Hangcha 1-3.5t R Series Internal Combustion Counterbalanced Forklift Truck - OPERATION and MAINTENANCE MANUAL
Hangcha 1-3.5t R Series Internal Combustion Counterbalanced Forklift Truck - OPERATION and MAINTENANCE MANUAL
Hangcha 1-3.5t R Series Internal Combustion Counterbalanced Forklift Truck - OPERATION and MAINTENANCE MANUAL
Original Instruction
This operation manual is the explanations that how to use 1-3.5t R series forklift truck
correctly. It will instruct you how to operate safety and precautionary maintenance. To
ensure safety and exert the truck’s potential, all the personnel that in charge of
operation, maintenance and management must read this manual thoroughly before
starting work with the forklift.
Compared with 1-3.5t N series internal combustion forklift truck, 1-3.5t R series
forklift truck has the following strengths: enhancing the power, improving 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 forklift truck assembled
attachments.
Our product design will update and perform better, so the content in this manual may
be not the same as the forklift you owned.
If you have any questions please keep touches with ZHEJIANG HANGCHA
ENGINEERING MACHINERY CO., LTD. sales department or let the agents know.
○
C DEC.2009 4th EDITION
Content
Foreword
1. GENERAL RULES.....................................................................................................................1
Instruments..............................................................................................................................3
Switches....................................................................................................................................5
Controls....................................................................................................................................6
Body and others.......................................................................................................................9
3. SAFETY INSTRUCTIONS......................................................................................................13
4. MAINTENANCE ......................................................................................................................19
6. OPERATION.............................................................................................................................35
Star-up....................................................................................................................................35
Traveling ................................................................................................................................36
Pick up....................................................................................................................................37
Stacking load..........................................................................................................................37
Remove load ..........................................................................................................................38
7. DEPOSIT ...................................................................................................................................39
8. MAINTENANCE ......................................................................................................................41
1
choose the right tool and assembly method. Depress the noise and libration as
soon as possible to reduce the noise pollute to circumstance.
20. The work road surface for forklift should be stability and unknit, cement,
blacktop or beton. If there are snows, ice, water or other eyewinker, bar.
Eliminate all, and then work. Otherwise the truck will be out of control and
lead the safety accident.
21. 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.
22. After take-down the hood, water tank cover board, overhead, backrest of mast,
unallowed to 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) Arrange for the modification or alteration to be designed, tested and
implemented by an engineer(s) expert in industrial trucks and their safety;
b) Maintain a permanent record of the design, test(s) and implementation of the
modification or alteration;
c) Approve and make appropriate changes to the capacity plate(s),decals, tags and
instruction handbook;
d) Affix a permanent and readily visible label to the truck stating the manner in
which the truck has been modified or altered together with the date of the
modification or alteration, and the name and address of the organisation that
accomplished the tasks.
2
2. NAME OF MAIN PARTS OR COMPONENT
Instruments
3
Hour meter [1] Caution
This meter measures working time If this light continues to stay lit or
of engine. Use meter to schedule lights up during operation, the pressure
lubrication and maintenance periods. is lower than 0.05Mpa and should be
checked immediately.
Water temperature gauge [2]
This gauge indicates the oil Glow indicator (C) [Diesel truck]
temperature in the torque converter Turn the key to “ON” position and
transmission box. In normal status, the the indicator lights up for a moment.
pointer is in green zone. (60~115℃) After the indicator goes out, turn the key
to . “Start” position
Caution
If the pointer points red zone, please stop Sedimentor indicator (D) [Use in W9、
the truck at once. Decrease the engine speed
to make the engine cool. Check the cooling W13、W15A diesel truck]
fluid if enough and the fan belt’s elasticity if In normal state, once the starter is
fit. set to “ON” position, this lamp
lights up. After the engine is started up,
it goes out.
Fuel gauge [3]
This lamp lights up when water in
The gauge indicates the fuel level in the
sedimentor reaches to a certain level,
tank when the key is at ┃(ON) position.
while the engine is running.
If this lamp continues to stay lit or
Charge (A)
lights up during the engine running,
This lamp indicates the battery
stopping the engine and discharge water
condition of charge. The lamp comes on
immediately.
when the ignition switch is set at “ON”,
but it goes out as the engine starts and
Caution
accelerator pedal is pressed.
Fuel injection pump will be damaged
if continue working when the light is up.
Caution
If the light continues to stay lit or Engine coolant temperature [E]
lights up during operation, the charging In normal state, once the starter is
rate is low and should be checked set to “ON” position, this lamp
immediately. lights up. After the engine is started up,
it goes out.
Oil pressure alert lamp (B) During work time if the oil
This lamp indicates the pressure temperature exceed the normal
condition of engine lube oil. Although it rang(60~120℃) the indicator light on.
lights up when the engine switch is set at
“ON”, once the engine starts up and the Caution
accelerator pedal is pressed, this lamp If the pointer enters the red range,
goes out. stop the operation instantly and slow
down engine speed to cool the coolant
and wait until the pointer goes into the
green range, and have a check then.
4
Switches
5
Light switch [6] Horn button [7]
This light switch can be pulled out Press the rubber cover at the center
at two steps. of steering wheel to sound horn.
Controls
Light Near Far Clear
Power
Stage light light -ance
0 ×
st
1 × × ×
nd
2 × × ×
(×) means connected
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 converter type
Switch)
6
Clutch pedal [8] (frictional clutch Forward-reverse [12]
type) Speed-select lever [13]
Press the clutch pedal fully, the
operator can uncouple the engine and
transmission.
When the clutch pedal released, it
allows power to flow through the clutch
from the engine to transmission.
Caution:
Do not run the lift truck with the
clutch in a half-clutch condition as much
Machinery transmission
as possible.
[12]F-front N-neutral R-backward
[13]1-low N-neutral 2-high
Inching pedal [9] (Torque converter Machinery gear box have four shifts, tow
type) are frontward and tow are backward.
As the inching pedal is pressed, the
Before gear-shifting, be sure to
oil pressure in the hydraulic clutch drops press the clutch pedal to the full. Always
accordingly (the needle of the oil brake to a full stop before reversing the
pressure gauge swings to the left) direction of travel. Shifting the level in
allowing the operator to perform inching reverse the back-up lights turn on.
operation. Use this pedal to inch the Tilt level [14]
truck while operating the hoist system at The mast can be tilted by operation
a high speed. of this tilt lever: pulling on this lever
When pressed to the full, this backwards will tilt the mast backwards,
inching pedal serves as a brake pedal and pushing it forwards will tilt the mast
also. forwards.
The tilt speed can be controlled by
Caution: tilt angle of the lever and accelerator
Do not use the inching pedal too pedal effort.
much. Long time use or use as rest would Caution
cause high temperature of transmission The tilt lock mechanism built in the
oil, or result in slipping of clutch. hydraulic control valve does not allow
the mast to tilt forwards while the engine
Accelerator pedal [11] is being shut down even if the tilt level
Press down the accelerator pedal, is pushed forwards.
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.
7
Warning
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]
8
forklift has no choke line. When turn off Warning!
the key switch, the engine will stop. a. Before adjusting the lever, you’d
Forward-reverse lever [20] better turn off the key switch.
b. Must stop the truck to adjust the
[Electrical Switch]
seat .
The forward reverse lever of truck
installed with electronic reserving is set
on the left of turning rod。
Forward—Forward N—neutral After
allocation—backward
Caution:
Do not forget to place the forward-reverse
lever in the neutral position before starting
the engine.
immediately replace new belt. The belt While maintaining under the cover hood, the
engine must be flameout to avoid hands or
can be used for 3 to 5 years, when found
other parts of the body being clamped by
something abnormal, it should be
running assembly. The engine can be
scrapped early.
no-flameout only when human body does not
Overhead guard
touch parts under cover hood, and to examine
The overhead guard used is strong
where the fault is by hearing.
enough to meet safety standard, and
protects the operator from falling
materials. It’s forbidden to use forklift
without overhead guard.
Hood and snap close
To avoid opening the hood at
discretion, a snap close is set here. Open
the snap close first then the hood can be
open.
Guy head
To avoid opening the hood at
discretion, the hood only can be opened
by specified tools. The guy head is the
specified tool.
Radiator cover hood
Must use special tools (socket spanner)
to open radiator cover hood.
You can open the radiator cover hood
even close the engine hood, so to inspect
the coolant fluid.
Hood
The 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
Caution:
fingers in the hood when closing it.
Retighten the bolt on the cover hood.
10
Radiator cap and coolant reservoir Steering column tilting angle
The reservoir is located inside the adjustment
hood.
The radiator is located under the
cover plate at the rear of the hood.
Warning!
Do not open the radiator cap
abruptly while water’s temperature is
higher than 70℃. Turn the cap a little to
the left to relieve the pressure in the
pressure in the radiator, and then remove
the cap.
Do not wear glove when removing
radiator cap.
The antifreeze fluid is dangerous
for your health, if touched to skin, please The tilting angle of the steering wheel is
wash clean by water. Do not allow adjustable to suit individual operators.
children access to antifreeze. The steering column is unlocked by
Fork stopper pushing down the lever at the left side of
It’s used to adjust fork spacing and turning rod, then adjust the angle suit to
to lock the forks in position. Pull up fork the driver, and pull up the lever to lock.
stoppers, turn 90°, according to loads
to handle the forks spacing. Caution:
a. After stop the truck and pull on the
parking brake lever then to adjust the
tilting angle of steering column.
b. After adjust the angle and pull the
steering wheel to make sure tighten the
lock rod.
Safety step and safety grip
The safety steps are provided on
both sides of the truck body. The safety
grip is provided on the front left pillar of
Warning! the overhead guard. Use the safety step
The forks should be set symmetrically and safety grip facing the truck when get
to machine centerline and fork stoppers on and get off the truck.
should 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.
11
Brake fluid reservoir 2.After addition of fuel is finished,
The brake fluid reservoir is securely close the reservoir cap. A
provided at the left of the cabinet. loose cap could cause fuel leak or fire
hazard in the worst case.
Hydraulic fluid reservoir cap
3.Before attempting to start the engine,
The hydraulic fluid reservoir cap is
make certain that the fuel reservoir cap
located at the right side in the hood. Fill
is securely tightened and that no fuel is
hydraulic fluid through this filler port.
split on or around the truck.
The cap is provided with the dipstick.
4.For the purpose of fuel level
After fill in clean hydraulic fluid, lock
inspection, never use naked flame such
the cap.
as a match or lighter.
Rearview mirror
There are two rearview mirrors on
the safeguard for operator to see rear
accident.
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.
12
should be prepared.
3. Safety instructions
Never fill the fuel tank with the
1. Only trained and authorized engine running.
operator shall be permitted to operate
5. Warm up the temperature of water
the truck. to 70℃ before operation; and cool down
2. Inspect the truck at periodic the temperature of water to lower than
intervals for oil or water leak, 70℃ after work.
deformation, lousiness, etc. If neglected, If the temperature of the water tank
the life of the truck will be shortened is higher than 70℃ , never open the tank
and in the worst case a fatal accident cap.
would occur.
Make sure to replace the “key safe 6. When using your truck in an enclosed
parts” at periodical inspection. space, make sure there is enough
Wipe off oil, grease or water from ventilation. If needed, use a ventilation fan.
the floor board and foot and hand Don’t work in a closed working space
controls, if any. because of the tail gas of truck is
Shut down the engine before dangerous to health.
inspecting the engine and its allied It’s forbidden to use truck under a
components. Especially use caution to circumstance of flammability and easy
the engine fan. to blast.
When inspecting the radiator or 7. Never mount or dismount the
muffler, exercise caution not to get moving truck. Use the safety step(s) and
burnt.
safety grip facing the truck when
3. Any time you find that the trucks mounting or dismounting the truck.
are not functioning properly, operation
of the truck should be halted and the
condition reported to the supervisor.
When doing maintenance in the
high place (such as mast, front and rear
lights) should be care of slide and
clamped.
If any warning lamp comes on,
move to a safe place and check or repair
the trouble.
When doing maintenance, take care
of edges and corners to lacerate hands, 8. Never attempt to work the controls
head and other parts of body. unless properly seated.
The sign of defect should be put on
Before staring, adjusting the seat so
the defecting forklift truck.
you can get easy access to all hands and
4. Don’t use an open flame to check
foot controls.
level, or for leakage, of fuel, electrolyte
or cooling water. 9. Before staring, make sure no one is
Never smoke while inspecting the under, on and close to the truck.
battery, handling fuel or working on the The forward-reverse lever is in
fuel system. There is a danger of neutral.
explosion. 10. Park the truck on a level surface
At working place fire extinguisher and apply the parking brake securely. If
13
parking on a grade is unavoidable, be
sure to block the wheel.
Put the forks on the ground or floor
and tilt a little forwards. Shut down the
engine and remove the key.
11. Operate the controls smoothly-don’t
jerk the steering wheel. Avoid sudden
stops, starts or turns.
12. Control speed and observe traffic
signs.
16. Keep your mind on your work.
When traveling on public roads or
17. Keep your head, hands, arms, feet
streets, obey all local traffic regulations
and legs within the cab. Never let them
13. Pay attention to the route of the
out of cab for any reason.
truck , be sure to make a wide sight.
14
21. Use head lights and required work 23. When operating loaded truck, have
light and clearance lights at night. And the rear end of your machine pointed
travel at a low speed. downhill. When operating unloaded
22. The work surface should be
truck, have the rear end of your machine
solidity and flatness such as cement road
pointed upgrade.
surface, bituminous macadam and beton
Never turn sideways on an incline.
road surface.
There is danger of the truck turning
The climatic conditions that the
over.
trucks designed for are: temperature is
–20℃—50℃; wind speed is lower than
5m/s; air relative humidity is less than
90%(20℃).
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 trash and debris. Pick
up anything that might puncture a tire or
let the load lose balance.
Slow down for wet and slippery
roads. Stay away from the edge of the
road. If unavoidable, use extreme
caution.
Rugged surface would cause
vibration of truck and noise. The high 24. When running down on a grade,
air pressure of tyres will cause vibration use engine idle speed. At the same time
and noise, too. use the brake pedal intermittently.
Do not operate the truck when the 25. It is dangerous to travel with forks
weather is execrable, such as windy, higher than appropriate position
thunder storm, snow and etc. regardless of whether loaded or not.
Keep the good traveling posture. (When
traveling, the forks should be 15 to 30
cm above the ground or floor.)
Do not operate the side shift
mechanism, if equipped, when the forks
are raised and loaded, since this will
cause the truck to be unbalanced.
A truck with attachments should be
considered as with loads.
15
26. Travel with load as low as possible
and tilted back. Do not use a man as an additional
counterweight. It’s quite dangerous.
27. Avoid braking too sharply or
31. ZHEJIANG HANGCHA
descending on a grade at a high speed.
ENGINEERING MACHINEARY CO.,
There is danger of loads falling down or
LTD. offers a variety of attachments,
the truck turning over.
such as forks, bucket, rotating roll clamp,
load grab or hinged forks. Don’t use
such attachments and special equipment
for applications other than specified.
32. Safeguard is used to prevent us
from hitting of the higher goods. Load
bracket is used to ensure loading stable.
The forklift truck without two items is
forbidden to be used.
33. Never permit anyone to stand or
walk under upraised forks or other
attachments if machine is so equipped.
28. Always brake to full stop before
reversing direction of travel.
29. Taking account of the shape and
material of loads 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.
30. Know the rated capacity of your Never permit anyone to stand on
lift truck and its attachment, if any, and
the forks.
never exceed it.
16
34. Don’t put your head or body into
the interspace of mast and safeguard,
what may cause life risk
Don’t put your hand into the
interspace of inner mast and outer mast
17
40. Use minimum forward and reverse
tilt when stacking and unloading 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 load farther. Never
attempt to tilt the mast beyond vertical
when the load is raised high.
To unloading loads from a high
place, insert forks into the pallet and
drive backwards, then lower the load.
Tilt the mast back after lowering. Never
attempt to tilt the mast with the load
raised high.
41. Don’t tow the truck that its engine
is in trouble, or steering system doesn’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 rear
supporting leg. The operator should be
familiar with position of the fire
extinguisher and its application.
44. Not allowed to carry small goods with
fork, should carry small goods with pallet.
45. Markings on the machine describe
warning and methods to operate the lift
truck. When operating the machine,
observe and follow all markings on the
machine in addition to this operator’s
manual.
Replace damaged or missing decals
and name plate.
18
4) Engine oil level check
4. Maintenance
Caution
More details for maintenance see When checking the engine oil,
《Preventive maintenance schedule》. should let the forklift truck on the level
8 hour (daily or every shift) check ground.
1). Check leaks: electrolyte, hydraulic When check the engine oil, it is exact
oil, brake fluid, coolant, oil in hydraulic when the engine is cool.
transmission gear box.
Check if the engine, connector of Remove the dipstick, clean the rod
hydraulic pipe, radiator and driving and reinstall. Pull it out again and check
system are leakage or not. Do not use an the oil level. The level should be within
open flame to check level, or for leakage, the mark on the dipstick.
of fuel, electrolyte or cooling water.
! Warning!
△
Don’t attempt to operate the truck if
leaked fuel is found through
pre-operational check. Correct the leak
before starting engine
2) Check appearance 5) Check water level in the radiator
Check the lamps and meters are normal Inspect the small reservoir tank to
or not. see the coolant level is between Min and
Check the tires, air pressure and bolts Max position when the engine is cool. If
there is no coolant any more in the
are loose or not.
reservoir tank, please add some coolant to
Check whether tires are damaged or
radiator, its freezing point is -35℃,and
pressure of tires is normal or not. add sub-radiator to MAX position.
3) Check fuel mass
△
! Warning!
When the water temperature of the
engine is higher than 70 degree, please do
not open the pressure cap of the radiator.
Loosen cap slowly to allow steam to
escape. After that, tighten cap securely. It
The fuel level gauge is provided on is good practice to use thick waste cloth
the indicator panel. Check that fuel level or the like when removing the cap. Avoid
is sufficient for the day’s work. The fuel putting on gloves, since you may get
filler port is provided at the rear left burnt at your hand if hot water splashes
pillar of the overhead guard. on it.
19
Caution Caution
Adding clean water to radiator. If When adding fluid, due should be
you use antifreeze, use the same brand of taken to prevent dirt or water from
antifreeze. entering the reservoir.
Pay attention to water reservoir and Brake fluid is dangerous to health,
cooling system in the hot season.. you should avoid touching it by skin.
△
! warning Replacing of brake oil
·antifreeze is harmful to person, if A. Lay forklift truck at designated
swallow, disgorge at once and go to ground, and lay it on level ground,
hospital. fall down fork to ground, loosen park
·do not let children add antifreeze. brake, put transmission gear neutral
position, cut off engine.
20
when leaving the factory) or DOT3 condition.
brake oil. 17) Instruments and sensors
Make sure that hour meter, water
8) Head lamp check temperature indicator, oil temperature
Make sure that the head lamp is indicator, transmission fluid sensor and
lighting when the key is at “ON” fuel sensor etc., properly.
position. 18) Brake pedal, inching pedal and
9) Turn signal check clutch pedal check
Make sure that the turn signal operates Drive truck slowly, press down brake
properly by moving the turn signal lever. pedal, and brake lamp lights.
10) Hand brake check Drive truck slowly, press down
① drive truck slowly. inching pedal, the speed of truck
② loosen hand brake lever, stop the becoming decrease, and press downward
truck, and truck has no deviation. more ,truck will be braked and stop
11) Back-up lamp and buzzer check Check function of clutch pedal, see
The back-up lamp comes on and
page 5《clutch pedal》。
buzzer sounds when the shift lever or
19) Tire pressure
directional control lever is placed in
reverse position. Turn the tire valve cap counter
12) Turning clock-wise and move it. Using a tire
Operate the truck running slowly. pressure gauge, measure the inflation
Turn the steering wheel to left and pressure, and adjusting it to the specified
right 3 round respectively. pressure, if needed. After making sure
Check that the steering forces are there is no sir leakage from the tire valve,
equal in right and left. reinstall the cap. Check that each tire does
13) Horn not get damaged at the tread surface or
Press the horn button to make side face or bending at the rim.
certain the horn sounds is normal or not.
14) Drivers seat adjustment
Make sure the driver’s seat is
properly located. If not properly, shift
the adjusting lever to back and move the
driver’s seat to a position which
provides easy access to all foot and hand
controls.
15) Shift lever(s) check
Check the shift lever(s) for
looseness and operation for smooth.
16) Lifting lever, tilting lever and
attachment lever check △
! Warning!
Check the loading levers (for lift, Since the forklift truck needs tires
tilt and optional attachment) for that have a high inflation pressure to
looseness and smooth operation.
carry heavy loads, even a small bending
Increase the rotate speed of engine ,
of rims or damage at the tread surface
make certain that the lifting lever, tilting
lever and attachment lever in good work could cause an accident.
21
△
! Warning!
Please maintain the air cleaner when truck
works 50-250 hours.
When using an air compressor, first After six times, please change air cleaner.
adjust the air pressure of the Note:If the working condition is bad,
compress-or. Failure to do so will cause the cycle of maintain and change air
a serious accident, since the compressor cleaner need more frequency.
delivers the maximum pressure.
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 air cleaner.
2. Take out air cleaner.
3. Clean the inside or outside of dust
by compress air.
! Warning
△
All nuts and bolts should be
properly installed and tighten before
△
! Caution:
1、Please wear defend glass to avoid the
inflating tire and rim assembly. An dust fly up into your eyes.
inflated tire contains potentially 2 、 It will damage the engine if not
explosive energy. Don’t over inflate.
maintain and change air cleaner on time.
2) Fan belt tension check
Tire pressure GB/T2982-2001:
Driving Turning
wheels wheels
Truck type
(Front (Rear
wheel) wheel)
1-1.8t 790KPa 1000KPa
2-2.5t 860KPa 860KPa
3-3.5t 830KPa 790KPa
22
Drop distance ②Check if there have leakage of oil
Engine cylinder and tubing.
(mm)
③Check the rollers’ rotation.
A498BT1-1 10-15 ④Check the mast if there have crack
and bend.
K21,K25 11-13 ⑤Operate the lever of lifting, tilting
and attachment, check the mast if it’s in
WF491GP 汽油机 New 5-7,old 7-9 good condition, and pay attention to
system operating sound.
4TNE92 New 8-12,old
4TNE98 10-14
5) Lift chain tension check
ISUZU ①Raise the fork about 10-15 cm above
8-12
C240PKJ-30 the ground and make it vertical.
New 9-11,old ②Press middle of the chain by thumb.
TD27
11-13 Make certain the tension for the right and
left chains are even.
Warning! ③Adjust the tension: Loosen the lock nut
If the belt has already been pulled 1, screw the nut 2 and adjust the chain to
make the equal tension, turning the
long, cut out or has no surplus, it should
adjusting nut 1 of the chain anchor pin.
be changed.
If the engine is still running, it’s not
permitted to carry on this check avoiding
fingers or sleeves being caught up in.
6) Lubrication of mast
4) Mast and forks
Lubrication here on schedule, refers
Check the mast and forks to make
to figure as below:
sure:
①There is no crack and bend on
the forks, and the forks are installed on
the fork bracket strongly.
23
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
Mast lubricate
Paint lubrication grease on the slide (6) Steering rod bar pin lubricate
support. (7) Steering cylinder pin lubricate
Note: 9) Bolt, nut tighten
a). The periods of paint lubrication Referrence the <<Maintain cycle chart>>
grease depend on the truck’s work 10) Hub nut torque check
condition. If works heavy, please paint Check hub nuts should be tightened
much more grease on mast. to the specified torque securely.
△
! Caution
Paint some lubrication grease; put
the truck stop on a smooth road, engine A. Hub nut
flameout and tight hand brake. Prevent B. Divided rim bolt (only for 1-1.8 ton)
hand or body is clamped, and prevents C. Drive shaft bolt
falling off from high place. Keep safe.
Specified torque N.m
1-1.8t 2-3.5t
Hub nut 157-176 441-588
7) Chain Lubrication
Take one brush with engine oil paint
two sides on chain.
24
Turning wheel(rear wheel) Height and the free clearance H:
Free Press
free clearance
height height
Brake
120-130 ≥60 1-3
pedal
touching bolt of
inching pedal –
brake pedal:
D. Rear hub nut ①0.9-3.4mm
Specified torque N.m Inching
120-130 ≥60 (NRW15A,QNR
pedal
1-3.5t W22A)
Hub nut 157-176 ②0 mm(besides
NRW15A,QNR
E. Divided rim bolt W22A)
11) Brake pedal, inching pedal and Clutch
clutch pedal check 120-130 ≥60 2-5
pedal
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
Press the brake pedal fully when the
flameout.
engine is running, the distance between
2) Take out the oil cover and bottom shell
brake pedal and front soleplate should
to plug, release the oil.
be more than 60 mm.
Check the inching pedal and clutch
pedal through the same method. △
! Caution
25
4) Dismantle the oil filter by tool. housing.
△
new oil filter.
7) Install new oil filter by hand,not ! Caution
spanner. Hot hydraulic oil and part will hurt
8)Referrence <<Table for the oil used in Body. Do not touch the hot hydraulic
the truck>>,oil preferred. oil and part.
1) Dismantle rubber mat and front
soleplate.
2) Dismantle filter, deal with
located statute.
3) Clean pedestal of filter, confirm
that the old gasket of pedestal have
be cleaned.
9)Start the engine,check leak oil around 4) Plus less hydraulic oil on the new
oil tuck and filter. filter gasket.
If leak obviously,this part is wrong 5) Install filter by hand. When the
install. filter get to pedestal, screw down
1/2-3/4 laps.
10) Warm-up engine enough,then 6)
flameout,check oil level later.fill if 5.Change hydraulic transmission
need. oil(first time, then semiannually)
Check the oil fluid surface,put the truck Let the truck at level ground, play-down
at ground flatly. the fork to floor, inclined back the mast,
strain brake handle. When transmission is
2.Plus lubricate to front and rear of at neutral position, engine is cutoff.
pin roll of Tilt cylinder
Clean the plus place,pile out the past oil. △
! Caution
26
3) Clean oil tuck then install.
4) Take out the dipstick.Add hydraulic
oil.See <<Table for the oil used in the
truck>>.
5) Startup engine.
6) Step on the brake pedal,operate the
engine,let the transmission at state of go
forward and backpedal so that the oil is
in clutch.
7) Let the transmission at neutral,strain
hand brake.
8) Take out the dipstick,inspect fluid
position.
9) If oil is not enough,add oil to keep it
between max and mix graduation.
10) Check the filter and oil tuck if
leakage.
11) Flameout engine,install front
soleplate. 8 Exhaust gas check
27
△
waste oil collect bottle, then use spanner
loosen oil orifice bolt counterclockwise. ! Caution
The other people step on the brake pedal Hot hydraulic oil and part will hurt
repeat on the truck at same time. Here body. Do not touch the hot hydraulic
the brake oil will burst forth from oil oil and part.
orifice, note the fluid lever of brake oil 1) Put one case(cubage is over 60 litre)
tank. Append new brake fluid when the under the hydrualic oil box.Dismantle the
lever fall. Screw down the bolt of oil oil tuck,let the hydrualic to case.
orifice when oil clear. 2) Dismantle hydrualic dipstick and fuel
3)The people step on brake pedal repeat box cover discreteness.
at culmination, not loose, the other 3) Take out the magnet from oil box to
people loose oil orifice bolt, screw down clean and rinse the oil orifice of box
it after brake oil gush completely. Then bottom by hydrualic oil.
inform the first people loose. Repeat 4) Clean and install the oil plug.
upwards operation till brake oil without 5) Fill hydrulic oil box.Referrence
air bladder. Note the fluid lever of brake <<Table for the oil used in the truck>>.
oil tank. Append new brake fluid when 6) Startup the engine and operate multiple
the liquid drop. valve joy stick and turn system,fill
Note: hydrualic oil in all system.
Transmission system forklift from Korea: 7) Check each hydrualic component and
add brake fluid (Brake oil pot) is Mobil pipeline if leakage oil.
Delvac Hydraulic SAE10W.
8) Close the engine,retract all cylinder
Other model: Caltex DOT3 or Choice
HZY3 brake liquid (note add after pole,check the oil level of hydrualic oil
factory) box.Add oil at graduation position.
4. Check clean and change hydraulic
return oil filter, respirator and strainer
Caution
Let the truck at level ground, play-down
Prevent dust, water into oil when add
the fork to floor, inclined back the mast,
brake fluid. The brake fluid is strain brake handle. When transmission is
venomousness, causticity, touch in at neutral position, engine is cutoff.
case, and please wash clean. 1) Loose the bolt of hydraulic oil box
cover board discreteness.
2. Steering wheel locked device 2) Take out return oil filter from top
lubricate cover broad.
Daub the lubricating grease on the 3) Install new filter by hand.
steering wheel locked device. 4) Take out the strainer from oil box.
3. Hydraulic oil change 5) Install new filter by hand.
Let the truck at level ground, play-down 6) Install oil box top cover board and
the fork to floor, inclined back the mast, screw down bolt.
strain brake handle. When transmission 7) Take out respirator.
is at neutral position, engine is cutoff. 8) Clean by lotion and desiccation.
9) Install respirator.
10) Startup the engine and operate
hydraulic system, let hydraulic oil in
all system. Check leakage.
28
11) Close the engine,retract all cylinder 4). Let the engine run fully.
pole,check the oil level of hydrualic 5). Stop the engine, after cool down fully,
oil box.Add oil at graduation still add cooling fluid to radiator up to
position. way out, and add cooling fluid to coolant
5.Change hydraulic transmission oil reservoir “MAX” position.
Refer to ‘Change hydraulic transmission 6).Check the drain cover if leakage.
oil’ from ‘Maintain monthly’.
6. Check, clean, change fuel filter
Note:
△
! Warning!
When the water temperature of the
In the dust and dirty work condition,
engine higher than 70 degree, please do
clean fuel filters per one month and
changes per six months. not open the pressure cap of the radiator
1. Take out the fuel filter discreteness. avoiding scald.
2. Take out transducer form it. The engine cooling fluid is prevent rust
3. Before install new one, install and frostbite. See 《Table for the oil used
transducer discreteness existing, put a in the truck》
little fuel on the filter airproof. 2.Front-wheel bear change lubricate
grease
Note Referrence<<Maintain manual>>drive
Before install, prohibit add fuel to filter, wheel hub,dismantle wheel hub.
otherwise accelerate the abrasion of fuel 3. Front-wheel bear change lubricate
system parts. grease
4 Install new filter discreteness. Referrence《Maintain manual》steering
5 Turn the new filter till the airproof axle content.
mat adhibit to surface. 4.Change steering axle gear oil
6 Screw down 2/3 loops. Let the truck at level ground. At neutral,
Maintain annually (2000 hours) engine flameout.
Increase the below content base on 1. Take out the oil plug, put oil to a case.
maintain semiannually. Clean oil plug.
1. Replace the engine cooling fluid 2. Install oil plug.
3. Take out breathe freely plug and oil
fluid position plug. Put the oil from orifice
bend to steering axle shell until oil
overflow from level plug. See add mete
anew.
4. Press level and bend plug.
5. Start-up forklift. Movement the engine
let the steering wheel control handle at
neutral.
1).Open the radiator cover and loosen 6. Take out level plug. Keep oil level until
the drain cover, let the oil flow out, then overflow.
wash the cooling system.
2). Screw down the drain cover.
3). Add cooling fluid to radiator up to
way out.
29
Other 100mm height.
1. Fuse and relay 3) Place chocks behind rear wheels to
The fuse box is at middle of instrument prevent movement of forklift.
and nearside of steering wheel. Before 4) Loosen wheel nuts 1-2 turns each by
replace a new one fuse, please find out turning them counter-clockwise.
the cause of problem at first. 5) Tilt mast fully backward, and place a
Please replace the same capacity fuse. wooden block under each side of outer
See “fuse and relay” on page 16. 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.
. Warning!
2. The change of tyre
a. When removing tire from wheel rim,
do not remove rim set bots and nuts
△
! Warning!
before releasing air.
b. Make sure that wooden blocks used
When using an air compressor, first to support lift truck are solid, one-piece
adjust the air pressure of the units.
compress-or. Failure to do so will cause c. Never get under forklift while it is
a serious accident, since the compressor supported only by wooden blocks.
delivers the maximum pressure.
9) Retighten the wheel nut temporarily.
To make sure safe, put the tyre in a
defend casing when charge. 10) Start the engine, and take out the
wooden block.
11) Tilting backward the mast and lower
down the mast slowly, then take out the
wooden block under the outer mast and
rear wheel.
12) Retighten the wheel nut with right
tightens torque.
13) Inflation tyre again to right air
pressure.
Front wheel
1) Place lift truck on level concrete.
2) Start engine and raise carriage about
30
turning them counter-clockwise.
△
! Warning!
31
5. The operation of engine too hot
If the engine is too hot, do not
stop it at once, do it as follow:
① Movement engine low speed;
② Open the engine cover to
airiness
③Stop when water temperature
fall;
③ Check the cooling fluid, add
water, if need.
Caution
·Clean the radiation fin by compress
air
or vapour, put the muzzle to radiator a
right angle.
32
5. Structure and stability of truck
It is very important for operator to know the truck’s structure and relationship between load
and stability.
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.
33
Caution the stability zone of the barycenter
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
driving 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 trucks shall
overturn in the corresponding direction.
34
“START”. Release key when engine
6. Operation starts.
△
! Warning!
Warm engine
Do not pull out the choke button.
Before operating the truck, check all Press down the accelerator pedal
controls and warning devices for proper halfway and cold. Crank the engine by
operation. If any damage of fault is turning the ignition key to “START”.
Release key when engine starts.
found, don’t operate truck until corrected.
Caution
Star-up Do not press down the accelerator
pedal fully when starting warm engine.
Starting diesel engine This operation may harden the engine
Make sure that the shift lever(s) and starting. Pressing down the accelerator
loading levers are in neutral and hold pedal several times will cause harder
position. starting.
Turn the ignition switch to ON position
after turning the ignition switch to
Caution
START position.
The starting time should less than 5
seconds a time, the interval between two
Caution
starting should much than 2 minutes.
If you can not start the engine in 5
seconds, should switch to OFF, after 2
After engine has started
minutes then start it again.
Warm up the engine (for about 5
If you can not start the engine 3
minutes)
times continuously should check the
Check the rotation (sound or gear) of
truck to the core.
the engine.
Caution Caution
If the temperature is lower than –5 Diesel model
degree, crank the engine by turning the After starring up the engine,
ignition key to “START”. Release key accelerate it’s speed to the arrange of
when engine starts. 1800-2000r/min, and warm it without
work.
Gas model
Starting gasoline engine
After cranking the engine, push in
Make sure that the shift lever(s) and
the choke button step by step observing
loading levers are in neutral and hold
the warm-up condition and stability of
position.
speed of the engine. Push in the choke
Cold engine.
button fully after making sure the engine
Pull out the choke button fully.
is completely warmed up.
Depress the accelerator pedal to the
floor two or three times and release it. ·Check the combustion (or misfiring)
With your foot OFF the pedal, crank the sound.
engine by turning the ignition key to ·Check the condition (density) of
35
exhaust. ·Always stop the truck before reversing
·Make sure that all the warming lamps are the direction of travel.
off. ·When gear shifting from high to low
·After thoroughly warming up the speed or vice versa, once increase the
engine, operate the loading levers 2 to engine speed and release accelerator
3 times in their full stroke and check pedal. At the same time, press the clutch
their working conditions. pedal while shifting the shift lever into
Traveling the desired position. Then press the
Hold the knob on the steering wheel accelerator pedal while releasing the
with your left hand and get the right clutch pedal.
hand ready for loading working, lightly
Torque converter type machines
putting it on the wheel.
·Always stop the truck before reversing
Set the bottom of the fork 15 to 20 cm
above the ground and fully tilt back the the direction of travel.
upright. ·Shift the shifting lever.
Slow down
Clutch type machines
Since the machine uses the
synchromesh transmission, it is not
necessary to perform the double clutch
operation. Remove your foot from the
accelerator pedal, press the clutch pedal
to the full, place the speed shift lever
Check the safety around the machine into the “first speed” position, and press
and give a signal when starting the the accelerator pedal while releasing the
engine. clutch pedal.
Clutch type
Depress the clutch pedal and engage Torque converter type machines
the shift levers. Release accelerator pedal depression
Release the parking brake lever. a little, and press the brake pedal, if
Gradually release the clutch pedal needed.
while depressing the accelerator pedal to Steering
start the machine. Unlike general passenger-cars, the
Caution steer wheels are located at the rear of the
Do not rest your foot on the clutch truck. These cause the rear of the truck
pedal while you are driving. to swing out when a turn is made.
Slow down the truck and move
Torque converter type toward the side to which you are turning.
Depress brake pedal and engage the
forward-reverse lever. The steer hand wheel should be turned a
Release the parking brake lever. bit earlier than as with the front wheel
Release brake pedal and depress the steering car.
accelerator pedal to start the machine. Stopping or parking the truck
Gear shifting 1. Slow down and press the brake pedal
Clutch type machines to stop the truck (in the case of
36
clutch type machine, the clutch pedal
is used).
2. Place the shift lever in neutral.
3. Apply the parking brake by pulling
up on the parking brake lever.
4. Down the forks on the ground, and
tilt the mast forward maximum.
5. Place the key switch in “OFF” to
shut down the engine. In the case of
the diesel truck, pull out the engine
stop button. Remove the key and
keep it.
Caution
·Don’t dismount from the moving
machine.
·Never jump off the machine.
37
• After making sure the fork tips leave
the load, lower the forks to the basic
position (15 to 20 cm off the ground).
• Tilt the mast backwards.
Warning!
Never tilt the mast with loads
upraised 2m or more.
Don’t leave or dismount from the
truck when the load is raising high.
Remove load
• When approaching the area where the
load is to be retrieved, slow down your
truck.
• Stop the truck in front of the load so
that the distance between the load and
fork tips is about 30 cm.
• Check the condition of the load.
• Tilt the mast forward until forks
become horizontal. Elevate forks up to
the position of the pallet or skid.
• Make sure forks are positioned
properly for the pallet. Move forward
slowly to insert forks into the pallet as
far as possible and then stop the truck.
Caution
If the forks 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 on the forks, then lower
the pallet or skid on 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 travel is unobstructed
and back away slowly.
• Lower forks to a height of 15 to 20 cm
above the ground. Tilt the mast
backward fully and move to the
desired area.
38
In cold weather, it needn’t to discharge
7. Deposit
the antifreeze, but the cold water should
Deposit daily be removed completely.
Park your truck on a level Deposit the truck for a long time
ground-preferably in a wide area. If Deposit the truck for a long time,
parking on a slope is unavoidable, position fill up the truck body and counter
the truck so that it cross the slope and weight with block to reduce the load of
block the wheels to prevent accidental roll. the two rear wheels.
Make sure the shift level on neutral
position.
△
! Warning!
Pull the hand brake. a. The block must be single and hard
Shut down the engine and control the enough to support the truck.
lift and tilt level several times so that the b. Don’t use a block with high than
inner pressure in the hydraulic tube will 300 mm(11.81 inch).
decreased. c. Lift the truck to height of placing on
Take down the key and deposit it in a the bearing block.
safe position. d. Place two same size blocks under the
left and right sides of the truck.
Warning!
e. After supporting the truck with block,
You should tell the manager if you
swing the truck forward, backward, left
find any failure about the truck, then
and right, check its safety.
repair it immediately.
39
4.Start the engine once a week. If the
water has already been let out, add water
in the radiator. Then start the fork
lightly.
5.In summer, it is not recommendatory to
park the fork on asphalt road.
Running after deposit for a long time
1. Get down the antirust oil from the
exposed parts.
2. Vent the gear oil of the 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, then install on
the truck.
7. Check others carefully such as start,
running, turning, lifting etc.
8. Warm-up your truck
40
8. Maintenance
Preventive maintenance schedule
○ — Check, revise, adjust
× — Replace
Note: (1) If the working place has much duty or other pollutions, the times of maintenance should
be increased.
(2) If the parts are abnormal such as engine power descends, emit black smoke or
noise increase before the replacing time is coming, it should be check. Sometime it
needs to adjust diesel nozzle pressure and fuel atomization.
Note:
1. The fork lift truck needs inspection and maintenance termly, make it in good
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 require.
6. Maintenance on schedule
7. After you make maintenance, you’d better make a record.
8. Forbid to repair the fork lift truck if you haven’t been trained.
41
Checki Monthly Trimonthly Semiannually Annually
Service required Tools
ng Item (180-200hrs) (500 hrs)
(1000 hrs) (2000hrs)
1. Check the valve clearance
○ ○ ○ ○
clearance is correct gauge
2. Fan belt tension
○ ○ ○ ○
check
3. Retighten cylinder
○ ○ ○ ○
head bolt
4.Clean the outface of
○ ○ ○ ○
radiator(1)
5. Replace engine oil
× × × ×
(1)
6.Replace the oil
cleaner (diesel engine) × × × ×
(1)
7. Replace engine
×
cooling fluid
8. Clean the air cleaner
× × ×
element(gasoline
engine)
Replace the air cleaner ○ ○ ○ ○
element (diesel engine)
9. Drain the water of
oily water separator ○ ○ ○ ○
Engine (diesel engine)
10. Clean or replace the
filter element of air ○ ○ × ×
cleaner
11. Idling of engine tachometer ○ ○ ○ ○
42
Maintenance of chassis and body
Checking Monthly Trimonthly Semiannually Annually
Service required Tools
Item (180-200hrs) (500 hrs) (1000 hrs) (2000hrs)
Check clutch pedal for free
travel and clearance between
○ ○ ○ ○
pedal surface and floor when
Clutch
clutch is unlocked
Release bearing lubricate
○ ○ ○
43
Checking Monthly Trimonthly Semiannually Annually
Service required Tools
Item (180-200hrs) (500 hrs)
(1000 hrs) (2000hrs)
Lubrication of chains ○ ○ ○ ○
Bolt’s Grade
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
22 225~284 284~343 343~431 502~669
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 table, if it can’t be found, the grade is 8.8.
44
Periodic replacement of key safe parts
· Some parts can’t be found damnification or mutilation though schedule maintenance.
In order to make sure the safety of truck, please replace these parts termly listed
in following table. If there is any off-normal happened on these parts before
replacement time, please replace it deservedly.
45
Table for the oil used in the truck
Description Shop sign,Code name Capacity(L) Remark
45 1∽1.8t
Gasoline 90
60 2∽3.5t
0#(summer ) 45 1∽1.8t
Diesel
-10#∽-35#(winter) 60 2∽3.5t
Besides winter :CD grade15W/40, 5 1∽1.8t
Winter :CD grade 10W/30
Diesel engine Or according to engine maintenance
OIL manual(arctic-alpine :5W/30 CD or 6.5∽7.5 2∽3.5t
according to engine maintenance
manual)
Up DE grade 15W/40 5 1∽1.8t
Gasoline Or according to engine maintenance
Engine OIL manual(arctic-alpine :CALTEX
6.5∽7.5 2∽3.5t
API SAE 5W-30)
L—HM32 35∽40 1∽1.8t
Hydraulic oil
(arctic-alpine: L—HV32) 45∽50 2∽3.5t
5.5 1∽1.8t
GL—5 85W/90
Gear oil 8 2∽3.5t
API GL—5 80W/90(Caltex) 6.5 exclusive use
Choice HZY3 brake liquid(add
when leaving factory)or DOT3 1.5 Besides M type
Brake liquid brake liquid
Mobil delvac advanced hydraulic
1-1.5 For M type
oil SAE10W
Antirust -35# car antifreeze(add when
antifreeze 10∽11
liquid leaving factory)or FD-2 antifreeze
Industrial Electrode of Storage
2#
Vaseline battery
Lubrication Currency lithium group lubricate
grease grease
Remark :the 1∽3.5 t trucks have been added antirust antifreeze liquid, you
need not discharge the liquid even at cold winter. Add the liquid according to original
requirement if need. Replace the liquid every 2 years normally. If the truck has not
been added antirust antifreeze liquid, users can add the liquid according to
requirement. The cooling water must be discharged at winter if the truck has not been
added antirust antifreeze liquid.
46
Hydrodynamic power transmission oil
Shop sign,
Description Capacity(L) Remark
Code name
CPQD10/15/18N-RW7,
CPQD20/25N-RW7
CPQD30/355N-RW7,
CPCD10/15/18N-RW10,
CPCD20/25N-RW10,
CPCD30/35N –RW10;
CPQD10/15/18N-RW21,
CPQD20/25N-RW22
CPQD30/35N-RW22,
CPCD20/25N-RW27,
6-8
CPCD30/35N-RW27,
CPCD10/15/18N-RW32,
CPCD20/25N-RW32,
CPCD20/25N-RW33,
CPCD30/35N-RW33,
Hydrodynamic
power DEXRON—III CPCD20/25N-RW15A
transmission (Caltex) CPCD30/35N-RW15A,
oil CPQD20/25N-RW22A
CPQD30/35N-RW22A,
CPQD20/25/30/35N-RW26-Y
CPCD10/15/18N-RW32M
CPCD20/25N-RW32M
10 CPCD20/25N-RW33M
CPCD30/35N-RW33M
CPCD20/25N-RW10B
CPCD30/35N –RW10B
CPQD20/25N-RW22B
4 CPQD30/35N-RW22B
CPCD20/25N-RW32B
CPCD30/35N-RW33B
47
Lubrication system drawing
fill
replace
48
Notice:
1. The detail of lubricating oil for different truck can refer to “Table for the oil used in
the truck”
2. Lubrication for mast, please see the 8 hour (daily or every shift) check .
Environment protection
1. Please do the clean and maintenance of the truck at the specified spot.
2. Before remove the pipe, connector and related parts, please use the specified
container to contain 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, hydrodynamic power
transmission oil and gear oil should be replaced under 70 ℃ because the temperature
will be high after long running, no touching with skin, or you will be scald or
corroded.
49
Scutcheons
There are many scutcheons and labels on the different position of the truck.
50
1. typeface label 2. danger label 3.fuse label 4. diesel label 5.gasoline label
6. Tonnage label 7. Danger label 8. Danger label 9. Product nameplate
11. Safety belt label 12. Shift label 13. Operate 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
51
1、typeface label
3、fuse label
4、diesel 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.
52
7、danger label
The inner and outer mast, fork frame are all lifting slip parts. The hands are not
allowed to reach the place between the inner and outer mast.
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 caused
by miss operating the mast handle.
8、danger label
Ⅰ Ⅱ
12、shift label
53
13、14 operate labels
Hydraulic truck
Mechanism truck
54
19、warning label
23、noise label
LWA
25、hang label:express the hang position and method. When hanging, the rope
should not touch the light and even destroy it.
55
26、CE label
27、No water flushing label: at the right safety supporting leg where is the channel
for engine air. No water is allowed to enter into the transom window, no water can be
entered into when washing truck.
28、antifreeze label
replace
56
32、horn label
Detail:
57
9. Truck’s convey, lifting, towing
Convey
• 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 towing rod on the bottom of the counter balance is used to pull and drag the truck, For
installing the rod, first remove the towing rod and then install the ropes. After that, loose the
rod.
Note: Loosen the brake lever.
Warning
a. Don’t tie the steel wire ropes on the unfixed position
b. Don’t carry a load to steel wire ropes suddenly.
58
10. Type signification
1-1.8t
Rated
capacity(t)/
Model Engine Main transmission
Load
center(mm)
YQXD18H1Hydrodynamic
Wan feng WF491
CPQD10/15/18N-RW7 power transmission gear
Gasoline box
YQXD18EHydrodynamic
ISUZU C240PKJ-30
CPCD10/15/18N-RW10 power transmission gear
Diesel box
1/500、
YQXD18HBHydrodynamic
K21 Gasoline 1.5/500、
CPQD10/15/18N-RW21 power transmission gear
(NISSAN) 1.8/500
box
YQXD18EHydrodynamic
CPCD10/15/18N-RW32 YANMAR4TNE92Diesel power transmission gear
box
Korea hydraulic
CPCD10/15/18N-RW32M 4TNE92-HRJ Diesel
transmission gearbox
59
2-2.5t
Rated
capacity(t)/
Model Engine Main transmission
Load
center(mm)
YQXD25Hydrodynamic
CPCD20/25N-RW10
ISUZU C240PKJ-30 power transmission gear box
Diesel (ISUZU)
CPCD20/25N-RW10B OKAMUR transmission
60
3-3.5t
Rated
capacity(t)/
Model Engine Main transmission
Load
center(mm)
YQXD30Hydrodynamic power
CPCD30/35N –RW10 C240PKJ-30 transmission gear box
Diesel
(ISUZU)
CPCD30/35N –RW10B OKAMUR transmission
WanFengWF491 YQXD30H1Hydrodynamic
CPQD30/355N-RW7
gasoline power transmission gear box
YQXD25AHydrodynamic power
CPCD30/35N-RW27 A498BT1-1Diesel
transmission gear box
NISSAN2STF150
TD27 Diesel
CPCD30/35N-RW15A Hydrodynamic power
(NISSAN)
transmission gear box
YANMAR4TNE92 YQXD30Hydrodynamic power
CPCD30N-RW32
Diesel transmission gear box
YANMAR4TNE98 YQXD30Hydrodynamic power
CPCD30/35N-RW33
Diesel transmission gear box
YANMAR4TNE98 OKAMUR Hydrodynamic power
CPCD30/35N-RW33B
Diesel transmission gear box
GM3.0LPGsingle YQXD30G1Hydrodynamic
CPQD30/35N-RW26-Y
fuel engine power transmission gear box
4TNE98-BQFLC Korea hydraulic transmission
CPCD30/35N-RW33M
Diesel gearbox
61
11. Performance parameters of R series IC forklift
1—1.8t R series
Overall dimension(L×W×H)
2225×1080×1995 2265×1080×1995 2300×1080×1995
(exclusive forks)
6.5-10-10PR/2 6.5-10-10PR/2 6.5-10-10PR/2
Tyre (F/R)
5.00-8-10PR/2 5.00-8-10PR/2 5.00-8-10PR/2
Displacement cc 2237
Diesel
62
Model CPCD10N-RW32 CPCD15N-RW32 CPCD18N-RW32
Overall dimension(L×W×H)
2225×1080×1995 2265×1080×1995 2300×1080×1995
(exclusive forks)
6.5-10-10PR/2 6.5-10-10PR/2 6.5-10-10PR/2
Tyre (F/R)
5.00-8-10PR/2 5.00-8-10PR/2 5.00-8-10PR/2
Displacement cc 2659
Diesel
63
Model CPQD10N-RW21 CPQD15N-RW21 CPQD18N-RW21
Overall dimension(L×W×H)
3145×1080×2110 3185×1080×2110 3220×1080×2110
(including forks)
6.5-10-10PR/2 6.5-10-10PR/2 6.5-10-10PR/2
Tyre (F/R)
5.00-8-10PR/2 5.00-8-10PR/2 5.00-8-10PR/2
Rated
37KW/2300 r/min
capacity/rpm
gasoline
Max torque/rpm 142N·m/1600 r/min
Displacement cc 1982
64
Model CPCD10N-RW10 CPCD15N-RW10 CPCD18N-RW10
mechanical / / /
Max traveling
speed Km/h
hydraulic 14.5 14.5 14.5
Displacement cc 2369
65
2-3.5t R series
66
Model CPQD20N-RW22A CPQD25N-RW22A CPQD30N-RW22A CPQD35N-RW22A
Wheel thread
965/970 965/970 1005/975 1005/975
(F/R)mm
Voltage/Capacity
12/60/20h
Ah
type K25
Rated
gasoline
44KW/2500r/min
capacity/rpm
Max torque/rpm 179N·m/1600 r/min
Displacement cc 2472
67
Model CPCD20N-RW10 CPCD25N-RW10 CPCD30N-RW10
/ / /
Max traveling
speed Km/h
hydraulic 20.5 20.5 19
Displacement cc 2369
68
Model CPQD20N-RW22 CPQD25N-RW22 CPQD30N-RW22 CPQD35N-RW22
Displacement cc 2472
69
CPCD25N- CPCD30N- CPCD35N-
Model CPCD20N-RW10B
RW10B RW10B RW10B
type (OKAMURA)
70
Model CPQD20N-RW22B CPQD25N-RW22B CPQD30N-RW22B CPQD35N-RW22B
Voltage
12/60/20h
/Capacity Ah
type K25
Rated
capacity 44KW/2500r/min
gasoline
/rpm
Max torque
179N·m/1600 r/min
/rpm
Displacement
2472
cc
71
Model CPQD20N-RW7 CPQD25N-RW7
/
Max traveling speed Km/h
hydraulic 22.5
2T 25
Grade full load %
2.5T 20
wheelbase mm 1650
2T 2525×1155×2120
Overall dimension(L×W×H)
(exclusive forks)
2.5T 2600×1155×2120
7.00-12-12PR/2
Tyre (F/R)
6.00-9-10PR/2
Voltage/Capacity Ah 12/100/20h
type WanFengWF491GPgasoline
Displacement cc 2237
Diesel
Rated capacity/rpm 41 KW/2800r/min
72
Model CPCD20N-RW27 CPCD25N-RW27
/
Max traveling speed Km/h
hydraulic 20.5
wheelbase mm 1650
2t 2525×1155×2120
Overall dimension(L×W×H)
(exclusive forks)
2.5t 2600×1155×2120
7.00-12-12PR/2
Tyre (F/R)
6.00-9-10PR/2
Voltage/Capacity Ah 12/100/20h
Displacement cc 3168
Diesel
Rated capacity/rpm 45KW/2500r/min
73
CPCD25N-RW33
CPCD20N-RW33
Model CPCD20N-RW32 CPCD25N-RW32 CPCD25N-RW33
CPCD20N-RW33B
B
Rated capacity Kg 2000 2500 2000 2500
74
Model CPCD20N-RW33M CPCD25N-RW33M
mechanical /
Max traveling
speed Km/h
hydraulic 19
wheelbase mm 1665
Displacement cc 3319
Diesel
Rated capacity /rpm 44.3KW/2300r/min
75
Model CPQD30N-RW7 CPQD35N-RW7
mechanical /
Max traveling speed Km/h
hydraulic 21
3t 20
Grade full load %
3.5t 18
wheelbase mm 1760
3t 4255
Service weight Kg
3.5t 4555
3t 2760×1225×2010
Overall dimension(L×W×H)
(exclusive forks)
3.5t 2810×1225×2160
28×9-15-12PR/2
Tyre (F/R)
6.50-10-10PR/2
Voltage/Capacity Ah 12/100/20h
Displacement cc 2237
Diesel
76
Model CPCD30N-RW27 CPCD35N-RW27
l /
hydraulic 19
3T 25
Grade full load
%
3.5T 20
wheelbase mm 1760
3t 4255
Service weight
Kg
3.5t 4555
Overall dimension(L×W×H)
3185×1080×2110
(including forks)
28×9-15-12PR/2
Tyre (F/R)
6.50-10-10PR/2
Voltage/Capacity Ah 12/100/20h
Displacement cc 3168
Diesel
77
CPCD30N-RW33 CPCD35N-RW33
Model CPCD30N-RW32
CPCD30N-RW33B CPCD35N-RW33B
Rated capacity Kg 3000 3500 3000
3t 4255 4255
Service
weight Kg
3.5t 4555 4555
Overall
dimension(L×W×H) 3145×1080×2110 3185×1080×2110
(including forks)
28×9-15-12PR/2 28×9-15-12PR/2
Tyre (F/R)
6.50-10-10PR/2 6.50-10-10PR/2
Voltage/Capacity Ah 12/100/20h 12/100/20h
YANMAR 4TNE92-HRJ
type YANMAR 4TNE98-BQFLC Diesel
Diesel
Displacement cc 2659 3319
Diesel
78
Model CPCD30N-RW33M CPCD35N-RW33M
wheelbase mm 1760
3t 4280
Service weight
Kg
3.5t 4555
Overall dimension(L×W×H) 3820×1225×2150(3t)
(including forks) 3870×1225×2150(3.5t)
28×9-15-12PR/2
Tyre (F/R)
6.50-10-10PR/2
Voltage/Capacity Ah 12/100/20h
Displacement cc 3319
Diesel
Rated capacity/rpm 44.3kW/2300r/min
79
CPCD20N CPCD25N CPCD30N CPCD35N
Model
-RW26-Y -RW26-Y -RW26-Y -RW26-Y
Rated capacity Kg 2000 2500 3000 3500
80
12. Operation, disassembly and installation of cab
.
.
81
The operation of cab:
1. Open left door with key, enter into cab.
2. Close door, make sure left and right door close before working.
3. The glass of left and right door can be moved by draw button on the glass.
4. The rear door can be opened by loosing lock buckle.
Disassembling cab:
1.Stop the truck on solid and smooth level ground; close switch , pull down hand
brake.
2.Remove 4 bolts from left front and right front legs. To high position exhaust, the
fastening bolts should be removed
3.Pull out 4 rubber plugs 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 the bolts
which connect head frame and support legs, after fastening support legs and truck
body, then fastening connected bolts connected head frame and support legs, fastening
torque of bolts connected support legs and truck body :T=137~167 N·m. bolts for
connecting head frame and support legs:T=110~140 N·m
82
13. Operation and notice about LPG forklift
More details refer to 《OPERATION AND MAINTENANCE MANUAL and SERVICE
MANUAL of 1-3.5t R series LPG forklift (American IMPCO combustion
system)(Italy BRC combustion system)》.
LPG fuel system consists of LPG cylinder, petrol solenoid valve, LPG solenoid
valve with filter, LPG vaporizer, adapter, LPG-petrol select switch and level
indication. LPG comes from the LPG cylinder, passing through the combination valve,
the high-pressured pipe, the filter, and the solenoid valve in sequence, enters the LPG
vaporizer to vaporize, then mix with air in certain proportion in the adapter, and
combust in the engine cylinder to drive the forklift truck to work.
There is double fuel switch at the top surface of instruments panel
(1)the operation of double fuel switch
D. Turn switch to LPG,then fuel is becoming LPG;
E. Turn switch to GAS,then fuel is becoming gasoline.
F. Neutral position, LPG and gasoline are both stopped.
(2)Starting up the engine
1. By gasoline
Shut off LPG, switch 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 switch on the LPG switch for several seconds,
turn the ignition key to start the motor-----the engine is started by LPG;
b. Starting up when there is petrol in the carburetor: it is some difficult to
start up when there is petrol in the carburetor, you should switch the select switch to
the neutral position, start up the engine by petrol. When petrol in the carburetor is
about to be used up and the engine is running slower, switch on the LPG switch to
fuel by LPG. Or after petrol in the carburetor is used up and the engine is halted,
switch on the LPG switch, turn the ignition key to start the motor-----the engine is
started.
(3) Change fuel during the engine runs
1.Change from LPG to petrol:
Directly switch the select switch from the LPG position to GAS position, the
engine fuel is changed from LPG to petrol.
83
2.Change from petrol to LPG:
Shut off the petrol switch, When petrol in the carburetor is about to be used up,
the engine runs slower, switch on the LPG switch rapidly to fuel by LPG.
Outpouring limit valve
Once the outpouring limit valve is opened (see FIG A), LPG is flowing to the
LPG solenoid valve through the outlet When outpouring exceeds the stated value, or
the pipe is broken, the outpouring device on the valve will be closed automatically. If
leaving the forklift unused for a long term, you should close the limit-outpouring
valve.
Adapter
The adapter is to mix the vaporized LPG with air and to send them into the
engine to meet kinds of working conditions according to the engine.
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 container is full.
c.Level indication
The digital shows percentage of the remainder volume.
d.Outpouring limit valve
When outpouring exceeds the stated value, or the pipe is broken, the outpouring
device on the valve will be closed automatically.
e. Safety valve
Safety valve will open automatically when pressure in cylinder is over the standard
pressure.
2. Main parameters
Work temperature:-40~+60℃;Work pressure :2.2MPa;opening pressure of
safety valve:2.5±0.2MPa;Max. copacity :80% of cylinder volume。
84
3.Cylinder structure
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.
85
Metal band bracket
86
Remove cylinder and charge
Notice :
1. Please avoiding cylinder hit counterpoise when taking it down form truck.
2. 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℃.
87
Table 1 technique parameter of LPG special for vehicle
Quality parameter
Item component com
Trial
position
1# 2# 3#
Butadiene
≤0.5 ≤0.5 ≤0.5
(1,3butadiene )
100ml remainder after
remainder
a
evaporation pressure can be evaluated by GB/T 12576, measured by GB/T 6602 when arbitration。
b
component can be measured by SH/T 0230,but measure by SH/T 0614 when arbitration.
c
density can be measured by GB/T 12576,but measured by SH/T 0221 when arbitration.
d
Total sulfur content can be measured by SY/T 7508,but measured by SH/T 0222 when arbitration.
88
Procedure of replacing LPG cylinder
(1)Take canvas glove to avoid the leaking gas to frostbite finger when gas
changing.
(2)Make sure the place is clear and the air is ventilating when charging LPG,
it is forbidden to smoke ,keep away from other naked flame
(3)Fill LPG as following: Lay the LPG cylinder flat, and set the charging limit
valve upward, then screw off the dust 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 up to truck, and fix it, let the arrow(○
1 )be upward, then
insert the fixed pin to cylinder.
89
Buckle belt bracket
c. Pull buckle belt downward with left hand, pull d. Keep the buckle belt tensioning and keep the lock
out the lock buckle with forefinger, middle finger buckle out, revolve strain device downward with
and third finger in right hand, and push up to touch right hand till touch cylinder.
cylinder at the same time.
e. Keep it tensioning with left hand, hold the strain f. Turn downward till touch cylinder.
device , loose lock buckle ,and rotate strain device
several times till it can not be pushed.
(8)Make sure there is no leaking before using, if there is some leaking, close outlet
shutoff valve(○
3 ) in time, turn on the forklift input connector,(○
5 )。
90
Notice :after installing cylinder, then connect the connecting pipe with quick
connector, open outlet shutoff valve ○
3 ,smear every joint with soap bubble to check
whether the joint is leaking, if there is leaking at joint, eliminate the problem, then fire
forklift. Please close outlet shutoff valve○
3 when the forklift is finishing working.
Notice during usage
(1) When charging LPG assemble, at first open inlet shutoff valve, close outlet shutoff
valve, when charge is done, close inlet shutoff valve.
(2) When take assembly to the truck, it should be fixed and make the arrow direction
upward, and inlet shutoff valve closed. Connecting inlet connector with assembly
outlet port, and then revolve to tighten, 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 maintain, it is forbidden to repair by self. And
keep apart the abnormal cylinder.
(7) This assembly has 2 ways to fill LPG, one is volume and the other is weight.
Weight: make sure the cylinder stand vertically when filling LPG. Volume: make sure
the cylinder lay horizontally when filling LPG, and let the direction mark up.
(8) Please obey the 《gas cylinder safe supervise rule》awarded by the State Bureau of
Quality and Technical Supervision when charging ,transporting, depositing ,using and
inspecting.
91
(9) When fixing and disassembling cylinder please do it lightly, it is forbidden to hit
other object. Keep cylinder assembly intact and do not disassemble, adjust and replace
components.
(10) The LPG conform to GB11174 can be recharging; the maximum volume is no
more than 80% of cylinder.
(11) The LPG must be charging at the place awarded by qualified Quality and
Technical Supervision Bureau, it is forbidden to charging by self
(12) Charging unit must vacuumize or displace with nitrogen when the new or
recheck cylinder is using at the first time.
(13) Before reinstalling cylinder, lay the cylinder horizontal perpendicular to
installing sign, close outlet shutoff valve, open inlet shutoff valve, see the finger of
fluid indicator wether is lifting with the charging fluid when charging. Stop charging
when the limit charging valve is working in time, and check whether the finger of
fluid indicator is at the correct position. Close inlet shutoff valve after charging out.
(14)Check the forklift truck fully ahead to ensure 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 minutes halt, you should shut off the LPG switch and the
outpouring valve.
(17) Cylinder must be avoiding under the blazing sun for quite a long time, and keep
it far away from heat source, and forbidden to heat cylinder with heat source which
the temperature is more than 40℃
(18) It should have no less than 0.5% the cylinder volume to remain.
(19) It is forbidden to modify cylinder mark and color sign.
(20) Cylinder must be taken to the special unit per 5 years to inspect, the unit have
qualification awarded by pressure vessel safety supervisor bureau.
(21)Observe the level indication frequently during operation, if it is found that LPG
consumption is not in proportion to working time, you should stop to check where is
leakage, and shut off power, the LPG valve and all valves concerned at once to take
good measure in time.
92
(22)Park the truck at the shady and ventilated site; close the valves on the 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.
93
Service & maintenance
1.This truck has been taken pressure trial and performance test before leaving
factory. If there is performance failure, strictly forbid repairing without permission.
2.Close the valves on the LPG cylinder before disassembly and maintenance of the
LPG device.
3.Suitably adjust the measure valve, for LPG consumption is changing with season.
4. Check and clean often the air cleaner and the LPG filter, 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 routine care for the whole LPG fuel system after every one year working,
that is, clean the vaporizer, check airproof capacity of each tie-in in the high
pressurized pipes and the low pressurized pipes.
94
14. Operational method of maintenance free lead acid battery
1. Maintenance free lead acid battery and its application
Maintenance free lead acid battery is used for power start engine ,and it can
be for voltage regulation and overload generator substitute power ,it has
following strengths: low internal resistance, stable end voltage, large support current,
low water cost, huge capacity, nice starting performance at low temperature, light
pole corrosion , light mass, low fault rate, convenient maintenance. The batteries are
all sealed besides 2 vent hole (for overflowing a little air from battery) at the side of
battery.
2. Storage and maintenance
1) Storage
The place for storing battery should be clean, dry, airy, and the battery should be
charging every 3 months.
2) Maintenance
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 densimeter at battery are invisible,
then charge or replace battery;
3.Notice for usage
Battery can produce explosive gas, electrolyte has corrosive, and the current can burn
skin from battery producing, please flush immediately when electrolyte touch skin or
eyes, then go to hospital if serious.
l) Human body, especially the head should be far away from battery, and the
protected glass must be wearing.
2)Forbid battery emerging in naked fire or spark.
3)Connect active and negative pole with electrical equipment correctly to avoid
burning battery or electrical equipment.
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4)To avoid short circuit of battery, the electric things are forbidden to cover at
battery.
4.Check
There is a little ball in battery capacity display, this ball can change its color 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.
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15. Use, installation and safety rules of attachment
HANGCHA will choose attachment that according with International standard
ISO2328《Forklift pothook fork and install size of carriage》,such as clamp, rotator,
paper roll clamp, carrying ram, side-shifter etc.
1、Attachment use.
(1) Know well the content of nameplate on attachment, read the instruction
manual before
Usage.(Especially the manual from attachment company)Before operate the
attachment, the people should be trained and obtain the qualification.
(2) It should be understand the basic capability and operate methods of
attachment. Especially the admit load, lift height, size of cargo and adapt range of
attachment.
(3)Operate the multi-functional attachment, such as with side-shifter, clamp or
rotator, it is not allowed that two action at one time. Operate one functional then do
another one.
(4)Prohibit the cargo at a high position when truck move with attachment. If
the size of cargo is too big, prohibit the truck move on. Transport the cargo, make sure
that 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
300mm.
(6)In the range of the projection forth 2m of the lower of attachment and cargo,
prohibit stand to avoid the suddenness except the driver position under overhead.
(7)It is not allowed that an emergency brake in moving. Run slowly with load.
(8)Prohibit outside force when attachment working.
(9)It couldn’t be use at malfeasance situation and overstep normal work range
(10)When the attachment failure, prohibit use without check.
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repair.
(6)Check the drive of attachment timing or turn the component if fray or block,
change betimes.
(7)Check each element if in normal under load attachment is work in gear. If
not, check the hydraulic pressure loop, find out the broken part, change air poof or
whole loop part.
2、Attachment assembly
!Caution
1、Untempered technology licence of our company, any refit at safety and capability
to attachment is strict prohibit.
2、Fact rating load capacity should be the least of rating load capacity, the load
capacity of attachment, colligate load capacity of truck. Generally speaking, the
colligate 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 orientation stability of forklift.
5、To these attachment with rotating function, such as paper roll clamp, bale clamp,
muti-purpose clamp, drum clamp, it needs to weld chock block in the joint of carriage
beam and attachment to prevent move from side to side in the operation.
6、Assembly the attachment of below catch orientation, it need to adjust the clearance
between below catch and beam of carriage.
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16. Related safety instruction and standard (for trucks
exporting to Europe or option)
The model by CE certification which according to the following instruction and
standard: DIRECTIVE 2006/42/EC OF THE EUROPEAN PAMENT AND OF THE
COUNCIL, DIRECTIVE 2000/14/EC OF THE EUROPEAN PAMENT AND OF
THE COUNCIL, EN1726-1:1998(Engineering Industry truck safety standardize),
EN12053:2001, EN1175-2:1998, EN13059:2002 coordinate standard.
z Main safety factor will be according with DIRECTIVE 2006/42/EC OF THE
EUROPEAN PAMENT AND OF THE COUNCIL and EN1726-1:1998 、
EN1175-2:1998 standard.
z Noise will accord with EN12053:2001 and 2000/14/EC.
The sound pressure level at Sound radiation sound
Model
operator position unit:dB(A) power level unit:dB(A)
CPYD10N-RW 85.2 102.8
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z Vibration parameters will be accord with ISO5349-2:2001、EN13059:2002.
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浙江杭叉工程机械集团股份有限公司
ZHEJIANG HANGCHAENGINEERING MACHINERY CO.,LTD.
地址:杭州市石桥路 398 号 邮编:310022 Website: http//www.zjhc.cn
Add:398 Shi Qiao Road, Hangzhou 310022 E-Mail:[email protected]
Tel:+86-571-88926666 Fax: +86-571-88144682
EC DECLARATION OF CONFORMITY
MANUFACTURE
Name: Zhejiang Hangcha Engineering Machinery Co., Ltd.
Address: 398 Shiqiao Road, Hangzhou 310022, P. R. China
THE TECHNICAL DOCUMENTATION WAS COMPILED BY:
Name:
Address:
Post:
HEREBY DECLARES THAT THE PRODUCT DESCRIBED BELOW:
Description: Industrial truck – Counterbalanced Lift truck
Model:
Serial number: Net engine power: kW
Manufacturing year:
COMPLIES WITH THE PROVISIONS OF THE FOLLOWING EUROPEAN
DIRECTIVES:
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 power level: dB
COMPLIES WITH THE PROVISIONS OF THE FOLLOWING
HARMONIZED STANDARDS:
EN 1726-1 Safety of industrial trucks - Self-propelled trucks up to and
including 10 000 kg capacity and industrial tractors with a drawbar
pull up to and including 20 000 N
Annex I of Machinery Essential health and safety requirements relating to the design and
Directive 2006/42/EC construction of machinery
Done at (place): Name of the signatory:
On (date): Title:
Signature:
101
浙江杭叉工程机械集团股份有限公司
ZHEJIANG HANGCHAENGINEERING MACHINERY CO.,LTD.
地址:杭州市石桥路 398 号 邮编:310022 Website: http//www.zjhc.cn
Add:398 Shi Qiao Road, Hangzhou 310022 E-Mail:[email protected]
Tel:+86-571-88926666 Fax: +86-571-88144682
EC DECLARATION OF CONFORMITY
MANUFACTURE
Name: Zhejiang Hangcha Engineering Machinery Co., Ltd.
Address: 398 Shiqiao Road, Hangzhou 310022, P. R. China
THE TECHNICAL DOCUMENTATION WAS COMPILED BY:
Name:
Address:
Post:
HEREBY DECLARES THAT THE PRODUCT DESCRIBED BELOW:
Description: Industrial truck – Counterbalanced Lift truck
Model:
Serial number: Net engine power: kW
Manufacturing year:
COMPLIES WITH THE PROVISIONS OF THE FOLLOWING 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
COMPLIES WITH THE PROVISIONS OF THE FOLLOWING
HARMONIZED STANDARDS:
EN1726-1 Safety of industrial trucks - Self-propelled trucks up to and
including 10 000 kg capacity and industrial tractors with a drawbar
pull up to and including 20 000 N
Annex I of Machinery Essential health and safety requirements relating to the design and
Directive 2006/42/EC construction of machinery
Done at (place): Name of the signatory:
On date): Title:
Signature:
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17. Maintain record
Maintain
Date Item of maintenance
personnel
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ZHEJIANG HANGCHA ENGINEERING MACHINERY CO., LTD
Manufacturing 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: [email protected]
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