HANGCHA CPD10-A Operation And Maintenance Manual Download

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charge in short time when it is necessary.

–

If a non-automatic charger is used, the

charge voltage, current and charge time

should be adjusted, and check the rate of

battery electrolyte timely, so as to make

sure that the charge of battery group is in

good condition. The adjust parameters

please refer to “battery charging” in the

follow.

–

Do not continuously charge.

–

Continuously charge several batteries will

cause

charger

overheat

even

damaged. You can use the charger again

after it has been rested for an hour.

–

Select the charger according to battery‟s

voltage and capacity (refer to parameter

table).

Battery charging

There are two charge mode can be adopted,

including intelligent charging and constant

current charging. For the first charging, adopt

the constant current charging.

All the batteries of the new truck are not added

electrolyte.

Electrolyte confect

Type

Parameter

Name

D-420

D-500

D-630B

Specific gravity of acid

1.265g/cm

1.275g/cm

Water

and

vitriol

Volume ratio

3.1:1

2.6:1

Quality Ratio

1.7:1

1.65:1

Vitriol Ratio

1.835g/cm

Vitriol standard

Suitable for GB4554-84
or special for battery

Specification for distilled water:

Ingredient

Index

Appearance

No color crystal

Dry residue %

≤0.005

Resistively(25

Ω·cm

≥7×10

Fe %

≤0.0004

Cl %

≤0.0005

Mn %

≤0.00002

Organic

compound

(calculating

oxygen) %

≤0.0002

Magnesium

oxide+calcium

oxide %

≤0.005

Ammonium %

≤0.0008

Nitrate or nitrite %

≤0.0005

Confect course

–

Wear the blinkers, rubber overshoes and

rubber glove.

–

Please pay attention to add the acid to

water slowly, churning up at the same

time, make it mix equality.

CAUTION



Don’t po

ur the water to the acid, in

order to avoid the temperature of

liquid surface turning high suddenly

to cause boiling and splashing out

to hurt someone.

–

When the electrolyte is cooled to 30

℃

pour it into battery. It is proper to pour the

electrolyte 15-20mm above the protection

piece (without a dobber) or 1mm distance

between dobber and cover (with a

dobber).

–

Only when the temperature of the

electrolyte is below 35

℃

(after about 3-5

hours), can be first charged.

CAUTION



The time that is from pouring the

electrolyte into the battery to

starting first charging can’t be

Summary of Contents for CPD10-A

Page 1: ... A CPD10 15 18 20 25 30 35 AC3 CPD10 15 18 20 25 30 35 AC3F CPD10 15 18 20 25 30 35 AC4 CPD10 15 18 20 25 30 35 AC4F CPD10 15 18 20 25 30 35 AD2 CPD25 ALC3 CPD25 ALC3F CPD25 ALC4 CPD25 ALC4F CPD25 ALD2 OPERATION AND MAINTENANCE MANUAL Original Instruction HANGCHA GROUP CO LTD 5 2013 ...

Page 2: ...244 Curtis 1253 1 8 500 CPD20 A Curtis 1244 Curtis 1253 2 0 500 CPD25 A Curtis 1244 Curtis 1253 2 5 500 CPD30 A Curtis 1244 Curtis 1253 3 0 500 CPD10 AC3 Curtis 1236 Curtis 1253 1 0 500 CPD15 AC3 Curtis 1236 Curtis 1253 1 5 500 CPD18 AC3 Curtis 1236 Curtis 1253 1 8 500 CPD20 AC3 Curtis 1236 Curtis 1253 2 0 500 CPD25 AC3 Curtis 1236 Curtis 1253 2 5 500 CPD30 AC3 Curtis 1236 Curtis 1253 3 0 500 CPD3...

Page 3: ...1236 1 5 500 CPD18 AC4F Curtis 1236 Curtis 1236 1 8 500 CPD20 AC4F Curtis 1236 Curtis 1236 2 0 500 CPD25 AC4F Curtis 1236 Curtis 1236 2 5 500 CPD30 AC4F Curtis 1236 Curtis 1236 3 0 500 CPD35 AC4F Curtis 1238 Curtis 1236 3 5 500 CPD25 ALC3 Curtis 1236 Curtis 1253 2 5 500 CPD25 ALC3F Curtis 1236 Curtis 1253 2 5 500 CPD25 ALC4 Curtis 1236 Curtis 1236 2 5 500 CPD25 ALC4F Curtis 1236 Curtis 1236 2 5 50...

Page 4: ... in of the new truck 40 9 Daily Maintenance 41 10 Driving and Operation 45 Driving 45 Traveling 45 Turning 45 Stopping or parking 45 Loading 46 Stacking load 46 Un stacking load 47 Check after operation 47 11 Deposit 48 12 Battery 49 13 Maintenance summarization 58 Preventive maintenance schedule 59 Replace the key safe parts termly 66 Table for bolts tightening torque 67 Table for oil used in the...

Page 5: ... main components Item Description 1 Fork 2 Load backrest 3 Mast 4 Rearview mirror 5 Overhead guard 6 Driver s seat 7 Counterweight cover 8 Counterweight 9 Towing pin 10 Rear wheel 11 Battery behind cover hood 12 Front wheel ...

Page 6: ...2 2 Displays and Controls ...

Page 7: ...ng lever 18 Tilting lever 19 Emergency disconnect switch 20 Parking brake lever 21 Warning light switch 22 Steering column positioning device 23 Brake pedal 24 Accelerator pedal 25 Steering wheel 26 Key switch 27 Locker of battery cover hood 28 Locking bolt of battery side plate 29 Air spring 30 Fuse box 31 Fork stopper ...

Page 8: ...rmation Graphic illustrations on the multi function display act as warning indicators Through the multi function display on the right button can also check fault code and parameter setting Item Display A Battery capacity display B Service hours display C Operating mode display D Travel speed or fault code display F Crawl speed indicator G Fault indicator H Battery low capacity indicator I Lifting ...

Page 9: ...d in short time and climbing big gradient slop but it costs more energy so the mode will not be used in normal state except emergency P mode is power mode All kinds of index are lower than that of super mode It is applied for the case of long distance transporting and needing higher power or speed E mode is economical mode All the parameters are optimized Working in this mode can save power so it ...

Page 10: ... the indicator is on and the mast lifting speed drops to remind user to charge the battery as soon as possible Seat switch indicator J Red When operator leaves the seat the light will be on and the truck will be unable to travel or lift This function needs the seat to equip with seat switch optional Parking brake applied indicator K When parking brake applied the light up Button Mode settings or d...

Page 11: ...re version information language settings LCD contrast settings LCD brightness settings programmer settings and exit ADVANCED SETTINGS This menu needs password Through the example below shows how to use the button settings parameter For example The language from english switch to chinese In the main display interface press the menu button over 2 seconds and then enter the main menu Select the OPERA...

Page 12: ...ugh the up button or down button select the chinese language Refer the steps return the main display interface The language has been set up Note this instrument supports two languages of Chinese and English it will set to your wanted language and if you want to switch the language please refer to the above example for operation ...

Page 13: ...D B Communicate indicator C Error indicator D Low battery warning E Speed limited indicator F Accelerate indicator G Parking brake indicator H Entrance button I Speed limited button J Accelerator limited button K Backup button L Backup button M Switch button of hour indication ...

Page 14: ...or lights are on at the same time buzzer beep When LED shows no power please charge battery as quick as possible Speed limited indicator E When this lamp lights it meanings the truck working at low speed mode The maximum speed of truck decreased Press button 1 you can switch the high speed and low speed mode Accelerate indicator F When this lamp lights on it means the truck working at low accelera...

Page 15: ...button is no use for operator Backup button L 4 This button is no use for operator Switch button of hour indication M 5 Push this button it will display the total hours of truck as follow figure Push again it switch to the total traction hour Push the button once again it switch to speed display mode ...

Page 16: ...being pressed In this case the travel direction switch should be returned to neutral and move you foot from the accelerator pedal Then the truck can be operated Combined light switch 16 Control the turn signal lights headlights and front small lights working condition This combined light switch is composed of turning light switch and big small lamp switch Turning light indicates the traveling dire...

Page 17: ...ute the function of key switch Parking brake lever 20 Secures the truck when stationary Use this parking brake lever to park the lift truck And the parking brakes are applied on the front two wheels by pulling up on this lever To release the parking brakes move the lever forwards There is a micro switch at the left side of the parking brake lever tense the lever makes running invalid For the truck...

Page 18: ...heel operation is caused when the steering motor comes to a stall To put the power steering in operation again restart the steering motor without delay Key switch 26 Switches control current on and off Removing the key prevents the truck from being switched on by unauthorised personnel The key switch has two on off position you should push the Direction switch lever to neutral and loose the accele...

Page 19: ...k Take down the old fork Firstly locate the fork to the middle decline it to the ground and make the mast forward then operate the truck traveling backward the fork will be taken down Change new fork Firstly make the fork dead against the truck and forklift s mast to the bottom then operate the truck traveling forward aim at the two gaps and beams and raise the mast Adjust the position of the fork...

Page 20: ... hood open the right side battery hood when adding oil After fill in clean hydraulic fluid tighten lock the cap Air leakage plug There is an air leakage plug on the oil tank to let air in the tank goes out You d better often check the plug and see whether been jammed Head lights and combination lights Two headlights and combination lights turn signal show width lamp are installed at the front side...

Page 21: ...o set the seat to a lesser weight push the weight adjustment lever left To set the seat to a greater weight push the weight adjustment lever right To adjust the seat position Pull up the longitudinal adjuster and push the driver s seat forwards or backwards to the desired position Engage the longitudinal adjuster in position again WARNING The longitudinal adjuster must be securely located in the d...

Page 22: ...lt and check that it locks Adjust the seat belt to your body shape without squeezing your hip and without over slack Regular verification of seat belt related to Cut or frayed straps Worn or damaged hardware including anchor points Buckle or retractor malfunction Loose stitching WARNING In no event should the lift truck be used if the seat belt is defective fixing locking cuts tears etc Repair or ...

Page 23: ...y in seat Do not jump Lean forward hold on tight steering wheel brace feet Lean your body away from inpact WARNING If the truck is about to tip over never undo the restraint belt and try to jump out This will only increase the risk of serious injury or death ...

Page 24: ...rresponding forward or reverse signal output the vehicle forward and reverse power is cut off meanwhile the alerting signal outputs buzzer and indicator lights are on when the park brake hangs or the driver sits correctly it exits the alerting condition the driver sits down again travel selector switch hangs in the forward or reverse gear the vehicle forward and reverse power recovers Forklift Wor...

Page 25: ...travel when the driver leaves the seat the traction motor will not work and the vehicle will stop Double locked it is said that the system limits the forklift s travel and mutil way valve s work the masts will not lift or down Forklift Parking Brake Control In any vehicle state when the driver sits incorrectly there is no seat pressure switch input meanwhile do not pull the parking brake there is ...

Page 26: ...ph Warning label and name plate must be legible at all times Replace if necessary R E E G M E T S C N Y P O HYD OIL 液压油 No Description 1 Nameplate 2 Warning label Do not step onto or beneath the load 3 CE label For CE 4 Lift method 5 Strap points for crane lifting For CE 6 Warning label No climbing ...

Page 27: ...ph 10 Use specified fuses only For CE 11 Warning label Please abide by the operation instructions 12 Hydraulic label Adding hydraulic oil For CE 13 Noise label 14 Tight point label For CE 15 HANGCHA black decal 16 Tire pressure For CE 17 Series and tonnage label 18 Hand brake label For CE 19 Emergency stop 20 Warning label stick in the L H leg Procedure when truck in danger of tipover notice ...

Page 28: ... 10 Ground clearance Min mm 100 100 100 120 120 125 11 Braking distance Max m 2 5 2 5 2 5 2 5 2 5 2 5 12 Overall Dimension Length to fork face mm 2098 2098 2098 2342 2342 2502 Width mm 1120 1120 1120 1265 1265 1265 Height to safeguard mm 2050 2050 2050 2075 2075 2110 13 Service weight Include battery box kg 2940 2940 2940 3700 4180 5050 14 Battery Standard V Ah 48 420 48 420 48 420 48 630 48 630 8...

Page 29: ...00 8 Gradeability Laden Unladed 13 13 13 13 14 13 14 13 14 13 14 9 Turning radius Min mm 1900 1900 1900 2090 2090 2230 2310 10 Ground clearance Min mm 100 100 100 120 120 125 125 11 Braking distance Max m 2 5 2 5 2 5 2 5 2 5 2 5 2 5 12 Overall Dimension Length to fork face mm 2098 2098 2098 2342 2342 2502 2582 Width mm 1120 1120 1120 1265 1265 1265 1302 Height to safeguard mm 2050 2050 2050 2075 2...

Page 30: ...00 8 Gradeability Laden Unladed 13 13 13 13 14 13 14 13 14 13 14 9 Turning radius Min mm 1900 1900 1900 2090 2090 2230 2310 10 Ground clearance Min mm 100 100 100 120 120 125 125 11 Braking distance Max m 2 5 2 5 2 5 2 5 2 5 2 5 2 5 12 Overall Dimension Length to fork face mm 2098 2098 2098 2342 2342 2502 2582 Width mm 1120 1120 1120 1265 1265 1265 1302 Height to safeguard mm 2050 2050 2050 2075 2...

Page 31: ...aded 13 14 13 14 13 14 13 14 9 Turning radius Min mm 2090 2090 2230 2310 10 Ground clearance Min mm 120 120 125 125 11 Braking distance Max m 2 5 2 5 2 5 2 5 12 Overall Dimension Length to fork face mm 2342 2342 2502 2582 Width mm 1265 1265 1265 1302 Height to safeguard mm 2075 2075 2110 2110 13 Service weight Include battery box kg 3700 4180 5050 5450 14 Battery Standard V Ah 48 630 48 630 80 500...

Page 32: ...ed Laden Unladed km h 14 5 14 5 7 Lifting speed Laden Unladed mm s 250 400 8 Gradeability Laden Unladed 15 16 9 Turning radius Min mm 2230 10 Ground clearance Min mm 125 11 Braking distance Max m 2 5 12 Overall Dimension Length to fork face mm 2490 Width mm 1265 Height to safeguard mm 2110 13 Service weight Include battery box kg 4580 14 Battery Standard V Ah 80 500 15 Motor Driven motor kW 15 0 A...

Page 33: ...s removed you may use the forklift If trouble occurs when lifting cargo to Climb or descend or the storage battery electrolyte the hydraulic fluid the brake fluid has the revelation please organizes the personnel to repair immediately 4 Operator must wear helmet safety shoes and work clothes 5 Because there will bring exploding gas in the bosom of the battery prohibit any flame nearby it absolutel...

Page 34: ...s to be handled use a proper attachment and tools Avoid hoisting the load with wire rope hung on the forks or attachment since the wire rope may slide off If needed a qualified personnel for slinging operation should perform making use of a hook or crane arm attachment Take care not to protrude the forks out of the load The protruded fork tips may damage or turn over the adjacent load 14 Know the ...

Page 35: ...zed model or operate with long attachment be extremely careful of load end swing at corners or in narrow aisles Be alert for others 24 Use minimum forward and reverse tilt when stacking and un stacking loads Never tilt forward unless load is over stack or at low lift height When stacking loads on a high place once make the mast vertical at a height of 15 to 20 cm above the ground and then lift the...

Page 36: ... stand or walk under upraised forks or other attachments if machine is so equipped If unavoidable use a safety stand or block to prevent a possibility of fork attachments falling down or moving unexpectedly 33 Inspect the surface over which you will run Look for holes drop offs obstacles and look for rough spots Look for anything that might cause you to lose control bog down or upset Clear away tr...

Page 37: ...1 Move the truck to the place which respects traffic when it anchors If the reason is brake or turn system move it by a suitable truck Reference the part of truck move Other reasons use a suitable truck to traipse tie the cord outside of truck Please abide by the traffic regulations when traipse the truck on calzada 42 After take down the hood water tank cover board overhead backrest of mast unall...

Page 38: ...mperfectly unexpected drop may occur 48 Only in the event that the truck manufacturer is no longer in business and there is no successor in the interest to the business may the user arrange for a modification or alteration to a powered industrial truck provided however that the user a Arranges for the modification or alteration to be designed tested and implemented by an engineer s expert in indus...

Page 39: ...device to hoist the truck Lifting Use the steel wire ropes to tie the holes in the two side of the outside mast s beam and the hook of the counter balance and then use the lifting device to hoist the truck The steel wire rope attach to the counterweight should through the safeguard gap and make the safeguard not be distorted WARNING When hoist the truck don t coil the overhead guard with the steel...

Page 40: ...he truck Turn off key and pull out power switch Loosen the brake lever Set switch lever to neutral position WARNING Don t tie the steel wire ropes on the unfixed position Don t carry a load to steel wire ropes suddenly The truck would be damaged if you tow it with the electric lock working ...

Page 41: ...x board and large roller It is very important to distinguish the difference of the gravity center of loads for evaluating the truck s stability WARNING If the truck will turn over do not attempt to get out of the truck because the speed of overturn is much faster than your speed You should hold the steering wheel handle stretch your feet and this practice will let you in the seats Operator fastens...

Page 42: ...CAUTION The stable region of the load center In order to make the truck stable the combined center must be in the triangle which is made up of two points that the two front wheels attach ground and the midpoint of the back axle If the combined center is in the front driving axle the two front wheels become two fulcrums the truck will overturn If the combined center departures the triangle the truc...

Page 43: ...ps moving one force works forwards So it s dangerous to brake suddenly because it causes one large force works forwards and it s easy to cause truck overturn or load slide off When the forklift makes a turn will exert a centrifugal force outward from the curve center This strength pushes forklift outwards and causes it to turn over About stability region is very small so decelerate when turning If...

Page 44: ...observed while the machine is in a stage of 100 hours of operation Must prevent the new battery from over discharging when early used Usually should recharge when discharging down to 20 Perform specified preventive maintenance services carefully and completely Avoid sudden stop starts or turns Oil changes and lubrication are recommended to do earlier than specified Limited load is 70 80 of the rat...

Page 45: ...ace or side face Make sure the wheel felloe is not bended WARNING Since the tires of forklift truck need have a high inflation pressure to carry heavy loads even a small bending of rims or a little damage at the tread surface could cause an accident When using an air compressor at first adjust the air pressure of the compressor Otherwise it will cause a serious accident since the maximum pressure ...

Page 46: ...brake lever is adjusted by the bolt on the top of lever The force increases clock wise screwing and decreases counter lock wise screw CAUTION To step the brake pedal is helpful to tighten or loose the hand brake lever 6 Check accelerate pedal The acceleration changes as the stroke changes 7 Brake fluid level check Open the brake lubricated cap cover Check the fluid level in the range allowed If la...

Page 47: ...11 Check battery Check the battery whether be installed firmly Check proportion of electrolyte Refer to Battery section Check the terminal for loose or damage Otherwise it will be adjust or replace Pull in the plug and close the hood Turn on the key switch 12 Instrument check include battery capacity and error diagnose Refer to instrument section 13 Lifting lever tilting lever attachment lever Che...

Page 48: ...Check steering system Turn the wheel right and left separately to check steering system 18 Turn signal horn and other lamp check Make sure that the turn signal operates properly by pull push turn signal switch Make sure that the sound of horn is properly by press the horn button Check the other lamp and back up buzzer 19 Battery maintenance Refer to battery section 20 Other For instance pay attent...

Page 49: ...ion Hold the steering wheel with your left hand and attach your right hand Traveling Step the accelerate pedal slowly the truck will travel forward or backward Decrease speed Loosen the accelerate pedal slowly the truck will decelerate CAUTION Decelerate the truck in the situations following Turning Close the goods or pallet Close the deposit area Enter a narrow passage The condition of road surfa...

Page 50: ...floor and make sure loads lay stably Then tilt the mast backwards fully and lift forks up to 15 to 20 cm off ground then start running When handling bulky loads which restrict your vision operate the truck in reverse except when climbing grades Stacking load When approaching the deposit area slow down your truck Stop the truck right 30 cm far away from the position where your load is to be deposit...

Page 51: ...s possible CAUTION If the forks are hard to be fully inserted use the following procedure Move forward and insert 3 4 of the forks Raise the forks 5 to 10 cm and move backward 10 to 20 cm with the pallet on the forks and then fall the pallet to the stack Move forward again to insert the forks fully Raise the forks 5 to 10 cm off the stack Check all around the truck to insure that the path of trave...

Page 52: ...rease Fill up the truck body and counter weight with stow wood to reduce bearing of the two rear wheels Operate the forklift once a week and be required to lift the forks to its max height many times Check the proportion and the level of electrolyte once a month Charge the battery equally once a month WARNING The stow wood must be single and hard enough to support the truck Don t use a stow wood h...

Page 53: ... truck when the electrolyte is shortage Inspection for electrolyte level every week When electrolyte level is low you must add distilled water to the level appointed WARNING The shortage of the electrolyte will cause the storage battery overheated even cause the system part of storage battery and electric combustion Vitriol include in the electrolyte can create burns see doctor for emergency treat...

Page 54: ... please do not charge Open forklift cover and battery lid when charging in order to release the explosive gas In the progress of charging electrical source switch and battery pin are not to pull out otherwise will destroy pin and electrical units The normal procedure is that press down the stopping button firstly and then pick out the pin Charger The battery group is equipped with JCD 35A 24 type ...

Page 55: ...olume ratio 3 1 1 2 6 1 Quality Ratio 1 7 1 1 65 1 Vitriol Ratio 1 835g cm 3 Vitriol standard Suitable for GB4554 84 or special for battery Specification for distilled water Ingredient Index Appearance No color crystal Dry residue 0 005 Resistively 25 0 C Ω cm 7 10 4 Fe 0 0004 Cl 0 0005 Mn 0 00002 Organic compound calculating oxygen 0 0002 Magnesium oxide calcium oxide 0 005 Ammonium 0 0008 Nitrat...

Page 56: ...es than rated capacity Truck type Battery type Charging voltage V Charging current A 1 st phase 2 nd phase 1 0t 1 8t D 420 72 40 20 2 0 t 2 5t D 630B 72 63 32 3 0 t 3 5t D 500 120 50 25 Charging time h 35 45 35 45 c Adjusting the specific density and height for the electrolyte If the specific gravity is smaller it will be adjusted as follow then take out some electrode from the battery pour the co...

Page 57: ...es often finds that single battery s proportion of voltage and electrolyte rises slowly during the course of charge and during the course of discharge its battery s proportion of voltage and electrolyte declines faster than most of other batteries Make equilibrium charge in the following case a Discharge voltage often drop down ending voltage b Discharge current is often larger c Not charge in tim...

Page 58: ...rake lever Open the hood cover Disconnect the battery plug Remove the lock pin Use the proper tools to pull up the battery If you choose the forklift whose battery case can be move out from the side you can use the fork to prop out the battery case tray Battery idsposal Batteries may only be disposed of in accordance with national environmental protection regulations or disposal laws The manufactu...

Page 59: ...ccording to environment and protection law rather than reject at will The proportion and level of electrolyte CAUTION If the level of the electrolyte is low using the battery will cause the battery over heat and shorten the battery s life 1 Inspect electrolyte The battery without a dobber It is proper to pour the electrolyte 15 20mm above the electrode plate The battery with a dobber Depending on ...

Page 60: ...adding it too much 3 Read the specific gravity The specific gravity of the electrolyte should change follow the temperature a Use thermometer to measure the temperature of electrolyte b Put the straw of densimeter into electrolyte uprightly extrude rubber tube with hand and the electrolyte will be sucked into the glasses tube and then the floater of the densimeter will float c Numerate the reading...

Page 61: ...at the standard temperature of 300 C Dt the specific gravity at the temperature of t0 C t the temperature of the distilled water during convert The specific gravity that was refered in this book is measured all at the temperature of 30 ...

Page 62: ...ctrolyte used at will and carry on handling according to the local environmental protection laws and regulations Maintenance on schedule After you make maintenance you d better make a record CAUTION No smoking You should shut off key switch and pull off the plug before service except some trouble shooting Clean the electric part with compress air do not with water Do not place your hands feet or a...

Page 63: ...ness 〇〇〇〇〇 Looseness of connecting wire 〇〇〇〇〇 Cleanness of the battery surface 〇〇〇〇〇 If there are tools on the battery 〇〇〇〇〇 The tightness and smoothness of air cap 〇 Far away from firing 〇〇〇〇〇 Controller Item Service required Tools D 8 h W 40 h M 166 h T 500 h S 1000 h Controller Check connector for worn 〇〇 Check contactor for running 〇〇 Check micromove switch for running 〇 ...

Page 64: ... 1000 h Heck wheel hub bolts for tighten torque Check for noise 〇〇〇〇〇 Check for oil leaks 〇〇〇〇〇 Change oil Check wheel hub bearing for looseness noise 〇〇〇〇 Clean and replace grease Leakage check 〇〇〇〇〇 Check wheel hub bolts for tighten torque 〇〇〇 Wheels Front Rear Wheels Item Service required Tools D 8 h W 40 h M 166 h T 500 h S 1000 h Tyre Check for charge pressure Barometer 〇〇〇...

Page 65: ... 〇〇〇〇 Check for operation 〇〇〇〇〇 Steering Gear box and valve Check mounting bolts for looseness 〇〇〇 Steering axle Check king pins for looseness or damage 〇〇〇 Check for deflection deformation cracks or damage 〇〇〇 Check for fixing condition Test hammer 〇〇〇 Steering cylinder Check for operation 〇〇〇〇〇 Check for oil leaks 〇〇〇〇〇 Check for looseness when fixing or hinging 〇〇〇 ...

Page 66: ... Rod Cable etc Check for operation 〇〇〇 Check connections for looseness 〇〇〇 Check decelerator connector lug for abrasion 〇〇 Hoses and Pipes Check for damage leakage or collapse 〇〇〇 Check connection or clamping parts for looseness 〇〇〇 Brake master cylinder and wheel cylinder Check for leakage 〇〇〇〇〇 Check for fluid level Change brake fluid 〇〇〇 Check master cylinder and wheel cylinder f...

Page 67: ... looseness 〇〇〇〇〇 Check for operation 〇〇〇〇〇 Control valve Check for oil leak 〇〇〇〇〇 Check relief valve and tilt lock valve for operation 〇〇〇 Measure relief pressure Oil press gauge 〇 Hose Piping Hose Reel Swivel Joint Check for oil leak looseness collapse deformation and damage 〇〇〇 Replace hoses 1 2 years Hydraulic Pump Check hydraulic pump for oil leak or noise 〇〇〇〇〇 Check pump ...

Page 68: ...eck forks for damage deformation or wear 〇〇〇 Check for stopper pins for damage or wear 〇〇 Check fork base and hook welding for defective cracks or wear 〇〇〇 Mast Lift Bracket Check weld between cross members with outer and inner masts for defective cracks or damage 〇〇〇 Check tilt cylinder bracket and mast for defective weld cracks or damage 〇〇〇 Check outer and inner masts for defective wel...

Page 69: ...n signal Check for proper operation and tight installation 〇〇〇〇〇 Horn Check for proper operation and tight installation 〇〇〇〇〇 Light Lamps Check for proper operation and tight installation 〇〇〇〇〇 Buck up Buzzer Check for proper operation and tight installation 〇〇〇〇〇 Meters Check meters for proper operation 〇〇〇〇〇 wire Wire damage or looseness 〇〇〇〇 Looseness of Electric circuit ...

Page 70: ...the parts are abnormal before the replacing time is coming it should be replaced immediately Key safe part s description Term of using year Brake hose or tube 1 2 Hydraulic hose for lifting system 1 2 Lifting chain 2 4 High pressure hose hose for hydraulic system 2 Brake oil cup 2 4 Brake master cylinder brake slave cylinder cover and dust sleeve 1 Inner hermetic rubber matter 2 Rubber pad of the ...

Page 71: ...54 69 69 88 83 98 121 162 16 88 108 108 137 127 157 189 252 18 118 147 147 186 176 216 260 347 20 167 206 206 265 245 314 369 492 22 225 284 284 343 343 431 502 669 24 294 370 370 441 441 539 638 850 27 441 519 539 686 637 784 933 1244 Note Use entirely 8 8 grade bolt in the important joint position Bolt s grade can be found in the head of the bolt if it can t be found the grade is 8 8 ...

Page 72: ...ity Remark Hydraulic oil Normally L HM32 Cold environment L HV32 35 L Gear oil GL 585W 90 4 5 L 1 0t 1 8t 6 L 2 0t 3 5t Brake Fluid Choice HZY3 or DOT3 1 5 L Industrial Vaseline 2 Electrode of storage battery Lubrication grease Automobile general lithium base lubricant ...

Page 73: ...ited value of combination carrying capacity of forklift and attachment It is not allowed that partial load at high position It is a short time work for attachment with side shifter Partial load is around 100mm Above 5 ton including 5 ton the side shifter movable within 300mm In the range of the projection forth 2m of the lower of attachment and cargo prohibit stand to avoid the suddenness except t...

Page 74: ...ity safety to avoid the attachment glide around carriage in using After hang attachment embed the rise catch block to the gap of top beam let the offset of centre line of attachment and carriage is less than 50mm Otherwise it will be affect the landscape orientation stability of forklift To these attachment with rotating function such as paper roll clamp bale clamp muti purpose clamp drum clamp it...

Page 75: ...g water system Optional Makeup of the automatic filling watering system Automatic Watering Plug End Plug Floater T piece L piece Flow Indicator with filter 6mm 8mm 10mm watering pipe Male Female couplings Kv10 and KV6 etc Water Tank ...

Page 76: ...end the service life How to correctly install the water tank choose proper floaters how to confirm the specification quantity of the installed accessories according to different types of battery including correct application rules for automatic watering plug watering pipe T L pieces and male female couplings as well as the cleaning of the flow indicator We will give you a brief introduction for th...

Page 77: ...choose In order to achieve our expected standard and completely reflect the effectiveness of the automatic watering system the most important thing is to choose proper floaters At present our company can offer a rule for the client to make judgment and choose the type of floater see diagram The diagram the installation way of the floaters T T1 5 17mm T approaching 47 50 5 58 61 72 Float 13 16 5 24...

Page 78: ... less than 200mbar You d better conduct watering within the specified periods because frequent filling will lead to overflowing for too much water which will do great damage to the storage battery Note Filling after finishing charging is the best ideal state besides do not filling before charging Cleaning During the period of development and long term practical application the leak tightness of au...

Page 79: ...oater of the automatic watering plug can reach correct water level when the level rises in the cell the pressure closes the valves and prevents further water entering the cell When the system finishes watering the flow indicator will stop running and you can see the water level indicator clearly through the top of the watering system Besides the material of floater can avoid damage and ineffective...

Page 80: ...CTIVE 2006 42 EC OF THE EUROPEAN PAMENT AND OF THE COUNCIL and EN1726 1 1998 EN1175 1 1998 standard The design and manufacture of electrical element comply with the low voltage standard 2006 95 EC Noise will be according with EN12053 2001 and 2000 14 EC Sound pressure level on the operator s position is lower than 75dB A measurement uncertainty is 1 5dB A Vibration parameters are measured accordin...

Page 81: ...Maintenance record Date Maintain content Maintainer ...

Page 82: ... CO LTD Address For OVERSEAS USERS Address 88 Donghuan Road Lin an Economic Development Zone 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 CPD10-A, Operation And Maintenance Manual

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