HANGCHA R Series 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 R Series

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: ...proving 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...

Page 3: ...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...

Page 4: ...RKLIFT 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...

Page 5: ...te 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...

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...

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 In...

Page 8: ...rator 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...

Page 9: ...fter 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 ru...

Page 10: ...und 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 Shif...

Page 11: ...h 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 travelin...

Page 12: ...ning 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 del...

Page 13: ...urely 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...

Page 14: ...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 C...

Page 15: ...d 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...

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...

Page 17: ...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 f...

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 ad...

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 sn...

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...

Page 21: ...cle 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...

Page 22: ...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 s...

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 th...

Page 24: ...o 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 lo...

Page 25: ...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 le...

Page 26: ...r 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 c...

Page 27: ...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 t...

Page 28: ...lace 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...

Page 29: ...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 2...

Page 30: ...e 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 po...

Page 31: ...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 loos...

Page 32: ...ition 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 oi...

Page 33: ...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...

Page 34: ...kward 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 g...

Page 35: ...orklift 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 f...

Page 36: ...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 ope...

Page 37: ...ller 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...

Page 38: ...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 th...

Page 39: ...h 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...

Page 40: ...ting 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...

Page 41: ...d 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 handlin...

Page 42: ...e 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 C...

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...

Page 44: ...rankcase 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...

Page 45: ...orking 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 d...

Page 46: ...ing 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 o...

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 clea...

Page 48: ...ting 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 2...

Page 49: ...lowing 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 rub...

Page 50: ...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...

Page 51: ...0 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...

Page 52: ...ortaxis 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 hydrau...

Page 53: ...he 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 abov...

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

Page 55: ...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 Hy...

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 o...

Page 57: ...O 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...

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...

Page 59: ...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 carefu...

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...

Page 61: ...mber 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...

Page 62: ...nvey 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 tr...

Page 63: ...on 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...

Page 64: ...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...

Page 65: ...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...

Page 66: ...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 2...

Page 67: ...in 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 exclusiv...

Page 68: ...adius 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...

Page 69: ...urning 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 Ove...

Page 70: ...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...

Page 71: ...30 130 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 4...

Page 72: ...5 130 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...

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...

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...

Page 75: ...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 455...

Page 76: ...2 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...

Page 77: ...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...

Page 78: ...ning 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 dimensi...

Page 79: ...c 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...

Page 80: ...1 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 dim...

Page 81: ...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 dimensi...

Page 82: ...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 in...

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 incl...

Page 84: ...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...

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

Page 86: ...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 sup...

Page 87: ...tch 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 Startin...

Page 88: ...ne 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...

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...

Page 90: ...finger 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 T...

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 c...

Page 92: ...eet 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 sulf...

Page 93: ...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...

Page 94: ...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 s...

Page 95: ...hten 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 i...

Page 96: ...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 swit...

Page 97: ...e 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 LP...

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 ag...

Page 99: ...nce 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 c...

Page 100: ...or 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 eno...

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...

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 us...

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...

Page 104: ...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 emis...

Page 105: ...nery 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 Dire...

Page 106: ...CTIVES 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 asses...

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

Page 108: ...acturing 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...

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HANGCHA R Series, Operation And Maintenance Manual

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Summary of Contents for R Series

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