Slip ring 10 O ring 11 diaphragm 12 Rotary stator pari 13 Rear cover 14 Bolt 15 Stop block 16 Couple axle 17 Valve disk valve sleeve pair 18 Shell 19 Steel ball 20 Stop bolt 41 Ac HANGCHA 3 3 Steering cylinder refer to Fig 5 3 Steering cylinder is of double acting piston type The two end of piston is connected with steering spindle through rod The oil from full hydrostatic power steering gear makes piston rod move left and right so as to turn truck lift and right K C 4 AE 8 9 10 1112 13 14 15 1 Earbob 2 Elastic stop ring for hole 3 Plain radial bearing 4 Round wire snap ring 5 Dustproof ring 6 O
21. lt s RBI Alternator ua C40A lt ke Dx On G5 dead lamp amp signal lamp switch S FT Unt E 84 L Ge Ww 3 4 fo hy o C X Wi X X X ied X XIX BE EL lt A K1 F1 50A EH jr BES EI 004 CS p X3Smr UNA NW gH HH Starter Postti Bl Be ee RI RE Preheat X X X F2 504 FF X X 06 4 s Run X X X E02 E01 get um Start X xX X X X f Pete m OO Gg SC X4 X Spark plug d AA K7 AM er S Instruct ign is 009 O ANN A Ak Carburetor ue 2 De ME ON o H HX WS Fuse F8 10A AE OA e 1X0 85mm 9 o SIF ui C9 HRHAKN Charge indicator lamp URES DOWER 4 lg DE S101 mEREKN DIL pressure indicator lamp 3 His Relay 008 T d lg 014 e 104 EKEK DI temperature indicator lamp 4 __ Normally open switch b B A vi d y F7 10A TR 4 o temperature gouge E103 XE Woter temperature sensor 9 R Normally closed switch oJMM MLE i i VA l c 016 HE amp Fuel quantity gauge weep 012 Ro HERRE Fuel quantity sensor 6 e 1 BM Morpoe die thron snitch A 4 HER Timer E Ko 7 SG AS Flasher 8 Kei R Solenoid se KZ ET T al g OL o 4 WRC Orword solenoid valve 9 q WA Horn o 018 7 fERAK Reverse solenoid valve 0 fe PRS Sensor 4 1 GO NE Bulb 4 Q i ZFWEK LeFt reversing lamp y 4 021 54 F C 4 eis Buzzer GI AflEX Right reversing lamp Hoe 3 wv ER Resistance 2 BERES Reverse warner Q a UKWX Left turn signal lamp Front 4 DOS Glow plug F6 10A K11 GO DST
22. 03 mER Fuel quantity sensor 1 gt 63 ittt Timer 028 035 024 se KZ SE SL o 2 7 MAAL Or word solenoid valve O Li E l O 1 AEAMA Reverse solenoid valve 025 3 4 D 026 69 Zzf H Left reversing lamp Gi amp tX Right reversing lamp 4 MC GtUS EX Revercse warner amp DIE xWE amp WHX Front le t steering lamp 022 S Ge KEE v O Gi bee t EkEWSWX Reaorc le ft steering lamp k O e e z 020 O TE Gi Se Z gn Eront zriobt steering lamp s2 69 ak mN Rear right steering lamp 8 F5 10A E S3 919 C9 1 Warning lamp d me amp DES 4 Z xX Left stop lamp 017 018 F9 10A CQ 3 3 amp tixXx RIght stop lamp gt HTEZ Resever fuse F10 20A HYKKH Resever fuse HOL razioa S C i J5 016 WY HORN j F3 15A Sex lt 8A Gi v WHHX Insteument panel lamp vim 71 n O o S Gi WRAXN Instrument panel lamp 010 O Gc 9 E a Em XX Reor lef t width lamp 24 3 ye S Q 1 E EN Rear right width lamp 3 012 mM G9 ZEXN Left head lamp ol 4 amp i amp XW Right head lamp Ka e DI t ront left width lamp 01 I e Hel mzRA Front right width lamp 0 ele SU JN We BA Fig 8 CPCD20 25 30 35SN RW27 electrical system schematic diagram Ziki 150A AK 150A
23. 2 Disconnect the wiring connector 3 Remove bolt astigmatism glass then replace faulty bulb with new one 4 Assembly is the opposite procedures Instrument sensor and relay Inspect whether relay circuit is on connect or disconnect Col with proper voltage supplied by battery and then use multimeter with ohm to check whether contactor is on Disassembly and installation Combination meter assembly 1 Remove 4 fixed bolt from meter crust Notice that when installing and removing please make instrument surface tilt an angle to avoid damaging the screw thread of fixed parts on truck 2 Take out wiring harness from sleeve and then instrument can be brought out 3 There is transparent plastic cover to cover so it can prevent dust and water and it is fixed by 6 plastic clip buckle please press down plastic buckles lightly to take out plastic cover when removing 4 To install reverse removal procedures 81 sr HANGCHA 1 Fastening bolt of meter shell 2 Flameout lever 3 Rear work light switch Fuel meter temperature meter hour meter and alarm lamp 1 Remove fastening bolt on meter plate then separate meter plate and meter shell 2 Remove fastening bolt on front protect hood then separate front protect hood and meter plate 3 Remove meter plate 4 Remove fastening bolt from PC plate then remove meters 5 Remove alarm lamp from PC plate all alarm lamp can be removed from compound meter individually
24. 35N RW32 electrical system schematic diagram Head lamp amp signal lamp switch Positio s LS p AE o EP X With X X X Head trp X XIX sat re hent amp stort switch OK xi B1 B2 Acc C R1 R2 Preheat X X X ff XI X Run EX X X Start X X X X X Number Sign Instruction ite Fuse e JUR ERWE Banked batter 3 Fi we Relay 4 1 RE Vor ally open switch 9 r BTE Normally closed switch 6 AIRE noe dowie tior sric 7 SG NX Flasher 8 Ki UM Solenoid 9 WWA Horn 0 A KRG Sensor l XH Bulb P I KYR Buzzer J vr Resistance 4 WA Glow plug 5 Bl Diode 6 7 BIS Pointer gauge 7 d EHe Control box 8 4 Bai Pre hent amp start snitch ane 0c8 000007 cc9628
25. C HANGCHA 3 C240 PKJ 30 Diesel 3 1 Specifications Type No Of cyclingdrs borexstroke Piston displacement L Compression ratio Rated power rotate speed Max Torque rotate speed Min Rotate speed under no load Min Fuel consumption ratio Direction of rotation Firing order Cooling system Lubrication system Injection nozzles Air cleaner Oil pump Water pump Thermostat Voltage Current Generator Generating type Voltage starter Output power Oil volume Valve clearance Nozzle inj pressure Injection timing C240 PKJ ISUZU chamber type Wax pellet type 12V 35A AC silicon rectifier 12V 2kW 6 1L API CD or better 0 45mm 120kg cm BTDC9 3 2C240 Diesel Maintenance 3 2 1 Retighten Cylinder Head Bolts When engine is cold retighten should be made in the sequence shown twice T 79 N m 97 Nm Two steps First 55 N m 68 Nm Second 79 N m 97 N m 3 2 2 Adjusting Intake and Exhaust Valve Clearance Making as 2 2 2 Valve clearance Hot Intake amp exhaust 0 45 mm 3 2 3 Checking And Adjusting Fan Belt Fan belt deflection 8 mm 12 mm Pushing force 98N 3 2 4 Changing Engine Oil and Oil Filter Refer to 2 2 4 Oil Capacity 6 1 L 3 2 5 Changing engine coolant See 2 2 5 3 2 6 Cleaning radiator outside See 2 2 6 3 2 Checking cooling system hoses and connections See 2 2 7 3 2 8 Cleaning or replacing air cleaning filter See 2 2 9 3 2 9 Remove water from th
26. Combined back lamp Brake and width lamp Steering lamp Reverse lamp 12V 21W 5W 12V 21W 12V 10W Combined meter Floodlight Caution light 78 sir HANGCHA Location of light Rear work light optional _ Rear compound light Big Headlight Front compound light LIGHT SWITCH DISASSEMBLE 1 Remove the assembled instrument 2 Remove knob ring nut amp spacer 3 Disconnect wiring terminal SE ETE GEE GEES GEE 79 sr HANGCHA TURN SIGNAL LAMP SWITCH REMOVAL 1 Remove assembled instrument 2 Remove bolt disconnect wiring terminal 3 Fixing sequence is opposite to removing sequence 42 mm 1 65 in Turning light switch Turning column After installing turn signal lamp switch insure the distance between turn signal lamp switch and top of steering column is 42mm Location of switch Junction point L 1 3 No continuity Front headlight Disassembly 1 Remove securing nuts of the big little lamp 2 Take apart the wiring connector 3 Remove bolt lens then replace faulty bulb with new one 4 Assembly is the opposite procedures 80 sr HANGCHA Front combination lamp Disassembly and assembly 1 Remove fixing bolt of bracket 2 Disconnect the wiring connector 3 Remove bolt astigmatism glass then replace faulty bulb with new one 4 Assembly is the opposite procedures REAR COMBINATION LAMP 1 Remove fixing bolt of bracket
27. Instrument panel lamp 4 deu SG DEE oles 3 2 5 ZBWWX Left turn signal lamp Rear 5 Pk Diode Gees 0 oo AWENX Right turn signal lamp Front Alit 6A 024 3 HE Po RE bi Gi RR Instrument panel lamp 6 Q BANA Pointer gauge S3 Q 4 SES Hiot turn signal lamp Rear ae mye 026 a 8 Ve do 7 E EE Control box AES AA E F5 10A 1x0 85mn B p 025 Se 027 2 6 3 L aert brake lamp i TUA Pre hent amp stort switch F10 20A d d AWx Rignt brake lam e DR RR Ho euer fuse e a F9 10A l W e4 Resever fuse F4 10A js HO 3 e BEER G 925 tt Horn 1 X1 25mn GH WABDX Instrument panel lamp 4 DES a BEAT t T T ai BA T Gi T DREI Instrument panel lamp S p Iden IN AE 1 QB Z RKM Reor left width lamp o3 5 3 N o 9 9 lis SHRE Rear right width lamp 3 4 3 I Gi 3 EKN Left head lamp 032 sj USA GI 3 amp XN Right head lamp 933 gH 4 AHTRK Front left width lamp CPI PT NA vlr AR Q ed amp WAXX Freont nright width lamp J J UP Fig 5 CPQD20 25 30 35N RW22B electrical system schematic diagram
28. LEE vd K1 F1 504 003 004 002 dm MI 009 010 o S10 WW S E01 Fe soA 006 ox C 008 BL Reo ol 060 005 E04 hee Rl 30 0 KE 007 pe 07 050 Pad 0 038 037 KA 1 5106 1 o 401 1036 o3 10 RAK Preheat indicator lamp 09 027 r L RI SR ja SS S RRAN Charge indicator lamp 0 2 028 em e S101 es i Ss d WEGN Lil pressure indicator lamp H11 2 029 a i l AL wie separation indicator lanp n 030 pes 05 EBI temperature indicator lamp 2 Q 031 y S10 i 032 Y r S103 Ion 033 fe F7 10A C8 7 63 SS v3 026 034 14 3 12 024 Se F6 10A S9 5 4 Q 6 2 l gt K111 O 021 023 o ues gt 025 5 152 15 SI 3 6 022 SCH Gi 7 H02 l S9 i SI se sn F5 10 93 020 Ae O9 018 019 53 9 10A Gi TUEWReZ Resevenr fuse F10 204 MERK H Resever fuse H01 S 4 104 016 017 Le S6 G9 m 4 F3 15A 011 4 Gi 4 l O O a GO ol 7 o 9 9 014 1 Q S 3 4 9 3 013 k 7 eS 1 g ots Q T 1 012 K3 S eit Bottery 12V DC ARA Alternator Ra Starter AE Glow plug HAERE Preheat sensor SH Detector HERRE Wk EHE WER pressure sensor il water separator il temperature warner KERRE Water temperature sensor EB ER Fuel quantity sensor WR A Timer
29. OIL temperature indicator lamp mk Woter temperature gauge n V em EH S 10 ZERA Water temperature sensor w Fuel quantity gauge 020 MM Eon T ED R103 WERRe Fuel quantity sensor DA i d 4 3 HER Timer APR Gy 1X0 85mm Ke NJ 4 Es SS K7 039 Z BL eS 2 H RERR F Oorword solenoid valve o 7 O 4 3 1 7 Ei HFEA Reverse solenoid valve 023 3 4 y 3 AUETA Fuel shut off solenoid switch 4 024 gt amp 6 AMEN Left reversing lamp 4 Gi 2 4 amp BEX Right reversing lamp cz H0 M GERES Reverse warner LS Ee z me 3 AWRAX Left turn signal lamp Front AMEN 6A ZAMAERXI T indi Sen T 69 6 2 Zi urn left ME lamp 1 X0 85mm 026 B Gi E vO Zktwk Left turn signal lamp Rear 1 025 SL SG eg TES RQ s ERERK RIght turn signal lamp Front Gi UNS HERN Tunn right indicator lamp ART BE F 2 10 JR AA SE e m EEKRA RIght turn signal lamp Rear SEN 3 amp AfsM Left brake lamp F 10 20A do PM 3 BEE Muer fuse m B o SXX Right broke lamp FO 10A ERN W e HBD He euer fuse 2 ao Ne E AERA 44 HA arr not S4 ee EE T BSIPV Hoen so Gi T a WHUDX Instrument panel lamp E3 15A BREER BA T GI 1 gt M Instrument panel lamp p XL2Smm o 69 ARAKM Rear left width lamp a FO mE d 034 Nus cy K3 Gees ARM Rear right width lamp 3 4 5 69 3 AKXM Left head lamp 036 o 038 Q 4 4 amp AW Right head lamp SEH Q Ll a RARM Front left width lamp gl amp WRXX Front rignt width lamp e
30. Tilting cylinder 64 KS Fig 8 3 Containers forklift mast 1 Outer mast 2 Inner mast 3 Chain 4 Free lifting cylinder 5 Fork arm carrier 6 Fork arms 7 Side move cylinder 8 Left lifting cylinder 9 Right lifting cylinder 10 Load backrest 11 Tilting cylinder e Kies SS ac L ki Fig 8 4 3 grade full free lifting mast 1 Outer mast 2 Middle mast 3 Inner mast 4 Front cylinder chain 5 Free lifting cylinder 6 Fork arm carrier 7 Fork arms 8 Chain 9 Left lifting cylinder 10 Right lifting cylinder 11 Load backrest 12 Tilting cylinder 65 Ac HANGCHA 2 wf 3 S 4 m y GE EE gt is e MIL E f j E 6 ae K ma a IP f A H E 1 f ES Fig 8 5 Lifting cylinder Used in fig 10 1 10 4 1 Piston 2 Dustproof ring 3 Gasket ring 4 O ring 5 Guide sleeve 6 Cylinder 7 Piston 8 Support ring 9 Protect ring 10 gasket ring 11 0il nozzle assembly without left lifting cylinder 12 O ring 66 VU EA Wp e Ty K LULA RI INI FELT EEE P um um um m m RAA AVR EA EVE tt MN Ws D T lb GAR Z 77 ES Cur uno FEL D un un un FE LE uh un un un un un un ny un n vnd uec LE gd W 4 BUHL SSN UG Dd EES E N TAT ARE I LaL 7 7 i AL KO TH m TE 12 Fig 8 6 Free lifting cylinder
31. X SURYA AJ AY A X Number Sign Instruction HER Fuse C JUR leew Banked batter B MS we Relay 4 1 MI kom lly open switch 3 se WE Normally closed switch 6 AR hompe cable then sich 7 SG Ate Flasher 8 R AA Solenoid 9 ST M Horn 0 RS Sensor GO Im Bulb 2 Sr eis Buzzer J wv BH Resistance 4 FRE Glow plug 5 Hk Diode 6 P RIANZ Pointer gauge 7 i EHE Control box 8 Bai Pre hent amp stort snitch a ER Fig 1 CPQD10 15 18 20 25 30N RW7 electrical system schematic diagram AER 150A
32. and carriage side roller A B 0 2mm 1 mm A B 0 1mm 0 8 mm A B 0 1mm 0 8 mm Shims 0 5 mm 1mm a Number of shims must be the same on the right and left sides when using shims b After clearance adjustment push carriage assembly to see if it operates properly lt HC gt HANGCHA 5 Disassembly and installation of lifting jack N WARNING Keep body away from equipment 1 Turn out engine then make lifting jack falling into lowest condition that lower of piton rod is touched bottom of cylinder body so as to oil flowing back tank completely 2 Unscrew piston rod and bolt 3 Disconnect circle oil pipe remove high pressure tubes 4 Remove U bolt of outer mast fixation board and tighten skew of other side 5 Remove chain of outer mast 6 Attach wire rope to inner mast and remove left and right lifting jack with a lifting device 73 Ac HANGCHA 5 1 Disassembly Rated capacity is less than 2 5 t Remove cylinder head and guiding bush Rated capacity is more than 3 t Removes tighten skew and nylon stopper then remove cylinder head 1 Remove dust gasket ring 2 Remove Y ring with screwdriver CAUTION Please not use dust gasket ring removed O ring Y ring again must replace 3 Draw out piston rod remove Y ring on end of piston 5 2 Install and replace faulty parts 1 Cleanup parts with clean oil before installation 2 Then cleanup guiding bush and piston
33. e DR bom dowe tiro src SG Ate Flasher 8 K ba Solenoid 9 XL OES Horn 0 ran ke Sensor GO ri Bulb m wee Buzzer J vr BE Resistance 4 TAE Glow plug 3 46 Diode 6 7 HIAR Pointer gauge 7 d EHE Control box 8 MGT Preheat amp stort switch Dele J JU J JN WI JAER Be 150A Bek 150 EE 1 X3oMME 001 Ei x3omme D easa 0 ek Battery 12V DC lt lt 4 S lt s KB Alternator pe
34. from wheel hub by evenly tapping on its periphery with a wooden mallet CAUTION Be careful not to damage oil seal and outer race Inspection Stepped wear or cracks on axle shaft splines replace Seized scratched noisy or rusted bearing or improper Replace rotation of rollers Cracked or damage wheel hub Damaged oil seal felt ring Installation Install reverse order of removal 5 Bearing adjusting 1 Lubricate on taper roller bearing 2 Tighten roller bearing lock nut in wheel hub until wheel hub can no longer be rotated with one hand 3 From that position turn back lock nut approx 60 4 Turn back wheel hub two or three rotations so that bearing settles down 5 Again tighten lock nut until it can no longer be rotated with one hand then turn back approx 60 6 Install snap ring and settles down felt ring install lock washer so as to set its hole in the pin of snap ring Screw lock nut 7 Turn wheel hub back and forth two or three rotations to see if rotation starting torque is within specifications Rotation starting force 10N 29N refer to Fig 3 6 34 lt HC gt HANGCHA 8 Measure axial play of wheel hub to see if it is within specification Axial play is less than 0 10mm refer to Fig 3 7 35 UC GCHA HA IV Steering axle 1 General specifications Axle centre Axle body Center pivoted turn N Turnin Inside me Adjusting shim H turning 235 for end shaft of 0 5 1 0 1 6
35. gearbox to avoid leaking when working no disassemble freely hydraulic gearbox 5 2 To avoid affecting precision of installation and usage must prevent every installation surfaces torque converter and out gear knocking 5 3 Guarantee no more than 0 15mm runout for installation hole of engine flywheel no more than 0 1mm for flywheel end surface no more than 0 2mm for installation end surface of flywheel no more than or equal to 0 1mm for location position of 2 location pins on installation surface 5 4 Truck control mechanism must guarantee correct stroke of inching valve lever and secure location Inching valve lever can return its initial location when operator loosens pedal Inching valve characteristic graph see Fig 2 inching valve lever can move together with brake pedal must guarantee cut off the oil to clutch before braking and the stroke of inching valve lever is equal to or more than 14mm less than 22mm when shifting close inching valve first and then shift 5 5 When hoisting keep level ensure gearbox and reduction gearbox calm and avoid torque converter sliding out 5 6 Prohibit changing oil system of the gearbox To ensure gearbox work regularly lubricate well the circular oil of gearbox can not be used for other purpose and the oil should accord with required trademark 5 Keep work oil clean and no other impurity replace new oil after 50 hours usage for new truck and after every 1000 hours or reuse after long deposi
36. l gp 055 eee Water temperature gouge E103 AKEKRA Woter temperature sensor 5 p WE Normally closed snitch p 10 85mm SCH VEN 2 qo HRA Timer 6 e SAME Yonopdle doule throw sith K2 SG KJE Flasher SE j 8 k B R Solenoid SI 4 56 KZ 017 7 a H R AR Forward solenoid valve 9 g i Horn mm 7 018 ere A 7 fAERAK Reverse solenoid valve 0 f KE Sensor 1 69 Im Bulb 6 4 l a 4 L ABEM Left reversing lamp 5 e K l Buzzer 1 G9 J ABEN Right reversing lamp 3 HA Resict d esistance d BERES Reverse warner Q T KWEWX Left turn signal lamp Front 4 WAE Glow plug 4 em WRBA Instrument panel lamp F6 10A 020 su 022 S eia 023 3 2 6 ZEKWA LeFT turn signal lamp Reor 2 Pr Diode V mm us 0 724 T4 1 4WEWA Right turn signal lamp Front 6 BARNE Do vem 4 G9 WHWW Instrerument panel lamp HAM Pointer gauge SSN S3 n Q Fltuk Right turn signal lamp Rear 7 T ki Control box BERE GAN G9 aX Warning lamp F5 10A 1x0 85mn 8 20 Dro gas Se 027 Q bie Z ert broke lamp HUGE Preheat start sutch F10 204 Q 9 9 ERK Right brake lamp HBD He euer fuse F9 10A l UAJe4 Resever fuse F4 104 d HOL s3 028 4 I NBG GA 029 HWY Horn 1X1 25mr 69 WABDX Instrument panel lamp S6 4 G9 fe WABDX Instrument panel lamp F3 15A Ab GA 6 3 p Linn 1 mu bi GI A RKM Rear left width lamp O ds J St o o s SHREX Rear right width lamp 3 4 5 031 Gi 3 ARM Left head lamp 032 ar
37. lamp LE I HHWK Inst me Fe e GI S ARMA Instrument panel lamp 1x1 25mm IN t Gi 7 Zbas n Reor Jeft width lamp 030 e d Q O Oo is G F FAN Rear right width lamp 3 4 3 R 3 Edert head lamp 032 Zr 034 Q 3 3 amp XW Right head lamp Se 9 ARAXM Front left width lamp Q ed AWAXX Front right width lamp Fig 4 CPQD10 15 18N RW21 CPQD20 25 30 35N RW22 Head lamp amp signal lanp switch ms 113145 o Uff X Qd X X X 1 ead lap X X X Pre heat amp start switch OK bal B1 BE Acc C RI Preheat X X X FF X X Run X X X Start X X X X X Number Sign Instruction ite Fuse e IE EB Banked battery 3 EE 468 Relay 4 1 RR Normally open switch 5 p E Normal closed sith 6 e HA emt dowe tiror sic d SG HS Flasher 8 x WW Solenoid 9 id n Horn 0 J fe Sensor CO m Bul 2 Y Hs Buzzer 3 vv BH Resistance 4 WA Glow plug 5 BL AE Diode 6 P BEIS Pointer gauge 7 ET 88 Control box 8 SC Ba Preheat amp start snitch POSE electrical system schematic diagram AE 19
38. mast which include side shift is named container fork lift truck mast see Fig 8 3 Side shift cylinder of container fork lift truck mast can be side shifting only when goods don t placed appropriate position In another condition side cylinder should set center Structure of left and right lifting cylinder of more than or equal to 3 t see fig 8 7 fig 8 8 Structure of left and right lifting cylinder of less than or equal to 2 5 t see fig 8 9 fig 8 10 63 3 3 Triple full free lift mast Triple full free lift mast fig 8 4 is composed of outer mast middle mast and inner mast middle mast and inner mast can flex There are different specifications in this series of height 4m 4 3m 4 5m 4 8m 5m 5 5m 6m 6 5m 7m etc It is different from double full free mast that mostly it includes middle mast and its two postpose long lifting jacks are both piston type cylinder fig 8 5 and its oil system rather complex than oil system of double full free mast Free lift cylinder structure see fig 8 6 Fig 8 1 Double stage wide view mast 1 Outer mast 2 Inner mast 3 Load backrest 4 Fork arm carrier 5 Fork arms 6 Chain 7 Lett lifting cylinder 8 Right lifting cylinder 9 Tilting cylinder 10 Roller WS M NN UL ld I Fig 8 2 Double grade full free lifting mast 1 Outer mast 2 Inner mast 3 Chain 4 Free lifting cylinder 5 Fork arm carrier 6 Fork arms 7 Left lifting cylinder 8 Right lifting cylinder 9 Load backrest 10
39. reer rrr rrr rrr rrr rrr rrr rrr errr rere 52 4 Control valve TTT 55 5 Hydraulic piping BEE 57 VIll Lifting system 1 Assemble debugging data TTC TCR Ce PP Trouble diagnoses and Corrections EER R HEER HEER HEER E EER EE EE P EE EE EE EE NEER EER EEEEEEEEEEEEEEE Summary Disassembly and installation of lifting jacks ee 2 3 4 Removal and adjustment D 6 Disassembly and installation of tilting cylinder EE N IX Electrical system Noticing proceeding OT debugging EER EE EEEEEEEEEEEAEEE EE EE EE EE EE EE EE EEEEE EE EE EE EER EE EEEEEEE sr HANGCHA Power System 1 Engine for Forklift Parameter K21 Japan LM Rated output KW Rated output KW WW BT Rated rotate speed Max torque Nm Speed r min Preston chi Service weight kg 161 o RW22 CPQ10 15 18N RW21 CPQD20 25 30 35N RW22 CPQD10 15 18N RW21 CPQD20 25 30 35N RW22A CPQD20 25 30 35N RW22B Parameter EE EN 20 LS 30 Rated output Rated rotate speed Forklift truck model Service weight kg Max torque Nm Speed Fm 139 1800 139 1800 CPC10 15 18N RW9 CPC10 15 18N RW10 CPCD10 15 18N RW9 CPCD10 15 18N RW10 CPC20 25 30 35N RW9 CPC20 25 30 35N RW10 CPCD20 25 30 35N RW9 CPCD20 25 30 35N RW10 CPC20 25 30 35N RW9B CPC20 25 30 35N RW10B CPCD20 25 30 35N RW9B CPCD20 25 30 355N RW10B Parameter BY491GP Baiyang IMPCO GM3 0L A498BT1 1 Rated rotate speed Max torque Nm 161 1800 2200 189 1600 18
40. with hydraulic pressure oil the same as oil box trademark 3 Dust or dunghill doesn t drop into lifting Jack 4 The order of installation is reverse the order of disassembly 5 Install Y ring on piston 6 Install piston rod assembly into clean cylinder body 74 CAUTION The end of cylinder body mast slick and clean installation must set center avoid scratching Y ring 7 Install replacing dust gasket ring and Y ring in guiding bush and cylinder head NOTICE Apply hydraulic pressure grease which trademark is the same as tank on guide sleeve installed gasket ring 8 Rip cylinder head into piston rod screw down cylinder body 6 Disassembly and installation of tilting cylinder AN WARNING Noticing proceedings when removing cylinders Attach wire rope to outer mast avoiding mast fall down after removing tilting cylinder Keep body away from equipment no standing under the fork arm carrier 1 Lay down fork arm carrier completely 2 Remove bolt on the left and right bracket of outer mast moreover pull axis out 3 Remove oil pipe to the inlet of tilting cylinder 4 Remove bolt on the bracket of Chassis and pull pin out then move tilting cylinder 5 The order of installation is reverse the order of disassembly sr HANGCHA 6 1 Disassembly of parts 1 Squeeze tilting cylinder with pliers then pull piston rod come and go as opening of inlet and outlet on the tilting cylin
41. 0A Aat 150A 1x35mme pf rm 0 1 E dee 9 X Bottery 12V DC 3 E lt
42. 24 sir HANGCHA tt 18 i eQ E T MESES RW o gt E V e Hu d E gt ly d E icis 7 T C 31 il NE EX 5 ben sE SE ST TI gt reverse pressure oil ees y 9 Mi 77 lubricating oil i APA ST ER SP ED forward pressure oil Kies LE OR 22 zo xe A see e gt 2 yr E GEBARE 3 1 plate 2 piston 3 O ring 4 forward gear ratio gear 5 backhaul spring 6 reverse gear 7 bearing 8 ring A 9 input shaft assembly 10 restrain ring A 11 needle bearing 12 restrain ring A 13 elastic snap ring for shaft 14 spring seat 15 steel ball 16 plug 17 ring A 18 septa 19 disc 20 clip ring Fig 2 7 hydrodynamic power clutch 4 5 2 Disassembly assembly sequence 1 Take off the bearings 7 on the left and right sides 2 Separately take off the forward gear ratio gear 4 reverse gear ratio gear 6 disc 19 septa 18 3 Separately compress the spring 5 take off the snap ring 13 remove the piston 2 and spring 5 Assembling procedures is contrary to those of disassembly NOTE Flush the piston cavity of the input shaft assembly oil route clean the other parts except the disc Replace the ring A B if it is damaged Replace the snap ring Replace the disc if it is overly abraded or bend Restrained ring A B should face to gears After assembled rotate the gears it should be freely rather than locked 25 sr HANGCHA 4 6 Reduction transmi
43. 4 016 G9 d amp AX Right head lamp 093 s Vo ERRRR Front left width lamp H Pr NA N dch VEE gE BHRBN Front right width lamp Jl JA NWCC Wh Fig 7 CPQD20 25 30 35N RW22B Y3 electrical system schematic diagram AXI 15045 BL 150A
44. 6 1600 1800 Speed r min Forki ruck model CPQ D 10 15 18N RW7 CPQD20 25N RW26 Y CPCD20 25N RW27 CPQ D 20 25 30N RW7 CPQD30 35N RW26 Y CPCD30 35N RW27 Forklift truck model HANGCHA JE Ex NE NN HW33 CPCD20 25N RW33B CPCD20 25N RW33M CPCD30 35N RW33 CPCD30 35N RW33B CPCD30 35N RW33M CPCD10 15 18N RW32 CPCD20 25N RW32 CPCD30 35N RW32 CPCD20 25N RW15A Forklift truck model CPCD30 35N RW15A Specifications structure and maintenance methods for engine see ENGINE MAINTENANCE MANUAL Specifications structure and maintenance methods for model TD27AA engine see KEY COMPONENTS IMPORTED FROM NISSAN SERVICE MANUAL Check value of end gas after maintaining engine and the value must be according to following figure Engine power CO HC NO PT particle KW EN RED h ERN h ENDE h g kWeh 18 185P lt 37 ED HC Aus d amp HANGCHA 2 NISSAN K21 K25 gasoline 2 1 Specification Specification Model ar K25 Water cooled four cycle in line overhead valve type Type Cylinder No stroke mm 4 89 Displacement L 2 472 Direction of rotation Clockwise cooling fan Firing order 1 3 4 2 Intake Hot 0 38 Exhaust Hot 0 38 Cooling System Water cooled forced circulation Lubrication System Forced Lubrication Carburetor model 210030 42 Fuel pump Film type Air clear Paper element Oil pump Gear type Oil filter Paper element Water pump Centrifugal Thermostat Wax p
45. 6 zr 038 Q 4 11 037 Gi 2 KWARM Front right width lamp Fig 11 CPCD20 25 30 35N RW33B electrical system schematic diagram Positio dead lamp amp signal loep switch S d 4 X LES ps RAAT Pre hea amp start switch OK xal BL B2 Ace C RI RP Preheat X X X FF IX LX Run X X X Start XIX X X X Number Sign Instruction 1 Bite Fuse d HI EA Bonked batter 3 Mg d Relay 4 l We ally open switch 9 gt iE Normally closed switch 6 HA rope double ror sith 7 scH NX Flasher 8 K N Solenoid p VL Horn KR Sensor X Bulb as Buzzer WH Resistance WA Glow plug 5 HE Diode 6 HARE Pointer gauge 7 db EWE Control box 3 V R a Ba Pre heat amp start snitch V CV CH 30 JON NW 33 SY HANGCHA GROUP CO LTD HANGCHA Address For OVERSEAS USERS Manufacturing Site 88 Donghuan Road LinAn Economic Development Zone Hangzhou P R of China B ZIP 311305 Registered Address 398 Shi Qiao Road Hangzhou P H of China m ZIP 310004 Fax 0086 571 88926789 0086 571 88132890 Web http www hcf
46. AEREB Reverse warner Q T3 ElWEBX L eft turn signal lamp Front a WABHXI Insteument panel lam Ku c9 S S F6 10A 020 022 SI ei a 023 EFKWX LeFt turn signal lamp Rear t IN dA SG 0777 74 mikMX Right turn signal lamp Front GER GQ WRHXT Instrument panel lamp RAD S5 Q JE H EKMM Rignt turn signal lamp Rear ABER AA Ut C9 k Warning amp i ei LY 7 FO 104 1x0 85mm 025 Sc 027 Gi 6 EWXN Left brake lamp F10 20A Q 2 3 amp SX RIght brake lamp e BERN RH uer fuse F9 105 e HB RR Me euer fuse F4 10 lt Hoi 53 008 WIPV Hoen VEE AA 029 1 xL2Smri GQ M WRHDX Instrcrument panel lamp l S6 Gi E 4 WREX Instrument panel lamp MEE 1 031 6 1xLa5mm m oS RRN Rear left width lamp O Uo 5 Ge O Oo Oo 3 9 E EM Rear right width lamp 3 4 5 QH AKR Left head lamp 032 SR 034 Q amp K Right head lamp we Q AW EX Front left width lamp ec AHRBM Front right width lamp Head lamp amp signal lamp switch pos LS 1413 o DF X hp X X X i aud X X X Pre heat amp start switch Uk imi BI B2 Acc C RI Re Preheat X X X FF X X Run X X
47. E EER E EER E EE EEEEEEEEEEEEE 38 4 Kingpin and steering spindle 38 5 Wheel bearing adjustment DTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTOTTTTOTTTTTTTTTTTTTTTETT 38 V Steering system eee RER RE ER RE ERR EER EER E ER EER ER EER ER EE EER EE ER EE EER EER EER RE ER EER EER E EER E EER N 39 1 Data PPP eee E EER EEEEEEEEEEEEEEEEEEEEEEEE EE EE EE EER EEEEEEEEEE EE eer rrr rrr rrr rrr rrr rrr rrr rrr rr rrr uuu uuu uan 39 2 Trouble diagnoses TTT 39 3 Summarize EER R EER R EER E EER EEEEEEEEEEEEEEEEEEE EE EE EE EE reer eee ere errr rrr rr rrr rrr rrr rrr errr rrr rrr rrr rrr 40 4 Install steering system Peete eee etree eee etree eee ee eee eee eee eee C 42 Vl Brake system P RE EER EE ER EER EE RE EE EER EE EER EER EER EER EER EE EER EER RE EER EER 2 AN 43 1 Trouble and diagnoses and cCorrectlONS EER EER R RE EE ER RR RR RR RR Rae 43 2 Summary OPE EER R EER E EER EEEEEEEEEEEEEEEEEEEE EE EE EE EER EEEEEEE e E EE EE EE EER EER E EER E EER E EER E EER RR uuu uuu uuu 44 Vil Hydraulic system eee eee eee eee eee eee eer er eer rere ere errr eer reer ree etree ere etree eee eee 48 1 Data EER R EER R EER E EER EEEEEEEEEEEEEEEEEEEEEEEE EE EE EE EER EEEEEEEEEEE EE EE EE EE EE EER EER E EER E EER E EER EEEEEEEEEEEEEEEE 48 2 Trouble diagnoses and corrections EER EER EER EER R EER E EER RR RR RR RR Rae 50 3 Main pump EER R EER R EER E EER EEEEEEEEEEEEEEEEEEEE EE EE EE EE ere errr errr
48. EEEEEEEEEEEEEEEEEEEE EE EE EE EER EEEEEEEEEEE EE EE EE EE EE EER EER E EER R EER E Ru uuu RR uuu uuu uan 17 2 Data EER R EER R EER R EER EEEEEEEEEEEEEEEEEEEEEEE EE EER EE EER EEEEEEEEEEEE EE EE EE EE EE EER EER EER E EER R EER uuu EEEEEEEEEEEEEE 18 Working principles eee eee eee ere eee ree errr reer etre eee reer rere tree rrr etree etree etree etree 19 4 Structure EER R EER R EER E EER EEEEEEEEEEEEEEEEEEEEE EE EE EE EER EEEEEEEEEE EE EE EE EE EE EER EER EER E EER E EER EEEEEEEEEEEEEEE 21 5 Notice about installation and Bere IR ER EE do ORE ER EE 30 6 Cause and solutions BBMBMBMB M s 30 I Driving KW 31 1 Date EER R EER R EER E EER EEEEEEEEEEEEEEEEEEEEEEEE EE EE EE EER EEEEEEEEEEE EE EE EE EE EE EE EER E EER E EER E EER E EER uuu RR uu uuu uan 31 2 Trouble diagnoses and cCorrectlONS eee EE 31 3 Assembly and disassembly of driving KAELL 32 4 Axle shaft and wheel hUD TEER EER EER EER R RE EER RR RR RR RR EER EER R EER R RR RR RR RR EER ER 33 5 Bearing adjusting ere eee eee eee eee ree ere eee reer eee eer eee ree ere errr ere eee eee eee EE EEE N 34 IV Steering axle EER EER RR R RR EER RR RR RR RR EER R RR RR EER R RR RR RR EER R RR RE RR RR RR RR RR RR RR 36 1 General specifications DTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTETOHE 36 2 Trouble diagnoses COrFECHONS ret 36 3 Steering axle EER R EER R EER EEEEEEEEEEEEEEEEEEEEEE EE EE EE EER EEEEEEE EER E EE EE EE EER EER EER
49. Et At HEAN Lef t WEIX Lef ARKMN Left turn amp WEWX RIght turn ZER Right ARN Right indicator lamp ABEM Left reversing lamp ABIEX Right reversing lamp turn indicator lamp At urn signal lamp Front signal lamp Rear signal lamp F ront turn signal lamp Rear turn ERE Reverse warner BAUMAX Fuel shut off switch XX Worning lamp AWXX Left brake lamp amp WAX Right brake lamp RV Horn WEHR Instrument WRET Instrument panel lamp ARERWX Reor left width lamp ARARKH Rear right width lamp EKXN Left head lamp AXAN Right head lamp ZWRXX Front left width lamp ARAB F ront right width lamp panel lamp Fig 3 CPCD20 25 30 35SN RW15A electrical system schematic diagram Head lamp amp signal lamp switch s 1 3 4 5 o ff X Within X X 1 ead lm X XIX Pre heat amp start switch OK ndm BI Be Acc C R1 RE Preheat X X X PR JA Run X X X STorU XIX AK X Number Sign Instruction HH Fuse e JE fi Banked battery 3 pg Mg Relay 4 HA Normally open switch 9 r BAR Normally closed switch 6
50. G as5R3J1 Taam JO UI Ieag Jauu e e pur diT 1e astadn qny 181432 is a 991 2 1 D p auriPoq 1SNIy1 A Surun Jo urdaury Japur Hut daat 49400 9WOB Ig i Notice Replace rubber block shock absorber between 3000 3500 hour 37 sr HANGCHA 3 Steering axle Remove wheel hub Jack up and support forklift truck body with wooden blocks Remove tire Remove hubcap Remove steering spindle nut Pull off hub assembles Remove bearing inner race Caution a Not to drop bearing inner race b Be careful not to damage oil seal 4 Kingpin and steering spindle 1 Remove rod 2 Loose lock bolts see fig 4 2 3 Remove grease nipples on kingpin 4 Remove kingpin caution Hold kingpin to prevent it from dropping See fig 4 3 5 Take off spindle thrust bearing and shim NE Fig 4 2 Fig 4 3 INSPECTION 1 Replace spindle if cracked 2 Replace bearing if its rollers or roller surfaces are rusted or nicked 3 Replace steel sleeve if it distortion out of round cracked 4 Replace thrust bearing and dust cap if them damaged Installation To install reverse the order of removal Careful observes the following 1 Always insert kingpin from lower side 2 Install thrust bearing set the tighten ring below the support and loosen ring Pack all grease between dust proof inside loosen ring and tighten ring 3 Adjust axial play to spec
51. HA DS EE of Cae er e SS ZZ Fig 7 6 5 Hydraulic piping The high pressure oil from main pump goes to control valve and divide it to two parts by priority valve inside control valve one of them preferentially goes to steering gear control steering cylinder excess part goes to lifting cylinder or tilting cylinder When lifting and tilting spool is in neutral high pressure oil return oil tank directly from pass way When pulling lifting spool high pressure oil goes by throttle valve and then push piston rod under lifting cylinder piston When pushing lifting spool it is that bottom of lifting cylinder piston connects with low pressure line and then piston rod drops by deadweight and weight of cargo In this time oil from lifting cylinder goes by unidirectional speed limiting valve so as to control the falling speed When operating tilting spool high pressure oil goes to front house of tilting cylinder and another connects with low pressure line so as to make mast tilt forward or backward The cut off valve is used under right lifting cylinder its function is to prevent goods falling suddenly when oil pipe is busting 57 170
52. O S 3 4 5 QH 016 Ts 033 at 4 038 sol 4 E 69 t SuX Bottery 12V AW Alternator Ra Starter XUEE Spark plug YRER Timer DC HEHOM Charge indicator lamp il pressure indicator lamp RB AN temperature indicator lamp GER Wo ter temperature sensor Ar ER AE or word solenoid valve BERAR Revers Ka solenoid valve ABEN Left reversing lamp SREL Hoh reversing lamp AEKEB Reverse warner EWAWX Left turn signal lamp Front WRX Instrument panel lamp EBKWX Left turn signal lamp Rear amp WENX RIght turn signal lamp Front ARBA Instrument panel lamp ABRAM Right turn signal lamp Rear Ban Warning lamp AMK Left brake lamp AHAM Right brake lamp IV Horn KEET Instrument KEET Instrument panel lamp panel lamp AAEM Rear left width lamp HERKK Reor right width lamp EKN Left head lamp AKM Right head lamp AWREN E AWREN F nont ront left width lamp right width lamp WU Pre hent amp stort snitch Head lamp amp signal lamp switch
53. Oil seall 20 Axle shell 21 support sleeve 3 Assembly and disassembly of driving axle WARNING Be careful when removal and installation driving axle as it is heavy Raise front end of forklift truck and support frame with wooden blocks 1 Remove mast assembles 2 Slightly raise axle with a hoist and place wooden blacks under differential gear carrier and transmission case 3 After placing a pan under axle case loose oil plug drain oil from axle case 4 Disconnect brake nuts from left and right cylinders see fig 3 1 CAUTION plug brake tube openings to prevent oil from flowing out sir HANGCHA 5 Disconnect brake cable at hand brake lever 6 Remove front wheels 7 Remove axle shaft 8 Support driving axle with wire ropes and lifting device 9 Remove bolts securing axle mounting bracket to frame see fig 3 2 10 Remove nuts securing axle case to differential gear carrier see fig 3 3 11 Remove driving axle assemble 13 14 Remove brake drum remove wheel hub Remove axle mounting bracket and brake component from axle tube 15 Remove oil seal from axle tube 16 To install driving axle assemble in the reverse order of removal Observe the following 1 When installing axle mounting bracket and brake component apply a coat of calcium grease to axle tube 2 Apply 1 3 2 3 of volume of calcium grease to wheel hub then install them on axle tube 3 Install oil seal with its part number
54. age is excessively worn bent or damaged replace with new one If throttle valve shaft is excessively bent replace with new one 2 Checking Auto choke Mechanism Visually check auto choke mechanism for deformed linkage etc Before starting engine depress accelerator pedal one time After starting engine ensure engine speed decreases to specified idle rom mE Throttle valve Cam lever and fast idle cam Differs with ambient temperature During engine starts 1 or 2 ratchet position afte1 warm up 3 or 4 rachet position After warm up Fully open Idle position Ambient Fully Fast idle temperature 20 C closed position sr HANGCHA 3 Checking Bimetal 4 Inspect insulator for cracks or chips Start engine Touch bimetal case to gasket for damage or deterioration ensure It is hot Simple check method and electrode for wear or burning Using circuit tester check bimetal for If the are excessively worn replace continuity Continuity must exist with new spark plug 5 Check spark plug gap spark plug type FR2A D T 20 N m 29N m Ensure PTC heater becomes hot when engine Is started Simple check method Using circuit tester check TPC for continuity must exist 5 Choke Valve Inspection Ensure clearance does not exist between Side electrode fast idle cam and cam lever when choke valve is closed by hand ES gen 036 ial Adjustment Adjust cam drop time adjusting screw until chok
55. and cover are made of aluminum alloy they are light and rigid The drive gear and driven gear are integrated with their respective shafts which are held against the pump body with bearing The bearing made of special material serves both as bearing for each shaft and as side plates for the gear flank At the drive shaft side an oil seal is press fitted into the pump body to provide oil tightness performance Oil tightness between pump body and pump cover is secured with a packing of a special shape Main pump maintenance remove refer to Fig 7 1 f Hold the pump in a vice lightly and remove blot 12 g Remove pumps cover 1 and remove seals 8 9 10 and 11 h Remove forward end cover 7 8 9 10 and 11 i Remove bearing 3 4 and gear 5 6 from pump body 2 If remove bearing difficult you can press gear j For the convenience of correct reassemble it is to put the disassembled parts as shown in Figs 7 1 Clockwise Fig 7 1 clockwise gear pump 1 End cover 2 Gear plate 3 Bearing 4 Bearing 5 Driving gear 6 Driven gear 7 Front end cover 8 Seal ring 9 Seal ring 10 Seal ring 11 Seal ring 12 Bolt 13 Lock washer 14 Oil seal 15 Snap ring The main pump of 1t 1 8t G26 is the same as the above mentioned pump just the direction of turning is not the same 52 lt HC gt HANGCHA 3 2 2t 3 5t main pump 2t 3 5t hydraulic system adopts CBHZG model gear pump Gear pump CBHZG is an external gear pump with axial interval sel
56. at the position of forward gear ratio or the reverse gear ratio the oil route from the slide valve to onward clutch or the reverse clutch is connected to make the clutch do its work respectively when the one clutch works the other clutch s disc and septa are separated the cooling oil lubricate it and take the heat away when the inching pedal works through operating the inching valve some or a majority of oil from the clutch comes back into the tank through the inching valve lever at this time the oil circle of the torque converter is the same as at the idle motion middle location F FR VREES JEF eee ES R LE g EES MEE WAXAY MPg oil pressure for clutch 4 ass SSSSASSSSS SSS ab RR rere heen p mc EER ES RY UN NN SEED SS SES plunger stroke 0 2 Ts inching valve speciality curve PERE Ta 91 4 throttle hole pressure be 7yP9 sale ed 3 we R VG AERE rd 1 11 4MPo KEE ET mem em X P r Li EE 7 E DEEP NW of torque converter 9 IL W rt 15MP9 vi ou lines 1 oil strainer 2 oil pump 3 main adjustment pressure valve 4 inching valve 5 buffer valve 6 shift control valve 7 relief valve 8 oil strainer 9 cooling device Fig 2 2 oil route for YQX18 25 30 model hydrodynamic power transmission gear box 20 sr HANGCHA 4 Structure 4 1 Hydraulic transmission 4 1 1 Structure Introduction Structure of hydraulic transmission gear
57. box see Fig 2 3 There are 3 types of hydraulic transmission gearbox to select YQX D 15 type YOX D 25 type YQX D 30 type Hydraulic transmission gearbox consists of hydraulic torque converter gear box reduction amp differential Power from engine is converted by hydraulic torque converter 13 and then the power is transmitted from turbine to clutch assembly 6 of gearbox gearbox consists of clutch assembly 6 Shaft 11 output gear 12 idler Shaft 9 Cover control valve5 Inching valve 14 Charging pump 4 etc Reduction is consisted of output shaft 10 spiral bevel gear 16 gear shaft 1 etc Two ends of gear shaft is supported by tapered roller bearing 2 There equips with adjusting shims to both ends to adjust bevel gear imprint backlash and bearing clearance After passing reduction power from transmission gearbox slows down and generates differential from differential assy 15 and transmits to wheel through axle shaft gear and half shaft 8 is transmission gearbox shell body where installs gear shift shifting clutch reduction gear and differential Gearbox body plays the same role as tank besides used for installs the input and output shaft the oil strainer in the bottom of it filtrate the oil flowing to the oil supply pump pipe oil strainer ll oil add cover and oil leveler on the top of the shell body cover 4 1 2 Disassembly assembly sequence Disassemble hydraulic transmission gearbox as followed A Open oil drain plug dischar
58. c transmission gear box sketch 1 elastic plate 2 turbine wheel 3 stator wheel 4 impeller wheel 5 turbine shaft 6 oil pump 7 gear forward gear ratio 8 clutch disc 9 septa 10 gear reverse gear ratio 11 input shaft assembly 12 gear shaft 13 gear ring 14 half axle gear 15 differential assembly 16 planet gear 17 helical bevel gear 18 idler shaft 19 output shaft 20 output gear 21 idler wheel 19 sr HANGCHA 3 2 hydraulic oil pipe system see fig 2 2 After the engine starts oil supply pump absorbs the oil from the tank on the bottom of gear box through the oil strainer the oil flows into the control valve then separate itself into two parts the one part for hydrodynamic power clutch the others for the torque converter The oil for hydrodynamic power clutch flows into main pressure valve pressure at 1 1MPa 1 4MPa then separate itself into two parts the one part into inching valve and shift control valve the others into overflow valve pressure at 0 5MPa 0 7MPa and supply for the blade wheel of torque converter The oil from the torque converter Is cooled when passing through the radiator then it lubricates the hydrodynamic power clutch at last the oil comes back into the tank When at idle motion the oil route from the shift control valve to clutch is closed At this time the main pressure valve is opened the oil absolutely flows into the torque converter through the overflow valve when the shift control valve is
59. circuit and turn off ignition switch and then disconnect battery ground cable DESCRIPTION Cables are covered with color coded vinyl for easy identification In the wiring diagram colors are indicated by one or two alphabetical letters It is recommended that the battery be disconnected before performing any electrical service CABLE COLORS Cable colors are indicated by one or two alphabetical letters B black BR brown G green L blue LG Light green R red W white Y yellow S gray P purple The main cable is generally coded with a single color The others are coded with a two tone color as below B W Black with white stripe G Y Green with yellow stripe INSPECTION Inspect all electrical circuit referring to wiring diagrams Circuits should be tested for continuity or short circuit with a conventional test lamp or circuit tester Before inspecting circuit ensure that Each electrical component part or cable is securely fastened to its connector or terminal Each connection is firmly in place and free from rust and dirt No cable covering shows any evidence of cracks deterioration or other damage Each terminal is a safe distance away from any adjacent mental parts Each cable is fastened to its proper connector or terminal Wiring is kept away from any adjacent parts with sharp edges Wiring is kept away from any rotating or moving parts Cables between fixed portions and moving parts are long enough to wi
60. d 69 t AERAN Right turn signal lamp Rear S2 Gi AHERN RIght turn indicator lamp 8 F5 10A SURT ECAA 3 019 C9 p 7 mW Worning lamp 4 VA EN E us G i EWA Left brake lamp 9 104 Q SE d amp WXX Right brake lamp WEAEE REsever fuse F10 20A WWez Resever fuse HOL BARE I lt 4A S4 F4 104 1 x1 25mm d id WE m WAV Horn Jg Gi 1 WHWDX Instrcument panel lamp S6 e HI Gare Wok SA 61 WHWDX Instrcument panel lamp Y 1x1 2 5mm Lf MN 69 7 ZEWEN Rear left width lamp 51 n o o o S C9 i TI A FKM Rear right width lamp 0 3 A SLOL sed eg 1 EKM Left head lamp Ole ale Se Q AM Right head lamp 011 G9 Ll 5 AM EN Front left width lamp Q ed AWOXXUFront right width lamp Fig 2 0 CPCD10 15 18N R W9 W10 electrical system schematic diagram Head lamp amp signal lamp switch Positio E 13 4129 o I X ah X X x teed lamp X XIX
61. d lining surface Grind or replace e Improper contact of linings Grind or correct Unequal braking Worn lining Replace i k Worn warped rusted or damaged Correct or replace side brake drums Improper operation of wheel cylinder Correct or replace Improper sliding shoes Adjust Loose back plate blots Tighten or replace Replace Adjust or replace Clean Warped back plates Improperly adjusted wheel bearing Clogged oil lines No free play of brake pedal Adjust Improper shoe sliding Adjust Improper operation of wheel cylinder Adjust or replace Faulty piston cup Replace e Weak or broken return springs Replace e Clogged master cylinder returns port Clean e Clogged oil lines Clean Wheel bearing out of adjusting Adjust or replace e Lining surface harden or foreign Repair or replace particles on it Warped back plates or loosed blots Repair or replace Brake shoes warped or improper install Repair or replace Worn linings Replace Loose wheel bearing Repair Brake dragging Brake noise 43 Ac HANGCHA 2 Summary The brake system is the front two wheel braking type consisting of a master cylinder brakes and brake pedal 2 1 master cylinder The 2t 3 5t master cylinder contains a valve seat check valve return spring primary cup piston and secondary cup which are kept in place with stop washer and stop wire T
62. d not touch the bottom of the pulley groove 2 Check belt deflection by pushing midway between pulleys Fan belt deflection 11mm 13mm Pushing force 98N 2 2 4 Changing engine oil and oil filter 1 Start engine and warm up engine sufficiently then stop engine 2 Remove oil filler cap and oil pan drain plug and allow oil to drain WARNING Be careful not to burn yourself as the engine oil may be hot Milky oil indicates the presence of cooling water and finds the cause takes corrective measure Oil with extremely low viscosity indicates dilution with gasoline T19320000 3 Clean and install oil pan drain plug with washer Oil pan drain plug 29N m 39N m 4 Using tool remove oll filter 5 Wipe oil filter mounting surface with a clean rag 6 Smear a little engine oil on rubber gasket of new oil filter 7 Install new oil filter Hand tighten ONLY Don t use a wrench to tighten the filter 8 Refill engine with new recommended engine oil referring to Recommended Lubricants Check oil level with dipstick Oil capacity 3 6 L 9 Start engine check area around drain plug and oil filter for any sign of oil leakage If any Leakage is evident these parts have not been properly installed 10 Warm up engine sufficiently Then stop engine and wait a few minutes Check oil level If necessary add engine oil When checking oil level park the forklift on a level surface 2 2 5 Changing Engine Coolant
63. damaged parts as lt HC gt HANGCHA Lift roller to mast clearance adjustment 1 Set roller pitch of inner and outer masts to L dimension Then proceed with the following adjustment Dimension L unit mm Max lift height a ar 2 Adjustable range A with shims a Dimension 0 1mm 0 6mm lt 2 t b Dimension 0mm 0 5mm 2 5t 3 t One or two may not using rubber pad Dimension 0 1 0 6mm if no rubber pad Orientation pin ensure that side roller is vertical to inner mast track ol if NG P i TUM 9 HE 3 Itis suitable that clearance of roller and outer mast is about 0 8mm 1mm Clearance can t adjustable Replace it if roller wear too much 4 Apply lubrication butter to interface of inner mast and outer mast interface of roller and mast To prevent sand from entering it is decided whether to apply lubrication or not in the area where sand blown by wind heavily 71 lt HC gt HANGCHA Clearance of back up metal and mast Steel Adjust clearance B to 0 4mm 0 8mm with shims which may not use Thickness of shim is 0 5mm or 1mm Apply a coat of grease to back up metals Install mast and lifting jack on forklift truck Connect circle tube and high pressure tube 4 4 Left and right cylinder height adjustment 1 Install left and right lifting jack on mast pin must be installed into orientation hole of outer mast lower cross beam 2 Install u
64. der so remaining oil is discharged tilting cylinder 2 Screw earring bolts 2 loosely and screw earring 1 out 3 Remove cylinder head guiding bush 4 Draw out piston rod assembly 4 see as follows 5 Remove all dust gasket rings O ring and Y ring 6 Remove dust gasket ring in the cylinder head Means is the same as discharging of dust gasket ring in the cylinder head of lifting jack see disassembly and installation of lifting jack 7 Remove O ring outside in the guiding bush 8 Remove O ring and Y ring in the inner hole of guiding bush see Fig disassembly and installation of lifting jack CAUTION No using dust gasket ring and Y ring removed 6 2 Install tilting cylinder after replacing ring The order of installation is reverse to the order of disassembly but should notice follow proceedings 1 Lubricate parts with clean hydraulic pressure oil 2 Avoid dust and oil dirty dropping into tilting cylinder 3 Avoid scratching the end of cylinder body and inlet and outlet for oil 4 Push piston rod to cylinder body when setting center especially avoid scratching Y ring 5 Before installing guiding bush wipe hydraulic pressure oil backing boardched with employment oil trademark in the middle of O ring and Y ring in the inner hole of guiding bush 6 Don t scratch O ring outside in the guiding bush when installing 7 Remember install nylon stopper and tighten screw after screw cylinder head
65. e body 13 inching slide valve Fig 2 6 inching valve Inching valve is installed outside the gear box Inching valve lever 7 is connected to the inching pedal lever when put foot down inching valve lever moves to the right side so it reduces the oil pressure for clutch make the truck inching moving by slide the clutch disc 4 5 Hydrodynamic clutch Refer to fig 2 7 4 5 1 Summarizer Wet and multi blade hydrodynamic clutch is installed on the input shaft of the hydrodynamic gear box assign the pressure oil to the forward or reverse clutch through the control valve so the truck can travel in forward or reverse direction All the gears in the gear box Is the mesh always gear Every clutch of the YQX30 model clutch assembly consists of 4 interphase installed septa 18 4 disc 19 and a piston 2 Every clutch of the YQX18 model clutch assembly consists of 3 interphase installed septa 18 3 disc 19 and a papilionaceous plate a piston 2 YQX18 model clutch assembly is different from the YQX25 30 clutch only for this The ring 17 installed in the outer rounder of the piston o ring 3 in the input shaft for ensuring be airproof when the piston is working When at idle motion the piston does not work the septa separates from the disc When change over the gear ration the pressure oil makes the piston septa and disc impacted transmit the power from the torque converter to the forward gear ratio gear or the reverse gear 6 depending on friction
66. e fuel Water should be drain when the bobber gets to the alert draining line 1 Loosen the drain plug at the lower top of the fuel filter 2 Drain the fuel in the fuel body together with the mixed water 3 Be sure to tighten the drain plug on completion of draining 3 2 10 Fuel system air bleeding The entry of air into the fuel system will cause hard engine starting or engine mal function When once the servicing such as emptying the fuel tank air bleeding for the water segregator or the fuel filter element change etc Is done be sure to conductor air bleeding Crank pulley 7 sir HANGCHA 13 sr HANGCHA Bleeding procedure 1 Loosen the bleeding screws on the fuel injection pump 2 Loosen the feed pump knob 3 Depressing the pump knob until no bubbles are visible in the flowing fuel from the loosened bleeding screws 4 Tightening two bleeding screws and feed pump knob 3 2 11 Fuel filter element change 1 Loosen the fuel filter by hand or using wrench counterclockwise Discard the fuel filter element 2 Wipe oil filter mounting surface with a clean rag 3 Smear a little engine oil on rubber gasket of new oil filter 4 Fill a little fuel into the fuel filter this helps the air bleeding 5 Turn in the new fuel filter until the filter gasket comes into contact with its sealed face 6 Use a filter wrench to turn the fuel filter by additional 2 3 of a turn 4 TD27AA di
67. e valve is close completely Cam drop time adjusting screw is properly adjusted at the factory before delivery Do not attempt to adjust it in the field unless necessary 2 2 13 Check and replace spark plug 1 Disconnect spark plug wire at boot 2 Remove spark plugs with spark plug wrench 3 Clean plugs in sand blast cleaner 8 2 2 14 Checking Distributor 1 Inspection Ignition coil Use circuit tester measure primary coil resistance between terminals Mand 2 and measure secondary coil resistance between terminals Dor and secondary terminal Primary coil resistance 0 90 1 2 Q Secondary coil resistance 20kO 29 KO 2 Pickup assembly Using circuit tester measure pickup coll resistance Specifications 4200 5400 Ensure tester pointer deflects when moving standard screwdriver s blade near pickup coil s iron core 3 Carbon contacts If spherical surfaces of all contacts are worn replace with new cap assembly 4 Cap rotor Check for cracks or damage 5 Signal rotor Check for bends or damage 6 Vacuum control Using vacuum pump apply vacuum to diaphragm Linkage must be attracted 7 Inspection after reassemble Measure air gaps between signal rotor and pickup assembly Specifications 0 35mm 0 45mm 8 Cleaning Distributor Inside Blow dust off inside of distributor with dry compressed air lt C gt HANGCHA Secondary terminal HANGCHA 2 2 15 Checking and adjus
68. ellet type Standard clearance of switchboard 0 35 0 45 Type FR2A D Plug gap mm 80 9 Type A7T03371 Voltage current iN CO cO Valve clearance mm 210030 41 opark plug lt Type MOOOT65381 Planetary gear type Voltage V Output power kW Type opeed control system Operation of control mechanizing Max Engine speed under no laden Max Engine speed under laden de CO OT Pneumatic By controlling mix tare amount By suction negative pressure 3600 r min 3000 r min 12 60 iil O D jueuoduuJoo ulen e m CO nO l Go ala O1 N No PO Co Capacity V A h Full charge specific gravity at 20 C Reference Engine oil capacity L data Coolant volume 1 28 sr HANGCHA 2 2K21 K25 Maintenance 2 2 1 Retighten cylinder head bolts When the engine is cold retighten should be made in the sequence shown T 68 6 N m In two steps 2 2 2 Adjusting intake and exhaust valve clearance 1 Start engines and warm it up sufficiently Then turn off engine 2 Remove valve rocker cover 3 Rotate crankshaft Set No 1 cylinder in top dead center on its compression stroke and then adjust valve clearance Gi Set NO 4 cylinder in top dead center on its compression stroke and adjust valve clearance 0 Valve clearance Hot Intake amp exhaust 0 38mm 2 2 3 Checking and Adjusting Fan Belt for Tension 1 Visually inspect for cracks fraying wear or lubricity The belt shoul
69. em and it compose fork lift truck work equipment This equipment is performing framework of load and unload Commonly common masts have simple mast Double mast and Triple mast class mast framework type Fork lift truck what is made in our company backing boardch Double high visibility mast Double full free lift mast including container mast Triple full free lift mast mast framework adopted is CL model juxtaposition roller type 3 1 Double high visibility mast Double mast is composed of outer mast which can t lift and inner mast which can lift Lifting jack bottom is fixed on outer mast below cross beam oriented with pin Piston rod extremity is joined with upper cross beam of inner mast cylinder body is fixed on outer mast fixation board with U bolt Commonly free lift range is 100mm 130mm which is difference with different tonnage Two lifting jacks Fig 8 5 is right are laid out back of outer mast to realize high visibility two lifting jacks are laid outside of outer mast Fork arm is hung on fork arm carrier by hook Roller combined roller side roller is installed middle of roller outside and side roller It is adopted combined roller in 1 1 8 tonnage forklift truck is installed on fork arm carrier Combined roller is installed on below of inner mast Pressure oil from hydraulic control valve is entered into lifting jack by unidirectional speed limiting valve forced piston and piston rod rising thereby forced inner mast rising At t
70. ement parts with a little gear oil to prevent them from coming into being instant dry friction while early running oO c Each part should be assembled correctly d Each part should be running smoothly to prevent it from getting stuck e Be sure to tighten firmly each joint bolt 4 7 Case and control valve Case and control valve is installed inside the shell of gear box It consists shell body case 1 and control valve 3 There are a gearlever shaft 2 and an overflow valve 4 installed on the shell body case keep the oil pressure for torque converter between 0 5MPa 0 7MPa prevent the air erode N T dd 1 shell body 2 gearlever shaft 3 assembly of control valve 4 overflow valve Fig 2 9 case and control valve The assembly of control valve consists Main pressure valve 10 Buffer valve 15 shift control valve 1etc See Fig 2 10 21 sr HANGCHA DD i 11 12 13 DP 20 elt i NS Y Si ES gies L qum ELLE py iy Sui Na Y ei E ERE Gg Zig N LA pa ETT LET IS AT A ee E JN ET 1 slide valve 2 valve body 3 plug 4 flexible straight pin 440 5 spring 6 flexible straight pin 4 35 7 plug 8 spring 9 spring 10 piston 11 drain plug 12 spring 13 steel ball 14 spring 15 valve core Fig 2 10 control valve Main pressure valve also called fixed pressure valve the oil pressure for controlling the hydrodynamic clutch is at 1 1 MPa 1 4MPa assigns the oil to the relief valve then to t
71. esel 4 1 The maintenance of TD27AA diesel TD27AA diesel requests a high quality for the maintenance of Air cleaner and the fuel filter and the filtering of diesel 4 4 1 Cleaning and changing the air cleaner Dry paper model The filter must be cleaned and changed in the maintenance schedule if the motor is working in the dusty environment the air cleaner should be cleaned and changed in time 14 4 4 2 Checking the oil filter Checking and changing the oil filter 1 Remove the censor s head of oil filter 2 Loosen the valve to drain the fuel 3 Remove the sensor of oil filter or draining valve 4 Remove the oil filter 5 Connect the censor of oil filter to the new oil filter 6 Fix the new oil filter You can only tighten the oil filter by hand 7 Connect the censor s head 8 Remove the air from the fuel system Fuel removing system see 4 1 4 Draining water 1 The water should be drained in schedule and it should be drained even the buzzer alarm 2 Remove air from the fuel system 3 There must have a container under the oil filter 4 1 3 Filtering the diesel oil The oil should be filtered strictly before they are added into the oil container 4 1 4 Remove the air of fuel The air should be removed absolutely To avoid splash of oil the seat of the motor and pump should be wrapped by a piece of cloth If the motor can t work after air removing loosen the eject pipe shake the s
72. experimental environment of system 55 sr HANGCHA Oil input Q Oil return 2 M22X 1 5 e To redirector EA 7 S PS L P L KG UG Abd A BA KEA SiS OC tem g KN TT E Ess e RSA G F E B re Se Z 7 J CH i Mi A RAN NN aa AE ET A N D A D al Ce vr ak I i ir chant eee e Sa Ze P Kai D e G A Cav i PSA Mech Aa ETE let mik Ge MM U ELISA NYE i r OW Mk AL L ap Ze SRM LA D NN K GT AK TIL Le ur Main safety valve Flow divide safety valve MINA T ET D H PG TETT EL LZ ICE He Fig 7 5 4 2 Adjusting the pressure of the main relieve valve The pressure of the main relieve valve is all ready adjusted in the factory and it can t be adjusted generally The following is an example of 3t truck to specify how to adjust the pressure 1 Put 125 percent of the rated load 3750kg on the forklift stable 2 Step the accelerated pedal to the end control the lift pole if the forklift can get the height of Omm 300mm the main relieve valve is all right Otherwise adjust it as step 3 3 If the forklift can t work enhance the pressure main relieve valve remove the front soleplate loosen the tightening nut of the main relieve valve screw the adjusting nut clockwise to enhance the pressure of the main relieve valve If the height of lift is higher than 300mm screw the adjust nut anti clockwise to reduce the pressure 4 Step the accelerated pedal to the end t
73. f compensation and radial hydraulic balance By using special structure low noise comparing with those in symmetry backing boarderials used in the parts effectively improve the performance and make it reliable i g DU sleeve in bearing double metal backing boarderial of side plate AL alloy die casting of front and rear cover extruding AL alloy of middle section etc CHBZG left rotation see fig 7 2 right rotation see fig 7 3 The difference of counter clockwise and clockwise pump is 3 shape backing plate The direction of them is different Fig 7 2 CBHZG counterclockWise rotation gear pump left 1 Snap ring 2 Oil seal 3 Mounting flange 4 Seal plate 5 3 shape backing plate 6 Pressure plate 7 Bush 8 Driven gear 9 Drive gear 10 Gear plate 11 End cover 12 Washer 13 Mounting bolt o3 sr HANGCHA 8 Fig 7 3CBHZG clockwise Right rotation gear pump 1 Snap ring 2 Oil seal 3 Mounting flange 4 Seal plate 5 3 shape backing plate 6 Pressure plate 7 Bush 8 Driven gear 9 Drive gear 10 Gear plate 11 End cover 12 Washer 13 Mounting bolt 54 sr HANGCHA 4 Control valve Two pieces type control valve consists of four pieces of valve body two plungers a relief valve and a divided valve Four pieces of valve body are assembled with three blots and nuts Tilting plunger is fitted by tilting lock self valve According to requirement of work device it is capable to add combined lock vale and rotat
74. facing to the inside of forklift truck 4 Attach seal tape PVC white to drain plug then installed after cleaned it 6 Replenish axle case with gear oil Tighten vent plug after clearing 1t 1 8t hydro transmission forklift GL 5 6 1t 1 8t mechanical transmission forklift Gear oil L 2t 3 5t hydro transmission forklift except 85W 140 3 2 RW15A N NSN 8 21 3 5t mechanical transmission forklift APIGL 5 L 3 2 Only type N RW15A QN RW11A lift truck 80W 90 Vent plug should clear instantly to prevent pressure inside of wheel hub from rising 4 Axle shaft and wheel hub Remove 1 Raise the front end of forklift truck and support frame with wooden blocks 2 Remove front wheel and axle shaft 3 Remove lock nuts lock washers snap ring felt ring adjusting nut Use special tools 33 sr HANGCHA 4 Remove brake drum refer to Fig 3 4 If brake drum is difficult to remove a Remove adjusting hole plug Then with flat blade screwdriver extend adjusting hole turn adjusting ratchet wheel by 10 notches To contract brake shoe lining refer to Fig 3 5 b evenly tapping on brake drum with brass bar or wooden mallet backing plate assembly adjusting nut Fig 3 4 Fig 3 5 5 Remove wheel hub be careful not to drop bearing inner race 6 Remove oil seal and inner bearing as an assembly by evenly tapping on periphery of seal with a wooden mallet and brass bar 7 Remove bearing outer race
75. g A KERRE Water temperature sensor WAAR Timer Solenoid iMERX Preheot indicator lamp KEHAN Charge indicator lamp 4 XESEX UI pressure indicator lamp HARARET Cil water separator indicator lamp Y RRE temperature indicator lamp ZOEERA Water temperature sensor E WERKRA F vel quantity sensor Wh e Timer H R AA Forward solenoid valve Reng Reverse solenoid valve MRWDEX Fuel shut off solenoid switch at RY pi SN Left reversing lamp amp BEX Right reversing lamp fit4SES Reverse warner 7 ZWKWA Left turn signal lamp Front Y ZRiFK Turn left indicator lamp 1 Zktwk Left turn signal lamp Rear nv UKWA RIght turn signal lamp Front Amr Turn right indicator lamp SES Micht turn signal lamp Rear ZENS ert brake lamp SR Micht brake lamp 31 Worning lamp
76. ge oil out B Take out hydraulic torque converter 13 C Disassemble differential assy 15 case and control valve assy 5 oil supply pump 4 torque converter shell assembly 3 clutch assembly 6 14 inching valve assembly D Open Cover Bearing 17 take off Shaft Final Pinion 1 screw bevel gear 16 And decomposition tapered roller bearing 2 E Remove the support flake 7 the Take out output shaft 10 and shaft out all the parts F Remove other parts components Assembling procedures Please assemble with opposite procedures of disassembly 21 Ac HANGCHA oo A z EN Ki M rex SN RSS ae ka Fe hi n im ped H d Jee i i is TS L H aN ef 3 rift w IR Az Ke E 2j Pd OA ri ls i alle ES i dE x n ms 1 Shaft Final Pinion 2 tapered roller bearing 3 torque converter shell assy 4 oil supply pump 5 case and control valve assy 6 clutch assy 7 support flake 8 shell body 9 idler shaft 10 output shaft 11 idler wheel 12 output gear 13 hydraulic torque converter 14 inching valve assy 15 differential assy 16 screw bevel gear 17 Cover Bearing Fig 2 3 hydrodynamic transmission gear box 4 2 Torque converter see Fig 2 4 Torque converter Mainly by the impeller wheel turbine wheel stator wheel and other components Impeller wheel is driven by input shaft the fluid impacts blades of the turbine wheel along with blades of the im
77. he exterior of the cylinder is protected from dust by means of a rubber dust cover The piston is actuated through the push rod by operation of the brake pedal First as the brake pedal the push rod pushes the piston forwards The brake fluid in the cylinder flows back to the reserve tank through the return port until the primary cup blocks up the return port After the primary cup passes the return port the brake fluid in the cylinder is pressurized and opens the check valve flowing through the brake lines to the wheel cylinder Thus each wheel cylinder piston is forced outwards This brings the brake shoes into contact with the wheel drum and slows or stops the lift truck Meanwhile the cavity caused behind the piston is filled with brake fluid led through the return port and inlet port to lubricate the piston When the brake pedal is released the piston is forced back by the return spring At the same time the brake fluid in each wheel cylinder is pressurized by the force of the brake shoe return spring thus returning into the master through the check valve With the piston in its original position the fluid in the cylinder flows into the reserve tank through the return port The brake fluid in the brake lines and wheel cylinders has a residual pressure proportioned about 0 04MPa to the set pressure of the check valve which makes each wheel cylinder piston cup securely seated to prevent oil leakage and eliminates of vapor lock developing when
78. he same time one end of lifting chain on inner mast is fixed on outer mast the other is joined with fork arm carrier Fork arm carrier and fork arm is rising with inner mast rising to realize aim of lifting goods lt is basis model that our company offers forklift truck which lift 3 meter high It is especial model that our company offers forklift truck which lift height else 2 6 m 3 2 Double full free lift mast including container mast Double full free lift mast Fig 8 2 is also composed of inner mast outer mast fork arm carrier and etc is also belong to high visibility mast It is different from common standard type mast that two postpose long lifting jacks are both pole stopper type cylinder One piston rod is hollow hole of piston rod is dypassed for hydraulic pressure oil flowing into free lifting jack End of piston rod in two long lifting jacks is joined with upper branch of inner mast Besides short lifting jack who is installed middle of inner mast is named as free lifting jack Free lifting jack is also pole stopper type cylinder Fork arm can rising or falling when height go beyond 1400mm because inner mast dont rising when free lifting jack rising or falling There are different specifications in this series of height 2 5m 2 7 m 3 m 3 8m 4 m and etc Free lifting height is commonly about 1050 2100mm When lowest height of mast 22200mm lift height is 3m full free lift height is about 1500mm It can work inside container
79. ification with shims Axial plays less than 0 15mm 4 The character of seal tape faces outside Apple grease to roller of roller bearing also apply grease between lip and groove of seal tape 5 Pack all grease nipples with a sufficient of grease 5 Wheel bearing adjustment 1 Slowly rotate hub Tighten steering spindle nut until it can no longer be rotated with one hand 2 From that position turn back steering spindle nut 1 6 1 4 rotation Measure hub bolt force is 10N 30N 3 Make sure that hub rotates smoothly and that its axial play is within specification Axial play is less than 0 12mm 38 sr HANGCHA V Steering system 1 Data Steerina svstem tvpe Change direction rear wheel with power oe di steering 8 25 BE TH 15 18 Model 530 1322 dl hydrostaio PisPacementmlr 100 full hydrostatic Displacement ml r 100 J u eos gear Exon Open center low Open center low torque torque cylinder Wheel diameter mm 360 360 2 Trouble diagnoses Damaged or trouble of oil pump Failure Der Divide value is clogged or damaged Clean or replace steering wheel Damaged hose or connector block lines Replace or clean Divide value pressure too low Adjust pressure Air in oil lines Remove air High effort for The steering fails to turn to its natural steering position broken lock spring or insufficient Replace spring flat spring pressure Too much internal leakage in steering Check piston for cyli
80. ing valve main lifting tilti relief HI valve he a valve li lr H P AA Er to pump C h T LI Le a NIC A EN to redirector LL ME redirecter t Fig 7 4 Control valve for 1t 3 5t forklift truck 4 1 Main relief valve and flow dividing valve Main relief valve is a pilot valve it is used for limiting the maximum pressure of system Main relief valve disk is not opened in normal condition When the truck works at overload condition or hydraulic system faults come the system pressure is up to the set value of main relief valve the pilot valve disk firstly opens and then control valve disk opens to make system pressure not increase continuously so it ensure system safe oteering relief valve is a directly operated type valve Its set value is lower than main relief valve when steering system occurs faults or load is too big pressure is up to set value by spring and pressure overcome spring and friction force to open relief valve So it ensures steering system safe One end of pilot valve disk connects with oil inlet of steering valve and the other end connects with steering valve outlet signal port so it make the pressure difference keep invariableness pilot valve supply proper oil flow according to the rotated speed of steering wheel by driver Extra oil flows to supply other working devices via control valve This device can improve system efficiency reduce oil temperature improve
81. lectrical system schematic diagram Positio dead lamp amp signal lamp switch 2 S 4 off ith lg X end lp XXX X X X va B ii ve Wer amp stort switch Ok ball 81 Be lacc C R1 Re Preheot X X X FF IX EX Run X X X Stary X X X X X Number Sign Instruction ite Fuse e HI f Bonked batter 3 Fa KES Relay 4 Wm Normally open switch 9 r ST Normally closed switch 6 D I node double tror sit 7 scH NX Flasher 8 Sei ba Solenoid 9 a Horn 0 f ee Sensor l GO HE Bulb d YY ee Buzzer 3 vv B L Resistance 4 ENF HME Glow plug 5 Bk AE Diode 6 7 ERRIA Pointer gauge 7 d E Control box 8 ARE Pre hent amp start snitch IOC aus IEA 93 0c8 00000 2c9S8 s0 X Battery 12V DC Ke Alternator A EXIV Stor ter WE Glow plu
82. lic control valve Replace it spring IS inoperative 1 Caused by piston jamming or The fork arms carrier bent piston rod Repose DIE tally pas moves up and down 2 Too much dirt is accumulated in sluggishly E the cylinder Strip it down and clean Adjust clearance with thrust metal and carriage side roller 1 Carriage bracket assembly out of adjustment 2 Insufficient clearance between Adjust clearance with inner and outer masts or rollers and rollers mast Forks are lifted or lowered 3 Biting foreign backing Remove foreign backing non smoothly boarderials between moving part boarderials Apply grease on contact 4 Insufficient lubrication surfaces of sliding parts butter 5 Bent carriage bracket assembly Repair or replace Forks are lifted unevenly 1 Lift chains out of adjustable Adjust lift chains iffen r ir 1 Grease sti ened 0 dirt Clean and lubricate lift accumulated on lift roller and mast dnd rollers sliding surfaces Lift roller does not rotate 2 Improperly adjusted lift roller Adjust 1 Insufficient lubrication Lubricate 2 Improperly adjusted lift roller By adjusting shims and rubber pad piston rod is in touch with bottom of cylinder body after inner mast is in touch with rubber pad Excessive mast noise 3 Rubber pad on lower of outer mast is useless for container fork lift truck 60 sr HANGCHA Probable cause Comeciveacio
83. lock valve Replace valve core and tilt lock when control valve as an assembly lever is used Broken tilt locks spring Replace spring while engine is off Damaged tilt valve plunger O ring Replace O ring VEE Replace tilt relief valve when tilting Malfunctioning tilt relief valve p forward assembly Valve body and spool valve is Replace spool valve with Lowering worn and clearance between specified clearance distance of them is too great mast is big Spool valve is not in centre Keep being in the centre when spool valve is in the Cylinder seal abated Examine and repair cylinder centre Taper valve is worn or blocked by Replace or clean taper valve dirt e i Damaged or distorted d Replace spring reposition spring Spool valve is Dirt exist between valve body and not return spool valve neutral position Blocked control device Adjusted Not coaxial parts at reposition Reinstall be coaxial Faulty seal of joint Check and retighten Leakage Loose seal plate er plate and Loosed lock nut of relief valve and connect nut between plate and Tighten plate 51 sr HANGCHA 3 Main pump 3 1 W21 main pump 1 1 8t W21 main pump is a gear type consisting of a pump body pump cover a pair of gear bearing and seal ring This pump uses pressure balance type bearing and a special lubrication method so as to get the minimum clearance of the gear flank Since the pump body
84. ly Notice wipe lithium lubricating grease on guide rail C and do it usually e 46 sir HANGCHA Brake Release m _ T torque 9 1 11 8 Lasso of brake Slope less than 2 mm Handle Adjust bolt of tension 19 25 TJN m Fig 8 3 hand brake 47 pa Suc HANGCHA VI Hydraulic system 1 Data Main pump 1t 1 8t CBT F425 AFH6L CBT F425 AFP CBHZG F25 ALQ CBHZ F25 ALH6 Engine power take off type gear Output pressure Rated Max MPa 20 25 2t 3 5t CBHZG F26 5 AL L CBHZB F28 2 AT CBHZG F30 ALQL Model CBHZ F30 AL CBHZG F32 AL L CBHZ F32 ALH6L SES CBHZG F32 ALP CBT F432 AFH6L CBHZ F32 ALH6 CBHZB F32 AT Engine power take off type gear Output pressure Rated Max MPa la 48 lt C gt HANGCHA Control valve 1t 1 8t N030 611100 000 2 spools Model N030 611200 000 3 spools N030 611300 000 4 spools Double slide valve with overflow divided valve and tilt lock valve T Bu 14 5 can lift 11096 of rated load cannot lift 12596 rated load L min pressure 8 840 95 Divide 65 valve Flow rate 8x1 L min 2t 3 5t R163 611100 000 2 spools Model R163 611200 000 3 spools R163 611300 000 4 spools Double slide valve with overflow divided valve and tilt lock valve ar Da 17 5 can lift 110 of rated load cannot lift 125 rated load Rated flow rate pressure Divide MPa 8 8 0 25 Flow rate 49 HANGCHA 2 Trouble diagnoses a
85. n Comeciveacion 1 Excessive wear occurs between the oil pump body and gears causing too much clearance 2 The lifting jack piston Yx ring has worn resulting in excessive inner Replace Yx ring leaks 3 Springs of the multiple control valve and its relief valve are Replace inoperative oil leaks 4 Excessive wear occurs of the hydraulic control valve resulting in excessive oil leaks Replace the worn parts or the oil pump Replace Insufficient lift power or no lift movement Dismantle for regrinding the joint surfaces and reassemble the valve Tighten the joint nuts and inspect the seal for damage Change the wrong hydraulic oil or stop 7 The hydraulic oil temperature is operation for reducing the too high Oil viscosity is too low and oil temperature Find out the rate is insufficient the reasons for high oil temperature and eliminate the trouble 8 The load carried is beyond the Observe the lifting capacity designed capacity limit 5 Oil leaks occur between the hydraulic control valve sections 6 Leakage occurs in the hydraulic pipe 61 sr HANGCHA 62 N30M300 000000 000 Lifting Mast assembly Tightening torque See foregoing table sr HANGCHA 3 Summary The lifting system is composed of inner and outer mast fork arm carrier fork arm load backrest chain roller lifting jack and tilt cylinder etc Oil line system hydraulic pressure syst
86. n ADA kj ke 1x4 0mm S GS FT S4 b Ge VVV EER SSA K1 F1 50A ER Ed ER EI 004 D r 005 007 1 AES 150 1x35mr 4 AIV ils RXWVStonrter CZ 90506 i a z Sem E02 E01 gt d R o Cnr ES K RB Spark plug Wy O O pe Ke p mm UNES EEG SE 009 O ANN filte Carburetor AES 6A MT 1x0 85mm 9 69 XWX Chorge indicator lamp lg ue S101 a WERZA UIL pressure indicator lamp 008 llo 014 4 Q gt 5104 EKSAT DIL temperature indicator lamp F7 10A Wee oa ee uge 8104 KifkRe Water temperature sensor p 1 x0 85mm nm l 4 mz ED 016 WEA F vel quantity gauge WERRE Fuel quantity sensor 63 SS d HRA Timer 5 6 KZ I D Sl o 5 01 A M BMR Forward solenoid valve EL ue o E a 018 fEBHM Reverse solenoid valve 3 4 1 EREK LeFt ing I T 69 dd Left reversing lamp 1 4 G9 LA A EKN Right reversing lamp 02 SZ 2 flEREE Reverse warner L 73 EHEWN Left turn signal lamp Front a WRRAXM Instrument panel lam F6 10A KH SI C9 p p 020 Ss 022 gt odes 2 5 4 EEKWX Left turn signal lamp Rear Ne O v ERKRA Right turn signal lamp Front HH 6A 024 74 1 X0 85mpt eo 3E WHHDX Instrcument panel lamp SO Q EERRA RIght turn signal lamp Rear 026 8 Be AE AA 9 BaX Worning lamp FS 104 1X085mm gos Se 027 Q 6 3 WaNT Left broke lamp F10 204 Q9 2 3 d amp WXX Right brake lamp e BB OR HG Guer fuse F9 10A e HB RRE He ever fuse F4 104 See mm s3 d KSE SS wyIT Horin 1x1 25mri GH WRAX Instrument panel
87. nd corrections Main pump 4 Low oil level in tank Add oil to specified level No oil from oil pump Clogged suction pipe or Clean oil line and tank If oil is dirty strainer change Worn bearing damaged Replace faulty parts backup ring and O ring Readjust to specified pressure using discharge pressure gauge oressure on Retighten suction side pipe oil pump Add oil in oil tank Air in oil pump Check pumps oil seal Do not operate pump until bubbles in tank disappear Cavitation due to crushed suction hose or clogged strainer Air being sucked from loose suction side joint Noisy oil replace with new oil having proper pump viscosity for temperature at which pump is to be operate to operate when oil temperature is normal on oe cause of bubbles and Bubbles in hydraulic oil in Bubbles in hydraulic oil oil on oe Oil leakin Faulty oil seal on pump from oil m faulty O ring worn Replace faulty parts pump sliding surfaces on mes Adjust or replace crushed hose and clean strainer Retighten each joint Cavitation due to too high oil viscosity 90 sr HANGCHA Control valve Loose of pressure adjust screw Readjusted and retighten Pressure of Distorted or damaged p lief valve is adi j eplace re pressure adjust spring NO EN Worn or blocked relief valve core Replace or clean too low Pump abated Examine and repair pump Fork tilt forward worn or damaged tilt
88. nder sealing zigzag or Too much oil flow to steering cylinder Adjust divide value Track travel wobbly Oil is not sufficient in oil tank Add oil normal noise Suction piping or filter clogged Clean or replace leakage Damaged sealing of oriented bush of replace steering cylinder or hose or connector 39 sr HANGCHA 3 Summarize Steering system is composed of full hydrostatic power steering gear and steering cylinder 3 1 Full hydrostatic power steering gear assemble refer to Fig 5 1 Full hydrostatic power steering gear assemble include cyclical full hydrostatic power steering gear column and steering wheel Column and steering wheel can be adjust 8 back or forth to fit all driver When engine stops running rotate steering wheel with 1kg force slightly after leaving hands steering wheel should be return 10 auto backing boardically Steering wheel Qa u Bracket of steering colulmn Tilt steering clamp Steering column 4 Tilt handle Redirector Fig 5 1 steering wheel 40 lt HC gt HANGCHA 3 2 Full hydrostatic power steering gear refer to Fig 5 2 When power steering pressure oil flows from valve disk and valve sleeve pair to rotary stator valve pair then drive rotary to rotate followed as steering wheel and drive oil entering into left or right cavity of cylinder and drive steering tire to turn by piston rod When the engine stops running the pump does not supply oil
89. ne shaft by using the spline transmits the power to the gearbox through the turbine shaft 22 Gi Ce Ga Gi Oe OC ON im i Ab sir HANGCHA 1 drain plug 2 elastic plate 3 turbine wheel A stator wheel Fig 2 4 Torque converter 4 3 Oil supply pump Refer to fig 2 5 Oil supply pump is installed on the torque converter body Driving gear 9 is connected to the impeller wheel driven by engine it mesh with the driven gear 11 and supply oil for the torque converter hydrodynamic gear box 1 straight pin 5 sleeve 9 driving gear 13 pump housing 13 12 2 bolt M8 x 35 6 oil seal 10 sleeve AL ea AG S Sei nm a SOOO SASS EC a wm D 227 qii A 7 AAN TS wan SE E EA ll FI AP 7 Ss Poy A INN uU Al c 3 bolt M8 x 25 7 threaded plug 11 driven gear Fig 2 5 oil supply pump ov f 163 n ta 5 bearing thrust ball 6 bearing ball 7 snap ring 8 turbine shaft 9 one way clutch 10 impeller wheel 4 ring 8 o ring 12 stator seal 23 sr HANGCHA 4 4 Inching valve 1 2 L Le S jJ gr 2 P a ed Ra DE TTT oa ar SE E edere E eo ed G CD M 10 11 12 13 3 RE CL AL ESN LA NN as NNNVama IN HAT Lot Poe A roty IK SSA p 1 threaded plug 2 threaded plug 3 elastic snap for hole 4 spring oplug6 o ring 7 inching valve lever 8 spring 9 elastic snap for hole 10 oil seal11 block 12 inching valv
90. ng 8 Cylinder 9 Piston rod 10 piston 11 support ring 12 OSI ring 68 AC N N SF ENE Mac d r CSS LFF 7 ec ed A OH O JON P 10 DO mz a K we EH H il mm aye GEO mm dm zm A ge amer MT Ze en er M7 AT DA ZZ M22x1 577 Fig 8 10 free lifting cylinder used in 8 2 8 3 1 Dustproof ring 2 Cylinder cover 3 Guide sleeve 4 O ring 5 O ring 6 sealring 7 deflation plug 8 O ring 9 Cylinder assembly 10 Plunger rod 11 Support ring 12 Stop ring Less than or equal to 2 5t cylinder 4 Removal and adjustment N WARNING Be careful when removing and installing the forks carriage and mast as they are heavy 41 Remove forks assembly 1 Unlock fork lock pins by pulling them and move forks to cutout portion in the middle of carriage bracket assembly 2 Pull lower portion of fork to remove its lower jaw and lift it out AN WARNING a Keep hands and feet away from forks when removing and installing forks carefully Keep feet and hands clear b Do not remove forks from the end of the fork bar Severe injury can result if the fork is dropped and mast 1 Attach wire ropes to carriage bracket assembly and lift carriage bracket assembly up with a lifting device 2 Remove chain attaching nuts and detach chains from carriage bracket assembly lt HC gt HANGCHA N Fork lift arm carrier assembly 3 Remove car
91. not help the compression there is leakage pass on the gasket surface Oil and water in combustion chambers can result from this problem 2 2 9 Cleaning or Replacing Air Cleaning Filter Dry paper type It is necessary to clean the element or replace it at the recommended interval and more frequent maintenance should do in other dirty operating conditions 2 2 10 Cleaning or Replacing Fuel Stained Element The fuel strainer element should be checked cleaned or replaced periodically 2 2 11 Checking Fuel lines Check fuel lines for proper attachment leaks cracks damage loose connections chaffing and deterioration If necessary replace any damaged or defective parts lt HC gt HANGCHA 2 2 12 Checking carburetor lve PTC heater Croke va Throttle valve Diaphragm adjusting screw Accelerating pump Push rod eg 3 Band clamp Cam drop time adjusting screw Push rod lever Fuel cut Bimetal case solenoid valve FICD Idle adjusting screw Throttle adjusting screw Throttle drum 1 Checking Linkage And Valve Remove air horn Visual check dirt and linkage of interior carburetor visual check wear or damage of connecting parts Check throttle valve shaft for wear by moving it by hand It must not moved no free play Check operation opening and closing of throttle valve and choke valve Maintenance If carburetor is excessively soiled disassemble and clean If link
92. o make the forklift in the height range of Omm 300mm Otherwise adjust it as step 3 5 Retighten the tightening nut fix it on the front soleplate Warning The load should be put stably Don t adjust if the pressure is already adjusted correctly 4 3 Operation of tilt lock valve Tilting lock valve is fitted by lock self valve to prevent vibration owing to back pressure inside tilt cylinder and avoid casualty because of miss operation According to common structure it can operate tilt spool to tilt forward after engine is 56 sir HANGCHA off but using the tilt lock valve when engine is off it cannot tilt mast forward even push the lever of operation valve the structure is shown as Fig 7 6 Connector of valve body A B connects separately with frond and rear house of tilt cylinder piston When pulling out spool high pressure oil P enters connector A oil in rear house returns to oil tank T in this time mast is in tilting backward When pulling tilting spool high pressure oil enters connector B by high pressure oil lock valve in spool works to make A to connect with low pressure When engine is off or stop lock valve in spool cannot work without high pressure oil so that connector A can not connect low pressure line and mast cannot tilt forward also there is not back pressure in tilt cylinder tilting cylinder A B WAS NPG SS N NGT N GSSSSSSSS S S S Sr Niro dE H N U E
93. o touch front tires 6 Tilt mast forward until front tires are raised from surface 7 Support forklift truck by putting additional wooden blocks under each side of front end frame 8 Stop engine 9 Remove wheel tire nuts and brake drum Remove half shaft lock nut and washer 10 Remove wheel hub and brake drum 11 Replace brake shoes with new ones 12 Install brake drum 13 Adjust shoe to drum clearance rotate wheel counterclockwise and at the time press down brake pedal several times 14 Take out every padding block take out according to reverse procedures when inserting 15 Make sure no person or obstacle is around forklift then operate forklift in reverse at 2km h to 3km h set foot on brake pedal 2 3 times 16 2 4 Hand brake device The hand brake device adopts a hand pulling soft brake wire cable device It makes use of auto assist pressure linings type brake together with foot brake Only when parking truck use the hand brake If it occurs for foot brake malfunction use hand brake to stop the truck Make sure that drive system is working normally before adjusting hand brake 1 Adjust nut B to make the length is 68mm and then lock nut B 2 Adjust nut A to adjust hand brake pull force the pull force of point P in Q direction is in the range of 147N 196N when locking hand lever 3 After adjusting hand brake lever correctly loosen hand brake lever make sure brake loose completely 4 Make sure hand brake device work normal
94. orklift com E mail sales hcforklift com
95. orque converter Buffer valve also called adjustment valve between the inching valve and the shift control valve When the control valve is all opened the buffer valve begins to work for reducing the impact when the hydrodynamic clutch is connecting Shift control valve assign the pressure oil to the forward or reverse clutch so as to make the gear box change the gear ratio 28 sr HANGCHA Structure of Automatic shift valve used for automatic shift type YQXD25A YQXD30A YQXD25A YQXD30A YQXD25H YQXD30H YQXD25H1 YQXD30H1 YQXD25G1 the YQXD30G1 the except connect shell same of all except same of all except connect shell connect shell similarities and Electrical shift seer Electrical shift differences compare with YQX18 eda compare with YQX30 Automatic shift valve Electrical shift YQXD18HA Automatic shift YQXD18E hydraulic YQXD18H1 transmission YQXD18HB gearbox the same of all eee Ne e 3 6 electromagnetic shift valve 13 small spring of fixed pressure valve 15 elasticity columnar pin C3 16 round plug of fixed pressure valve 17 round plug of control valve 18 big spring of control valve 19 small spring of control valve 21 bolt 22 shell body 23 gasket 29 sr HANGCHA 9 Notice about installation and usage 5 1 Before installation first clean oil of oil seal on surface of hydraulic
96. peller wheel by the effect of centrifugal effect mechanical energy is converted into fluid kinetic energy transmit the torque to output shaft fluid flows out of the turbine change it s direction by the effect of the stator wheel so a part of the fluid comes back to the impeller wheel at a definite angle At this time there has a conversed effect torque to drive the stator wheel so as to make the output torque increased than the input torque when the rotation speed is increasing and near the input rotation speed the fluid s flow angle begins to decrease the torque of the input shaft decreases At last the fluid flows into blades of the stator wheel on the conversed direction make the original conversed torque have a conversed effect hence the output torque is less than the input torque for preventing this to happen the clutch in the stator can rotate freely when above things happens This kind of the converted torque mode can ensure high efficiency steady operation YJH265 torque converter is welded together can not break down The torque converter in the transmission device connects to the fly wheel of the engine through the elastic plate it goes with the rotation of the engine The inner torque converter is full of the oil driving gears connects to the impeller wheel by using the spline so as to drive the oil supply pump supply oil for the torque converter and hydrodynamic power gear box The turbine wheel connects to the turbi
97. pper of piston rod on inner mast Inner mast lay evenly in the direction of left right upper and lower If it is not even please adjust by putting washer between hole of cylinder support and upper end of piston rod 3 Installs U bolt onto cylinder hand tighten nuts and lock it with two tighten nuts Screws down tighten bolt and nuts to avoiding loosing 4 5 Lifting chain adjustment Installs fork arm carrier on inner mast and install lifting chain then install two 72 nuts on end of every side With mast set Straight up lower carriage completely Temporarily adjust clearance of carriage to 74mm 76mm above ground f necessary adjust with chain adjusting nut To adjust tension of lift chain lower lifting jack until fork is on the ground and adjust chain adjusting nut three every side so that dimension C will be as listed below when the middle portion of chain is pressed by a finger Dimension C 25mm 30 mm 4 6 Clearance of fork arm carrier assembly and rollers adjustment 1 Measure inside width A between Inner masts Make measurements at the top bottom and center cross beam sections 2 Measure right and left pitches B B B of carriage side roller carriage roller and thrust metal 3 Calculate A B A B and A B Each result shows clearances between each roller and inner mast Adjust shims of each roller evenly on the left and right and make clearances between smallest part of inner mast
98. r of circulating converter chamber 265 D mm Max efficiency n Transmission 19 2065 15 3652 17 4972 ratio 19 2065 15 3652 17 4972 Hydrodynamic 125mm x 81mm x 2 mm power overall dimension length X width X height 740 X 470 X 450 830 X 470 X 450 mmx mmx mm sir HANGCHA 3 Working principles 3 1 Hydrodynamic transmission gear box power transmit Gear box transmission sketch see fig 2 1 torque converter Is driven by engine through a elastic plate 1 it rotates the impeller wheel 4 in this way the fluid flows at high speed into the turbine wheel 2 and rotates the turbine wheel Stator wheel make the torque converter effective through turbine shaft 5 it transmit the torque to input shaft assembly 11 When at forward gear ratio reverse clutch at idle motion transmit order is that 11 7 20 19 12 13 drives the differential 15 to output the torque When at reverse gear ration onward clutch at idle motion transmit order is that 11 10 18 21 20 19 17 12 13 drives the differential 15 to output the torque Onward and reverse clutch are controlled by shift control valve Oil pump 6 is inner mesh gear pump it is driven by engine through impeller wheel oil pump supply the oil for the system after hydrodynamic torque converter works the oil flows into the radiator then into gear box lubrication clutch disc bearings and gears 14 1312 111098 7 6543 2 1 19 20 21 Fig 2 2 YQX18 25 30 model hydrodynami
99. riage bracket assembly from inner mast 4 Detach high pressure hose lift hose and low pressure hose 5 Support mast assembly with wire ropes i qu T i L r NR A iy i A i t i f i 6 Pull out tilt cylinder pivot pin 7 Remove mast support caps 69 sr HANGCHA 8 Remove mast assembly 9 To install mast assembly reverse order of removal 4 2 Disassembly AN WARNING Be careful when disassembling the masts as they are heavy Remove lifting jack 1 Place mast flat on ground Remove lifting jack attaching bolts bolts and tighten screw 2 Slide inner mast then remove lifting cylinders Remove roller 1 Slide inner mast out until rollers are exposed and remove little rollers with bearing puller Make two pieces of round board about 10mm thick and their diameter are 53 and 58 covered on the seat of roller Then remove the compound roller and main roller with bearing puller 2 Unclench rollers carefully if no bearing puller or rollers would be smashed 70 Remove inner mast Attach wire rope to middle of inner mast and slide it out with a lifting device INSPECTION 1 Check lift rollers roller shafts and associated parts for wear or damage 2 Replace required 4 3 Assembly and adjustment N WARNING Be careful when assembling the masts as they are heavy Lift roller Slide inner mast into outer mast and securely attach lift rollers
100. ring 7 Sealring 8 Protected ring 9 O ring 10 Guide sleeve 11 O ring 12 Glyd Ring 13 Scutcheon 14 Cylinder 15 Piston rod Fig 5 3 steering cylinder 4 Install steering system Careful observe the following 1 Hydraulic tie in blots and piping must be cleaned while installing 2 Check oil lines arrangement for properness whether it is reverse order of steering direction or not refer to steering system 3 Steer wheel to end left and right to make sure whether it is equably of steering force and smooth of steering 4 Jack up rear wheel and steer slowing wheel left and right and repeat it Bleed air of hydraulic lines and cylinder When engine stops running rotate steering wheel with 1kg force slightly after leaving hands steering wheel should be return 10 autobacking boardically 42 sr HANGCHA VI Brake system 1 Trouble and diagnoses and corrections condition Probable cause Corrective action Oil leakage in brake lines Correct and replenish Air in brake lines Bleed air Water or oil on linings Clean or replace Insufficient brake Uneven wear or contact of brake Grind or replace force linings Improper functioning of master cylinder Correct or replace or wheel cylinder Clogged oil lines Clean Uneven tire pressure Adjust Brake out of adjustment Adjust Water or oil on brake linings Clean or replace Foreign particles in brake drum Clean e Deteriorate
101. sir HANGCHA 1t 3 5t R Series Internal Combustion Counterbalanced Forklift Truck SERVICE MANUAL LE HANGCHA GROUP CO LTD Jun 2011 5 EDITION Foreword The manual is the introduction of structure working principle and serving of 1t 3 5t R series internal combustion counterbalance forklift truck For safety and performance of truck all in charge of operation maintenance and management must read and comprehend this manual well The manual also applies to container fork lift trucks It is forbidden anybody without training and qualification to maintain 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 LTD Content Foreword I Power System eee eee eee eee eee eee rere eee eee eee rere errr etree ere etree reer eee eee eee 1 1 Engine for Forklift s00000000nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnunnnnnnnnnnnnnnnnnnnnnne 1 2 NISSAN K21 K25 gasoline TTT 3 3 C240 PKJ 30 Diesel eee EER R EER R EER EEEEEEEEEEEEEEEEEEEEEEEE EE EE EE EER errr reer errr rer rr rr rrr rrr rrr 12 4 TD27AA diesel EER EER R EER E ER RR RR RR RR ER EER R EER R RR RR RR RR EER R RR EER RR RR RR RR RR RE 14 II Hydrodynamic transmission torque converter mH 17 1 Summary EER R EER R EER E EER
102. ssion and differentials 3 4 5 77 1 MW A S S UN N N 6 N N N NN IM oc gt gt NS bh Wi n n IN AR 7 UIN me S Z MY a Mr en SHS AD t 7 ie EE A SSN SS 7 7 Ce 18 17 G 4 Gm u 7 id 1 Gear ring 2 Bolt 3 Bearing holder 4 Ball bearing 5 Thrust washer 6 Taper roller bearing 7 Bearing cover 8 gasket 9 O ring 10 Output shaft 11 Pinion 12 Helical bevel gear 13 Column pin 14 Gear shaft 15 Gear shaft II 16 Semi axle gear 17 Gasket 18 Planetary gear Fig 2 8 Reduction gear Differential 4 6 1 Reduction gear as shown in Fig 2 8 Reduction gear is in the front of transmission which reduces the speed of output shaft of transmission and increase the torque from output shaft to differential reduction gear is mainly composed by a small helical bevel gear on the output shaft a big helical bevel gear and a small gear shaft the big helical bevel gear is fixed ina small gear shaft through spline two ends of small gear shaft are all holden by taper roller bearing and adjusted gap by shim 4 6 2 Differential as shown in Fig 2 8 Differential is installed on front hull by bearing holder through ball bearing on both ends which front end connect with axle carriage Differential carriage is divided into left and right half which is composed of two semi axle gears and four planetar
103. tar up motor until the fuel overflows from the eject pipe Tighten the nut of the eject pipe If the motor operates unstably run twice or third times in high speed Without air vent screw Method A Move the priming pump up and down until you can feel the sudden clear adding pressure Method B 1 Loosen injection pump bleeder screw or disconnect return hose and priming 2 Make sure that fuel overflows at bleeder screw tube end then tighten it connect hose lt HC gt HANGCHA 15 sr HANGCHA With air vent screw Method A 1 Loosen the air vent screw 2 Move the priming pump up and down until no further air bleed comes out of the air vent screw 3 Tighten the air vent screw 4 Move the priming pump up and down until there is suddenly more resistance in the movement Method B 1 Loosen the air vent screw 2 Move the priming pump up and down until no further air bleed comes out of the air vent screw 3 Tighten the air vent screw 4 Loosen injection pump bleeder screw or disconnect return hose and priming 5 Make sure that fuel overflows at bleeder screw tube end then tighten it connect hose Checking Priming Pump Before checking priming pump make sure that fuel filter is filled with fuel 1 Disconnect fuel return hose Place a Suitable container beneath hose end 2 Pump priming pump and check that the fuel Overflows from the hose end If not replace priming pump 16
104. the lift truck is sharply braked Brake principle of brake master cylinder of 1t 1 8t forklift is similar 1 Lock nut 2 Rod 3 Duct cover 4 Light spring 5 Gasket ring 6 Piston 7 Primary cup 8 Spring 9 Raffinate valve 10 Valve seat 11 Cylinder body Fig 6 1 Master cylinder 44 lt HC gt HANGCHA 2 2 Brake 1t 1 8t 3t 3 5t forklift right hand structure please see fig 6 2 2t 2 5t structure of forklift hand brake is similar to 3t 3 5t 15 16 1 Brake mount bracket 2 Wheel cylinder body 3 Cylinder return spring 4 Rubber cap 5 Piston 6 Cylinder dust cover 7 Push rod 8 Air bleeder cap 9 Air bleeder screw 10 Brake shoe assemble front 11 Brake shoe assemble rear 12 Guider 13 Adjuster cable 14 Adjusting bolt 15 Pawl 16 Spring 17 Brake shoe return spring 18 Return spring 19 Parking brake rod 20 Strut level 21 Spring 22 Bolt 23 Washer 24 Snap ring 25 Guider 26 Spring support rod 27 Spring bracket 28 Spring 29 Plug 30 Oil connector 31 Bush 32 Brake steel cable 33 pin Fig 6 2 1t 1 8t 3t 3 5t forklift truck right brake 45 Ac HANGCHA 2 3 Replace brake shoe Place the forklift truck on level concrete otart engine and raise carriage about 100mm Place chocks behind rear wheels to prevent movement of forklift truck Loosen wheel nuts two or three turns each Tilt mast fully backward and place a wooden block under each side of outer mast N WARNING Do not allow wooden blocks t
105. thstand shocks and vibrations 9 The wiring keeps a safety distance with the high temperature thing such as the vent pipe Control box Component removal 1 Turn key switch OFF 2 Press lock buckle on control box and open the cover 3 Remove fuse and relay from box INSPECTION If fuse is broken replace with new one Refer to figure as follow a lf fuse is blown be sure to eliminate cause of problem before installing new fuses b Never use fuse higher than specified rating c Check the fixed bracket of fuse If rust and dirt appears polish with crocus paper till fixed bracket and interface is becoming new Fuse fixed bracket contacted abnormally can increase pressure drop and heat even make the circuit work abnormally e CON Om P W PO 4 1 Fuse location Fuse identification Meter and indicator lamp e Filen Fuel cut off switch and preheat Standby For alarm lamp Fusible links A melting fusible links can be watched or touched easily if it is not uncertain of melting use multimeter or lamp to test Note D If fusible links is melted maybe because of short circuit current is too high No matter which reason please check and eliminate fault 2 Fusible links can cause heat do not enlace with adhesive tape do not put fusible near other rubber or wiring assembly Lighting System Bulb Specifications Headlight 12V 55W Small headlight Steering lamp Width lamp 12V 21W 12V 10W
106. ting 5 8 Fill in work oil run at neutral shift ford minutes then check oil height and the height should be within the specified range 5 9 New hydraulic gearbox should breaking in 50 hours after it is installed and the load is no more than 70 in breaking in process note oil temperature oil pressure and bolts loosen or not usually replace new oil after breaking in 6 Cause and solutions Causes and remedy 1 Friction discs seized or worn out Check friction discs for agglutination uneven contact or warp 2 Insufficient oil for torque converter Check oil pump for worn part and check the oil level 3 Bearing damaged Replace the bearing 4 Check lubricant line for blocking 5 One way clutch of torque converter seizure Replace the torque converter 1 Sealing washer wear Replace the worn sealing washer Oil leakage 2 Ageing or damage of rubber parts Replace the parts 3 Parts damaged and cracks Replace 1 Oil level too low Check oil level and refill oil to proper level 2 Sealing ring on clutch shaft and piston worn out or joint jammed Clutch pressure low when assembling Replace sealing ring and pay attention to and excessive joint when assembling vibration 3 Oil pump worn Replace oil pump 4 Oil strainer blocked Clean or replace 5 Check if the inching valve spool returns Efficiency deceased and oil temperature too high 30 sr Ill Driving axle 1 Date Full floating axle and truck bod
107. ting idle rpm and ignition timing START Start engines and warm it up sufficiently Run engine at idle speed for 2 minutes Race engine 2 000r min 3 000r min 2 or 3 times Under no load and then run engine at idle speed Check idle speed Under 650r min 700r min O K N G Adjust idle speed by turning Throttle adjusting crew Check ignition timing at idle speed B T D C degree K21 0 K25 0 Adjust ignition timing by turning distributor Race engine 2 000r min 3 000r min 2 or 3 times under no load and then rum engine at idle speed Adjust idle speed by turning throttle adjusting screw 700r min 50r min END CAUTION 1 Dont attempt to screw the idle adjusting screw down completely Doing so could cause damage to tip which in turn will tend to cause malfunctions 2 Make sure that the following parts are in good order Ignition system Engine oil and coolant levels Valve clearance Float level at idling speed Set shift lever in Neutral position 2 2 16 Adjusting Maximum Engine Speed Under No Load 1 Shift F R control lever into neutral 2 Run engine and set carburetor throttle valve at fully open position Check engine speed Maximum engine speed under no load 3600 r min 3 If engine speed is not within the specified range adjust it by turning governor adjusting handle Alignment mark sir HANGCHA Adjusting screw Adjusting handle
108. y direct Driving axle type install front wheel mr Tire Tirepressure 00000 7 0 2 x1 aga Pa Wheel hub rotation starting torque at hub blot 10 N 29 N Axial play of wheel bearing mm less 0 08 2 Trouble diagnoses and corrections condition Probable cause Corrective action loose driving axle and body connecting blots loose wheel nut Tighten Tighten Replace Adjust Replace Abnormal noises worn or damaged wheel hub bearing wheel hub bearing not properly adjusted worn axle shaft spliner mE Lubricate insufficient lubrication loose wheel nut Tighten Replace deformed wheel worn or damaged wheel hub bearing Replace Tighten Adjust Adjust Unstable driving loose driving axle and body connecting blots wheel hub bearing not properly adjusted Improper tire pressure worn or damaged axle shaft oil seal Replace Oil leakage final drive improperly installed Replace gasket loose drain plug Tighten 31 sr HANGCHA SC H ei 77 m m CO X Ed IND ei EE NO AH TILAR d H i XI y am 1 Wheel rim 2 Brake drum 3 Hub 4 Nut 5 Hub nut 6 Nut 7 Brake device 8 Washer 9 Bolt 10 Differential side shaft nut 11 Differential side shaft 12 Bolt 13 Oil seal 14 Tapered roller bearing 15 Agjusting nut 16 Lock nut 17 Pin 18 Paper mat 19
109. y gears Thrust ring is put between differential carriage and gears in order to have a clearance between pairs of gears Planetary gear is holden by gear shaft II Gear shaft I is secured to differential carriage by columnar pin and gear loop 1 is secured to differential carriage byream bolt The power from transmission transmits to wheel through semi axle gear and semi axle when it is reduced to come into differential driving by differential 4 6 3 Remove differential as shown in Fig 2 8 1 Take down bolts securing bearing seat of differential 2 Take down the section of differential from transmission 3 Loose and take down bolt 2 and column 13 detach differential left hull from right 26 sir HANGCHA hull 4 Take respectively down thrust washer 5 gear 14 planetary gear18 semi axle gear 16 washer 17 gear shaft 15 etc 4 6 4 Remove reduction gear as shown in Fig 2 8 1 Loose and take down the fixing bolts of two ends of bearing cover 7 Q Gently tap the front of pinion 11 near helical bevel gear 3 Take down bearing 6 pinion 11 helical bevel gear 12 Caution Be sure location of adjust shim 8 and adjust shim of both ends should be lay dividuall and not be mixed up 4 6 5 Assembly Assemble in the reverse order of removal but be sure a Prevent each fixing connecting face and gear tooth surface from knocking to be damaged Apply working faces of parts such as bearing gear seal ring and relatively mov

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