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CPD10/15/18/20/25/30J

CPD10/15/18/20/25/30J D1
CPD10/15/18/20/25/30/35J C1
CPD10/15/18/20/25/30/35J C2
CPD40/45/50J D1
CPD40/45/50J C2

15t J Series Counterbalanced Battery Forklift Truck

OPERATION AND MAINTENANCE


MANUAL

Original Instruction

HANGCHA GROUP CO., LTD.


Dec. 2010 5th edition
FOREWORD
Thanks for you purchasing our J series battery forklift truck.

Four wheel counterbalanced battery forklift truck is our companys new product. It has the character of
small turning radius, beautiful shape, small dimensions, low gravity, good stability, superior performance.

This operation manual is the explanations that how to use 1-5tJ series forklift truck correctly. It will instruct
you how to operate safety and precautionary maintenance. To ensure safety and exert the trucks potential,
all the personnel that in charge of operation, maintenance and management must read this manual
thoroughly before starting work with the forklift.

As the improvements of products of our company, maybe there are some differs between this operation
manual with your forklift truck.

If you have any questions please keep touches with HANGCHA GROUP CO., LTD. sales department or
let the agents know.

Tow electric Rise electric Rated capacityt/


Truck model
control control load centre distancemm
CPD10/15/18/20/25/30J 1244(CURTIS) EVC255(CURTIS) 1.0/500,1.5/500,1.8/500,2.0/500,

CPD10/15/18/20/25/30J D1 ACS(Danaher) ACS((Danaher) 2.5/500,3/500

1.0/500,1.5/500,1.8/500,2.0/500,
CPD10/15/18/20/25/30/35J C1 1238(CURTIS) EVC255(CURTIS)
2.5/500,3/500,3.5/300
1.0/500,1.5/500,1.8/500,2.0/500,
CPD10/15/18/20/25/30/35J C2 1238(CURTIS) 1236(CURTIS)
2.5/500,3/500,3.5/300

CPD40/45/50J D1 ACS(Danaher) ACS(Danaher) 4.0/500,4.5/500,5.0/500

CPD40/45/50J C2 1238(CURTIS) 1238(CURTIS) 4.0/500,4.5/500,5.0/500

Dec. 2010 5th edition HANGCHA GROUP CO., LTD.


CONTENT
Foreword
1. Name of main parts or component ......................................................................................... 1
2.Instrument and Controls .......................................................................................................... 2
Meter Panel ......................................................................................................................... 3
Controls ............................................................................................................................... 8
3.Body and Others .................................................................................................................... 10
4.Safety instructions ................................................................................................................. 12
5.The structure and stability of truck ....................................................................................... 17
6.Running-in of the new truck.................................................................................................. 20
7.Daily maintenance ................................................................................................................. 21
8.Driving and operation............................................................................................................ 25
Driving .............................................................................................................................. 25
Traveling ........................................................................................................................... 25
Turning .............................................................................................................................. 25
Stopping or parking ........................................................................................................... 26
Loading.............................................................................................................................. 26
Stacking load ..................................................................................................................... 27
Un-stacking load ............................................................................................................... 27
Check after operation ........................................................................................................ 28
9.Deposit .................................................................................................................................. 29
10.Storage battery..................................................................................................................... 30
The Automatic Watering System of the Forklift Battery................................................... 38
11.Maintenance summarization................................................................................................ 42
Preventive maintenance schedule...................................................................................... 43
Replace the key safe parts termly ...................................................................................... 49
Table for bolts tight torque ............................................................................................... 50
Table for oil used in the truck ............................................................................................ 50
12.Trucks convey, lifting, towing............................................................................................ 51
13.Parameters ........................................................................................................................... 52
14.Scutcheon ............................................................................................................................ 61
15.The use, assembly and safe rules of attachment.................................................................. 66
16.Related safety instruction and standard ............................................................................... 68
17.Maintenance record ............................................................................................................. 70
1. Name of main parts or component

1. Fork 2. Fork carriage 3. Mast 4.Lifting cylinder


5. Overhead guard 6.Steering wheel 7. Seat 8. Counterbalance
11. Left and Right battery
9. Rear wheel 10. Chassis 12. Front wheel
cover hood

1
2.Instrument and Controls

1. Steering wheel 2. Direction switches 3. Parking brake lever 4.Emergency disconnect switch
5. Adjusting lever 6. Brake pedal 7. Accelerator 8. Key switch
9.Turning signal switch 10. Lifting lever 11. Tilting lever 12. Meter panel
13. Horn button

2
Meter Panel gradient and so on is much higher. It is
applied for transporting mass of good in
CPD10/15/18/20/25/30/35JC1
short time and climbing big gradient slop
CPD10/15/18/20/25/30/35JC2
but it costs more energyso the mode will not be
CPD10/15/18/20/25/30J used in normal state except emergency.
Mode P is power mode. All kinds of
CPD40/45/50J C2 index are lower than that of super mode. It is
applied for the case of long distance
transporting and needing higher power or
speed.
Mode E is economical mode. All the
parameters are optimized. Working in this
mode can save power so it is applied for a
long time work after charging, and it is
suggested to work in this mode in normal
work-time.
Mode SPE is safe mode. Thus the max
vehicle speed is limited to about 7km/h. It is
applied for working in busy storage and
cabined room.
ABattery warning Notice: the default mode is mode E. after
As the following diagram shows, from power cutting every time, the work mode
the left to the right, the battery decreases resets to mode E no matter which mode it is
from full state to the only one case, which before power cutting, but the switch key is
represents that the battery leaves only 20%. still in the mode before turn off.
Thus the whole battery indicator bar will
twinkle, and the state indicator lamp will be
bright, now please stop working and charge
immediately.
The mode can be switched through the
mode switch button (G) among the mode of
S, P, E, SPE, as the above diagram shows.

CParking brake indicator lamp


NoticeCharging in time is very important,
otherwise it will affect the lift-span of
battery

BMode indication

When using the parking brake, the lamp will


As the diagram shows, the pictures be bright.
from the left to the right represent the mode
of S, P, E, SPE respectively
Mode S is super mode, thus the trucks DState indicator lamp
acceleration, deceleration rate, max climbing
3
When there is something wrong with
the electrical controller, or operate
improperly, the battery is in lower power,
the lamp will be bright and twinkles.

EError code display area

Display the error code of electrical


controller.

NoticeTRAVEL is the error code of tow


electrical controller, HYD is the error
code of pump controller. TRAVEL OK
means it works without error
Notice the error code of tow electrical
controller refers to the appendix.

FWork-time accumulate timer


When the truck key switch turns on, the
left hour timer will start to time. The
minimal resolution is 10% of an hour, the
other two hour timers are not used.

4
CPD10/15/20/25/30/35J D1
CPD40/45/50J D1

C M D
A B
F

S P EED 12 k m/h
B AT% 80

1 2 3 4 5

G L
H J K
I

The meanings of 6 indicators: Low battery warning (C)


When battery quantity is lower than 20%
of maximum capacity, the indicator lights
are on, at the same time, buzzer beep.
When LED shows no power, please
charge battery as quick as possible.
Communicate indicator (A)
Only lights on when record program,
usually it is no use.

Speed limited indicator (D)


When this lamp lights, it meanings the
truck working at low speed mode. The
maximum speed of truck decreased.
Error indicator (B) Press button 1, you can switch the high
When operation is wrong or the truck is speed and low speed mode.
in trouble, error code will display on the
dashboard. The error indicator lights on.

5
Accelerate indicator (E) Backup button (J)
When this lamp lights on, it means the This button is no use for operator.
truck working at low acceleration mode.
The maximum acceleration decreased.
Press button 2, you can switch the high
acceleration and low acceleration mode.
4

P Backup button (K)


This button is no use for operator

Parking brake indicator (F)


When pulling on the parking brake lever,
this lamp lights on.
5
Switch button of hour indicationL
Push this button, it will display the total
hours of truck, as follow figure:
Entrance button (G)
K E Y ON T IME 2 8H
This button is no use for operator.
B AT% 80

1 Push again, it switch to the total traction


hour.

T R AC T T IME 1 8H
Speed limited button (H) B AT% 80
Press this button to switch the high speed
and low speed. Push the button once again, it switch to
speed display mode.
Dashboard display LED (M)
2 When turn on the key switch, the system
will self-diagnose, the lamp will lights on
one by one. After self-diagnose, LED
Accelerator limited button (I) will display truck speed and battery
capacity. You can know your trucks
Press this button to switch the high working condition through the LED
acceleration and low acceleration. dashboard.
Key switch
3 The key switch has two on/ off
position, you should push the Direction
switch lever to neutral and loose the
accelerator pedal, then turning the key
switch to on position clockwise.

6
Caution! Rear big lamp switch (optional)
1. Turning the key switch on does not Rear big lamp switch (push\pull) has
make the forklift truck move, if the only one shift.
Direction switch lever is not in the neutral Connector battery Far light
position or the accelerator pedal is pushing. Position
2. Error code maybe appear, dont worry 0
about it. 1
3. The Direction switch lever should be Means connected
returned to neutral and move you foot from Caution!
the accelerator pedal. Then the truck can be This light does not relate to key switch
operated. position, so please dont forget to turn off
4. Then the error code should be the rear big lamp when you leave the
disappeared. truck.
Horn button [13] Fuse box
Press the rubber cover at the center of J\JC1\JC2 Series
steering wheel to sound horn. The horn
sounds even when the key switch is in
the off position.
Combined light switch [9]
This combined light switch is composed
of turning light switch and big/small
lamp switch. Turning light indicates the
traveling direction. When turn on the
switch, the lamp flashes.

Forward Left turning lamp flashes


Neutral Lamp goes off 1st is a diode preventing from connecting
Backward Right turning lamp flashes in reverse.
2nd is a control circuit fuse (10A).
Caution! 3rd and 4th are fuses for light and horn
The turn signal lever does not circuit. (10A respectively)
automatically return to the neutral 5th is light fuse 10A.
position. Reset it by your hand. 6th is spare fuse 10A.
Big/small lamp switch has two shifts. JD1
First shift small lamp lights on; second
1st is control circuit10A.
shift big and small lamp both light up.
2nd is main contact circuit fuse 10A.
Emergency disconnect switch [4] 3rd is instrument fuse 10A.
When happen emergency, presses down 4th and 5th is light fuse 10A.
the emergency disconnect switch, and 6th is spare fuse 10A.
then the main power of the truck will be Caution!
cut off, the truck stops working. When replace a new fuse, please choose the
same capacity fuse of the old one.
Caution!
Please dont use the emergency
disconnect switch to substitute the
function of key switch.

7
Controls pressed, the forklift trucks moved
forward. When the lever is pushed
Steering wheel [1]
backward, the forklift trucks moved
The steering hand-wheel is operated backward.
in the conventional manner, that is, when Caution!
the wheel is turn right, the truck will turn While traveling, if change the
to the right; when the wheel is turn left, Forward- Reverse lever, electric braking
the truck will turn to the left. The steer will operatespeed will lower until stop
wheels are located at the rear of the truck. then travel to the opposite direction.
These cause the rear of the truck to swing
out when a turn is made. Warning!
Warning! Turning the key switch on does not
This truck is provided with the make the forklift truck move, if the
power steering, so heavy hand-wheel Forward-Reverse lever is not in the
operation is caused when the steering neutral position or the accelerator pedal
motor comes to a stall. To put the power is being pressed. In this case, the
steering in operation again, restart the Forward-Reverse lever should be
steering motor without delay. returned to neutral and move you foot
Parking brake lever [3] from the accelerator pedal. Then the
truck can be operated.

Use this parking brake lever to park


the lift truck. And the parking brakes are
applied on the front two wheels by Lifting lever [10]
pulling up on this lever. To release the
parking brakes, move the lever forwards.
There is a micro switch at the left
side of the parking brake lever, tense the
lever makes running invalid.
For the truck of CE: if you leave the seat
without tensing the lever, it will warn and
remind you to tense the lever.

Warning!
If parking on a grade is unavoidable, be sure to
block the wheel. The forks can be raised or fell by
Forward-reverse lever [2] pulling backwards or pushing the lever.
Lifting speed can be controlled by tilt
The forward-reverse lever is used for
backwards angle of lever and the
switching between forward and
lowering speed can be controlled by tilt
backward moves. When the lever is
forwards angle of the lever.
pushed forward and accelerator pedal

8
Tilting lever [11] Caution!
Loosen the accelerator pedal when truck
is working, truck can make soft brake

The mast can be tilted by operation


of this tilt lever. Pulling on this lever
backwards will tilt the mast backwards,
and pushing it forwards will tilt the mast
forwards. The tilt speed can be controlled
by tilt angle of the lever.

Caution!
The tilt lock mechanism built in the
hydraulic control valve does not allow
the mast to tilt forwards while the
electricity is being shut down even if the
tilt lever is pushed forwards.
Pedals
Brake pedal [6]
Press this pedal to slow or stop the
truck. At the same time, the brake light
comes on.
Caution!
No permitted to press the brake pedal and
the accelerator pedal at same time,
otherwise, it is harmful to the traveling
motor.
Accelerator pedal [7]
As the accelerator pedal is slowly
pressed, the drive motor start turning and
the forklift truck will start to move.
According to the force applied to the
pedal, the speed is adjusted with not
steps.

Warning!
Before open the key switch to press
the accelerator pedal, the more function
digital indicator shall show alarm
information. Then you must release the
accelerator pedal.

9
3.Body and Others the storage batteries.
You can lift up the hood with little
Seat effort with an aid of hood damper. To
Adjust operator seat to the position lock the hood, push down on the front of
where is comfortable for you and hood until it covered.
provides easy controls. Before Caution!
proceeding with work, adjust operators Be careful do not to catch you fingers in
the hood when closing it.
seat and make sure that it is securely
Depress the spring insurance before you close
locked. Adjust the operator weight the hood, then press the head of the hood.
through rock- suspends system level. The
rear of the seat is adjustable. Left & Right battery cover hood
Seat switch (only for trucks exporting The battery is covered hood, one left
to Europe or option) and one right. When you want to take off
For the safe of truck, when you leave the hood, you should take off the knob at
the seat longer than 5 seconds, the truck first.
will stop traveling.
Safety belt Fork stopper
Please keep back and waist close to
seat as far as possible, and fix safety belt
at the same time.
Inspect whether bolts fixed belt are
loose or not. Do not use belt with a knot.
Do not make belt press on stiff or fragile
things, and do not make belt attrite with
sharp things to avoid wearing. Do not
make seat backrest too be tilted;
otherwise safety belt may not extend
correctly.
Do not remove any part of belt at
will. Please often inspect the belt used Fork stoppers are locked the forks in
frequently, if found any abnormal, position. To adjust fork spacing, pull up
replace it at once. And the life for use is fork stoppers, turn 90and shift the forks
3-5 years, scrap it ahead of schedule if to the desired position. The fork spacing
found any abnormal. should be adjusting according to loads to
There is a safety belt on the seat, be handled.
before you operate the forklift truck,
please fasten the seat belt to protect Warning!
yourself. The forks should be set
Overhead safe guard symmetrically to machine centerline and
The overhead guard used is strong fork stoppers should always be locked
enough to meet safety standard, and again.
protects the operator from falling There are one gap on the below
materials. The top gap is used to lift the beam. It is used to attach goods.
batteries. It is forbidden for use a truck It is forbidden to lock the fork on the gap
that does not with safeguard. position, to prevent the fork fall off from
the gap.
Hood In the middle of the above beam, a
bolt used to prevent fork works here.
The hood can be swung up fully to Please change the bolt as soon as it is
provide easy examining and maintenance of damaged.

10
Change fork Steering column tilting angle adjuster
Take down the old fork: Firstly,
locate the fork to the middle, decline it to
the ground and make the mast forward,
then operate the truck traveling backward,
the fork will be taken down.
Change new fork: Firstly, make the
fork dead against the truck and forklifts
mast to the bottom, then operate the truck
traveling forward, aim at the two gaps
and beams, and raise the mast. Adjust the
position of the fork.
Safety step and safety grip
The tilting angle of the steering
The safely steps are provided on column is adjustable to suit individual
both side of the truck body. The safely operators. Turn the hand lever upward to
grip is provided on the front left pillar of release the steering column and locked
the overhead guard. Use the safely step by turning it downward.
and safely grip when mounting and
dismounting the truck. Hydraulic oil reservoir cap
The hydraulic oil reservoir cap is
Brake fluid reservoir cup
located at the right rear end, below the
The brake fluid reservoir cup is battery hood; open the right side battery
located at the meter board. hood when adding oil. After fill in clean
hydraulic fluid, tighten lock the cap.
Caution!
The brake fluid is poisonous, be Air leakage plug
careful do not drop down. When add There is an air leakage plug on the
brake fluid, be careful do not let dirt and oil tank to let air in the tank goes out.
other thing drop into reservoir cup. Youd better often check the plug and see
whether been jammed.

Head lights and combination lights Chair disconnecting switch

Two headlights and combination When the operator leaves seat, this
lights (turn signal, show width lamp) are switch cut off, and the power of truck is
installed at the front side of the truck. cut off.
Take care of the lights, and wipe dirt, if Safety seat belt (for the trucks
any, and replace any damaged light exporting to Europe or option)
immediately.
There is a safety belt on the seat,
Rear combination lights before you operate the forklift truck,
The combination lights at the rear please fasten the seat belt to protect
side serve as turn signal, show width yourself.
lamp, brake lamp, and back-up lamp. Pay Rear big lamp (for the trucks
attention to keep them from being exporting to Europe or option)
damaged or covered with dust, if any,
The rear big lamp is set on the
clean or replace immediately.
safeguard. If it is broken, please replace a
new one at once.

11
4.Safety instructions
1. Only trained and authorized
operator shall be permitted to operate the
truck.

4. Operator must wear helmet, safety


shoes and work clothes.
5. Because there will bring
exploding gas in the bosom of the battery,
2. Inspect the truck at periodic prohibit any flame nearby it absolutely.
intervals for oil or water leak,
Do not let any tools close the two
deformation, lousiness, etc. If neglected, terminal of the battery to avoid spark or
short life of components will be caused short circuit.
and in the worst case a fatal accident 6. The movement road of forklift
would occur. should be solid and smooth coagulation
make sure having replaced good road or similar to the road suitable for
parts during periodic check. vehicle. Recheck the state of working
Wipe off oil, grease or water from the ground.
floor board and foot and hand controls, if The considered climatic conditions
any. when the forklift designs are:
Strictly prohibit smoking and spark Temperature - 20-50; the wind
nearby the storage battery when checking speed does not surpass 5m/s; the air
it. relative humidity is not bigger than 90%
If maintenance on high position, (temperature 20). The forklift is not
such as mast, front and rear lamp, please suitable in the flammable explosive
be careful to prevent fall down or be working conditions.
clamped. 7. Never mount or dismount the
Be careful do not be scalded when moving truck. Use the safety step(s) and
inspect the motor, controller and etc. safety grip facing the truck when
3 whatsoever in trouble, you must mounting or dismounting the truck.
stop the forklift, hang a mark of danger
or trouble and take off the key, at the
same time inform the manager. Only
after the trouble is removed, you may use
the forklift.
If trouble occurs when lifting cargo,
to Climb or descend, or the storage
battery electrolyte, the hydraulic fluid,
the brake fluid has the revelation, please
organizes the personnel to repair
immediately.

12
8. Never attempt to work the
controls unless properly seated.
Before starting, adjust the seat so
you can get easy access to all hand and
foot control.
9. Before starting up, make sure that:
Please fasten seat bolts.
The parking brake lever is applied
securely. 15. Keep your mind on your work.
The forward-reverse lever is in 16. Keep your head, hands, arms,
neutral. feet and legs within the confines of the
Before staring, make sure no one is operators compartment. Never stretch
under, on and close to the truck. out for any reason.
Dont step the accelerate pedal or
control the lifting lever or tilting lever
before turning on power.
10. Operate the controls smoothly.
Avoid sudden stops or turns.
It is dangerous to make a sharp
brake. Otherwise the truck has the
possibility of overturn.
11. Pay attention to the route of the
truck; be sure to make a wide sight.
12. Never allow other person(s) to
ride on the forks, pallets or on the truck. 17. The pallet and skid used should
13. Taking account of the shape and be strong enough to endure the load.
material of loads to be handled, use a Never use damaged or deformed ones.
proper attachment and tools. 18. We afford all type of attachment,
Avoid hoisting the load, with wire such as rotating roll clamp, bale clamp,
rope hung on the forks or attachment, side shifter, and crane jib etc. You should
since the wire rope may slide off. If refit the truck under ours license if you
needed, a qualified personnel for slinging want. It is forbidden to refit it by
operation should perform, making use of yourself.
a hook or crane arm attachment. 19. Safeguard protect you do not be
Take care not to protrude the forks hurt by the goods fallen. Load bracket
out of the load. The protruded fork tips protect you load goods smoothly. It is
may damage or turn over the adjacent forbidden to use truck without safeguard
load. or load bracket.
14. Know the rated capacity of your 20. It is forbidden to walk down the
lift truck and its attachment, if any, and fork or the attachment.
never exceed it. It is forbidden to walk up the fork or
Do not use a man as an additional stand on the fork.
counterweight. Its quite dangerous.

13
reverse tilt when stacking and
un-stacking loads. Never tilt forward
unless load is over stack or at low lift
height.
When stacking loads on a high
place, once make the mast vertical at a
height of 15 to 20 cm above the ground
and then lift the load farther. Never
attempt to tilt the mast beyond vertical
when the load is raised high.
To un-stack loads from a high place,
insert forks into the pallet and drive
backwards, then lower the load. Tilt the
mast backwards after lowering. Never
attempt to tilt the mast with the load
raised high.
21. It is forbidden to put your hands,
arms or head stretch between the mast 25. It is dangerous to travel with
and safeguard. Once clamped, the life forks higher than appropriate position
has danger. regardless of whether loaded or not.
It is forbidden to put your hands in Keep the good traveling posture. (When
inner and outer mast. traveling, the forks should be 15 to 30 cm
above the ground or floor and the mast
tilted backward)
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.
22. The goods is liable to drop
turning or passing rough road when it 26. Watch for branches, cables,
departures the center. And the forklift doorways, or overhangs. Pay caution
may turn over more probably. when working in congested areas.
Slow down and sound horn at cross
23. Dont stack loads on forks in aisles and other locations where vision is
such a way that the top of loads exceeds restricted.
the load backrest height. If unavoidable, When make a turn, be sure the
make sure the load is fastened. When speed of the truck is lower than the 1/3
handling bulky loads that restrict your max. of allowable speed.
vision operate the truck in reverse or
have a guide. When lead by a guide,
make sure you understand hand, flag,
whistle or other signals. When handling
long loads such as pipe, lumber etc or in
the case of the Large-sized model, or
operate with long attachment, be
extremely careful of load end swing at
corners or in narrow aisles. Be alert for
27. Affirm keeping some distance
others.
from roadside and flat roof.
24. Use minimum forward and

14
28. Before driving over a dock-board 31. Never lift loads with the truck
or bridge-plate, be sure that it is properly inclined. Avoid loading work on a grade.
secured and strong enough to sustain the
weigh. 32. Never permit anyone to stand or
walk under upraised forks or other
29. When operating loaded truck, attachments if machine is so equipped. If
have the rear end of your machine unavoidable, use a safety stand or block
pointed downhill. to prevent a possibility of fork
When operating unloaded truck, attachments falling down or moving
have the rear end of your machine unexpectedly.
pointed upgrade.
Do not make a turn on the grade, in 33. Inspect the surface over which
order to avoid overturn. 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, pay more attention.
Do not operate the truck when the
weather is execrable, such as windy,
thunder storm, snow and etc. Especially
when wind speed is higher than 5m/s,
dont operate the truck outside.

34An accumulator is required for


controller. Forbid to touch within B+ and
B- to prevent from wounding by
electricity. Before checking or cleaning,
please connect loads (contactor circuit or
horn for example) between B+ and B-
first to discharge for capacitor of
30.the goods is liable to drop turning or
controller.
passing rough road when it departures the
center. And the forklift may turn over more 35. Pulling the hand brake when
probably. parking on flat. If necessarily parking on
ramp, you should place the wedges under
wheels.
Descending the fork to the ground
and keeping a little forward tilting, shut
off key switch and take off key.
Pull out the battery plug.
The parking place must be far away
from fireworks.

15
36. You can tow the forklift to the load cargo.
safe place with towing pin when the
forklift cant run. 43. There are enough light at truck
Dont tow the truck which steering work ground. At night, open the head
system or brake system has been lamp to collocate enough lamp-house.
damaged.

37. There is operating method and 44. Only in the event that the truck
warning label on the truck. Please manufacturer is no longer in business and
operate the truck obey the rules on the there is no successor in the interest to the
label and this manual. Often inspect the business, the user may arrange for a
nameplate, when damaged or lost please modification or alteration to a powered
replace it. industrial truck provided, however, that
the user shall:
38. Fire extinguisher must be a) Arrange for the modification or
prepared at working place. Users can alteration to be designed, tested and
select fire extinguisher along with truck, implemented by an engineer(s) expert in
and it usually is fixed on rear supported industrial trucks and their safety;
leg of safety shelf, it is easy to pick. b) Maintain a permanent record of
Driver and manager should be the design, test(s) and implementation of the
familiar with the position and operation modification or alteration;
of fire extinguisher. c) Approve and make appropriate
changes to the capacity plate(s), decals,
39. Please use stock when conveying tags and instruction handbook;
little goods, it is forbidden to use fork d) Affix a permanent and readily
directly. visible label to the truck stating the
manner in which the truck has been
modified or altered together with the date
40The work road surface for forklift
of the modification or alteration, and the
should be stability and unknit, cement, name and address of theorganisation that
blacktop or beton. If there are snow, ice, accomplished the tasks.
water or other eyewinker, bar. Eliminate
all, then work. Otherwise the truck will
be out of control and lead the safety
accident.

41. Move the truck to the place which


respects traffic when it anchors. If the
reason is brake or turn system, move it
by a suitable truck (Reference the part of
truck move); Other reasons, use a suitable
truck to traipse, tie the cord outside of
truck. Please abide by the traffic
regulations when traipse the truck on
calzada.

42. After take-down the hood, water


tank cover board, overhead, backrest of
mast, unallowed to operate the truck or

16
5.The structure and stability of truckPrevent the forklift to turn
over!
It is very important for operator to know the trucks structure and relationship between
load and stability.

Caution the structure of the truck


The basic structure of the truck is mast (include mast and
forks) and body (include tire).
The lift truck keeps the balance of weight between
the truck body and the load on the forks with the center
of the front wheels as a fulcrum when the rated
capacity load is placed in position.
Due care should be paid to the gravity center of
loads and forklift to maintain the stability of the truck.

Caution Load center

There is difference in gravity because of the loads


shape, such as box, board and large roller. It is very
important to distinguish the difference of the gravity
center of loads for evaluating the trucks stability.

Warning!
If the truck will turn over, do not attempt to get out of the truck because the speed of
overturn is much faster than your speed. You should hold the steering wheel handle, stretch
your feet, and this practice will let you in the seats. Operator fastens the safety belt please.

17
Caution Gravity center and stability
The combined gravity center that is
composed of the forklift center and the load
gravity center determine the stability of lift
trucks.
When unloaded, the barycenter does not
change; when loaded, the barycenter is
determined by the truck and the loads center.
The barycenter is also determined by the
tilting and lifting of the mast.
The combined center is determined by these
factors:
Loads size, weight and shape
The lifting height
The tilting angle
The acceleration
The radius of turning
The road and grades angle
The attachments

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 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.

Caution The max. loadweight and load center distance

The load center distance is defined that: the


distance between the load center and the fork
carriage or the front of the fork carriage. The max.
load means the maximum load the truck can charge
at the normal load center distance. The relation
between the max. load and load center distance
shows on the capacity chart. You should reduce the
weight of load if the load center distance inclines to
the fork carriage.

18
Caution Capacity chart

The chart given shows the relation between the


load center and the weight of loads.
Before loading, make sure that the load and the
load center distance in the range of capacity chart.
If the loads shape is complex, put the most
weightily part on the middle of the forks, and
close to the fork carriage.

Caution Velocity and acceleration


One object will keep quiescence until force works on it. Also, a moving object will
keep moving until force works on it .This is just inertia.
According to inertia, when truck starts moving, one force works backwards, and when
truck stops moving, one force works forwards. So, its dangerous to brake suddenly,
because it causes one large force works forwards, and its easy to cause truck overturn or
load slide off.
When the forklift makes a turn, will exert a centrifugal force outward from the curve
center. This strength pushes forklift outwards and causes it to turn over. About stability
region is very small, so decelerate when turning. If the cargo transported at the high
position, its easier to turn over.

19
6.Running-in of the new truck
We recommended operating the machine under light load conditions for the first stage
of operation to get the most from it. Especially the requirements given below should be
observed while the machine is in a stage of 100 hours of operation.
1. Must prevent the new battery from over discharging when early used. Usually should
recharge when discharging down to 20%.
2. Perform specified preventive maintenance services carefully and completely.
3. Avoid sudden stop, starts or turns.
4. Oil changes and lubrication are recommended to do earlier than specified.
5. Limited load is 7080% of the rated load.

20
7.Daily maintenance Warning!
The earnest complete maintenance, can When using an air compressor, at first,
keep the forklift to be at the good status. And adjust the air pressure of the compressor.
the safety of the truck is related with your Otherwise it will cause a serious accident,
job and your life. since the maximum pressure of compressor
! Warning higher than the pressure tire can bear.

except checking lights and operating


capability, you should shut off the key Tire Pressure (GB/T2982-2001)
switch and pull out the plug before checking
electric system. Driving
Truck Turning wheel

prohibit operate forklift with trouble. wheel


type (rear wheel)

little trouble brings big accident. (front wheel)

1. Inspect oil leakage: include hydraulic 1-1.5t 860KPa 1000KPa

oil, electrolyte and brake fluid 1.8t 1000KPa 1000KPa

Inspect connector of the oil pipe and 2-2.5t 850KPa 900 KPa
storage battery to see whether there is any
3.0t 850KPa 900KPa
leakage. Use your hand or eyes to inspect,
Forbid to use a flame. 3.5t 850KPa 900KPa

4-5t 930 KPa 860KPa


2. Inspect tire
Caution!
Turn the tire valve cap counter
clock-wise and move it. Using a tire pressure Above for the pneumatic tire pressure, is not
gauge, measure the inflation pressure, and suitable the solid tire.
adjusting it to the specified pressure, if
needed. After making sure there is no air
leakage from the tire valve, reinstall the cap.
Check that each tire does not get damaged at
the tread surface or side face. Make sure the
wheel felloe is not bended.

Warning!
Since the tires of forklift truck need have a
high inflation pressure to carry heavy loads,
even a small bending of rims or a little
damage at the tread surface could cause an
accident.

21
Warning!
All bolts and nuts should be screw tight
to the stipulation torque after the tire and the
wheel felloe was assembled, then charge is
allowed. Types have expansion energy after
changing, so the tire pressure does not
surpass the rating.
Please put the tire in a protection frame
or tie it with a iron chain when charging to
Tighten torque refers to <<Bolt tighten
prevent accident happening. torque force table>>

3. Replace tire Truck type Front nut Rear nut


When the tire is damaged, you should
1-1.8t 157-176 N.m 76-107 N.m
replace it in time. Use a jack to make the tire
just beyond ground, then put a wood block 2-3.5t 441-588N.m 157-176 N.m
under the chassis. Loosen nut or ,
4-5t 441-588N.m 157-176 N.m
replace a new tire. Tighten the nut crossly
and symmetrically.
5. Check brake pedal
4. Inspect the torque of hub nut Step the brake pedal, check it for
Check the torque of hub nut whether meet slowness or block. The proper brake distance
the requirement. is 2.5m when free load. Adjust the height of
Hub nut pedal to 115125mm. Adjust brake booster
Divided rim bolt (some trucks do not push rod clearance to 1-3mm. The brake
have ) lamp should be lighted when the brake pedal
Driving axle bolt steps on 10-20mm.
Rear hub nut
Divided rim bolt
6. Check the parking brake lever
Driving wheel (front wheel, expect 1-1.5t)
The force of hand brake lever is adjusted by
the bolt on the top of lever. The force
increases clock-wise screwing, and decreases
counter lock-wise screw.
Caution
To step the brake pedal is helpful to tighten
or loose the hand brake lever.

turning wheel(rear wheel), driving wheel(1.5t)

22
7. Check accelerate pedal 5) Loose the cap of hydraulic oil, pull
The acceleration changes as the stroke out dipstick
changes. 6) Set a plate under the chassis, then
loose the fuel drain plug, and put the old oil;
8. Brake fluid level check 7) Dispose the old oil according to local
Open the brake lubricated cap cover. Check environmental protection laws;
the fluid level in the range allowed. If lack, 8) Twist the fuel drain plug, join the new
please add, and check if there is air mix into hydraulic fluid, and inspect whether have a
the pipe. leakage;
9) Start the truck, lifting for 3-5 times,
Caution and tilting for 3-5 times;
Please use brake fluid with one type, do not 10) Add hydraulic oil to required scale.
mix.
Dont spatter the brake oil onto the surface 11. Drivers seat adjustment
of paint otherwise the paint will be damaged. Make sure the drivers seat is properly
When adding fluid, due should be taken to located. If not properly, shift the adjusting
prevent dirt or water from entering the lever to the right and move the drivers seat
reservoir. to a position which provides easy access to
all foot and hand controls. After adjustment,
9. Check hydraulic oil shake the drivers seat a little to be sure that
Loose the cap of hydraulic oil inside of right it is securely locked. Adjust the weight.
frame, pull out dipstick and check it if the oil
level is between the scales. Add oil when 12. Check battery
lack. Check the battery whether be installed
firmly.
Check proportion of electrolyte. Refer
to battery section.
Check the terminal for loose or damage.
Otherwise it will be adjust or replace.

10. Replace hydraulic oil


Replace hydraulic oil once half year on
schedule.
1) Stop the truck on smooth ground;
2) Turn steering wheel right to the
bottom, and enable the fuel drain plug to
have the enough space; Pull in the plug and close the hood.
3) Tilt mast backwards to the bottom, and Turn on the key switch
fall the forks to the ground
4) Pull on the hand brake

23
13. Instrument check (include battery and left chains are equal.
capacity and error diagnose) Adjust the chain tension: loosen the
Refer to instrument section. lock nut (1) and adjust the chain by nut (2),
then locked nut (1).
14. Lifting lever, tilting lever,
attachment lever
Check the lifting lever, tilting lever and
attachment lever for looseness. Return
position well.

15.Mast
Check the mast and the forks to insure
that:
1) The fork does not have crack and
distortion. Forks were installed
firmly and correctly.
2) Check the oil cylinder, oil pipes for
leakage.
3) Check the rotation of idler wheel
4) Check the mast for crack or
distortion
5) Lifting lever, tilting lever,
attachment lever
Check the mast whether works normally, 18. Check steering system
whether have unusual sounds. Turn the wheel right and left separately
to check steering system.
16. Mast lubrication
You should grease lubrication to the 19. Turn signal, horn and other lamp
orbit of mast on schedule base on check
requirement. Make sure that the turn signal operates
Adjust the lubricate schedule according properly by pull/push turn signal switch.
to your working condition. Add times when Make sure that the sound of horn is
busy. properly by press the horn button
To coordinate forklift's operation, Check the other lamp and back-up
grease lubrication to the guide pulley and in buzzer.
outer upright mounting.
20. Battery maintenance
Refer to battery section.
17. Lift chain tension check
Raise the fork about 10-15 cm above 21. Other
the ground vertically. For instance, pay attention to abnormal
Push the middle of the chain with the noise.
thumb. Make sure the tension for the right

24
8.Driving and operation backward.


! Warning 6 Loosen the hand brake lever
Before operating the truck, check all controls
Step the brake pedal and push the
and warning devices for proper operation. If
any damage or fault is found, dont operate hand brake lever to the front position.
truck until corrected. Hold the steering wheel with your left
Driving hand and attach your right hand.
1 Open the cap, and insert the storage
battery plug, then close the cap. Traveling
Step the accelerate pedal slowly, the
truck will travel forward or backward.

Decrease speed
Loosen the accelerate pedal slowly, the
truck will decelerate.
Warning:
Dont step the accelerate pedal and brake
2 Set the direction switch to neutral pedal at the same time.
position
3 Turn on key switch Caution:
Decelerate the truck in the situations
Hold the steering wheel with left
following:
hand and turn on the key switch with right turning;
close the goods or pallet;
hand.
close the deposit area;
4 Tilt back the mast enter a narrow passage
the condition of road surface is bad.
Control the lifting lever to set the
bottom of the fork 150-200mm above the Turning
Unlike general passenger-cars, the
ground. Control the tilting lever to fully
turning wheels are located at the rear of
tilt back the mast. the truck. This cause the counterbalance
swing out when turning.
5 Control direction lever
Slow down the truck and turn the
Forward Push the direction lever steering wheel toward the side which you
are turning. The steering wheel should be
forward.
turned a bit earlier than as with the front
BackwardPull the direction lever wheel steering car.

25
be handled.
! Caution
The pallet should be evenly positioned
Drive the truck slowly and control the across both forks.
steering wheel carefully, assure there is
Insert forks into the pallet as far as
enough space to steer. possible.

Stopping or parking
To raise loads from the ground

Slow down and press the brake pedal to Firstly, lift the forks 5 to 10 cm off
the ground or floor and make sure loads lay
stop the truck.
stably.
Place the shift lever in neutral.
Then tilt the mast backwards fully
Pull up the parking brake lever.
and lift forks up to 15 to 20 cm off ground
Down the forks on the ground, tilt
then start running.
mast forwards fully.

When handling bulky loads which restrict
Place the key switch in OFF to shut
your vision, operate the truck in reverse
off the battery. Remove the key and
except when climbing grades.
keep it.
Caution
Dont dismount from the moving truck,
never jump from the truck.
Dont parking the truck on the working
road.

Loading

The forks should be adjusted properly to
maintain the balance of load.

Place the truck right in front of the load to

26
Caution:
Stacking load
Decelerate the truck in the situations

When approaching the deposit area slow following:
turning;
down your truck. close the goods or pallet;

Stop the truck right 30 cm far away from close the deposit area;
enter a narrow passage
the position where your load is to be the condition of road surface is bad.
deposited.

Check the condition of the deposit area. Un-stacking load

Tilt the mast forward until forks become
When approaching the area where the
to horizontal. Raise forks until they are a load is to be retrieved, slow down your
little higher than the deposit position. truck.

Move forward to place the load directly
Stop the truck 30 cm far from the load.
over the desired area and stop the truck.
Check the condition of the load.

Make sure your load is just over the
Tilt the mast forward until forks become
desired area. Slowly lower the load into horizontal. Elevate forks up to the position
position. Make sure the load is securely of the pallet.
stacked.
Make sure forks are positioned properly

Do necessary lift-tilt operations and then to the pallet. Move forward slowly to
back away to make the forks leave loads. insert forks into the pallet as far as

After making sure the forks leave the load, possible.
lower the forks to the basic position (15 to Caution
20 cm off the ground). If the forks are hard to be fully inserted,

Tilt the mast backwards. use the following procedure: Move
Warning! forward and insert 3/4 of the forks. Raise

Never tilt the mast with loads upraised the forks 5 to 10 cm and move backward
2m or more. 10 to 20 cm with the pallet on the
Dont leave or dismount from the truck forks, and then fall the pallet to the stack.
when the load is raised high. Move forward again to insert the forks
fully.


Raise the forks 5 to 10 cm off the stack

27

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.

Check after operation


Clean and check the truck after operation:

Damage or leakage.

Add grease if necessarily.

Check the tire if it is damaged or inset
with foreign body.

Check the wheel hub nut if it is loose.

Check the height of electrolyte surface.
If you havent lift the fork to the max.
height in the day, you should lift it to the
max. height 23 times.

Caution
If you find any trouble, must repair it in
time.

Prohibit operate the forklift before
repairing it completely

28
9.Deposit Warning
Daily Depositing a. The stow-wood must be single and
Park your truck at the area appointed, hard enough to support the truck.
and block the wheels to prevent b. Dont use a stow-wood higher than
accidental roll. 300mm11.81 inch.
Make sure the shift lever on neutral c. Lift the truck to the height of
position.
placing on the stow-wood.
Pull up the hand brake lever.
Shut off key switch and operate the lift d. Place two same size stow-woods
and tilt lever several times so that the under the left and right sides of the truck.
inner pressure in the hydraulic tube will e. After supporting the truck with
decrease. stow-wood, swings the truck forward,
Cramp out the electrical outlet.
backward, left and right, check its safety.
Take out the key and deposit it in a safe
position. Operate the forklift once a week,
and be required to lift the forks to its max.
Deposit the truck for a long time
height many times .
On the basic of the daily depositing
Check the proportion and the level
you should do these checks and of electrolyte once a month
maintenance additional: Charge the battery equally once a
month.
Take out plug to prevent discharge and
place in shade.
Brush antirust oil on those parts which
is exposed such as piston rod and axle Working after long deposit
easy-rusted. Get rid of antirust oil.
Cover breather hole and so on which Discharge the gear oil from driving
humidity easy to enter. axle, decelerator box, and clean up the
Cover the whole truck with mantle internal of them. Add new oil.
All lubrication points add the oil
Charge the battery then install it to
(grease).
truck, and do not forget to connect the
Fill up the truck body and counter
down-lead.
weight with stow-wood to reduce
bearing of the two rear wheels. Check carefully before starting,
include start, advance, and back off,
turning, lift, fall, tilt and so on.

29
10.Storage battery
When electrolyte level is lowyou must
add distilled water to the level appointed.
Attention for using battery:
1. No firing Warning

Explosive gas can be produced in the

1. The shortage of the electrolyte will
internal of batterysmokingflame and
cause the storage battery overheated,
sparkle ,each can easily cause battery
even cause the system part of storage
explosion.
battery and electric combustion.
2. Vitriol include in the electrolyte can
create burns, see doctor for emergency
treatment quickly if touch it un-carefully.
Splashing to the skin or eyeswash with

water 15~20 minutes;
Splashing to the clothes take it off

immediately

Careless drinkingInstead of plenty of
2. Protection against electric shock water and milk.
3 Wearing glassesrubber overshoes and
Warning
rubber glove.

Battery has high voltage and energy.

Do not bring short circuit.

Do not approach tools to the two poles of Remaining clean battery
the batterywhich can cause the sparkle. Keep dryness and cleanness on the
surface of battery .the poles for
connection are also dry and clean.
3. Correct wire connection
Operator must screw down the vent-cover
Not allowing instead anode of
of battery.
cathodeotherwiseresulting in sparkle or
burning or explosion.
Warning
4. Do not over-discharge 1. Do not use dry cloth or fiber cloth to

If you use the energy of battery till the clean the batteryavoiding static to cause
forklift cant move, you will shorten its the explosion.
working hours. 2. Pull out battery plug.

When the display of battery shows low 3. Cleaning with wet cloth.
capacity, please charge it quickly. 4. Wearing glassesrubber overshoes and
rubber glove.
5. Inspection for electrolyte

Forbidden to use the truck when the
electrolyte is shortage.

Inspection for electrolyte level every
week.

30
Check connections whether there is
loosen, fasten if any.
When wire or electrical outlet was
damagedplease do not charge.

Measure in summer
In summerwater in the electrolyte is
easy to evaporatethereforeelectrolyte
must often be inspected if electrolyte is
lowyou must add distilled water to the
level appointed. 4. Open forklift cover and battery lid when
chargingin order to release the explosive
Warning
gas .
5. In the progress of chargingelectrical
Filling with distilled water beyond the source switch and battery pin are not to
regulated range, Spilt electrolyte will pull outotherwise will destroy pin and
electrical units. The normal procedure is
cause corrosion and electricity leakage.
that:
Measure in winter press down the stopping button firstly
Keep effective and good surrounding for and then pick out the pin.
charging.
To prevent dischargingwhen it is Charger
cold pull out the battery pin. 1. The battery group is equipped with
JCD-35A-24 type automatic high frequency
Take measuressuch ascovering battery
computer to charge. The input power supply
for warmth. is AC single-phase with 220V, input current
Charge in time after work. is not lower than 15A. The output voltage is
DC36V and its max. charge current is 35A.
The charging process is automatic, the detail
Attentions for charging of using method please refer to the charger
1. Please charge in the well-ventilated and operate manual.
2. Connect with earth wire when the charge
appointed site.
is used.
2. Mark no smoking when charging. 3. To replace fusemake sure that the input
3. Inspect wire and electrical outlet. and output circuits are disconnected.

Before chargingplease examine wire 4. Only professional person is allowed to
disassemble the cover to check and repair.
and electrical outlet whether been 5. Do not rebuild or disassemble charger.
damaged. 6. In high temperature season, pay attention

31
to prevent the charge from destroy caused Specification for distilled water:
by high temperature. Stop the charge in Ingredient Index
short time when it is necessary.
Appearance No color crystal
7. If a non-automatic charger is used, the
Dry residue % 0.005
charge voltage, current and charge time
0
should be adjusted, and check the rate of Resistively(25 C)cm 7104
battery electrolyte timely, so as to make sure Fe % 0.0004
that the charge of battery group is in good Cl % 0.0005
condition. The adjust parameters please Mn % 0.00002
refer to battery charging in the follow.
Organic compound
8. Do not continuously charge. 0.0002
(calculating oxygen) %
Continuously charge several batteries will
cause charger overheat even be damaged. Magnesium oxide +
You can use the charger again after it has calcium
0.005
been rested for an hour. oxide
9. Select the charger according to batterys %
voltage and capacity (refer to parameter Ammonium
table) 0.0008
%
Nitrate or nitrite % 0.0005
Battery charging
1. There are two charge mode can be Confect course
adopted, including intelligent charging Wear the blinkers, rubber overshoes
and constant current charging. For the
and rubber glove.
first charging, adopt the constant current
Please pay attention to add the acid
charging.
All the batteries of the new truck are not to water slowly, churning up at the
added electrolyte. same time, make it mix equality.
Electrolyte confect
CAUTION
Type D-500
Parameter Dont pour the water to the acid, in
D-420 D-630B
order to avoid the temperature of liquid
Name D-700
surface turning high suddenly to cause
Specific gravity boiling and splashing out to hurt
1.265g/cm3 1.275g/cm3
of acid someone.
Volume When the electrolyte is cooled to
Water 3.1:1 2.6:1
ratio 30, pour it into battery. It is proper
and
Quality to pour the electrolyte 15-20mm
vitriol 1.7:1 1.65:1
Ratio above the protection piece (without a
Vitriol Ratio 1.835g/cm3 dobber) or 1mm distance between
dobber and cover (with a dobber).
Suitable for
Only when the temperature of the
Vitriol standard GB4554-84 or special
electrolyte is below 35 (after
for battery
about 3-5 hours), can be first
charged.

32
4.5-5 times than rated capacity.
Caution Charging Charging current(A)
The time that is from pouring the Truck Battery
voltage 1st 2nd
electrolyte into the battery to starting type type
(V) phase phase
first charging cant be exceeded 12
hours. 1-1.8t D-420 72 40 20
The specific charging cable should
be connected to charging machine. 2-2.5t D-630B 72 63 32

3t,3.5t D-500 120 50 25


Caution
Be sure to notice that the polarity 4-5t D-700 120 70 35
sign on the plug must keep comfortably
to the out specific charging end node. Charging timeh 35-45 35-45
When the charging cable is
connected to the storage batteries, please c. Adjusting the specific density and
pay attention to keeping comfortably on height for the electrolyte
the polarity sign. Otherwise maybe you If the specific gravity is smaller, it will
will damage your battery.
be adjusted as follow: then take out
some electrode from the battery, pour
Inspect the compounded sulfuric acid that its
The voltage value that the power specific gravity is 1.400g/cm3.
needed is the number of the serial If the specific gravity is larger, it will be
battery three times. adjusted as follow: then take out some
Battery voltage electrode from the battery, pour some
Truck type Battery
V
distilled water, but you must keep the
1-1.8t D-420 48 electrode height accord with demand
d. After adjusting, you should keep
2-2.5t D-630B 48
charging on 1 hour; make the density
3t,3.5t D-500 80 of electrode even upper and under. At
this time we have finished the first
4-5t D-700 80
charging.
Inspect the charging machine. e. Close the pouring plug and clean the
Inspect every batterys polarity. battery surface acid, then you can use
Charging ways time, current as the it.
form Caution
a. 1st phasemost of the single batterys During the charging, the temperature
terminal voltage steps up to 2.4 V of electrolyte should not be exceeded
b. 2nd phasethe electrode give off a 45 Otherwise you should low the
temperature. If the temperature do not
large number of bubbles, the voltage
lowing, you should stop recharging
and the specific gravity steadies 4
till the temperature drop down.
hours and the charging value gets to

33
occur disequilibrium among the voltage,
Daily charging the density and the capacity.
The battery that has been made the
Compared to most of the batteries ,
first charging and used regular, then often finds that single batterys
charged again, is named daily charging. proportion of voltage and electrolyte
Its way is almost same as the first rises slowly during the course of charge
charging. and during the course of discharge, its
The recharging value is 1.2 times batterys proportion of voltage and
than the last electric discharging. But the electrolyte declines faster than most of
electric-change for new batterys fore other batteries.
five times should be 1.5 times than the Make equilibrium charge in the
last electric discharging. following case
During any charge, the temperature a. discharge voltage often drop down
of electrode should not be exceeded ending voltage
450C otherwise it should be taken b. discharge current is often larger
measures such as reducing artificially c. Not charge in time after discharge
charging current or lowing the d. The electrolyte is mixed with
temperature. If the temperature doesnt impurity with a little harm.
drop, you should stop charging, till the e. It often be charged deficient or has
temperature dropping down. not been used for a long time
Charging current(A) f. After taking out the battery group
Charging
Truck Battery
1st 2nd for checking or cleaning settling.
voltage
type type
(V) phase phase The method of Equilibrium Charge
Firstly, charge the battery normally,
1-1.8t D-420 72 55 25 and then rest for 1 hour after the
end of charge.
2-2.5t D-630B 72 88 44
Charge it again with the current
3t,3.5t D-500 120 70 35 belongs to the second normally
charge until the electrolyte gives
4-5t D-700 120 96 47 off a large number of bubbles, then
stop charging for 1 hour.
Charging timeh 4-6 6-10
Repeat it several times as
Adopt intelligent charging for the mentioned above until the voltage and
daily charging. The first five charging the density keep invariable and the
should using Equilibrium Charge battery gives off a large number of
according to the intelligent charger bubbles immediately when charge
operate manual. again.

Equilibrium Charge Complementarity Charge



During using of the battery, it often If one days work cannot be fulfilled

34
with one charge, carry out opportunity
5. Use the proper tools to pull up the
charge during breaks.

When the temperature of circumstance battery


is low, carry out opportunity charge.

Charge for long-term storage


Carry out equilibrium charge before
storing.
Carry out equilibrium charge once
every 15 to 30 days during the storage
period.
The special orders storage battery The weight and dimension of Battery
Model
carries on the charge according to
1-1.8t
"Accumulator Instruction for use". Weight (kg)
Min. 700
Max. 900
Battery replacement
Dimension(mm) 465980780
Caution
Be sure that the voltage, the
Model
capability, the size and the weight of 2-2.5 t
Weight (kg)
the new battery are according with the
forklift truck before replacing the Min. 800
battery. Max. 1000
Forbid to use battery with Dimension(mm) 5701028780
different voltage or capacity or weight
except being promised by factory.
Model
3 -3.5t
Weight (kg)
Min. 1200
Replacement step
Max. 1500
1. Stop the forklift truck on the plain
ground pull up the hand brake lever. Dimension(mm) 7101028780
2. Open the hood cover.
3. Disconnect the battery plug.
Model
4-5 t
Weight (kg)
Min. 1900
Max. 2200
Dimension(mm) 8001128780

4. Remove the lock pin.


35
Caution
The box must be pulled up with
using 4 holes of the pothook at the same
time. It is not allowed to pull up with
only two holes. Otherwise, the
asymmetric power will cause the battery
damaged.
The steering wheel and other
equipment should not be bumped, avoid
being damaged when pulling up the
battery box.
2 Replenish the distilled water
6. After exchange the full electricity of Wear the blinkers, rubber overshoes
battery, plug into the lock pin, shut to and rubber glove.
the hood cover, and plug into the pin of
Using the measuring cylinder to
the battery hard.
take out the distilled water with a
The waste electrolyte of the
replaced battery should be dealt certain quantity.
according to environment and protection Open the battery cover for every
law rather than reject at will. battery cell.
Imbibe distilled water with injector
The proportion and level of electrolyte and then supply it into the battery.
The battery with a dobber
Caution When the red dobber rises, the
If the level of the electrolyte is low, white line is appeared, please stop to
using the battery will cause the
replenish the distilled water.
battery over-heat and shorten the
batterys life.
1 Inspect electrolyte
The battery without a dobber
It is proper to pour the electrolyte
15-20mm above the electrode plate.
The battery with a dobber
Depending on the dobber of the
winded cover, and read the level
position of the electrolyte.

36
The battery without a dobber
When the electrolyte is above
15-20mm of the electrode plate, stop
replenishing the distilled water.
After replenishing the distilled water,
close the pouring plug and battery
cover.
Using the damp cloth to clean the
surface of every battery cell.

CAUTION
It is not permitted to overrun the
appointed tiptop level when replenishing
the distilled water. Adding it too much
will result in leakage of electrolyte, and
it will damage the truck when charging 2Specific gravity measure
and discharging. Using the densimeter to measure the
Draw it out with injector if adding specific gravity.
it too much.

3 Read the specific gravity


1 The specific gravity of the
electrolyte should change follow the
temperature.
Use thermometer to measure the
temperature of electrolyte.
Put the straw of densimeter into
electrolyte uprightly, extrude rubber tube
with hand and the electrolyte will be 3Conversion of the specific gravity
sucked into the glasses tube and then the
The specific gravity at the
floater of the densimeter will float.
Numerate the reading of the standard temperature of 300C should be
densimeter. converted as follow
NoticeThe dobber of densimeter must D30= Dt + 0.0007(t - 30)
rise uprightly without depending on the Where D30 the specific gravity at
glass pipe.
the standard temperature of 300C
Dt the specific gravity at
the temperature of t0C.
t the temperature of the
distilled water during convert.
The specific gravity that was refered
in this book is measured all at the
temperature of 30.
37
The Automatic Watering System of the Forklift Battery
1. Automatic Watering System
Makeup of the Automatic Watering
System

Automatic Watering Plug


End Plug
Floater
T-piece & L-piece
Flow Indicatorwith filter
6mm, 8mm ,10mm watering pipe
Male & Female couplings (Kv10 and KV6, etc.)
Water Tank

2. Application Specification & Installation

During the period of development and long-term practical


usage, the leak tightness of automatic watering system has received
complete recognition.
But when you use it, you need to keep the automatic watering
system clean and there cant be any filth on the surface.
How to properly install the automatic watering system
Our automatic watering system is easy to operate, no need to finish
watering the electrolyte in the storage battery by hand,
time saving and labor saving, besides, it can extend the service life.
How to correctly install the water tank, choose proper floaters,
how to confirm the specification & quantity of the installed
accessories according to different types of battery, including correct
application rules for automatic watering plug, watering pipe, T/L-
pieces and male/female couplings as well as the cleaning of the flow
indicator. We will give you a brief introduction for the above items
as follows:
Meanwhile we will offer detailed installation drawings to ensure that the clients can
correctly install and standardize the operation.
battery Watering head T-piece Flow 6mm 10mm end Male/female Water tank
spec. 6-10-6 indicator Waterin Watering plug K10 specification
T-piece filter g pipe pipe
24V 12 pcs 1 pcs 1 pcs 3m 5m 2pcs 1pcs 30L 1pcs
48V 24 pcs 1 pcs 1 pcs 5m 5m 2pcs 1pcs 30L 1pcs
80V 40 pcs 1 pcs 1 pcs 10m 5m 2pcs 1pcs 60L 1pcs

38
Automatic Watering System of Forklift Storage Battery-48V battery group

Floater

How to choose proper floaters correctly

According to different storage battery, we have five kinds of floaters for you to choose. In
order to achieve our expected standard and completely reflect the effectiveness of the
automatic watering system, the most important thing is to choose proper floaters.

At present our company can offer a rule for the client to make judgment and choose the type
of floater. (see diagram)
The diagram the installation way of the floaters

T =T1-(5~17mm)

39
T approaching 47 50.5 58 61 72
Float 13 16.5 24 27 38

Watering Pipe
Our company offers watering pipes of different types and the clients can choose what
they need according to the specification of the battery.
The watering pipe must be perfectly sealed with T-piece and L-piece.

Notes during the filling process:


1In order to ensure a safe watering process, we hereby recommend you to use flow
indicator (with filter), the flow indicator with filter can not only timely indicate whether it
finishes watering, but also avoid unclean impurities entering the battery to result interruption.
2The watering pressure should be within the range of 0.2-0.6, no less than 200mbar
3Youd better conduct watering within the specified periods, because frequent filling
will lead to overflowing for too much water, which will do great damage to the storage
battery.

NoteFilling after finishing charging is the best ideal state, besides, do not filling before
charging.

Cleaning
During the period of development and long-term practical application, the leak tightness
of automatic watering system has been completely approved.
When you use it, you must pay much attention to keep the automatic watering system
clean. No filth remaining on the surface.
The users should regularly clean the watering plug for the plug is a kind of plastic good.
Clean the surface directly with tap water and no need to use other detergent.

Structure Diagram of the Watering Plug

open close

40
Characteristics of the Automatic Watering System
No need to water by hand, labor saving.
No malfunction factor leading to damage the battery.
Easy & safe operation.
Ensure a precise electrolyte level in every battery cell.
Prevent leakage when watering.
Effectively avoid the acid liquid to erode the storage battery and the electrolytic bath.
Extend the service life of the battery.
Environment protection.
Save energy.

Function Introduction
Function of the automatic watering system: the floater of the automatic watering plug can
reach correct water level, when the level rises in the cell, the pressure closes the valves and
prevents further water entering the cell. When the system finishes watering, the flow indicator
will stop running and you can see the water-level indicator clearly through the top of the
watering system.
Besides, the material of floater can avoid damage and ineffectiveness.
As for the structure of automatic watering system, there is a terraced step, when the
electrolyte gas rises to the watering plug, the terraced part can prevent the leakage of the
electrolyte gas as well as quickly cool the electrolyte gas to make them go back to the storage
battery in time.

41
11.Maintenance summarization
The fork lift truck needs inspection and maintenance periodically so as to make it in
good working condition.
Inspection and maintenance are usually ignored; youd better find the problems and
solve it in time.
Use the orthodoxy spare part of ZHEJIANG HANGCHA ENGINEERING
MACHINERY CO., LTD.
Dont use different oil when changing or adding oil.
Forbid to repair the fork lift truck if you havent been trained.
Dont rave about oil and electrolyte used at will, and carry on handling according to the
local environmental protection laws and regulations.
Maintenance on schedule.
After you make maintenance, youd better make a record.

Notice

No smoking.
You should shut off key switch and pull off the plug before service.except some trouble

shooting.

Clean the electric part with compress air, do not with water.

Do not place your hands, feet or any part of body into the gap between the mast and
instrument.

The weight and dimension of the counterweight:
Tonnage 1-1.5t 1.8t 2-2.5t

Weight (kg) 426 600 770 743 1000

Dimension 2941070912 3291070912 3821134940


(mmmmmm)

Tonnage 3t 3.5t 4-4.5t 5t

Weight (kg) 1175 1495 1358 1522 1918

Dimension 3821134940 4621134940 4651280978 4651280978


(mmmmmm)

The dimension of mast

Model
1-1.5t 2-2.5t 3t 3.5t

Dimension
18951072480 19151118555 19551120580 19551120585
(mmmmmm)

Model
3.5t 4-4.5t 5t

Dimension
19551120585 22451350550 23951350555
(mmmmmm)

42
Preventive maintenance schedule
Battery Check, revise, adjust Replace
Checking Daily weekly Monthly Trimonthly Semiannually
Service required Tools
item (8 hrs) (40 hrs) (166hrs) (500 hrs) (1000 hrs)
Electrolyte level Eyeballing
Electrolyte proportion Densimeter
Battery quantity
Terminal

looseness
Looseness of connecting

wire
Storage cleanness of the battery
battery
surface
If there are tools on the

battery.
The tightness and
smoothness of air
cap
Far away from firing

Controller
Daily weekly Monthly Trimonthly Semiannually
Checking Item Service Required Tools
(8 hrs) (40 hrs) (166hrs) (500 hrs) (1000 hrs)
Check connector
for worn

Check contactor
for running

Check micro
move switch for
running
Controller Check the
connection
among motor,
battery and
power unit.
Check the
First time 2
controller error
diagnose system years

43
Motor
Daily weekly Monthly Trimonthly Semiannually
Checking Item Service Required Tools
(8 hrs) (40 hrs) (166hrs) (500 hrs) (1000 hrs)
Clean the foreign
body on the
motor
Clean or replace
the bearing

Check the
carbon brush and
commutater for
Motor worn, whether
spring is normal
Whether the
connection is
correct and firm.
Brush carbon
powder on shift
plate and shift

device.

Driving system
Checking
Daily weekly Monthly Trimonthly Semiannually
Service required Tools
Item (8 hrs) (40 hrs) (166hrs) (500 hrs) (1000 hrs)

Check for noise


Check for oil
leaks
Change oil

heck wheel Check wheel hub
hub bolts for bearing for
tighten loosenessnoise
torque Clean and
replace grease

Check wheel
hub bolts for
tighten torque

44
Wheels (Front, Rear Wheels)
Checking Service required Tools Daily weekly Monthly Trimonthly Semiannually
Item (8 hrs) (40 hrs) (166hrs) (500 hrs) (1000 hrs)
Check for charge
Barometer
pressure
Check for
abrasion cracks
or damage
Check for spikes
stones or foreign
Tyre
matter
Check the wheel

hub for damage
Check the split Test
body wheel hammer

hub-bolts for
looseness

Steering System
Daily weekly Monthly Trimonthly Semiannually
Checking Item Service required Tools
(8 hrs) (40 hrs) (166hrs) (500 hrs) (1000 hrs)
Check for

clearance
Check for radial

looseness
Steering wheel
Check for axial

looseness
Check for

operation
Check mounting
Steering Gear
bolts for
box and valve
looseness
Check king pins
for looseness or
damage
Check for
Steering axle deflection,

deformation ,cra
cks or damage
Check for fixing Test

condition hammer
Check for

operation
Check for oil
Steering
leaks
cylinder
Check for
looseness when
fixing or hinging

45
Brake system
Checking Daily weekly Monthly Trimonthly Semiannually
Service required Tools
item (8 hrs) (40 hrs) (166hrs) (500 hrs) (1000 hrs)

Check for free travel Scale


Check for pedal travel
Brake
Check for operation
pedal
Check for air mixed in
brake piping

Check for lever is securely


Parking
locked and has sufficient
lever stroke
brake
Check for operation
Check for operation
Rod, Check connections for
looseness
Cable,
etc Check decelerator
connector lug for
abrasion
Check for damage, leakage
Hoses or collapse
and Pipes Check connection or

clamping parts for looseness

Check for leakage

Check for fluid level,


Change brake fluid

Brake Check master cylinder and



master wheel cylinder for operation
cylinder
and Check master cylinder and
wheel wheel cylinders for fluid
cylinder leaks or damage

Check master cylinder


piston cup, and check valve
for wear or damage change

46
Hydraulic system
Checking Daily weekly Monthly Trimonthly Semiannually
Service required Tools
item (8 hrs) (40 hrs) (166hrs) (500 hrs) (1000 hrs)

Check for oil level,



Change oil
Hydraulic
reservoir Clean suction strainer

Clean foreign matter

Check levers for


Control
looseness
lever
Check for operation

Check for oil leak

Check relief valve


Control and tilt lock valve
valve for operation
Oil
Measure relief
press
pressure
gauge
Check for oil leak,
Hose, looseness, collapse,

Piping Hose deformation and
Reel & damage
Swivel Joint
Replace hoses.
1-2 years
Check hydraulic
pump for oil leak or
Hydraulic
noise
Pump
Check pump drive

gear for wear

47
Lifting system
Checking Daily weekly Monthly Trimonthly Semiannually
Service required Tools
item (8 hrs) (40 hrs) (166hrs) (500 hrs) (1000 hrs)
Check chain for tension, damage or rust
Add lubrication for chains
Chains & Check connection of chain anchor pin and
Sheave chain for looseness
Check sheaves for deformation or damage
Check sheave bearings for looseness

Attachment Perform general inspection


Check piston rod, rod screw and connection Test
for looseness deformation or damage hammer
Lifting
cylinder and
Check cylinders for operation
tilting Check for oil leak
cylinder Check pins and cylinder bushings for wear or
damage
Check forks for damage, deformation or
wear
Fork Check for stopper pins for damage or wear
Check fork base and hook welding for
defective cracks or wear
Check weld between cross members with
outer and inner masts for defective, cracks or
damage
Check tilt cylinder bracket and mast for
defective weld ,cracks or damage
Check outer and inner masts for defective
weld, cracks or damage
Check for defective weld, cracks or damage of
lift bracket

Mast & Check roller bearings for looseness


Lift Check mast support bushings for wear or
Bracket damage

Test (for 1st
Check mast support cap bolts for looseness
hammer
time
only

Check lift cylinder tall bolts, piston rod head
Test (for 1st
bolts, U-bolts, and piston head guide bolts for
hammer time
looseness
only
Check rollers, roller pins and welded parts for
cracks or damage

48
Others
Checking item Service required Tools Daily weekly Monthly Trimonthly Semiannually
(8 hrs) (40 hrs) (166hrs) (500 hrs) (1000 hrs)

Check for tight Test


installation
Overhead Guard hammer
& Load Backrest Check for
deformation, cracks
or damage
Check for proper
Turn signal operation and tight
installation
Check for proper
Horn operation and tight
installation
Check for proper
Light & Lamps operation and tight
installation
Check for proper
Buck-up Buzzer operation and tight
installation
Check meters for
Meters
proper operation
Wire damage or

looseness
wire
Looseness of

Electric circuit Joint

Replace the key safe parts termly


Some parts should be checked periodically to detect the damage, for improving the
safety, users should replace the parts periodically which are listed in the table as follows.
If the parts are abnormal before the replacing time is coming, it should be replaced
immediately.
Key safe parts description Term of using (year)

Brake hose or tube 1~2

Hydraulic hose for lifting system 1~2

Lifting chain 2~4

High-pressure hose hose for hydraulic system 2

Brake oil cup 2~4

Brake master cylinderbrake slave cylinder cover and dust sleeve 1

Inner hermeticrubber matter 2

49
Table for bolts tight torque
Unit N
m

Bolts Grade
diameter
4.6 5.6 6.6 8.8

6 45 57 68 912

8 1012 1215 1418 2229

10 2025 2531 2939 4458

12 3544 4454 4964 76107

14 5469 6988 8398 121162

16 88108 108137 127157 189252

18 118147 147186 176216 260347

20 167206 206265 245314 369492

22 225284 284343 343431 502669

24 294370 370441 441539 638850

27 441519 539686 637784 9331244

Note:
Use entirely 8.8 grade bolt in the important joint position.
Bolts grade can be found in the head of the bolt, if it cant be found, the grade is 8.8.

Table for oil used in the truck


Name Trademark, code name capabilityL Remark
22-25 1-1.8t
Normally: L HM32
Hydraulic oil cold environment :L-HV32 25-35 2-3.5t

40-45 4-5t

Use in driving axle and


Gear oil GL-585W/90 5
gear-box
Brake Fluid (Choice) HZY3 or DOT3 1.5
Industrial Vaseline 2# Electrode of storage battery
Automobile general lithium
Lubrication grease
base lubricant

50
12.Trucks convey, lifting, towing
Convey
The Fork Lift Truck is designed for material handling only, It is inappropriate for
long-distance transportation. If needed, the Fork Lift Truck must be transported by ship, train
or lorry, of 5T loading. Use a lifting pallet to hoist the truck.
Use the steel wire ropes to tie the holes in the two side of the outside masts beam and
the rear of trucks body, and then use the lifting device to hoist the truck.

Hoist the truck

Use the steel wire ropes to tie the holes in the two side of the outside masts beam and
the hook of the counter balance, and then use the lifting device to hoist the truck. The steel
wire rope attach to the counterweight should through the safeguard gap, and make the
safeguard not be distorted.

Warning
When hoist the truck, dont coil the overhead guard with the steel wire.
The steel wire ropes and the lifting device must be very firm to support the truck because
the truck is very heavy.
Dont lift the truck by hoist the overhead guard.
When lifting the truck, dont take yourself below the truck.

Towing
The towing rod on the bottom of the counter balance is used to pull and drag the truck.
Loosen the brake lever and turn off key switch.
Set switch lever to neutral position

Warning
a. Dont tie the steel wire ropes on the unfixed position.
b. Dont carry a load to steel wire ropes suddenly.
c. The truck would be damaged if you tow it with the electric lock working.

51
13.Parameters
Parameters of CPD10/15/18J

NO. Item Units CPD10J CPD15J CPD18J

1 Ratio capacity kg 1000 1500 1800

2 Load centre mm 500 500 500

Max. mm 3000 3000 3000


3 Lifting height
Free mm 135 135 135
Max. Lifting
4 Fully loaded mm/s 290 290 270
velocity
5 Tilting angle front/rear 5/10 5/10 5/10
Max. Traveling
6 Fully loaded mm/s 12 12 12
velocity
Max. Crawling
7 Fully loaded % 13 13 13
slope
8 Turning radius Min. mm 1780 1780 1815
Ground
9 Min. mm 110 110 110
clearance
Stopping
10 Max. m 2.5 2.5 2.5
distance
L mm 2080 2080 2115

11 Overall Dimension W mm 1090 1090 1138

H mm 2075 2075 2075


Include
12 Weight (self) kg 2770 2940 3090
battery
Standard V/Ah 48/420 48/420 48/420
13 Battery
Optional V/Ah 48/480 48/480 48/480

Driven kW 8 8 8
14 Motor
Lifting kW 7.8 7.8 7.8

Type MOSFET MOSFET MOSFET

Tow Danaher Danaher Danaher


15 Controller
Manufacturer
Lifting Danaher Danaher Danaher

Front 2 6.00-9/2 6.00-9/2 218-9/2


16 Tyre
Rear 2 5.00-8/2 5.00-8/2 5.00-8/2

52
Parameters of CPD10/15/18JC1

NO. Item Unit CPD10JC1 CPD15J C1 CPD18J C1

1 Ratio capacity kg 1000 1500 1800

2 Load centre mm 500 500 500

Max. mm 3000 3000 3000


3 Lifting height
Free mm 135 135 135
Max. Lifting
4 Fully loaded mm/s 290 290 270
velocity
5 Tilting angle front/rear 5/10 5/10 5/10
Max. Traveling
6 Fully loaded mm/s 12 12 12
velocity
Max. Crawling
7 Fully loaded % 13 13 13
slope
8 Turning radius Min. mm 2090 1780 1815
Ground
9 Min. mm 110 110 110
clearance
Stopping
10 Max. m 2.5 2.5 2.5
distance
L mm / 2080 2115

11 Overall Dimension W mm 1090 1090 1138

H mm 2075 2075 2075


Include
12 Weight (self) kg / 2940 3090
battery
Standard V/Ah 48/420 48/420 48/420
13 Battery
Optional V/Ah 48/480 48/480 48/480

Driven kW 6.8 6.8 6.8


14 Motor
Lifting kW 8.2 8.2 8.2

Type MOSFET MOSFET MOSFET

Tow CURTIS CURTIS CURTIS


15 Controller
Manufacturer
Lifting CURTIS CURTIS CURTIS

Front 2 6.00-9/2 6.00-9/2 218/2


16 Tyre
Rear 2 5.00-8/2 5.00-8/2 5.00-8/2

53
Parameters of CPD10/15/18JD1

NO. Item Unit CPD10JD1 CPD15JD1 CPD18JD1

1 Ratio capacity kg 1000 1500 1800

2 Load centre mm 500 500 500

Max. mm 3000 3000 3000


3 Lifting height
Free mm 135 135 135
Max. Lifting
4 Fully loaded mm/s 290 290 270
velocity
5 Tilting angle front/rear 5/10 5/10 5/10
Max. Traveling
6 Fully loaded mm/s 12 12 12
velocity
Max. Crawling
7 Fully loaded % 13 13 13
slope
8 Turning radius Min. mm 2090 1780 1815
Ground
9 Min. mm 110 110 110
clearance
Stopping
10 Max. m 2.5 2.5 2.5
distance
L mm / 2080 2115

11 Overall Dimension W mm 1090 1090 1138

H mm 2075 2075 2075


Include
12 Weight (self) kg / 2940 3090
battery
Standard V/Ah 48/420 48/420 48/420
13 Battery
Optional V/Ah 48/480 48/480 48/480

Driven kW 8 8 6.8
14 Motor
Lifting kW 7.8 7.8 8.2

Type MOSFET MOSFET MOSFET

Tow Danaher Danaher CURTIS


15 Controller
Manufacturer
Lifting Danaher Danaher CURTIS

Front 2 6.00-9/2 6.00-9/2 218/2


16 Tyre
Rear 2 5.00-8/2 5.00-8/2 5.00-8/2

54
Parameters of CPD20/25/30J

No. Item Unit CPD20J CPD25J CPD30J

1 Ratio capacity kg 2000 2500 3000

2 Load centre mm 500 500 500

Max. mm 3000 3000 3000


3 Lifting height
Free mm 140 145 145
Max. Lifting Fully
4 mm/s 250 250 230
velocity loaded
front/rea
5 Tilting angle 5/10 5/10 5/10
r
Max. Traveling Fully
6 mm/s 12 12 13
velocity loaded
Fully
7 Max. Crawling slope % 13 10 13
loaded
8 Turning radius Min. mm 2090 2090 2230

9 Ground clearance Min. mm 120 120 120

10 Stopping distance Max. m 2.5 2.5 2.5

L mm 2275 2325 2490

11 Overall Dimension W mm 1265 1265 1240

H mm 2100 2100 2100

Include
12 Weight (self) kg 3800 4020 5050
battery
Standar
V/Ah 48/630 48/630 80/500
d
13 Battery
Optional V/Ah 48/700 48/700 /

Driven kW 7 7 10
14 Motor
Lifting kW 8.6 8.6 10

Type MOSFET MOSFET MOSFET

15 Controller Tow CURTIS CURTIS CURTIS


Manufact
urer Liftin
CURTIS CURTIS CURTIS
g
Front 2 239-10/2 239-10/2 239-10/2
16 Tyre
Rear 2 187-8/2 187-8/2 187-8/2

55
Parameters of CPD20/25/30/35JC1

No. Item Unit CPD20JC1 CPD25JC1 CPD30JC1 CPD35JC1

1 Ratio capacity kg 2000 2500 3000 3500

2 Load centre mm 500 500 500 500

Max. mm 3000 3000 3000 3000


3 Lifting height
Free mm 140 145 145 145
Max. Lifting Fully
4 mm/s 250 250 230 210
velocity loaded
front/rea
5 Tilting angle 5/10 5/10 5/10 5/10
r
Max. Traveling Fully
6 mm/s 12 12 13 13
velocity loaded
Fully
7 Max. Crawling slope % 13 10 13 12
loaded
8 Turning radius Min. mm 2090 2090 2230 2310

9 Ground clearance Min. mm 120 120 120 120

10 Stopping distance Max. m 2.5 2.5 2.5 2.5

L mm 2275 2325 2490 2570

11 Overall Dimension W mm 1265 1265 1265 1302

H mm 2100 2100 2100 2100

Include
12 Weight (self) kg 3800 4020 5050 5400
battery
Standar
V/Ah 48/630 48/630 80/500 80/500
d
13 Battery
Optional V/Ah 48/700 48/700 / /

Driven kW 9.1 9.1 11.75 11.75


14 Motor
Lifting kW 8.6 8.6 10 10

Type MOSFET MOSFET MOSFET MOSFET

15 Controller Tow CURTIS CURTIS CURTIS CURTIS


Manufact
urer Liftin
CURTIS CURTIS CURTIS CURTIS
g
Front 2 239-10/2 239-10/2 239-10/2 2310-12/2
16 Tyre
Rear 2 187-8/2 187-8/2 187-8/2 187-8/2

56
Parameters of CPD20/25/30/35JC2

No. Item Unit CPD20JC2 CPD25JC2 CPD30JC2 CPD35JC2

1 Ratio capacity kg 2500 2500 3000 3500

2 Load centre mm 500 500 500 500

Max. mm 3000 3000 3000 3000


3 Lifting height
Free mm 145 145 145 145
Max. Lifting Fully
4 mm/s 250 250 230 210
velocity loaded
front/rea
5 Tilting angle 5/10 5/10 5/10 5/10
r
Max. Traveling Fully
6 mm/s 12 12 13 13
velocity loaded
Fully
7 Max. Crawling slope % 10 10 13 12
loaded
8 Turning radius Min. mm 2090 2090 2230 2310

9 Ground clearance Min. mm 120 120 120 120

10 Stopping distance Max. m 2.5 2.5 2.5 2.5

L mm 2325 2325 2490 2570

11 Overall Dimension W mm 1265 1265 1265 1302

H mm 2100 2100 2100 2100

Include
12 Weight (self) kg 4020 4020 5050 5400
battery
Standar
V/Ah 48/630 48/630 80/500 80/500
d
13 Battery
Optional V/Ah 48/700 48/700 / /

Driven kW 9.1 9.1 11.75 11.75


14 Motor
1
Lifting kW 8.6 8.6
0
Type MOSFET MOSFET MOSFET MOSFET

15 Controller Tow CURTIS CURTIS CURTIS CURTIS


Manufact
urer Liftin
CURTIS CURTIS CURTIS CURTIS
g
Front 2 239-10/2 239-10/2 239-10/2 2310-12/2
16 Tyre
Rear 2 187-8/2 187-8/2 187-8/2 187-8/2

57
Parameters of CPD20/25/30/ 35J D1
CPD20J
No. Item Unit CPD25J D1 CPD30J D1 CPD35J D1
D1

1 Ratio capacity kg 2000 2500 3000 3500

2 Load centre mm 500 500 500 500

Max. mm 3000 3000 3000 3000


3 Lifting height
Free mm 140 145 145 145
Max. Lifting Fully
4 mm/s 250 250 250 210
velocity loaded
front/rea
5 Tilting angle 5/10 5/10 5/10 5/10
r
Max. Traveling Fully
6 mm/s 14 12 14.5 13
velocity loaded
Fully
7 Max. Crawling slope % 14 13 15 11
loaded
8 Turning radius Min. mm 2040 2090 2230 2310

9 Ground clearance Min. mm 120 120 120 120

10 Stopping distance Max. m 2.5 2.5 2.5 2.5

L mm 2275 2325 2490 2570

11 Overall Dimension W mm 1265 1265 1265 1302

H mm 2100 2100 2100 2100

Include
12 Weight (self) kg 3800 4180 5050 5460
battery
Standar
V/Ah 48/630 48/630 80/500 80/500
d
13 Battery
Optional V/Ah 48/700 48/700 / /

Driven kW 10.5 10.5 10.6 10.6


14 Motor
Lifting kW 11 11 12.8 12.8

Type MOSFET MOSFET MOSFET MOSFET

15 Controller Tow Danaher Danaher Danaher Danaher


Manufact
urer Liftin
Danaher Danaher Danaher Danaher
g
Front 2 239-10/2 239-10/2 239-10/2 2310-12/2
16 Tyre
Rear 2 187-8/2 187-8/2 187-8/2 187-8/2

58
Parameter of CPD40/45/50J D1

No. Item Unit CPD40J D1 CPD45J D1 CPD50J D1

1 Ratio capacity kg 4000 4500 5000

2 Load centre mm 500 500 500

Max. mm 3000 3000 3000


3 Lifting height
Free mm 145 150 150
Max. Lifting Fully
4 mm/s 260 260 230
velocity loaded
front/rea
5 Tilting angle 6/12 6/12 6/12
r
Max. Traveling Fully
6 mm/s 13.5 13.5 13
velocity loaded
Fully
7 Max. Crawling slope % 14 14 13
loaded
8 Turning radius Min. mm 2650 2650 2650

9 Ground clearance Min. mm 219 219 226

10 Stopping distance Max. m 2.5 2.5 2.5

L mm 3015 3015 3015

11 Overall Dimension W mm 1380 1380 1380

H mm 2280 2280 2280

Include
12 Weight (self) kg 6550 6800 7250
battery
Standar
V/Ah 80/700 80/700 80/700
d
13 Battery
Optional V/Ah / / /

Driven kW 16.6 16.6 16.6


14 Motor
Lifting kW 25.4 25.4 25.4

Type MOSFET MOSFET MOSFET


15 Controller
Manufact
Danaher Danaher Danaher
urer

Front 2 250-15-16/2 250-15-16/2 250-15-16/2


16 Tyre
Rear 2 7.00-12-12/2 7.00-12-12/2 7.00-12-12/2

59
Parameter of CPD40/45/50J C2

No. Item Unit CPD40J C2 CPD45J C2 CPD50J C2

1 Ratio capacity kg 4000 4500 5000

2 Load centre mm 500 500 500

Max. mm 3000 3000 3000


3 Lifting height
Free mm 145 150 150
Max. Lifting Fully
4 mm/s 260 260 260
velocity loaded
front/rea
5 Tilting angle 6/12 6/12 6/12
r
Max. Traveling Fully
6 mm/s 13.5 13.5 13
velocity loaded
Fully
7 Max. Crawling slope % 14 14 13
loaded
8 Turning radius Min. mm 2650 2650 2650

9 Ground clearance Min. mm 219 219 226

10 Stopping distance Max. m 2.5 2.5 2.5

L mm 3015 3015 3015

11 Overall Dimension W mm 1380 1380 1380

H mm 2310 2310 2310

Include
12 Weight (self) kg 6550 6800 7200
battery
Standar
V/Ah 80/700 80/700 80/700
d
13 Battery
Optional V/Ah / / /
16.6@3100r 16.6@3100r 16.6@3100rp
Driven kW
pm pm m
14 Motor
25.4@1620 25.4@1620 25.4@1620
Lifting kW
rpm rpm rpm
Type MOSFET MOSFET MOSFET
15 Controller
Manufact
CURTIS CURTIS CURTIS
urer

Front 2 250-15-16/2 250-15-16/2 250-15-16/2


16 Tyre
Rear 2 7.00-12-12/2 7.00-12-12/2 7.00-12-12/2

60
14.Scutcheon
There are many scutcheons and labels on the different position of the truck.

61
STOP
EME
RG
EN CY

USE SPECIFIED FUSES ONLY

1.tonnage label 2. typeface label 3. ac label 4. danger label

5.danger label 6. danger label 7. CE label 8. hanging label

9. danger label 10. danger label 11. load curve scutcheon 12. warning label

13. product nameplate 14. hydraulic oil label 15.tight point label 16.hand brake label

17. urgent stop label 18. noise label 19.fuse label

62
1tonnage 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 off the power. Nobody
The word 30means the rated load is 3.0 is allowed on the truck, and the man
ton. If the lifting height increases or adds outside the truck is not allowed to operate
attachment, the rated load will decrease. the truck, preventing from accident caused
2typeface label by miss operating the mast handle.

6danger labeladhibit to the outside of


mast
3ac labelonly fro ac motor No allowed to stand on or down the mast,
or it is dangerous to your life.

4danger label NO entering label

7CE labelonly for truck exporting to


Warning: It is dangerous of your life. If Europe or option
the body is clamped among the mast ,
instrument frame and shield cabane, your
life will be dangerous. If the part needs to
be check or repaired, the inspection and
repair should be carried out after shutting
off the power. Nobody is allowed on the
truck, and the man outside the truck is not 8hang labelIt shows the hang position
allowed to operate the truck, preventing and method. When hanging, the rope
from accident caused by miss operating the should not touch the light and even destroy
mast handle. it.
LIFT METHOD

5danger label

63
910 danger label 13product nameplate

WARNING

14hydraulic oil label

11load curve scutcheon


It shows relation among 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 15tight point labelonly for truck
loading, check whether the load and the exporting to Europe or option
center distance of load are in the allowed
range show in the diagram of load capacity.
If the shape of load is complicated, make
the most heavy part place in the center of
the fork and approach the stop fork frame.

16hand brake labelonly for truck


exporting to Europe or option

12warning label
17urgent stop label

W A R N I N G
SERIOUS OR FATAL INJURY MAY RESULT TO YOURSELF OR OTHERS IF NOT FOLLOWED
This lift truck should not be operated by anyone who is not authorized and properly trained.
Read the Operators Manual and all warnings carefully,and make yourself familiar with your lift truck.
Operator's Manual and Service Manual are supplied with this truck or available from our forklift truck dealers.
Inspect and check your lift truck daily before and after use.Do not operate faulty or damaged lift trucks.
P

Repair work should be done by authorized and trained persons only.


EME

To protect from falling objects,make sure that the Overhead Guard and Load Backrest Extension are correctly mounted
STO

and in good condition.


Check the capacity of the battery and the condition of all kinds of switch,connecting plug,operating level, pedal,
tyre pressure and fastener.
RG
EN CY
Starting forklift truck:Realase parking brake and turn on the switch. After moving the shift lever to Forward
(or Reverse), depress the accelerator pedal to start truck. If making an error by procedure, the truck can not start.
When unloading, the weight and diemension should be within the permitted range on the capacity chart. Overload is
prohibited and set the cargo at the center of mast to avoid departure.
When traveling with loading, it is necessary to lift fork up to 300mm, tilt backward most and set the load closed
to the backrest. It is Pohibited to brake and turn suddently when travelling with loading.
Stop the truck steadily, turn the key to OFF position and remove it, move the shift level to "NEUTRAL" and set the
fork to ground.
When hoisting the battery case, it should take by four holes in the each side of the case. It is prohibited to hoist
only by two holes, otherwise, the case will be deformed to damage the battery.

64
18noise labelonly for truck exporting
to Europe or option

LWA

19fuse labelonly for truck exporting


to Europe or option

USE SPECIFIED FUSES ONLY

65
15.The use, assembly and safe rules of attachment
HANGCHA will choose attachment that according with International standard ISO2328Forklift
pothook fork and install size of carriage,such as clamp, rotator, paper roll clamp, carrying ram,
side-shifter ect.
1Attachment 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.
3Operate 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.
4Prohibit 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 cargeo, make sure that the distance of bottom of cargo and
ground is less than 300mm and mast incline back.
5The weight of cargo couldnt 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.
6In 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.
7It is not allowed that an emergency brake in moving. Run slowly with load.
8Prohibit outside force when attachment working.
9It couldnt be use at malfeasance situation and overstep normal work range
10When the attachment failure, prohibit use without check.

Check and maintenance:


1Check the clearance of carriage beam and below catch of attachment if accord the attachment
manual.
2Check the rise catch is right on the flute of fork carriage.
3Use the auto currency lithic-grease per 500 hours to bearing surface.
4If the tighten firmware become flexible.
5Check the tie-in of hydraulic pressure loop, if tube attaint. Prohibit use after repair.
6Check the drive of attachment timing or turn the component if fray or block, change betimes.
7Check 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.

66
2Attachment assembly

Caution
1Untempered technology licence of our company, any refit at safety and capability to attachment
is strict prohibit.
2Fact 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.
3Assembly go to in reason, credibility, safety to avoid the attachment glide around carriage in
using.
4After 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.
5To 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.
6Assembly the attachment of below catch orientation, it need to adjust the clearance between
below catch and beam of carriage.

67
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,
EN1175-1:1998, EN13059:2002 coordinate standard.

Main safety factor will be according with DIRECTIVE 2006/42/EC OF THE


EUROPEAN PAMENT AND OF THE COUNCIL and EN1726-1:1998EN1175-1:1998
standard.
The design and manufacture of electrical element comply with the low voltage standard
2006/95/EC.
Noise will be according with EN12053:2001 and 2000/14/EC.
Vibration parameters are measured according to standards of ISO5349-2:2001,
EN13059:2002, ISO2631-1:1997, and the result meets the requirement of 2002/44/EC.
Electromagnetism compatibility is measured according to standard of EN12895:2000
and meets the requirement of 2004/108/EC.

68

Zhejiang Hangcha Engineering Machinery Co.,Ltd.
398 310022 Website: http//www.zjhc.cn
Add398 Shi Qiao Road, Hangzhou 310022 E-Mailsales@zjhc.cn
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 Battery counterbalanced forklift truck with charger
Name: Electrical forklift truck
Model:
Serial number: Rated power: kW
Manufacturing year:
COMPLIES WITH THE PROVISIONS OF THE FOLLOWING EUROPEAN
DIRECTIVES:
2006/42/EC Machinery Directive
2004/108/EC EMC Directive
2006/95/EC LVD Directive

COMPLIES WITH THE PROVISIONS OF THE FOLLOWING HARMONIZED


STANDARDS:
EN 1726-1:1998 Safety of industrial trucksSelf-propelled trucks up to and
+A1:2003 including 10 000 kg capacity and industrial tractors with a
drawbar pull up to and including 20 000 N Part 1General
requirements
EN1175-1:1998 Safety of industrial trucksElectrical requirementsPart 1
General requirements for battery-powered trucks.
Annex I of Machinery Essential health and safety requirements relating to the
Directive 2006/42/EC design and construction of machinery

Done at ZHEJIANG HANGCHA ENGINEERING Name of the


(place): MACHINERY CO.,LTD. signatory:
On Title: Technical Director
(date):
Signature:

69
17.Maintenance record
Date Maintain content Maintainer

70
HANGCHA GROUP CO. , LTD.

Address for: OVERSEAS USERS


Manufacturing site: 88 Donghuan Road, LinAn Econimic Development zone,
Zhejiang, P.R.China ZIP:311305
Registered Address398 Shi Qiao Road, Hangzhou, P.R. China) ZIP :310004
Fax: 0086-571-88926789,0086-571-88132890
Web: http://www.hcforklift.com
E-mail: sales@hcforklift.com