HANGCHA CPCD25-XW33C-RT4 Operational And Maintenance Manual Download

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5. Lubrication system drawing

1. General motor lithium complex grease 2. Engine lubricating grease

3. Gear oil 4. Hydraulic oil
5. Torque converter oil 6. Brake oil

Note

：

1. The details of lubricating oil for different trucks are listed in the

Table for the oil

used in the truck.

2. Lubrication for mast,

please refer to Weekly Maintenance (40hrs)

Environment protection

：

1. Please perform truck cleaning and maintenance at specified locations.

2. Before removing the pipe, connector and related parts, please use the specified container for the

used liquid (include antifreeze liquid, engine oil, hydraulic oil, hydrodynamic power transmission oil,

gear oil, brake liquid, lubrication grease) and used battery.

The used liquid referred above should only be disposed of according to local environment

protection laws and regulations.

Safety awareness

：

The antifreeze liquid, engine oil, hydraulic oil, hydrodynamic power transmission oil and gear oil

should be replaced when it is below 70°C to avoid personal injury.

Summary of Contents for CPCD25-XW33C-RT4

Page 1: ...nance Manual Original Instruction CPCD30 35 XW43E RT CPCD25 XW43E RT CPCD30 35 XW33E RT CPCD25 XW33E RT CPCD30 35 XW33C RT4 CPCD25 XW33C RT4 CPCD30 35 XW43C RT4 CPCD25 XW43C RT4 CPCD30 35 XW98C RT4 CPCD30 35 XW98E RT2 CPCD25 XW98C RT4 CPCD25 XW98E RT2 HANGCHA GROUP CO LTD 12 2019 ...

Page 2: ...opted by this manual may vary from your truck structure This manual is also available for container forklift and forklift equipped with attachment Please contact Hangcha Group or your sales agent if you have any questions regarding this manual Standard model Load center mm in 500 19 7 Model CPCD15 CPCD18 CPCD20 CPCD25 CPCD30 Rated capacity kg lb 1500 3300 1750 3850 2000 4400 2500 5500 3000 6600 Mo...

Page 3: ...0 CPCD30 35 XW43C RT4 RTE350 120000 G00 CPCD25 XW43C RT4 RTE250 120000 G00 CPCD30 35 XW33E RT 4TNE98 BQFLC Diesel engine RTE350 120000 G00 CPCD25 XW33E RT RTE250 120000 G00 CPCD30 35 XW33C RT4 RTE350 120000 G00 CPCD25 XW33C RT4 RTE250 120000 G00 CPCD30 35 XW98C RT4 Kubota V2607 CR TE5 B Diesel engine RTC350 120000 G00 CPCD30 35 XW98E RT2 RTE350 120000 G00 CPCD25 XW98C RT4 RTC350 120000 G00 CPCD25 ...

Page 4: ...bility of truck 50 VI Operation 52 VII Parking 55 VIII Maintenance 57 1 Preventive maintenance schedule 57 2 Torque Specifications 66 3 Periodic replacement of key safe parts 67 4 Table for the oil used in the truck 68 5 Lubrication system drawing 70 IX Labels Stick various nameplate and mark at different position of the truck 71 X Truck transporting lifting towing 76 XI Main technical performance...

Page 5: ... for leakage of electrolyte hydraulic oil or brake oil when lifting goods or grade climbing leave truck in safe state and contact service technician immediately 19 During installation and assembly there will be noise and vibration Please choose the right tool and assembly method Minimize the noise and vibration as soon as possible to reduce noise pollution 20 Rough Terrain forklift Truck mainly us...

Page 6: ...esigned tested and implemented by an engineer s expert in industrial trucks and their safety 2 Maintain a permanent record of the design test s and implementation of the modification or alteration 3 Approve and make appropriate changes to the capacity plate s decals tags and instruction handbook 4 Affix a permanent and readily visible label to the truck stating the manner in which the truck has be...

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

Page 8: ...ator warning indicator E Neutral position start up indicator F OPS indicator G Transmission oil temperature warning light H Parking indicator I Preheat indicator light J Oil water seperator Indicator light K Engine oil pressure warning light L Charging indicator light M Left turning indicator N Right turning indicator ...

Page 9: ...normal status LED Displayed in the range of 40 110 Caution If LCD display in the red zone please stop the truck at once Decrease the engine speed to make the engine cool Check the cooling fluid if enough and the fan belt s elasticity if fit Fuel gauge B The gauge indicates the fuel level in the tank when the key is at ON position Suggest filling up the fuel tank after work every day ...

Page 10: ...normal rang 60 120 C the indicator light on Caution If the pointer enters the red range stop the operation instantly and slow down engine speed to cool the coolant and wait until the pointer goes into the green range and have a check then Parking indicator H Parking indicator shows on means brake is affected Please loosen the parking handle hand brake handle the parking indicator will shows off Wa...

Page 11: ...s the battery condition of charge The lamp comes on when the ignition switch is set at ON but it goes out as the engine starts and accelerator pedal is pressed Caution If the light continues to stay lit or lights up during operation the charging rate is low and should be checked immediately Left turning indicator M Right turning indicator N When the truck turns left the indicator is set forward th...

Page 12: ...ation and maintenance periods Caution When reaching the first 100h the spanner logo will flash one hour at regular intervals to reminder of the maintenance to the forklift Refer to monthly maintenance after first flash Refer to periodical maintenance schedule for per period Take the actual flashing time as standard Charging indicator This lamp indicates the battery condition of charge The lamp com...

Page 13: ...y stop according to an engine fault table troubleshooting Can be judged according to the fault indicator lamp flash code Can be based on the fault indicator flash code judgment or ECU diagnostics port connected to diagnostic equipment read the fault code information stored in the ECU For more information see engine manual Only Cummins engine forklift truck When this light is on it means one import...

Page 14: ...severely If condition stays and starts engine protection shut down then this indicator will flash 30 seconds before engine shut down to warn the impending shut down Air filter indicator When the light is on it indicates the air inlet system is blocked stop the truck and clean the air filter Seat belt warning indicator Optional When this light is on it means not wearing a seatbelt or not locked Acc...

Page 15: ...ation and maintenance periods Caution When the time meter increases every 100h the factory default time interval is 100h which is adjustable the spanner logo will flash one hour at regular intervals to reminder of the maintenance to the forklift Refer to monthly maintenance after first flash Refer to periodical maintenance schedule for per period Take the actual flashing time as standard Charging ...

Page 16: ... be damaged Neutral position start up indicator Put the steering handle in the neutral position when truck on the temporarily stop the light will indicated on The truck can be started up only in the neutral position It s prohibited for truck in the neutral position sliping when it s on the slope Transmission oil temperature warning light Hydraulic Forklift In normal state once the starter is set t...

Page 17: ...egeneration reminder will automatically go out which also means that the particulate matter processing is completed What the driver has to do is to reduce the light load running time as much as possible in order to increase the exhaust temperature and shorten the regeneration time In the second case prompt to stop and start parking regeneration Parking regeneration meets the following conditions T...

Page 18: ...I 15 The third case is service regeneration DPF has been seriously blocked the engine has reduced power and torque limit the forklift cannot work normally contact the after sales service to complete the service regeneration Engine fault indicator Electronic controlled engine When the engine gets out of order this Indicator will be on then it must immediately stop Press the key on the right side of...

Page 19: ...play page Main page key 2 or key 3 Language switch press key 3 to switch language Chinese English Return to main page press key 1 to return to main page 蓄电池电压发动机转速机油压力转速负载 Ash 负载 SOOT 负载进气温度行驶速度 VDC r min km h Bar Battary Voltage Ash Load Engine Speed SOOT Load Oil Pressure Intake Air Temperature Load RPM Vehicle Speed VDC r min km h Bar KUBOTA diesel engine B 3 Settings page 1 Set page actio...

Page 20: ...g regeneration Return to the setting page press key 1 to return to the setting page 3 Maintenance reminder maintenance page a Remaining hours query page 重置返回 Reset Back Reset press the key 2 to jump to the maintenance time reset page to reset the remaining hours of maintenance to the Set the initial value maintenance interval Back press key 1 to return to the setting page b Maintenance time reset...

Page 21: ... 3 Combination switch 4 Key switch 5 Lift control lever 6 Tilt control lever 7 Cup holder 8 Instrument 9 Rocker switch 10 Accelerator pedal 11 Brake pedal 12 Inching pedal 13 Wiper spray lid 14 Emergency disconnect switch 15 Parking brake lever 16 Steering wheel adjustment switch 17 Reversing lever ...

Page 22: ...l passenger cars It must be returned to the neutral position manually Turn on the headlamp and small lamp turn this switch and aim the position line on the switch knob to the relevant marking on the switch subject Key switch 4 O OFF This is the position at which the key may be inserted or removed ON The electric circuit is closed with the starter switch at ON After the engine starts the key remain...

Page 23: ...acket Push forward move to the left Pull backward move to the right Side shifting speed depends on the tilting angel of the handle and accelerator control Different attachment type has different working way so the operator must be familiar with the operation Cup holder 7 It is in the right side of the instrument It s designed for the operator to put the cup Rocker switch 9 Two wheel drive rough te...

Page 24: ... installed on the central differential for four wheel drive vehicle Its function is to improve the passing capacity of forklift in bad road conditions or extreme conditions that is when a wheel of the forklift idles the differential lock can quickly lock the differential so that the left and right wheels become rigid connection In this way most or even all of the torque can be transmitted to the n...

Page 25: ...on In case of brake system doesn t work or there is an emergency you can tighten this lever to stop the truck in urgency Normally it is prohibited to use parking brake as service brake Steering column tilting angle adjustment 16 The tilting angle of the steering wheel is adjustable to suit individual operators The steering column is unlocked by pushing down the lever at the left side of turning ro...

Page 26: ... in neutral can you start the engine Four wheel drive rough terrain forklift truck 1 1 gear 2 2 gear 3 3 gear Before changing the driving direction step down the brake pedal until the truck is completely stopped turn the lever and shift to the first gear shift backward to the second gear and then shift to the third gear To back up step on the brake pedal to decelerate turn the lever back and shift...

Page 27: ... turning the knob to inside it will be lowered Warning Turn off the key before adjusting the seat It s prohibited to adjust the position of the seat only when the truck stops In case of accident no seat adjustment is allowed in the process of travelling Make sure the lever is moved completely to separate the seat structure before the forward and rearward adjustment of th e seat and angle adjustmen...

Page 28: ...to protect the operator from falling objects and meets the safety standard Lock components To avoid opening the hood at discretion a snap close is set here Open the snap close first then the hood can be open Optional To avoid opening the hood at discretion the truck is equipped with lock Use the key to open the hood Hood The hood can be swung up fully to provide easy maintenance service You can li...

Page 29: ...cap slowly to allow steam to escape After that tighten cap securely It is good practice to use a thick waste cloth or the like when removing the cap Do not wear gloves when removing radiator cap Antifreeze is harmful to a person if swallowed seek medical advice immediately Keep antifreeze away from children Fork stopper Use it to adjust fork spacing Pull up fork stopper turn 180 adjust fork spacin...

Page 30: ... close the reservoir cap A loose cap could cause a fuel leak or lead to a fire hazard 3 Before starting the engine make sure no fuel has spilled on or around the truck 4 NEVER use light flame to check the fuel level Rearview mirror There are rearview mirrors on the upper right of overhead guard for operator to see behind the truck Head lamp Disassembly and assembly of the head lamp 1 Dismantle the...

Page 31: ...rhead guard pay attention to the safety 1 Take the whole rear combination lamp to the service place take off the lamp housing and screw off the four bolts at the back of the lamp housing 2 Take off LED plate loosen two bolts fixed the connector cut the connector and change a new LED plate 3 The installation procedure is contrary to the disassembly ...

Page 32: ...king on the truck Never fill the fuel tank while the engine is running 5 Warm water temperature to 70 C before operation If the temperature of the water is above 70 C DO NOT open the tank cap 6 When using the truck in an enclosed space make sure there is enough ventilation If needed use a ventilation fan DO NOT work in a closed working space because exhaust gases are harmful Caution Not allowed to...

Page 33: ...The work surface should be solid and level such as a cement road asphalt or concrete road surface For truck operation the following climatic conditions apply average ambient temperature for continuous duty 25 C maximum ambient temperature short term up to 1 h 40 C lowest ambient temperature for trucks intended for use in normal indoor conditions 5 C lowest ambient temperature for trucks intended f...

Page 34: ...shift mechanism if equipped when the forks are raised and loaded since this will cause the truck to become unbalanced A truck with attachments should be considered the same as a loaded truck 26 Travel with load as low as possible and tilted back the mast 27 Avoid braking too sharply or descending on a grade at a high speed There is danger of loads falling down or the truck turning over 28 Always b...

Page 35: ...ad guard which may cause loss of life DO NOT place hands into the interspace of inner mast and outer mast WARNING 34 When driver s ear noise is bigger than 80dB please adopt hearing protective measures Caution Rough or uneven road surface and tyre deformation may largen noise value 35 When load is to be retrieved from a pile enter the area squarely Engage forks into the pallet carefully 36 When tr...

Page 36: ... safety shoes etc Avoid wearing neckties or other articles of clothing which may present a hazard if they come into contact with truck components 44 The workplace should be equipped with a fire extinguisher In order to provide easy access to it the fire extinguisher is usually installed on the safety frame rear supporting leg The operator should be familiar with position of the fire extinguisher a...

Page 37: ...ks can ignite these materials as well Engine and exhaust surface temperatures increase after engine shutoff presenting increased fire hazard Check the engine compartment immediately following truck operation in areas containing combustible dusts fibers or paper and remove any foreign materials 48 In view of the irregular use of mobile phones by drivers which endangers the safety of life and proper...

Page 38: ...l when the engine is cool Remove the dipstick clean the rod and reinstall Pull it out again and check the oil level The level should be within the marks on the dipstick 5 Check engine coolant Inspect the small reservoir tank to see if the coolant level is between Min and Max position when the engine is cool If is lower than MIN add to MAX If there is no coolant in the reservoir tank check radiator...

Page 39: ...Brake fluid level check Check the fluid level in the brake fluid reservoir The level should be between the two seams of the reservoir When adding fluid due care should be taken to prevent air from entering the brake tube Caution When adding fluid due care should be taken to prevent dirt or water from entering the reservoir Brake fluid is dangerous to health you should avoid skin contact Brake oil ...

Page 40: ...ngine coolant temperature sensor oil pressure sensor etc function properly 17 Brake pedal and inching pedal check Drive truck slowly step down brake pedal and brake lamp lights Drive truck slowly step down inching pedal and check the inching pedal condition 18 Tire inspection and Tire pressure Check the tires for damage and whether the rims are deformation Turn tire valve cap counter clock wise an...

Page 41: ...antle filter end cap Take out the filter element Main filter outer filter Blow off the dust inner and outer of the outer filter element with dry compressed air Safety filter element inner filter hand beat clean avoid blowing with air Special attention Caution Pressure of compressed air must be under 205 kPa 2 1 kgf cm 30 psi Warning 1 Dust will blow into your eyes so please wear protective glasses...

Page 42: ...Lift chain tension check Raise the fork about 10 15 cm above the ground and make it vertical Press middle of the chain by thumb Make certain the tension for the right and left chains are even Adjust the tension Loosen the lock nut 1 screw the nut 2 and adjust the chain to make the equal tension and then screw down the lock nut 1 6 Lubrication of mast Lubricate the following parts periodically acco...

Page 43: ...ring cylinder pin lubricate 9 Bolt nut tighten Refer to the Maintain periodic chart 10 Hub nut torque check Check if tightening torque of hub nut meets standard Front wheel Hub nut Split type rim bolt Half axle bolt Tightening torque N m 2 0t 3 5t Hub nut 324 373 Rear wheel Rear hub nut Tightening torque N m 2 0t 3 5t Hub nut 157 176 Split type rear rim bolt some truck model without 11 Brake pedal...

Page 44: ...ng pedal 145 5 touching bolt of inching pedal brake pedal Chinese trans 6 12 Hand brake Make sure that the hand brake lever after pulled up still has good function when return 1 0t X5 0t the required tension when pulled up 245N 295N ...

Page 45: ...d check oil level fill if needed To check the oil fluid level place truck on level ground Warning When using different brands of oil always drain all previous oil before adding new engine oil On engines with DPF some of the fuel may mix with the oil during regeneration This may dilute the oil and increase the amount of oil If the oil is higher than the upper limit of the oil level gauge this means...

Page 46: ...Step the brake pedal get the engine idle running place the transmission in forward and backward so that the oil enters the clutch Place transmission in neutral apply parking brake Take out the dipstick inspect fluid position If oil is not enough add oil to keep it between max and mix marks Check the filter and oil plug for leaks Shut off engine install front soleplate 6 Air bleeding fuel system Di...

Page 47: ...e drain valve Over tightening will damage thread When shutting the valve uplift the valve and rotate in clockwise until screw down 8 Exhaust gas check Colorless Normal complete combustion Black Abnormal incomplete combustion Blue Abnormal oil burns White Abnormal water in combustion chamber Warning Don t start the lift truck in bad ventilation space There is carbon monoxide in the exhaust gas it i...

Page 48: ...device 3 Hydraulic oil change Park the truck on level ground lay down the forks on the floor incline the mast back and apply parking brake Put transmission in neutral position shut off the engine Warning Hot hydraulic oil and parts will hurt body Do not touch the hot hydraulic oil and parts Put one case volume is over 60 liters under the hydraulic oil box Dismantle the drain plug of oil tank let t...

Page 49: ...filters per one month and replace every six months Remove out the fuel filter Remove transducer Before installing new one install transducer existing put a little fuel on the filter airproof Caution Before installation do not add fuel to filter as this may accelerate the wear of fuel system parts Install new filter Turn the new filter till the airproof mat adheres to surface Screw down 2 3 loops ...

Page 50: ...ed to prevent rust and frost bite See Table for the oil used in the truck 2 Front wheel bearing change lubricating grease Refer to steering axle content in Maintenance Manual remove hub bearing and then replace lubrication grease 3 Rear wheel bearing change lubricating grease Refer to steering axle in Service Manual 4 Change steering axle gear oil Park the truck on level ground Put transmission in...

Page 51: ...st fully backward and place a wooden block under each side of outer mast Tilt mast forward until front wheels are raised from surface Caution Do not loose nuts before the front wheels leave the ground Support truck by putting wooden blocks under both sides of the front truck frame Stop the engine Take out the wheel nuts and replace the front wheel Caution a When removing tire from wheel rim do not...

Page 52: ...additional wooden blocks under both sides of the front truck frame as shown below Take out the wheel nut of rear wheel and then replace the wheel Warning a When removing tire from wheel rim do not remove rim set bots and nuts before releasing air b Make sure that wooden blocks used to support lift truck are solid one piece units c Never get under forklift while it is supported only by wooden block...

Page 53: ...r place the muzzle to radiator a right angle 5 The operation of too hot engine If the engine is too hot DO NOT stop it at once do as follows Reduce speed Open the engine cover Stop engine when water temperature drops Check coolant add water if need 6 Cleaning of DPF W98 The longer the DPF runs the more ash burnt residue is collected in the filter Too much ash build up adversely affects the DPF per...

Page 54: ...truck because the speed of overturn is much fast than you You should hold the steering wheel handle and this practice will let you in the seats Please tie safety belt Caution Gravity and stability Forklift stability depends on the common center of gravity of the forklift When the forklift is unloaded the center of gravity CoG remains unchanged When the forklift is loaded the center of gravity is f...

Page 55: ...ad capability chart This chart shows the relationship of MAX LOAD and the location of LOAD CENTER DISTANCE Check whether the load and load center distance is in the range referred by the chart Put the most important parts near the load backrest if the shape of goods is asymmetrical Caution speed and acceleration A static object keeps its static station which is not affected by outside force one dy...

Page 56: ...way and cold crank the engine by turning the ignition key to START Release key when engine starts Caution When the heat engine starts do not step the accelerator pedal to the end cause it may cause start trouble even step the pedal for several times Caution The time to start should be less than 5 seconds each attempt and the interval between attempts should be at least 2 minutes After engine has s...

Page 57: ...e For diesel trucks pull out the engine stop button Remove the key and take it with you Caution Be careful to get off Never jump off the truck Do not park the truck on travelling route 3 Pick up The forks should be adjusted sidewise to maintain proper balance of load Place the truck in front of the load to be handled The pallet should be evenly positioned across both forks Insert forks into the pa...

Page 58: ... the mast forward until forks become horizontal Elevate forks up to the position of the pallet or skid Make sure forks are positioned properly for the pallet Move forward slowly to insert forks into the pallet as far as possible and then stop the truck Caution If the forks cannot be fully inserted use the following procedure move forward and insert the forks 3 4 of the way Raise the forks 5 to 10 ...

Page 59: ...fill it with oil In cold weather it is not necessary to drain the antifreeze but the water should be completely drained from the radiator 2 Park the truck for a long time When parking the truck for a long period place blocks under the truck body and counterweight to reduce the load on two rear wheels Warning a The block must be single and hard enough to support the truck b Don t use blocks higher ...

Page 60: ... add with new gear oil Clean the hydraulic oil reservoir and fuel reservoir removing any dirt or water and add with new hydraulic oil fuel Check the clearance of the valve gas valve cap and other parts on the engine Add antifreeze to required level Charge the battery install on the truck and connect battery lead Check basic truck functions like starting running turning lifting etc Warm up your tru...

Page 61: ...cur check the truck immediately The problems may be corrected by adjusting the diesel nozzle pressure and fuel atomization Dispose of waste oil or electrolyte liquid according to local environmental protection laws and regulations Follow the maintenance schedule After performing maintenance keep a record Only use Hangcha parts 1 Preventive maintenance schedule Check revise adjust Replace Caution 1...

Page 62: ...rst time Tighten cylinder head bolt Torque wrench First time Check cylinder compression pressure Pressure gauge Distributor inner IC ignition system 1 Engine common rail engine added If rail pressure senor and its line operation is normal If accelerator pedal is normal Check for the rail pressure relief valve leakage and its function If ECU function and its wiring is normal Check camshaft sensor a...

Page 63: ...ily 8 hrs One and a half Monthly 250hrs 3months 500hrs Semi annual 1000hrs Annual 2000hrs Lubricat ing system Check for the oil leakage of engine Check oil capacity and cleanness Replace engine oil 1 First time Replace engine oil filter 1 First time Fuel system Visual check if oil leakage at pipeline pump or oil tank Replace fuel filter First time Check nozzle and adjust the pressure diesel engine...

Page 64: ...ed Tools Daily 8 hrs One and a half Monthly 250hrs 3months 500hrs Semi annual 1000hrs Annual 2000hrs Hydraulic transmission gear box Replace oil absorption filter First time 200h Leakage condition Check oil quantity and change oil First time 200h Inching pedal idle stroke and run condition Control valve and hydraulic clutch performance Inching valve performance Shift lever operation and loosen con...

Page 65: ...ge pressure Barometer Abrasion crack or damage If there is nail stone or other foreign body on the tyre Rim damage condition Split type rim bolt looseness Test hammer Steering system periodical maintenance schedule Check item Service required Tools Daily 8 hrs One and a half Monthly 250hrs 3months 500hrs Semi annual 1000hrs Annual 2000hrs Steering wheel Check clearance Check axial looseness Check ...

Page 66: ...rs 3months 500hrs Semi annual 1000hrs Annual 2000hrs Brake pedal Idle stroke Dividing scale Pedal travel Operation condition Check if there is air in the brake pipeline Parking brake control If brake is safe and reliable and owns enough travel Control performance Stick and dragline Control performance If connection loosen Pipeline Damage leakage fracture Connection clamp part looseness condition B...

Page 67: ...Brake baseboard Check if baseboard deforms Check if crack Flaw detection Check if loosen during installation Test hammer Hydraulic system periodical maintenance schedule Check item Service required Tools Daily 8 hrs One and a half Monthly 250hrs 3months 500hrs Semi annual 1000hrs Annual 2000hrs Hydraulic oil tank Check Hydraulic oil and replace Clear oil absorption filter element Replace oil retur...

Page 68: ...ortion Areometer Wire Wire harness damage and fix loosen condition Circuit joint looseness condition Steering indicator light Work and installation condition Horn Work and installation condition Light and bulb Work and installation condition Reversing buzzer Work and installation condition Instrument Instrument working condition Lifting system periodical maintenance schedule Check item Service req...

Page 69: ...n and wear condition Positioning pin wear and damage condition Fork root hook welded part crack or wear condition Mast fork carriage If the welded part between Inner and outer mast and beam has crack or damage If the welded part between mast and tilting cylinder has bad welding crack or damage If inner or outer masts have bad welding crack or damage If fork carriage bad welding crack or damage If ...

Page 70: ...st hammer Check deformation crack and damage Rearview mirror Dirt and damage condition Rear view condition Seat Check if bolt damage or loosen Truck body If chassis and beam damage or crack If rivet or bolt loosen Add lubricate grease or change oil Check chassis lubrication condition after clean Check oil in the oil tank Operator presence system Working condition 2 Torque Specifications Unit N m B...

Page 71: ...Note Use entirely 8 8 grade bolt in the important joint position Bolt s grade can be found in the head if it can t be found the grade is 8 8 3 Periodic replacement of key safe parts Some parts are not checked during routine maintenance Please refer to the table below for the average service life of these parts Replace them when their service life has expired sooner if they damaged Name of key safe...

Page 72: ...ur wheel drive Mobil 424 hydraulic transmission oil 6 5 Gear oil Steering axle General season GL 5 85W 90 heavy load gear oil winter GL 5 75W heavy load gear oil main decelerator 3 5L Left right wheel reducer 0 75L 2 0t 2 5t Four wheel drive The minimum temperature for 75W gear oil is 40 Brake Liquid Add to brake oiler Two wheel drive Choice HZY3 brake liquid add when leaving factory or DOT3 Four ...

Page 73: ...69 Description Shop sign Code name Capacity L Remark point POLYREX point with high temperature resistance Recommendatory diesel engine oil viscosity under different temperature Multigrade oil ...

Page 74: ...and maintenance at specified locations 2 Before removing the pipe connector and related parts please use the specified container for the used liquid include antifreeze liquid engine oil hydraulic oil hydrodynamic power transmission oil gear oil brake liquid lubrication grease and used battery 3 The used liquid referred above should only be disposed of according to local environment protection laws...

Page 75: ...CATION SYSTEM CHART 1 Danger label 2 CE label 3 Hang label 4 Hang label 5 Safety belt label 6 Load curve label 7 Hydraulic oil label 8 Hand injury risk label 9 Antifreeze label 10 Character label 11 Tie down label 12 Diesel label 13 Character label 14 Tonnage label 15 Warning label 16 Hood open label 17 Hand brake label 18 Operate label 19 Tire pressure label 20 Nameplate label 21 Lubrication syst...

Page 76: ...et Do Not Jump Brace Feet Hold on Tight Lean Away From Impact Truck can TIP OVER Risk of serious INHURY or DEATH 6 Load curve label It shows the connection among load center position and max load max lifting height Load capacity decreases if truck equips with sideshifter and attachment or lifting height increases Before loading please check whether the load and load centre in the range of load cap...

Page 77: ...ate faulty or damaged lift trucks To protect from falling objects make sure that the Overhead Guard and Load Backrest Extension are correctly mounted and in good condition Before starting engine always set forward reverse lever in neutral with hand brake on Drive carefully keeping forks and attachments as low as possible fully tilted backp Never Forward Keep a careful lookout for people obstructio...

Page 78: ...k or repaired the inspection and repair should be carried out after shutting down the engine There should not be person on the truck or others to operate the truck to avoid accidents by handling mast lever wrongly Serial number printing position Each truck has one unique chassis serial number and the printing position is at the front right of the chassis The print position of truck body serise num...

Page 79: ...75 risk when drive tires is slipping please use the differential locker of drive alxe Other condition please switch it as required See page 14 for details ...

Page 80: ...r long distance transportation The Fork Lift Truck must be transported by ship train or lorry of over 5T loading Tighten the brake lever place wood blocks to the front and rear wheels and bind the truck body with enough rope to avoid slippage during transportation Towing The towing rod on the bottom of the counter balance is used to pull and drag the truck for installing the rod first remove the t...

Page 81: ...travel speed without load km h 26 26 Ground clearance mm 270 270 Min outside turning radius mm 2900 2900 Max Grade ability Full load 21 20 Wheel base mm 1880 1880 Service mass kg 5120 5380 Overall dimension L W H include forks 4220 1599 2420 4220 1599 2420 Tyre F R 14 5 17 14PR 2 27 10 12 12PR 2 14 5 17 14PR 2 27 10 12 12PR 2 Battery V capacity Ah 12 90 12 90 Diesel engine Model Cummins QSF2 8T3NA...

Page 82: ...vel speed without load km h 26 Ground clearance mm 240 Min outside turning radius mm 2900 Max Grade ability Full load 26 Wheel base mm 1880 Service mass kg 4670 Overall dimension L W H include forks 4205 1597 2390 Tyre F R 14 5 17 14PR 2 27 10 12 12PR 2 Battery V capacity Ah 12 90 Diesel engine Model Cummins QSF2 8T3NA49 Rated capacity rpm 36 5kW 2500r min Max torque rpm 186N m 1500 r min Displace...

Page 83: ...m 245 245 Min outside turning radius mm 3300 3300 Max Grade ability Full load 50 52 Wheel base mm 1880 1880 Service mass kg 5600 5340 Overall dimension L W H include forks 4320 1599 2420 4320 1599 2420 Tyre F R 14 5 17 5 14PR 2 10 0 75 15 3 14PR 2 14 5 17 5 14PR 2 10 0 75 15 3 14PR 2 Battery V capacity Ah 12 90 12 90 Diesel engine Model Cummins QSF2 8T3NA49 Cummins QSF2 8T3NA49 Rated capacity rpm ...

Page 84: ...l speed without load km h 25 Ground clearance mm 235 Min outside turning radius mm 3300 Max Grade ability Full load 57 Wheel base mm 1880 Service mass kg 4850 Overall dimension L W H include forks 4305 1557 2390 Tyre F R 12 16 5 14PR 2 10 0 75 15 3 14PR 2 Battery V capacity Ah 12 90 Diesel engine Model Cummins QSF2 8T3NA49 Rated capacity rpm 36 5kW 2500r min Max torque rpm 186N m 1500 r min Displa...

Page 85: ...28 Ground clearance mm 270 270 Min outside turning radius mm 2900 2900 Max Grade ability Full load 22 22 Wheel base mm 1880 1880 Track F R mm 1250 1205 1250 1205 Service mass kg 5120 5380 Overall dimension L W H include forks 4220 1599 2420 4220 1599 2420 Tyre F R 14 5 17 14PR 2 27 10 12 12PR 2 14 5 17 14PR 2 27 10 12 12PR 2 Battery V capacity Ah 12 90 12 90 Diesel engine Model YANMAR 4TNE98 Rated...

Page 86: ...ravel speed without load km h 26 Ground clearance mm 240 Min outside turning radius mm 2900 Max Grade ability Full load 28 Wheel base mm 1880 Service mass kg 4670 Overall dimension L W H include forks 4205 1597 2390 Tyre F R 12 16 5 14PR 2 27 10 12 12PR 2 Battery V capacity Ah 12 90 Diesel engine Model YANMAR 4TNE98 Rated capacity rpm 42 1kW 2300 r min Max torque rpm 186N m 1700 r min Displacement...

Page 87: ...ad km h 26 26 Ground clearance mm 245 245 Min outside turning radius mm 3300 3300 Max Grade ability Full load 50 56 Wheel base mm 1880 1880 Service mass kg 5600 5340 Overall dimension L W H include forks 4320 1599 2420 4320 1599 2420 Tyre F R 14 5 17 5 14PR 2 10 0 75 15 3 12PR 2 14 5 17 5 14PR 2 10 0 75 15 3 12PR 2 Battery V capacity Ah 12 90 12 90 Diesel engine Model YANMAR 4TNE98 Rated capacity ...

Page 88: ...vel speed without load km h 26 Ground clearance mm 235 Min outside turning radius mm 3300 Max Grade ability Full load 60 Wheel base mm 1880 Service mass kg 4850 Overall dimension L W H include forks 4305 1557 2390 Tyre F R 12 16 5 14PR 2 10 75 10 15 3 14PR 2 Battery V capacity Ah 12 90 Diesel engine Model YANMAR 4TNE98 Rated capacity rpm 42 1kW 2300 r min Max torque rpm 186N m 1700 r min Displacem...

Page 89: ...load mm s 450 450 Tilt of the mast F B 10 12 10 12 Max travel speed without load km h 25 25 Ground clearance mm 270 270 Min outside turning radius mm 3300 3300 Max Grade ability Full load 50 54 Wheel base mm 1880 1880 Service mass kg 5340 3m mast 5780 6m mast 5600 3m mast 6040 6m mast Overall dimension L W H include forks 4320 1599 2420 4320 1599 2420 Tyre F R 14 17 5 14PR 10 0 75 15 3 14PR 14 17 ...

Page 90: ...440 6m mast 515 3m mast 440 6m mast Tilt of the mast F B 10 12 10 12 Max travel speed without load km h 26 28 Ground clearance mm 270 270 Min outside turning radius mm 2900 2900 Max Grade ability Full load 26 29 Wheel base mm 1880 1880 Service mass kg 5120 3m mast 5560 6m mast 5300 3m mast 5820 6m mast Overall dimension L W H include forks 4220 1599 2420 4220 1599 2420 Tyre F R 14 17 5 14PR 2 27 1...

Page 91: ...mm s 620 Tilt of the mast F B 10 12 Max travel speed without load km h 25 Ground clearance mm 240 Min outside turning radius mm 3300 Max Grade ability Full load 60 Wheel base mm 1880 Service mass kg 4850 3m mast 5300 6m mast Overall dimension L W H include forks 4305 1557 2390 Tyre F R 12 16 5 14PR 2 10 0 75 15 3 14PR 2 Battery V capacity Ah 12 90 Diesel engine Model Kubota V2607 CR TE5B Rated cap...

Page 92: ... 3m mast 610 6m mast Tilt of the mast F B 10 12 Max travel speed without load km h 26 Ground clearance mm 240 Min outside turning radius mm 2900 Max Grade ability Full load 29 Wheel base mm 1880 Service mass kg 4670 3m mast 5120 6m mast Overall dimension L W H include forks 4205 1557 2390 Tyre F R 12 16 5 14PR 2 27 10 12 12PR 2 Battery V capacity Ah 12 90 Diesel engine Model Kubota V2607 CR TE5B R...

Page 93: ...ery If the truck parks over 30 days in order to keep the battery in normal charging technique condition you should do the following 2 3 Battery check and maintenance Maintenance free battery check When the battery volume status is normal and electrolyte density reaches the standard the small ball is in green when the battery volume is insufficient and electrolyte density drops the color is white i...

Page 94: ...es not reach the standard it will be red when the electrolyte is acute shortage the shell should be carefully examined whether there is rupture leakage or battery failure The indicator of battery refers to the prompt on the battery label Low maintenance battery maintenance 1 Ensure that the battery electrolyte fluid level in the UPPER LEVEL 2 Disconnect negative earth wire to avoid discharging by ...

Page 95: ...n open fire or spark When battery connects electric equipment make sure the electric equipment is correctly connected with the battery positive and negative to avoid damage of electric equipment or battery Never cover electric things on the battery to avoid battery short cut To avoid electrolyte contact eyes skin or clothes Never let the children close the battery Emergency measure to electrolyte ...

Page 96: ...exceed the combined limit of the carrying capacity of forklift and attachment It is not allowed to have a partial load at high position It is a short time work for attachment with side shifter Partial load is around 100mm Above 5 ton including 5 ton the side shifter is movable within 300mm 6 In the range of the projection forth 2m of the lower of attachment and cargo prohibit stand to avoid the su...

Page 97: ... 3 Check assembly of attachment to ensure no movement on carriage 4 After hang attachment embed the rise catch block to the gap of top beam Ensure the center line of the attachment offset from the center line of the truck is less than 50mm Otherwise it will affect the lateral stability of the forklift 5 To attachments with rotating functions such as paper roll clamp bale clamp multi purpose clamp ...

Page 98: ...ar of forward or reverse the vehicle is able to start If the gear switch is shifted to second gear of forward or reverse the neutral indicator light flashes and the vehicle cannot start The forward or reverse power can recover if the gear switch hangs in neutral switch If the driver leaves the seat or unfastens the seatbelt if seat pressure switch is applied over 3 seconds in the process of travel...

Page 99: ...ck to the original position Abnormity of OPS Controller If it happens to encounter the following situations please park the forklift truck in a safe place and contact the local agency of Hangcha forklift for inspection a Shift the gear switch to first gear of forward or reverse but the neutral indicator light flashes when ready to start b The buzzer keeps alarming when the parking brake is already...

Page 100: ...75 2 1998 A1 2010 EN 16307 2013 A1 2015 Noise will according with EN 12053 2001 A1 2008 and 2000 14 EC 2005 88 EC Vibrational parameter will according with ISO 5349 2 2001 EN 13059 2002 A1 2008 Electromagnetism compatible will according with 2014 30 EU EN 12895 2015 Vibration and noise values are as follows noise measuring only 3 5 tons the remaining value should be less than 3 5 tons tonnage valu...

Page 101: ...Maschine product name Internal combustion counterbalanced Forklift Truck Produktbezeichnung commercial name Handelsbezeichnung function Funktion model CPCD30 XW43E RT CPCD35 XW43E RT CPCD25 XW43E RT CPCD30 XW33E RT CPCD35 XW33E RT CPCD25 XW33E RT CPCD30 XW98C RT4 CPCD35 XW98C RT4 CPCD25 XW98C RT4 CPCD30 XW98E RT2 CPCD35 XW98E RT2 CPCD25 XW98E RT2 Modell type Typ serial number above mentioned produ...

Page 102: ...98 XVI Maintenance record Date Item of maintenance Signature Remark ...

Page 103: ...CHA GROUP CO LTD Address For OVERSEAS USERS Address 666 Xiangfu Road Lin an Hangzhou Zhejiang China Fax 0086 571 88926789 0086 571 88132890 ZIP 311305 Web http www hcforklift com E mail sales hcforklift com ...

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HANGCHA CPCD25-XW33C-RT4, Operational And Maintenance Manual

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