HANGCHA CPCD10N-RW10 Operation And Maintenance Manual Download

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1-3.5t R Series Internal Combustion

Counterbalanced Forklift Truck

OPERATION AND MAINTENANCE MANUAL

Original Instruction

ZHEJIANG HANGCHA ENGINEERING MACHINERY CO., LTD.

DEC.2009 4

EDITION

Summary of Contents for CPCD10N-RW10

Page 1: ...1 3 5t R Series Internal Combustion Counterbalanced Forklift Truck OPERATION AND MAINTENANCE MANUAL Original Instruction ZHEJIANG HANGCHA ENGINEERING MACHINERY CO LTD DEC 2009 4th EDITION ...

Page 2: ...mproving the outline using buffer steering axle in addition besides the TCM and NISSAN main transmission are configured in our trucks we also configure Okamura main transmission in our trucks And there is different between masts of import and export trucks N series masts are used in the import trucks R series masts are used in export trucks This manual also applies to container forklift truck and ...

Page 3: ...9 5 STRUCTURE AND STABILITY OF TRUCK 33 6 OPERATION 35 Star up 35 Traveling 36 Pick up 37 Stacking load 37 Remove load 38 7 DEPOSIT 39 8 MAINTENANCE 41 Preventive maintenance schedule 41 Maintenance of chassis and body 43 Periodic replacement of key safe parts 45 Table for the oil used in the truck 46 Lubrication system drawing 48 Environment protection 49 Scutcheons 50 9 TRUCK S CONVEY LIFTING TO...

Page 4: ...ORKLIFT 83 14 OPERATIONAL METHOD OF MAINTENANCE FREE LEAD ACID BATTERY 95 15 USE INSTALLATION AND SAFETY RULES OF ATTACHMENT 97 16 RELATED SAFETY INSTRUCTION AND STANDARD FOR TRUCKS EXPORTING TO EUROPE OR OPTION 99 17 MAINTAIN RECORD 103 ...

Page 5: ...ate the truck or attachment on other position except the operator s seats 11 Do not carry the load unpackaged Be carefully to carry these goods with large size 12 Notice the load not drop from the load bracket for those trucks that overall maximum lift height is higher than 3 meters If necessary make some protective measure 13 Travel with load as low as possible and tilt back the mast 14 Before dr...

Page 6: ... operate the truck or load cargo 23 There are enough light at truck work ground At night open the head lamp to collocate enough lamp house 24 Only in the event that the truck manufacturer is no longer in business and there is no successor in the interest to the business the user may arrange for a modification or alteration to a powered industrial truck provided however that the user shall a Arrang...

Page 7: ... OF MAIN PARTS OR COMPONENT 1 Mast 2 Lifting cylinder 3 Backrest 4 Fork 5 Overhead guard 6 Steering wheel 7 Seat 8 Cover hood 9 Counterbalance weight 10 Rear wheel 11 Tilting cylinder 12 Front wheel Instruments ...

Page 8: ...erator pedal is pressed this lamp goes out Caution If this light continues to stay lit or lights up during operation the pressure is lower than 0 05Mpa and should be checked immediately Glow indicator C Diesel truck Turn the key to ON position and the indicator lights up for a moment After the indicator goes out turn the key to Start position Sedimentor indicator D Use in W9 W13 W15A diesel truck ...

Page 9: ...After the indicator goes out turn the key to Start position Caution 1 Do not keep the starter switch in the ON position while engine is shut down This result in a discharge battery 2 With the engine running do not turn the starter switch into the START position since there is a danger of the starter motor being damaged 3 Do not keep the starter engaged for more than 5 seconds at a time Wait about ...

Page 10: ...ound horn Controls 8 Clutch pedal frictional clutch type 9 Inching pedal torque converter type 10 Brake pedal 11 Accelerator pedal 12 Forward reverseand Speed slect lever frictional clutch type 13 Shift lever 14 Tilt lever 15 Lift lever 16 Steering hand wheel 17 Parking brake lever 18 Forward reverse lever Torque converter type Non electric switch 19 Choke line 20 Forward reverse lever Torque conv...

Page 11: ...ch Accelerator pedal 11 Press down the accelerator pedal engine rotating speed increase traveling speed of truck increased On the contrary when loosen the pedal engine rotating speed and truck traveling speed will decrease Forward reverse 12 Speed select lever 13 Machinery transmission 12 F front N neutral R backward 13 1 low N neutral 2 high Machinery gear box have four shifts tow are frontward a...

Page 12: ...rning This truck is provided with the power steering so heavy hand wheel operation is caused when the engine comes to a stall To put the power steering in operation again restart the engine without delay Parking brake lever 17 Pull the parking brake lever backward to park push it forward to release must pull the parking brake lever backward before driver leaving truck Forward reverse lever 18 Non ...

Page 13: ...curely locked Warning a Before adjusting the lever you d better turn off the key switch b Must stop the truck to adjust the seat Seat weight support adjusting Use spanner to adjust the bolt which is at the back of seat or adjust the knob for supporting the weight on seat at the lift side of seat adjust the hanging s weight basing on person s weight It s better to sit on the seat when adjusting Sea...

Page 14: ...e hood can be swung up fully to provide easy maintenance service You can lift up the hood with little effort with an aid of hood damper To lock the hood push down on the front of hood until it covers Caution Before open the hood the handle of the snap close should be pulled out first Use caution not to catch your fingers in the hood when closing it Caution While maintaining under the cover hood th...

Page 15: ...ld always be set The lower beams of fork have a hatch to load or unload forks The fork is forbidden to fix on the location where the hatch locates Check the bolt at the middle of the fork bracket which is used to prevent load fork at the hatch Steering column tilting angle adjustment The tilting angle of the steering wheel is adjustable to suit individual operators The steering column is unlocked ...

Page 16: ... good condition every time addition of fuel is made Warning Fuel handling 1 Stop the truck shut down the engine and apply the parking brake securely Make sure that there is no naked flame near the area Never smoke The driver should not remain seated when adding fuel 2 After addition of fuel is finished securely close the reservoir cap A loose cap could cause fuel leak or fire hazard in the worst c...

Page 17: ...t on the defecting forklift truck 4 Don t use an open flame to check level or for leakage of fuel electrolyte or cooling water Never smoke while inspecting the battery handling fuel or working on the fuel system There is a danger of explosion At working place fire extinguisher should be prepared Never fill the fuel tank with the engine running 5 Warm up the temperature of water to 70 before operat...

Page 18: ... or on the truck 15 Before driving over a dock board or bridge plate be sure that it is properly secured and strong enough to sustain the weigh Check the ground or floor condition of working area in advance 16 Keep your mind on your work 17 Keep your head hands arms feet and legs within the cab Never let them out of cab for any reason 18 When handling bulky loads which restrict your vision operate...

Page 19: ... surface would cause vibration of truck and noise The high air pressure of tyres will cause vibration and noise too Do not operate the truck when the weather is execrable such as windy thunder storm snow and etc 23 When operating loaded truck have the rear end of your machine pointed downhill When operating unloaded truck have the rear end of your machine pointed upgrade Never turn sideways on an ...

Page 20: ... forks out of the load The protruded fork tips may damage or turn over the adjacent load 30 Know the rated capacity of your lift truck and its attachment if any and never exceed it Do not use a man as an additional counterweight It s quite dangerous 31 ZHEJIANG HANGCHA ENGINEERING MACHINEARY CO LTD offers a variety of attachments such as forks bucket rotating roll clamp load grab or hinged forks D...

Page 21: ...acle then engage the load by driving forwards 37 Make certain that your load is well stacked and evenly positioned across both forks Don t attempt to lift a load with only one fork On the truck with an attachment such as a load grab make certain that the load is securely and correctly grabbed and pull the loading control level to the full increase to relief pressure 38 Never lift loads with the tr...

Page 22: ...t work correctly or its braking system has been disabled Obey the communication rules on the road when towing the truck 42 Dress the overalls or other protective uniforms suck as safety helmet safety shoes etc Don t dress necktie or other accouterments 43 The workplace should be equipped with fire extinguisher In order to get the fire extinguisher easily it s usually installed on the safety frame ...

Page 23: ... fuel filler port is provided at the rear left pillar of the overhead guard 4 Engine oil level check Caution When checking the engine oil should let the forklift truck on the level ground When check the engine oil it is exact when the engine is cool Remove the dipstick clean the rod and reinstall Pull it out again and check the oil level The level should be within the mark on the dipstick 5 Check ...

Page 24: ...to ground loosen park brake put transmission gear neutral position cut off engine B Remove rubber dustproof cap of oil drain port insert tube into oil drain port and wasted oil collection bottle and loosen oil drain screw at the same time the other person on truck press brake pedal again and again So the brake oil flows out from oil drain port watch the liquid level of brake fluid reservoir add ne...

Page 25: ...g lever and attachment lever check Check the loading levers for lift tilt and optional attachment for looseness and smooth operation Increase the rotate speed of engine make certain that the lifting lever tilting lever and attachment lever in good work condition 17 Instruments and sensors Make sure that hour meter water temperature indicator oil temperature indicator transmission fluid sensor and ...

Page 26: ...ir cleaner when truck works 50 250 hours After six times please change air cleaner Note If the working condition is bad the cycle of maintain and change air cleaner need more frequency The badly work condition with dust the cycle of maintain and change air cleaner will be short Advice maintains one time between 8 50 hours change it between 100 300 hours Maintain method 1 Take apart the cover of ai...

Page 27: ...rks to make sure There is no crack and bend on the forks and the forks are installed on the fork bracket strongly Check if there have leakage of oil cylinder and tubing Check the rollers rotation Check the mast if there have crack and bend Operate the lever of lifting tilting and attachment check the mast if it s in good condition and pay attention to system operating sound 5 Lift chain tension ch...

Page 28: ...place Keep safe 7 Chain Lubrication Take one brush with engine oil paint two sides on chain 8 Lubrication grease to below parts the detail please see Lubrication system drawing 1 mast bear lubricate 2 Brake pedal clutch type lubricate 3 Inching pedal tor con type lubricate 4 Steering axle shaft lubricate 5 Steering knuckle main bearing lubricate 6 Steering rod bar pin lubricate 7 Steering cylinder...

Page 29: ...t of inching pedal brake pedal 0 9 3 4mm NRW15A QNR W22A 0 mm besides NRW15A QNR W22A Clutch pedal 120 130 60 2 5 Notice QN RW22A is the shortening of CPQD20 25 30 35N RW22A RW15A is shorteningCPCD20 25 30 35N RW15A Maintain monthly 180 200 hours Increase the below content base on maintain per week 1 Change engine oil and oil filter 1 Start the engine warm up enough then flameout 2 Take out the oi...

Page 30: ...re dust change the hydraulic oil of transmission It is first time Let the truck at level ground play down the fork to floor inclined back the mast strain brake handle when transmission is at neutral position engine is cut off Caution Hot hydraulic oil and part will hurt Body Do not touch the hot hydraulic oil and part 1 Dismantle rubber mat and front soleplate 2 Dismantle filter deal with located ...

Page 31: ...e from sedimentor W10 W15A W32 W33Diesel truck When the sedimentor indicator lamp lights up it means need water discharge Put a container under the fuel filter Loosen away the drain bolt W15A then loosen the drain plug by turning 4 to 5 turns to dewater Fasten the drain bolt W15A and plug after the water was discharged 8 Exhaust gas check Colorless Normal complete combustion Black Abnormal incompl...

Page 32: ...sition engine is cutoff Caution Hot hydraulic oil and part will hurt body Do not touch the hot hydraulic oil and part 1 Put one case cubage is over 60 litre under the hydrualic oil box Dismantle the oil tuck let the hydrualic to case 2 Dismantle hydrualic dipstick and fuel box cover discreteness 3 Take out the magnet from oil box to clean and rinse the oil orifice of box bottom by hydrualic oil 4 ...

Page 33: ...e drain cover 3 Add cooling fluid to radiator up to way out 4 Let the engine run fully 5 Stop the engine after cool down fully still add cooling fluid to radiator up to way out and add cooling fluid to coolant reservoir MAX position 6 Check the drain cover if leakage Warning When the water temperature of the engine higher than 70 degree please do not open the pressure cap of the radiator avoiding ...

Page 34: ...ckward and place a wooden block under each side of outer mast 6 Tilt mast forward until front tires are raised from surface Caution Do not allow loose nuts before the front wheels leave away from the ground 7 Support forklift truck by putting additional wooden blocks under each side of the front end frame as shown below Stop the engine 8 Take out the wheel nut and replace the front wheel tire Warn...

Page 35: ...forklift truck by putting additional wooden blocks under each side of the front end frame as shown below 6 Take out the wheel nut of rear wheel and then replace the wheel 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 suppo...

Page 36: ...s If the radiation fin is build up it will lead over hot so use compress air vapour or water Caution Clean the radiation fin by compress air or vapour put the muzzle to radiator a right angle 5 The operation of engine too hot If the engine is too hot do not stop it at once do it as follow Movement engine low speed Open the engine cover to airiness Stop when water temperature fall Check the cooling...

Page 37: ...oller It is very important to distinguish the difference and the gravity center of loads Warning If the truck is going to turn over do not attempt to get out of the truck because the speed of overturn is much fast than you You should hold the steering wheel handle and this practice will let you in the seats Please tie safety belt Caution Gravity and stability The combined center that is composed o...

Page 38: ...n Caution the load 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 bracket if the shape of goods is complex Caution speed and acceleration A static object keep its static station which is not affected by outside for...

Page 39: ...th your foot OFF the pedal crank the engine by turning the ignition key to START Release key when engine starts Warm engine Do not pull out the choke button Press down the accelerator pedal halfway and cold Crank the engine by turning the ignition key to START Release key when engine starts Caution Do not press down the accelerator pedal fully when starting warm engine This operation may harden th...

Page 40: ...fting from high to low speed or vice versa once increase the engine speed and release accelerator pedal At the same time press the clutch pedal while shifting the shift lever into the desired position Then press the accelerator pedal while releasing the clutch pedal Torque converter type machines Always stop the truck before reversing the direction of travel Shift the shifting lever Slow down Clut...

Page 41: ...nd First lift the forks 5 to 10 cm off the ground or floor and make sure loads rest stable Then tilt the mast backwards fully and lift forks up to 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 Once stop the truck right in fro...

Page 42: ...te 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 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 or skid...

Page 43: ... of wheel boss and the piston of hydro cylinder is loose and whether the surface of piston has been pulled Check whether the wheels of mast roll stably Lift the lifting cylinder to the top and fill it with oil In cold weather it needn t to discharge the antifreeze but the cold water should be removed completely Deposit the truck for a long time Deposit the truck for a long time fill up the truck b...

Page 44: ...crankcase driving axle transmission box clutch type hydraulic transmission box torque converter type clear it and add with new gear oil 3 Clean out dirty things and water in the hydraulic oil reservoir and fuel reservoir add with new hydraulic oil 4 Check the clearance of the valve gas valve cap and other parts on the engine 5 Adding antifreeze or water to the required scale 6 Recharge the battery...

Page 45: ...working condition 2 Inspection and maintenance are usually ignored you must find the problems and solve it in time 3 Use the orthodoxy spare part of HANGZHOU fork lift truck general plant 4 Don t use different oil when changing or adding oil 5 Don t throw away the waste oil or electrolyte liquid as you wish Should deal with it depend on the local environmental protection laws and regulations requi...

Page 46: ...ling fluid 8 Clean the air cleaner element gasoline engine Replace the air cleaner element diesel engine 9 Drain the water of oily water separator diesel engine 10 Clean or replace the filter element of air cleaner 11 Idling of engine tachometer 12 Ignition timing gasoline engine 13 Spark plug gasoline engine 14 Check distributor point cover and rotor gasoline engine 1 15 Lining of distributor IC ...

Page 47: ... Transmission Replace oil 1 First time Check differential oil and replace it if needs Driving axle front axle Check connection and retighten moment Check and adjust brake pedal for free travel and clearance Replace brake fluid Check for proper brake operation Brake and inching system Check and inching brake pedal for free travel and clearance Check for oil level Change oil 1 Clean oil return sucti...

Page 48: ...fting system Check roller of mast and lifting bracket parts for cracks or damage Table for bolt s tight moment unit N m Grade Bolt s diameter 4 6 5 6 6 6 8 8 6 4 5 5 7 6 8 9 12 8 10 12 12 15 14 18 22 29 10 20 25 25 31 29 39 44 58 12 35 44 44 54 49 64 76 107 14 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 28...

Page 49: ...llowing table If there is any off normal happened on these parts before replacement time please replace it deservedly Name of key safe parts service life years Brake hose or hard tube l 2 Hydraulic rubber hose for lifting system l 2 Lifting chain 2 4 High pressure rubber hose or tube for hydraulic system 2 Grease cup for brake fluid 2 4 Tube for fuel 2 Sealing member rubber articles inside of hydr...

Page 50: ...W 90 Caltex 6 5 exclusive use Choice HZY3 brake liquid add when leaving factory or DOT3 brake liquid 1 5 Besides M type Brake liquid Mobil delvac advanced hydraulic oil SAE10W 1 1 5 For M type Antirust antifreeze liquid 35 car antifreeze add when leaving factory or FD 2 antifreeze 10 11 Industrial Vaseline 2 Electrode of Storage battery Lubrication grease Currency lithium group lubricate grease Re...

Page 51: ...30 35N RW22 CPCD20 25N RW27 CPCD30 35N RW27 CPCD10 15 18N RW32 CPCD20 25N RW32 CPCD20 25N RW33 CPCD30 35N RW33 CPCD20 25N RW15A CPCD30 35N RW15A CPQD20 25N RW22A CPQD30 35N RW22A CPQD20 25 30 35N RW26 Y 10 CPCD10 15 18N RW32M CPCD20 25N RW32M CPCD20 25N RW33M CPCD30 35N RW33M Hydrodynamic power transmission oil DEXRON III Caltex 4 CPCD20 25N RW10B CPCD30 35N RW10B CPQD20 25N RW22B CPQD30 35N RW22B...

Page 52: ...portaxis steering cylinder pin rear wheelbearing steering linkpin main pin of steering knuckle steering axle supportaxis 1 atuo generalpurpose lithium lubricating grease 2 engineoil 3 gear oil 4 hydraulic oil 5 torque converteroil 6 brake fluid fill replace clutch brake pedal clutch type fine motioin brake pedal hydraulic type mechanicalgear box clutch front wheeldrive bearing steering linkpin ste...

Page 53: ...the disused liquid include antifreeze liquid engine oil hydraulic oil hydrodynamic power transmission oil gear oil brake liquid lubrication grease and disused battery 3 The disused liquid referred above should be disposed according to the local environment protection law rather than pouring at discretion to pollute the environment Safety note The antifreeze liquid engine oil hydraulic oil hydrodyn...

Page 54: ...50 Scutcheons There are many scutcheons and labels on the different position of the truck ...

Page 55: ...e label 14 Operate label 15 Hand brake label 16 Load curve scutcheon 17 Load curve scutcheon 18 Load curve scutcheon 19 warning label 21 Fan cuts hand label 22 Belt nips hand label 23 Noise label 24 Hydraulic oil label 25 Hanging label 26 CE label 27 no water flushing label 28 Antifreeze label 29 Lubrication system label 30 Tight point label 31 Air pressure label 32 Horn label 33 LPG label ...

Page 56: ... label show the position for adding oil at the left rear supporting leg of the cabane Not for gasoline and LPG trucks 5 gasoline label show the position for adding oil at the left rear supporting leg of the cabane Not for gasoline and LPG trucks 6 tonnage label The word 30 means the rated load is 3 0 ton If the lifting height increases or adds attachment the rated load will decrease ...

Page 57: ...entering label Warning It is dangerous of your life If the body is clamped among the mast instrument frame and shield cabane your life will be dangerous If the part needs to be check or repaired the inspection and repair should be carried out after shutting down the engine Nobody is allowed on the truck and the man outside the truck is not allowed to operate the truck preventing from accident caus...

Page 58: ... the position of the load center max load and max lifting height If it has side moving and attachment the load decreases If the lifting height increases the load decreases Before loading check whether the load and the center distance of load are in the allowed range show in the diagram of load capacity If the shape of load is complicated make the most heavy part place in the center of the fork and...

Page 59: ...e 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 obstructions and the path of travel Watch clearance especially overhead and tai...

Page 60: ... front wheel drive bearing mast seat bearing front axis pin of tilt cylinder steering axle support axis steering cylinder pin rear wheel bearing steering link pin main pin of steering knuckle steering axle support axis 1 atuo general purpose lithium lubricating grease 2 engine oil 3 gear oil 4 hydraulic oil 5 torque converter oil 6 brake fluid fill replace clutch brake pedal clutch type fine motio...

Page 61: ...umber of truck body Each truck has a unique truck body series number its print position is at the right front side of the truck body Detail There is a label with the word on the cylinder the max weight of the LPG cylinder 52kg the max pressure of the LPG 2 2 M Pa the max weight the bracket can support 105kg ...

Page 62: ...onvey The forklift truck is designed for material handling and short distance transportation only It is inappropriate for long distance transportation The Fork Lift Truck must be transported by ship train or lorry of 5T loading Tighten the brake lever take woods to block the front ad tear wheels and bind the truck body with enough strong rope to avoid slippage during transportation Towing The towi...

Page 63: ...ion gear box CPCD10 15 18N RW10 ISUZU C240PKJ 30 Diesel YQXD18EHydrodynamic power transmission gear box CPQD10 15 18N RW21 K21 Gasoline NISSAN YQXD18HBHydrodynamic power transmission gear box CPCD10 15 18N RW32 YANMAR4TNE92Diesel YQXD18EHydrodynamic power transmission gear box CPCD10 15 18N RW32M 4TNE92 HRJ Diesel Korea hydraulic transmission gearbox 1 500 1 5 500 1 8 500 ...

Page 64: ...A NISSAN 2STF150 Hydrodynamic power transmission gear box CPQD20 25N RW22B K25gasoline NISSAN OKAMUR transmission CPCD20 25N RW33M 4TNE98 BQFLCdiesel Korea hydraulic transmission gearbox 2 500 2 5 500 CPCD20 25N RW15A TD27Diesel NISSAN NISSAN 2STF150 Hydrodynamic power transmission gear box CPCD20 25N RW32 YANMAR 4TNE92 Diesel YQXD25Hydrodynamic power transmission gear box CPCD20 25N RW33 YANMAR4T...

Page 65: ...N RW22A NISSAN 2STF150 Hydrodynamic power transmission gear box CPQD20 25N RW22B K25gasoline NISSAN OKAMUR transmission CPCD30 35N RW15A TD27 Diesel NISSAN NISSAN2STF150 Hydrodynamic power transmission gear box CPCD30N RW32 YANMAR4TNE92 Diesel YQXD30Hydrodynamic power transmission gear box CPCD30 35N RW33 YANMAR4TNE98 Diesel YQXD30Hydrodynamic power transmission gear box CPCD30 35N RW33B YANMAR4TN...

Page 66: ...4 5 Ground clearance mm 115 115 115 Min turning radius mm 1925 1970 2000 Max grade ability 20 20 20 wheelbase mm 1400 1400 1400 Wheel thread F R mm 890 900 890 900 890 900 Service weight Kg 2450 2740 2930 Overall dimension L W H exclusive forks 2225 1080 1995 2265 1080 1995 2300 1080 1995 Tyre F R 6 5 10 10PR 2 5 00 8 10PR 2 6 5 10 10PR 2 5 00 8 10PR 2 6 5 10 10PR 2 5 00 8 10PR 2 Voltage Capacity ...

Page 67: ...Min turning radius mm 1925 1970 2000 Max grade ability 20 20 20 wheelbase mm 1400 1400 1400 Wheel thread F R mm 890 900 890 900 890 900 Service weight Kg 2500 2740 2930 Overall dimension L W H exclusive forks 2225 1080 1995 2265 1080 1995 2300 1080 1995 Tyre F R 6 5 10 10PR 2 5 00 8 10PR 2 6 5 10 10PR 2 5 00 8 10PR 2 6 5 10 10PR 2 5 00 8 10PR 2 Voltage Capacity Ah 12 60 20h 12 60 20h 12 60 20h typ...

Page 68: ...radius mm 1925 1970 2005 Max grade ability 20 20 20 wheelbase mm 1400 1400 1400 Wheel thread F R mm 890 900 890 900 890 900 mechanical 2395 2685 2875 Service weight Kg hydraulic 2450 2740 2930 Overall dimension L W H including forks 3145 1080 2110 3185 1080 2110 3220 1080 2110 Tyre F R 6 5 10 10PR 2 5 00 8 10PR 2 6 5 10 10PR 2 5 00 8 10PR 2 6 5 10 10PR 2 5 00 8 10PR 2 Voltage Capacity Ah 12 60 20h...

Page 69: ...turning radius mm 1925 1970 2005 Max grade ability 20 20 20 wheelbase mm 1400 1400 1400 Wheel thread F R mm 890 900 890 900 890 900 mechanical 2395 2685 2875 self weight Kg hydraulic 2450 2740 2930 Overall dimension L W H including forks 3145 1080 2110 3185 1080 2110 3220 1080 2110 Tyre F R 6 5 10 10PR 2 5 00 8 10PR 2 6 5 10 10PR 2 5 00 8 10PR 2 6 5 10 10PR 2 5 00 8 10PR 2 Voltage Capacity Ah 12 9...

Page 70: ...s mm 2175 2235 2375 2415 full load grade 25 25 25 25 wheelbase mm 1650 1650 1760 1760 Wheel thread F R mm 965 970 965 970 1005 975 1005 975 Service weight Kg 3440 3765 4255 4555 Overall dimension L W H including forks 3600 1150 2120 3675 1150 2120 3820 1225 2150 3870 1225 2150 Tyre F R 7 00 12 12PR 6 00 9 10PR 7 00 12 12PR 6 00 9 10PR 28 9 15 12PR 2 6 50 10 10PR 2 28 9 15 12PR 2 6 50 10 10PR 2 Bat...

Page 71: ...130 130 Min turning radius mm 2175 2235 2375 2415 Max grade ability 25 25 25 25 wheelbase mm 1650 1650 1760 1760 Wheel thread F R mm 965 970 965 970 1005 975 1005 975 Service weight Kg 3440 3765 4255 4555 Overall dimension L W H including forks 3600 1150 2120 3675 1150 2120 3820 1225 2150 3870 1225 2150 Tyre F R 7 00 12 12PR 6 00 9 10PR 7 00 12 12PR 6 00 9 10PR 28 9 15 12PR 2 6 50 10 10PR 2 28 9 1...

Page 72: ...05 130 Min turning radius mm 2175 2235 2375 Max grade ability 20 18 18 wheelbase mm 1650 1650 1760 Wheel thread F R mm 965 970 965 970 1005 975 Service weight Kg 3440 3765 4255 Overall dimension L W H including forks 3600 1155 2120 3675 1155 2120 3820 1225 2150 Tyre F R 7 00 12 12PR 6 00 9 10PR 7 00 12 12PR 6 00 9 10PR 28 9 15 12PR 2 6 50 10 10PR 2 Voltage Capacity Ah 12 90 20h 12 90 20h 12 90 20h...

Page 73: ... 130 130 Min turning radius mm 2175 2235 2375 2415 Max grade ability 20 20 20 20 wheelbase mm 1650 1650 1760 1760 Wheel thread F R mm 965 970 965 970 1005 975 1005 975 Service weight Kg 3440 3765 4255 4555 Overall dimension L W H including forks 3600 1155 2120 3675 1155 2120 3820 1225 2150 3870 1225 2150 Tyre F R 7 00 12 12PR 6 00 9 10PR 7 00 12 12PR 6 00 9 10PR 28 9 15 12PR 2 6 50 10 10PR 2 28 9 ...

Page 74: ... grade ability 20 18 18 15 wheelbase mm 1650 1650 1760 1760 Wheel thread F R mm 965 970 965 970 1005 973 5 1005 973 5 Service weight Kg 3440 3765 4255 4555 Overall dimension L W H including forks 3600 1155 2120 3675 1155 2120 3820 1225 2150 3870 1225 2150 Tyre F R 7 00 12 12PR 6 00 9 10PR 7 00 12 12PR 6 00 9 10PR 28 9 15 12PR 2 6 50 10 10PR 2 28 9 15 12PR 2 6 50 10 10PR 2 Voltage Capacity Ah 12 90...

Page 75: ...0 130 Min turning radius mm 2175 2235 2375 2415 Max grade ability 20 20 20 20 wheelbase mm 1650 1650 1760 1760 Wheel thread F R mm 965 970 965 970 1005 975 1005 975 Service weight Kg 3440 3765 4255 4555 Overall dimension L W H including forks 3600 1155 2120 3675 1155 2120 3820 1225 2150 3870 1225 2150 Tyre F R 7 00 12 12PR 6 00 9 10PR 7 00 12 12PR 6 00 9 10PR 28 9 15 12PR 2 6 50 10 10PR 2 28 9 15 ...

Page 76: ...22 5 Ground clearance mm 105 Min turning radius mm 2175 2235 2T 25 Grade full load 2 5T 20 wheelbase mm 1650 Wheel thread F R mm 965 970 Service weight Kg 3600 3675 2T 2525 1155 2120 Overall dimension L W H exclusive forks 2 5T 2600 1155 2120 Tyre F R 7 00 12 12PR 2 6 00 9 10PR 2 Voltage Capacity Ah 12 100 20h type WanFengWF491GPgasoline Displacement cc 2237 Rated capacity rpm 41 KW 2800r min Dies...

Page 77: ...h hydraulic 20 5 Ground clearance mm 105 Min turning radius mm 2175 2235 Grade full load 25 wheelbase mm 1650 Wheel thread F R mm 965 970 Service weight Kg 3760 2t 2525 1155 2120 Overall dimension L W H exclusive forks 2 5t 2600 1155 2120 Tyre F R 7 00 12 12PR 2 6 00 9 10PR 2 Voltage Capacity Ah 12 100 20h type A498BT1 1 Diesel Displacement cc 3168 Rated capacity rpm 45KW 2500r min Diesel Max torq...

Page 78: ...rning radius mm 2175 2235 2175 2235 2t Grade full load 2 5t 20 20 wheelbase mm 1650 1650 Wheel thread F R mm 965 970 965 970 Service weight Kg 3760 3760 2t 2525 1155 2120 2525 1155 2120 Overall dimension L W H exclusive forks 2 5t 2600 1155 2120 2600 1155 2120 Tyre F R 7 00 12 12PR 2 6 00 9 10PR 2 7 00 12 12PR 2 6 00 9 10PR 2 Voltage Capacity Ah 12 100 20h 12 100 20h type YANMAR 4TNE92 HRJ diesel ...

Page 79: ...ic 19 Ground clearance mm 105 Min turning radius mm 2175 2235 2t Grade full load 2 5t 20 wheelbase mm 1665 Wheel thread F R mm 965 970 5 Service weight Kg 3440 3765 2T 3615 1155 2120 Overall dimension L W H exclusive forks 2 5T 3690 1155 2120 Tyre F R 7 00 12 12PR 2 6 00 9 10PR 2 Voltage Capacity Ah 12 100 20h type YANMAR 4TNE98 BQFLC diesel engine Displacement cc 3319 Rated capacity rpm 44 3KW 23...

Page 80: ...21 Ground clearance mm 130 Min turning radius mm 2375 2415 3t 20 Grade full load 3 5t 18 wheelbase mm 1760 Wheel thread F R mm 1005 973 3t 4255 Service weight Kg 3 5t 4555 3t 2760 1225 2010 Overall dimension L W H exclusive forks 3 5t 2810 1225 2160 Tyre F R 28 9 15 12PR 2 6 50 10 10PR 2 Voltage Capacity Ah 12 100 20h type WanFeng WF491GP gasoline Displacement cc 2237 Rated capacity rpm 41 KW 2800...

Page 81: ...m h hydraulic 19 Ground clearance mm 130 Min turning radius mm 2375 2415 3T 25 Grade full load 3 5T 20 wheelbase mm 1760 Wheel thread F R mm 1005 973 3t 4255 Service weight Kg 3 5t 4555 Overall dimension L W H including forks 3185 1080 2110 Tyre F R 28 9 15 12PR 2 6 50 10 10PR 2 Voltage Capacity Ah 12 100 20h type A498BPG Diesel Displacement cc 3168 Rated capacity rpm 45KW 2500r min Diesel Max tor...

Page 82: ...n turning radius mm 2375 2415 2375 3t 20 20 Grade full load 3 5t 20 wheelbase mm 1760 1760 Wheel thread F R mm 1005 973 1005 973 3t 4255 4255 Service weight Kg 3 5t 4555 4555 Overall dimension L W H including forks 3145 1080 2110 3185 1080 2110 Tyre F R 28 9 15 12PR 2 6 50 10 10PR 2 28 9 15 12PR 2 6 50 10 10PR 2 Voltage Capacity Ah 12 100 20h 12 100 20h type YANMAR 4TNE98 BQFLC Diesel YANMAR 4TNE9...

Page 83: ... 20 Ground clearance mm 130 Min turning radius mm 2375 2415 3t 20 Grade full load 3 5t 20 wheelbase mm 1760 Wheel thread F R mm 1005 973 3t 4280 Service weight Kg 3 5t 4555 Overall dimension L W H including forks 3820 1225 2150 3t 3870 1225 2150 3 5t Tyre F R 28 9 15 12PR 2 6 50 10 10PR 2 Voltage Capacity Ah 12 100 20h type YANMAR 4TNE98 BQFLC diesel Displacement cc 3319 Rated capacity rpm 44 3kW ...

Page 84: ...5 130 130 Min turning radius mm 2175 2235 2375 2415 Max grade ability 20 20 20 20 wheelbase mm 1650 1650 1760 1760 Wheel thread F R mm 965 970 965 970 1005 975 1005 975 Service weight Kg 3440 3765 4280 4555 Overall dimension L W H including forks 3600 1155 2120 3675 1155 2120 3820 1225 2150 3870 1225 2145 Tire F R 7 00 12 12PR 6 00 9 10PR 7 00 12 12PR 6 00 9 10PR 28 9 15 12PR 2 6 50 10 10PR 2 28 9...

Page 85: ...81 12 Operation disassembly and installation of cab ...

Page 86: ...s from left rear and right rear legs remove 4 bolts from left rear and right rear legs 4 Lift cab a little with crane 5 Remove switch connection of fan rain wiper alarm light etc remove wire from 4 support legs and slip into support legs 6 Put down cab slowly and lightly avoid pressing wire and keep wire intact Installing cab The installing procedure is opposite to removing procedure But remove th...

Page 87: ...itch on the petrol switch for several seconds after petrol is flowing into the floater room of the carburetor turn the ignition key to start the motor the engine is started by petrol 2 By LPG a Starting up when there is no petrol in the carburetor if there is no petrol in the carburetor before starting up you could start up the engine directly by LPG that is to shut off the petrol switch but switc...

Page 88: ...ine LPG cylinder 1 f unction It composed of safety valve LPG inlet quick fitting and other relevant accessories It supports and stores fuel and it is fixed at the back of truck The functions a shut off valve It control inlet and outlet line of the LPG b Charging limit valve open the charging limit valve to charge LPG till the charging device is automatically closed when 70 80 volume of the contain...

Page 89: ... Outlet shut off valve 6 Level indication 7 Inlet shut off valve 4 Cylinder replacement Paste safety operation procedures on cyliner 1 make the truck stay on flat and stability ground stop engine pull hand brake 2 remove cylinder a Close outlet shut off valve and remove outlet connector b Loosen cylinder fixed parts see followed Fig ...

Page 90: ...efinger middle finger and ring finger to pull lock buckle out 2 Keep 1 procedure and push up tighten device till touch cylinder 3 Keep the lock buckle out and pull downward the whole tighten device 4 Then buckle belt is loosened from tighten device 5 Remove the left tighten device from buckle belt by the same way ...

Page 91: ... Make sure the outlet shut off valve closed 3 When charging the place must have charging license which is awarded by Quality and Technical Supervision Bureau It is forbidden to charge by self and the component must accord with table 1 Notice a 1 may use more than 20 b 2 may use more than 10 c 3 may use more than0 ...

Page 92: ...heet copper corrosion 1 1 1 SH T 0232 Total sulfur content mg m3 270 270 270 SH T 0222 d sulphuretted hydrogen zero zero zero SH T 0125 free water zero zero zero Eyeballing 1 gaseity content total sulfur content is at 0 101 35kPa 2 can measure sample whether it exists free water by eyeballing when measuring density a evaporation pressure can be evaluated by GB T 12576 measured by GB T 6602 when ar...

Page 93: ...t cap on the charging valve plug the filling connector open the inlet shutoff valve to charge LPG till 80 rated volume of the container is full the charging device is automatically closed when 80 rated volume of the container is full take out the filling connector screw down the dust cap and the charging limit valve Check all parts and make sure they are all at intact condition 4 Lift the cylinder...

Page 94: ...g and keep the lock buckle out revolve strain device downward with right hand till touch cylinder e Keep it tensioning with left hand hold the strain device loose lock buckle and rotate strain device several times till it can not be pushed f Turn downward till touch cylinder 5 Make sure the inlet and outlet shutoff valve 2 3 are on closed state 6 Connect the inlet connector 5 with outlet valve 4 a...

Page 95: ...ghten open outlet shutoff valve make sure it no leak and convenient to use 3 It must check the cylinder assembly whether leak or not per charging and fixing it on truck 4 Please prevent dust to enter into the inlet and revolve dustproof cover after filling LPG out to protect the airproof of check valve 5 It is forbidden to change the pressure of safety valve 6 Call the qualified unit to check and ...

Page 96: ...e no leak of LPG then open the LPG outpouring valve on the LPG cylinder check more to ensure no leak of LPG fuel system before starting up 15 If there is LPG leak during operation shut off the LPG switch and the outpouring valve at once check every part and all connection to see if there is leak or loose and get rid of it in time Fuel by petrol before malfunction is removed 16 If there is 10 minut...

Page 97: ...he LPG cylinder Never insolate the truck in the sun long 23 Shut off power and all valves after the truck is garaged Keep good ventilation and extinguishing measure in the garage 24 Never repair the LPG cylinder valves or pipes at garages or parking lots any smoke on the truck ...

Page 98: ... replace it with a new one in time if there is any damaged 5 After finishing the LPG forklift debugging and one day well run or a full container of LPG is used up you should adjust the LPG vaporizer again to ensure proper ratio of fuel to air 6 Check the electric system after every three months have elapsed if any switch connection peg is oxidized or rusted and get rid of it in time 7 Take a routi...

Page 99: ...ance If truck will be stored over 30 days the following should be done z Insure the green point visual in inner capacity display z Disconnecting negative earth wire to avoid discharging by additional current release z Keep the battery charge completely if the battery can not be removed down from truck z Make a general schedule charge every 30 45 days z Check battery when the green point of liquid ...

Page 100: ...lor as density of electrolyte changing it is called electric eye The ball will be green when the capacity is normal density of electrolyte reaches the standard it will be white when capacity is not enough density of electrolyte does not reach the standard it will be red when the electrolyte is acute shortage look over whether the shell is broken leaking or the battery has fault ...

Page 101: ... the distance of bottom of cargo and ground is less than 300mm and mast incline back 5 The weight of cargo couldn t exceed the limited value of combination carrying capacity of forklift and attachment It is not allowed that partial load at high position It is a short time work for attachment with side shifter Partial load is around 100mm Above 5 ton including 5 ton the side shifter movable within ...

Page 102: ... load capacity of truck is the least Attachment load capacity just a count value of attachment pressure 3 Assembly go to in reason credibility safety to avoid the attachment glide around carriage in using 4 After hang attachment embed the rise catch block to the gap of top beam let the offset of centre line of attachment and carriage is less than 50mm Otherwise it will be affect the landscape orie...

Page 103: ... standard z Noise will accord with EN12053 2001 and 2000 14 EC Model The sound pressure level at operator position unit dB A Sound radiation sound power level unit dB A CPYD10N RW 85 2 102 8 CPYD15N RW 85 2 101 7 CPYD18N RW 85 7 101 9 CPYD20N RW 87 1 102 8 CPYD25N RW 87 1 102 9 CPYD30N RW 85 9 103 1 CPYD35N RW 85 5 103 4 CPQD10N RW 85 2 101 9 CPQD15N RW 85 2 102 1 CPQD18N RW 85 7 102 5 CPQD20N RW ...

Page 104: ...2 16 1 92 0 77 CPQD25N RW 2 22 1 78 0 49 CPQD35N RW 2 09 1 91 0 67 z Electromagnetism compatible is measured according to EN12895 2000 and the result meets the requirement of 2004 108 EEC z Engine emission is according to standard 97 68 EC and 2005 88 EC Model Synthetic acceleration from the seat to the operator body unit m s2 Model Synthetic acceleration from the seat to the operator body unit m ...

Page 105: ... 2006 42 EC Machinery Directive 2004 108 EC EMC Directive 97 68 EC Engine pollutant emission Directive 2000 14 EC 2005 88 EC Noise Directive Equipment according to the definition given by Annex I item 36 of Noise Directive Conformity assessment procedure followed Annex V of Noise Directive 2000 14 EC Holder of the technical documentation Name Address Measured sound power level dB Guaranteed sound ...

Page 106: ...ING EUROPEAN DIRECTIVES 2006 42 EC Machinery Directive 2004 108 EC EMC Directive 2000 14 EC 2005 88 EC Noise Directive Equipment according to the definition given by Annex I item 36 of Noise Directive Conformity assessment procedure followed Annex V of Noise Directive 2000 14 EC Holder of the technical documentation Name Address Measured sound power level dB Guaranteed sound power level dB COMPLIE...

Page 107: ...103 17 Maintain record Date Item of maintenance Maintain personnel ...

Page 108: ...facturing site 88 Donghuan Road LinAn Economic Development zone Zhejiang P R China ZIP 311305 Registered Address 398 Shi Qiao Road Hangzhou P R China ZIP 310004 Fax 0086 571 88132890 0086 571 88926789 Web http www hcforklift com E mail sales hcforklift com ...

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HANGCHA CPCD10N-RW10, Operation And Maintenance Manual

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