HANGCHA CPCD30/35-XW43E-RT Operational And Maintenance Manual Download

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OPERATION MANUAL

2.5-3.5T

Rough terrain forklift truck

Operational and Maintenance 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

Summary of Contents for CPCD30/35-XW43E-RT

Page 1: ...ance 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 CPC...

Page 2: ...pted 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 yo...

Page 3: ...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 1...

Page 4: ...ility 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 use...

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 ther...

Page 6: ...signed 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 Ap...

Page 7: ...f 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 F...

Page 8: ...tor 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 l...

Page 9: ...ormal 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 enou...

Page 10: ...ormal 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...

Page 11: ...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 li...

Page 12: ...tion 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...

Page 13: ...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...

Page 14: ...everely 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...

Page 15: ...tion 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...

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 ne...

Page 17: ...generation 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 possibl...

Page 18: ...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 th...

Page 19: ...e engine information display 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 Ash SOOT VDC r min km h...

Page 20: ...generation Return to the setting page press key 1 to return to the setting page 3 Maintenance reminder maintenance page a Remaining hours query page Reset Back Reset press the key 2 to jump to the mai...

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 Emergen...

Page 22: ...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 sw...

Page 23: ...cket 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 workin...

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...

Page 25: ...n 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...

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 complete...

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 sea...

Page 28: ...o 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 b...

Page 29: ...ap 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 Antifr...

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...

Page 31: ...head 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...

Page 32: ...ing 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 us...

Page 33: ...he 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...

Page 34: ...hift 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...

Page 35: ...d 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...

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 extingu...

Page 37: ...s 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 ope...

Page 38: ...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 t...

Page 39: ...rake 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 ente...

Page 40: ...gine 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...

Page 41: ...ntle 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 b...

Page 42: ...ift 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 th...

Page 43: ...ing 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...

Page 44: ...g 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 t...

Page 45: ...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 engine...

Page 46: ...tep 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...

Page 47: ...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 Abnorma...

Page 48: ...evice 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 Warni...

Page 49: ...ilters 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 Be...

Page 50: ...d 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 the...

Page 51: ...t 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...

Page 52: ...dditional 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 remo...

Page 53: ...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 te...

Page 54: ...ruck 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 Fork...

Page 55: ...d 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...

Page 56: ...ay 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 sta...

Page 57: ...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 fo...

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 th...

Page 59: ...ill 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 l...

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...

Page 61: ...ur 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 pr...

Page 62: ...st 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 s...

Page 63: ...ly 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 F...

Page 64: ...d 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 Chec...

Page 65: ...e 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 mainten...

Page 66: ...s 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 i...

Page 67: ...rake 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 Too...

Page 68: ...rtion 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...

Page 69: ...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 o...

Page 70: ...t 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...

Page 71: ...ote 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...

Page 72: ...r 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...

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: ...nd 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 h...

Page 75: ...y 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 la...

Page 76: ...t 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 l...

Page 77: ...te 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...

Page 78: ...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 l...

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: ...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 truc...

Page 81: ...ravel 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 dime...

Page 82: ...el 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 42...

Page 83: ...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...

Page 84: ...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...

Page 85: ...8 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 dimen...

Page 86: ...avel 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...

Page 87: ...d 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 for...

Page 88: ...el 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 43...

Page 89: ...oad 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 b...

Page 90: ...40 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...

Page 91: ...m 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 48...

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 Servic...

Page 93: ...ry 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...

Page 94: ...s 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 refer...

Page 95: ...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 bat...

Page 96: ...xceed 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...

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 cent...

Page 98: ...r 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...

Page 99: ...k 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 forkli...

Page 100: ...5 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 Electro...

Page 101: ...aschine product name Internal combustion counterbalanced Forklift Truck Produktbezeichnung commercial name Handelsbezeichnung function Funktion model CPCD30 XW43E RT CPCD35 XW43E RT CPCD25 XW43E RT CP...

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

Page 103: ...HA 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 hcforklif...

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