J 1-5t
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
1～5t J Series Counterbalanced Battery Forklift Truck
SERVICE MANUAL
Original Instruction
HANGCHA GROUP CO., LTD.
Dec. 2010 3rd edition
Truck model
Tow electric
control
Rise electric
control
Rated capacity（t）/
load centre distance（mm）
CPD10/15/18/20/25/30J
1244
(CURTIS)
1254
(CURTIS)
1.0/500,1.5/500,1.8/500,
2.0/500,2.5/500,3/500,
4/500,4.5/500,5/500
CPD10/15/18/20/25/30J D1
ACS
(INMOTION)
ACS
(INMOTION)
CPD10/15/18/20/25/30/35J C1
1238
(CURTIS)
EVC255
(CURTIS)
1.0/500,1.5/500,1.8/500,
2.0/500,2.5/500,3/500,3.5/300
CPD10/15/18/20/25/30/35J C2
1238
(CURTIS)
1236
(CURTIS)
1.0/500,1.5/500,1.8/500,
2.0/500,2.5/500,3/500,3.5/300
CPD40/45/50J C2
1238
(CURTIS)
1238
(CURTIS)
4/500,4.5/500,5/500
FOREWORD
Thanks for your purchasing our forklift truck.
4 wheel counterbalanced battery forklift truck is our company’s new product. It has the character
of small turning radius, beautiful shape, small dimensions, low gravity.
This operation manual is the explanations that how to use 1-3tJ series forklift truck correctly. It
will instruct you how to operate safety and precautionary maintenance.
To ensure safety and exert the truck’s potential, all the personnel that in charge of operation,
maintenance and management must read this manual thoroughly before starting work with the forklift.
This manual is applicable to container trucks.
Forbid repairing the truck if you haven’t been trained.
Our product design will update and perform better, so the content in this manual may
be not the same as the forklift you owned.
If you have any questions please keep touches with HANGCHA GROUP CO.,LTD.sales
department or let the agents know.
The meanings of model
Dec. 2010 3rd edition HANGCHA GROUP CO., LTD.
©
CONTENT
FOREWORD
1. DRIVING SYSTEM ............................................................................................................................. 1
1.1 ENGINE FOR FORKLIFT.............................................................................................................. 1
1.2 GEAR BOX ..................................................................................................................................... 8
1.3 DRIVING AXLE ............................................................................................................................. 9
2. STEERING SYSTEM......................................................................................................................... 14
2.1 STEERING DEVICE .................................................................................................................... 14
2.2 STEERING AXLE ........................................................................................................................ 15
3. BRAKE SYSTEM ........................................................................................................................... 19
3.1 MASTER CYLINDER .................................................................................................................. 19
3.2 FOOT BRAKE .............................................................................................................................. 20
3.3 HAND BRAKE DEVICE.............................................................................................................. 22
4. HYDRAULIC SYSTEM .................................................................................................................... 23
5. LIFTING SYSTEM ............................................................................................................................ 27
5.1 DATA ............................................................................................................................................ 27
5.2 FAULT .......................................................................................................................................... 28
5.3 MAST ............................................................................................................................................ 30
5.4 LIFTING CYLINDER .................................................................................................................. 32
5.5 TILTING CYLINDER .................................................................................................................. 32
6. ELECTRICAL SYSTEM .................................................................................................................... 33
6.1 CPD10/15/20/25/30J FORK .......................................................................................................... 33
6.2 CPD10/15/20/25/30/35J C1、CPD10/15/18/20/25/30/35J C2、CPD40/45/50J C2 FORK ......... 37
6.3 CPD10/15/20/25/30J D1 FORK .................................................................................................... 44
7. MAINTENANCE RECORD .............................................................................................................. 57
1
Model
Rated
Power
( kw)
Rated
Voltage
(V)
Rated
Current
(A)
Rated
speed
(r/m)
Max.
Speed
(r/m)
Excitations
Mode
Insulation
Grade
Cooling
Mode
Protecting
Grade
Ration
(m)
Weight
(Kg)
Remark
XQ – 5–3A
5.3
45
139
1700
3200
separate
excitation
F
IC01
IP20
60
95
tow
XQD –8.2-3D
8.2
45
172.8
1600
3200
series
excitation
F
IC01
IP20
5
65
work
Model
Rated
Power
( kw)
Rated
Voltage
(V)
Rated
Current
(A)
Rated
speed
(r/m)
Max.
Speed
(r/m)
Excitations
Mode
Insulation
Grade
Cooling
Mode
Protecting
Grade
Ration
(m)
Weight
(Kg)
Remark
XQ-7A
7
45
180
1200
2400
separate
excitation
F
IC01
IP20
60
112
tow
XQD-8.6-3D
8.6
45
248
1600
3200
series
excitation
F
IC00
IP44
5
72
work
Model
Rated
Power
( kw)
Rated
Voltage
(V)
Rated
Current
(A)
Rated
speed
(r/m)
Max.
Speed
(r/m)
Excitations
Mode
Insulation
Grade
Cooling
Mode
Protecting
Grade
Ration
(m)
Weight
(Kg)
Remark
XQ – 10.2 A
10.2
75
162.5
1500
/
separate
excitation
F
IC01
IP20
60
120
tow
XQD - 10 -3D
10
75
161.6
2000
/
series
excitation
F
IC01
IP20
15
83
work
1. Driving system
Drive system is composed most components such as electrical engineering, gear box, driving axle
detent tyre and wheel rim.
Gear box is two grades reduce speed gear, one grade straight gear and one grade planet gear. So the
gear box is very small.
Detent is a hoof detent, if you need know the particular content, you can see relevant portion of the
trig system.
1.1 Engine for Forklift
1.1.1Data
CPD10/15J/18J
CPD20/25J
CPD30J
2
Model
Rated
Power
( kw)
Rated
Voltage
(V)
Rated
Current
(A)
Rated
speed
(r/m)
Max.
Speed
(r/m)
Excitations
Mode
Insulation
Grade
Cooling
Mode
Protecting
Grade
Ration
(m)
Weight
(Kg)
Remark
YDQ6.8-4HC
6.8
31
222
1200
2000
AC
F
IC01
IP20
60
94
tow
XQD –8.2-3D
8.2
45
172.8
1600
3200
series
excitation
F
IC01
IP20
5
65
work
Model
Rated
Power
( kw)
Rated
Voltage
(V)
Rated
Current
(A)
Rated
speed
(r/m)
Max.
Speed
(r/m)
Excitations
Mode
Insulation
Grade
Cooling
Mode
Protecting
Grade
Ration
(m)
Weight
(Kg)
Remark
YDQ9.1-4HC
9.1
31
280
1200
2000
AC
F
IC01
IP20
60
110
tow
XQD-8.6-3D
8.6
45
248
1600
3200
series
excitation
F
IC00
IP44
5
72
work
Model
Rated
Power
( kw)
Rated
Voltage
(V)
Rated
Current
(A)
Rated
speed
(r/m)
Max.
Speed
(r/m)
Excitations
Mode
Insulation
Grade
Cooling
Mode
Protecting
Grade
Ration
(m)
Weight
(Kg)
Remark
YDQ11.75-4HC
10.6
51
180
1200
/
AC
F
IC01
IP20
60
110
tow
XQD - 10 -3D
10
75
161.6
2000
/
series
excitation
F
IC01
IP20
15
83
work
Model
Rated
Power
( kw)
Rated
Voltage
(V)
Rated
Current
(A)
Rated
speed
(r/m)
Max.
Speed
(r/m)
Excitations
Mode
Insulation
Grade
Cooling
Mode
Protecting
Grade
Ration
(m)
Weight
(Kg)
Remark
YDQ6.8-4HC
6.8
31
222
1200
2000
AC
F
IC01
IP20
60
94
tow
YDQ–8.6
8.6
31
248
1600
3200
AC
F
IC01
IP44
5
65
work
Model
Rated
Power
( kw)
Rated
Voltage
(V)
Rated
Current
(A)
Rated
speed
(r/m)
Max.
Speed
(r/m)
Excitations
Mode
Insulation
Grade
Cooling
Mode
Protecting
Grade
Ration
(m)
Weight
(Kg)
Remark
YDQ9.1-4HC
9.1
31
280
1200
2000
AC
F
IC01
IP20
60
110
tow
YDQ-8.6HC
8.6
31
248
1600
3200
AC
F
IC00
IP44
5
65
work
CPD10/15/18J C1
CPD20/25J C1
CPD30/35J C1
CPD10/15/18J C2
CPD20/25J C2
3
CPD30/35J C2
Model
Rated
Power
( kw)
Rated
Voltage
(V)
Rated
Current
(A)
Rated
speed
(r/m)
Max.
Speed
(r/m)
Excitations
Mode
Insulation
Grade
Cooling
Mode
Protecting
Grade
Ration
(m)
Weight
(Kg)
Remark
YDQ11.75-4HC
10.6
51
180
1200
/
AC
F
IC01
IP20
60
110
tow
YDQ - 10
10
51
161.6
2000
/
AC
F
IC01
IP44
15
80
work
Model
Rated
Power
( kw)
Rated
Voltage
(V)
Rated
Current
(A)
Rated
speed
(r/m)
Max.
Speed
(r/m)
Excitations
Mode
Insulation
Grade
Cooling
Mode
Protecting
Grade
Ration
(m)
Weight
(Kg)
Remark
YDQ16.6-4HC
16.6
51
250
3100
5000
AC
H
IC00
IP20
60
155
tow
YDB25.4-4
25.4
51
387
1620
3200
AC
H
IC00
IP20
5
115
work
Model
Rated
Power
( kw)
Rated
Voltage
(V)
Rated
Current
(A)
Rated
speed
(r/m)
Max.
Speed
(r/m)
Excitations
Mode
Insulation
Grade
Cooling
Mode
Protecting
Grade
Ration
(m)
Weight
(Kg)
Remark
TSP180/4-180-48V
10.5
31
280
1200
2000
AC
F
IC01
IP20
60
135
tow
TSW112/4-195-T-48V
11
31
285
2000
3200
AC
F
IC01
IP20
15
83
work
Model
Rated
Power
( kw)
Rated
Voltage
(V)
Rated
Current
(A)
Rated
speed
(r/m)
Max.
Speed
(r/m)
Excitations
Mode
Insulation
Grade
Cooling
Mode
Protecting
Grade
Ration
(m)
Weight
(Kg)
Remark
TSP180/4-180-48V
10.5
31
280
1200
2000
AC
F
IC01
IP20
60
135
tow
TSW112/4-195-T-48V
11
31
285
2000
3200
AC
F
IC01
IP20
15
83
work
Model
Rated
Power
( kw)
Rated
Voltage
(V)
Rated
Current
(A)
Rated
speed
(r/m)
Max.
Speed
(r/m)
Excitations
Mode
Insulation
Grade
Cooling
Mode
Protecting
Grade
Ration
(m)
Weight
(Kg)
Remark
TSP180/4-180-80V
10.6
51
180
1200
2000
AC
F
IC01
IP20
60
135
tow
TSW112/4-195-T-80V
12.8
51
216
2000
3200
AC
F
IC01
IP20
15
83
work
CPD40/45/50J C2
CPD10/15J D1
CPD20/25J D1
CPD30J D1
4
Model
Rated
Power
( kw)
Rated
Voltage
(V)
Rated
Current
(A)
Rated
speed
(r/m)
Max.
Speed
(r/m)
Excitations
Mode
Insulation
Grade
Cooling
Mode
Protecting
Grade
Ration
(m)
Weight
(Kg)
Remark
TSP180/4-200
16.6
52 ／ /
/
AC
F
IC01
IP20
60
/
tow
TSP160/4-250-T
25
49
387
1620
/
AC
F
IC01
IP20 5 /
work
electromotor
applied range
Height above sea level
No exceed 1200m
Remark
Environment temperature
highest/lowest
400C/-250C
Relative temperature
Until on the surface of motor dew 100%
Cooling air
Must not contain volatile gas
most work
current of the
motor
Tractor motor
Three times of rated current ,admit
time is one minute
Lifting motor、steering motor
One point eight times of rated current
,admit time is one minute
Admit temperature Rolling bearing（Environment
temperature not exceed 400C）
950C
From brush box catadrome side to surface of the
commutation
2～4mm
JD1
not
Cooling insulation resistance（When it approach work
temperature, please measure by 250Vmegohmmeter）
< 45V 0.5MΩ
45V～110V 1MΩ
Brush
Metal plumbagin brush trade J201 chart No 5CZ、578
JD1
not
CPD40/45/50J-D1
5
1.1.2 Failure diagnosis
Failure phenomenon
Possible cause
All of sheet copper nigrescence
Brush’s pressure is wrong
Parts of commutator according to
a certain order nigrescence
·parts is short circuit
·armature coil is short
·parts of commutator is not fasten to armature coils open circuit
Parts of commutator are
nigrescent, but without definite
rule
·commutator’s center line location change
·commutator’ s surface is rough, out of round
Brush wear and tear, change
colors and break
·motor vibration
·clearance between brush and box is bigger.
·working surface distance between the box and commutator is
bigger
·mice between parts of commutator extrude
·material of the brush is bad
·trademark of the brush is wrong
Sparkle strong
·motor overload
·commutator is unholy
·commutator is rough or out of round
·mica or parts of commutator extrude
·brush seat grinding is bad
·the pressure of brush is not enough big
·trademark of the brush is wrong
·the brush lock in the box
·the brush frame is loose or vibrational
·the polarity and tactic order of magnetic pole is wrong
The brush and wire heat
·the sparkle of brush is strong
·the brush is not contacted with the cable
·the cable is thinner
The brush have noise
·the surface of the commmutator is rough
CPD10-30
6
Separated
Excitation
motor
A1 --motor armature's head
A2--motor armature's end
F1—Separated
Excitation excitation's head
F2-- Separated
Excitation excitation's end
series
excitation
motor
A1 --motor armature's head
A2--motor armature's end
D1--shunt excitation's head
D2--shunt excitation's end
1.1.3The marker, sign and connecting type of exceed cable or terminal of motor
Connection mode
Series excitation motor
Separate excitation motor
7
1.1.4 Use and maintain
CPD10-30J
The commutator has four check windows, with which you can observe and maintain the
commutator and brush. There are four average distributing magnetic poles in seat. The magnetic pole
coil is made of F state copper thread, dipping with F state insulating varnish. Parts of stator and neutral
position of brush have been adjusted; users mustn’t unpack and adjust randomly.
·Check armature for rotation and void frictionize.
·Check outgoing line of electric machine for connection
·Brush should slide freely in the brush hold box.
·Check reverse chip for neatness, if need be，clear canaliculus between the reverse chip or the
commutator surface of powder, can used cleanly calico of soft and no thread downy , maybe surface
had oil ,calico can dip alcohol when wiping (stop process).
·check all fasteners whether fastened.
·brush’s shelf must reliable fastened, can’t become flexible. If need running or disassembly brush’s
shelf， must make out marker，can become flexible bolt. When the brush’s shelf reposition, aim at
marker line, screw down bolt, in order to keep brush in the former neutral location.
·winding isolating resistance should check of fix a date, when near work’s temperature, under rule data,
otherwise should put up dry.
·fix a date open window shutter, check inside part whether transmutation and reverse partial circs
whether up to snuff.
·you should often clean bed load and other dirt on the motor’s shell, in order to giving out heat quantity
best.
·Every half year check motor one time as follow:
a. Inspect exterior and clean the dust for the motor；
b. Clean or replace bearing, during running it is permitted to giving off abnormal noise for bearing；
c. Inspect the brush’s abrasion, if necessary replace it.
Burnishing for brush：
·When replaces the brush, using ―00‖ thin emery cloth to burnishing it. During burnishing you can haul
the emery cloth leftward or rightward.
·After burnish the brush and clean the commutator with emery cloth, the motor should lowered voltage
and limiting speed to running under load, in order to safety, till the brush’s working face is shined.
8
Trouble
Probably cause
Method of troubleshooting
When traveling or change
direction
Gear clearance is too big.
Too much worn of gear.
Adjust.
Replace.
Too much noise when traveling
Oil level is low.
Gear clearance is too big.
Too much worn of gear.
Add oil.
Adjust.
Replace.
1. Box
2.Bearing pedestal
3. Bolt
4.Bearing pedestal
5.O joint ring
8.Dual
articulated gear
9. Axletree 6206
10.Axletree 6307
11. dual articulated
gear
12.Axletree 6305
13.axes
14. O joint ring
15.Positioning
board
16. Bolt
17. Pinion
18. Axletree 6208
19. Tank cap
20. Bolt
21. Bolt
23.Pin
CPD10/15/18/20/25/30/35J C1
CPD10/15/18/20/25/30/35J C2、CPD40/45/50J C2
CPD10/15/18/20/25/30J D1、CPD40/45/50J D1
CPD10/15/18/20/25/30/35J C1 、 CPD10/15/18/20/25/30/35J C2 、 CPD40/45/50J C2 、
CPD10/15/18/20/25/30J D1、CPD40/45/50J D1 fork don’t have commutator and brush，not need
maintain. You must clear dust everyday.
1.2 Gear box
Gear box is two grades reduce speed gear, one grade straight gear and one grade planet gear. So the
gear box is very small.
9
24. Girth gear
25. bolt
26.nut
27.right differential
carrier
28.left differential
carrier
29. Gear shaft (I)
30. Face gear
31. Gasket
32. Planetary gear
33. Thrust washer
34. Axletree 6211
35. Straight pin
36.Gear shaft (II)
37. Paper gasket
38.pin
39. Lock plate
40. Lock washer
Type
1-1.8t
2-2.5t
3t
4-5t
Driving axle type
Full floating, axle and truck body direct install, front
Tire pressure
10.30MPa
Wheel hub rotation starting torque at hub blot N
10～29
Axial play of wheel bearing mm
less than 0.08
weight
125-130
195-198
202-208
350-380
condition
Probable cause
Corrective action
Abnormal noises
·loose driving axle and body connecting blots.
·loose wheel nut
·worn or damaged wheel hub bearing.
·wheel hub bearing not properly adjusted.
·worn axle shaft spliner.
·insufficient lubrication
Tighten.
Tighten.
Replace.
Adjust.
Replace.
Lubricate.
Unstable driving
·loose wheel nut.
·deformed wheel.
·worn or damaged wheel hub bearing.
·loose driving axle and body connecting blots.
·wheel hub bearing not properly adjusted.
·improper tire pressure.
Tighten.
Replace.
Replace.
Tighten.
Adjust.
Adjust.
Oil leakage
·worn or damaged axle shaft oil seal.
·final drive improperly installed.
·loose drain plug.
Replace
Replace gasket.
Tighten.
1.3 Driving axle
1.3.1 Data
1.3.2 Trouble diagnoses and corrections
10
1. Rim
2. Brake drum
3. wheel hub
4.Wheel nut
5. Wheel hub bolt
6. Bolt
7.Brake Assembly
8. Wash
9.Bolt
10. Half-axle nut
11. Half axle
12.Bolt
13. Oil seal
14. Taper roller
bearing
15. Adjusting nut
16. Lock nut
17.Pin
18. Paper shim
19. Oil seal
20.Axle case
21. Supporter
1-1.8t
2-3t
4-5t
Axle shaft bolt
○
A
44-58
73.5-88.3
105-156
Trig soleplate bolt ○B
76-107
118-147
157-176
nut connecting brake
drum and hub
○
C
260-347
324-373
324-373
Bolt and nut connecting
support plate and truck
body○D
260-347
324-373
324-373
Tyre nut○E
157-176
441-588
441-588
Tighten torque: N.m
Fig.3-1 Driving axle
11
GL-5
85W/90
Gear oil (L）
2.8
1-1.8t
3.2
2-3t
4.5
4-5t
1.3.3Driving axle assemble removal and installation
！ WARNING
Be careful when removal and installation driving axle as it is heavy.
1) Raise front end of forklift truck and support frame with wooden blocks.
2) Remove mast assembles.
3) Slightly raise axle with a hoist and place wooden blacks under differential gear carrier and
transmission case.
4) After placing a pan under axle case, loose oil plug, drain oil from axle case.
5) Disconnect brake nuts from left and right cylinders.(see fig.5-1）。
CAUTION：Plug brake tube openings to prevent oil from flowing out.
6) Disconnect brake cable at hand brake lever.
7) Remove front wheels.
8) Remove axle shaft.
9) Support driving axle with wire ropes and lifting device.
10) Remove bolts securing axle mounting bracket to frame.（see fig.5-2）.
11) Remove nuts securing axle case to differential gear carrier.（see fig.5-3）.
12) Remove driving axle assemble.
Fig.1-1 Fig.1-2 Fig.1-3
13）Remove brake drum，remove wheel hub.
14）Remove axle mounting bracket and brake component from axle tube.
15）Remove oil seal from axle tube.
16）To install driving axle assemble in the reverse order of removal. Observe the following:
① When installing axle mounting bracket and brake component, apply a coat of calcium grease to axle
tube.
② Apply 1/3～2/3 of volume of calcium grease to wheel hub，then install them on axle tube.
③ Install oil seal with its part number facing to the inside of forklift truck.
④ attach seal tape （PVC, white）to drain plug then installed after cleaned it.
⑤ Replenish axle case with gear oil. Tighten vent plug after clearing.
12
Stepped wear or cracks on axle shaft splines
Replace
Seized, scratched, noisy or rusted bearing or improper rotation of
rollers
Replace
Cracked or damage wheel hub
Replace
Damaged oil seal felt ring.
Replace
Vent plug should clear instantly to prevent pressure inside of wheel hub from rising.
1.3.4. Axle shaft and wheel hub
Remove
1）Raise the front end of forklift truck and support frame with wooden blocks.
2）Remove front wheel and axle shaft.
3）Remove lock nuts, lock washers, snap ring, felt ring, adjusting nut. Use special tools.
4）Remove brake drum（refer to Fig.5-4）；
If brake drum is difficult to remove: a. Remove adjusting hole plug. Then with flat-blade
screwdriver extend adjusting hole, turn adjusting ratchet wheel by 10 notches. To contract brake
shoe lining（refer to Fig.5-5）. b. evenly tapping on brake drum with brass bar or wooden mallet.
Fig.1-4 Fig.1-5
5）Remove wheel hub, be careful not to drop bearing inner race.
6）Remove oil seal and inner bearing as an assembly by evenly tapping on periphery of seal with a
wooden mallet and brass bar.
7）Remove bearing outer race from wheel hub by evenly tapping on its periphery with a wooden
mallet.
CAUTION：Be careful not to damage oil seal and outer race.
Inspection
Installation
Install reverse order of removal.
13
1.3.5 Bearing adjusting
1）Lubricate on taper roller bearing.
2）Tighten roller bearing lock nut in wheel hub until wheel hub can no longer be rotated with one
hand.
3）From that position, turn back lock nut approx. 600.
4）Turn back wheel hub two or three rotations so that bearing settles down.
5）Again tighten lock nut until it can no longer be rotated with one hand; then turn back approx.600.
6）Install snap ring and settles down felt ring, install lock washer so as to set its hole in the pin of snap
ring. Screw lock nut.
7）Turn wheel hub back and forth two or three rotations to see if rotation starting torque is within
specifications. Rotation starting force： 10～29N（refer to Fig.1-6）；
8）Measure axial play of wheel hub to see if it is within specification. Axial play is less than 0.08mm
（refer to Fig.1-7）.
Fig.1-6 Fig.1-7
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1. Steering wheel
3.Upside steering
column
8.Gimbal
10. Down side
steering axle
12. Bearing
13. Snap ring
14.Down side
steering column
17. Steering gear
18. Priority valve
19. Clamp bolt
22. Clamp lever
26.Hydraulic
switch
2. Steering system
Steering system include rear steering axle and steering device.
2.1 Steering device
It consists of steering wheel, upside steering column, downside steering column, bearings, steering gear,
priority valve, clamp bolt and hydraulic switch etc. You can adjust the steering angle forward and
backward by yourself. Refer to fig. 2-1.
Fig. 2-1 Steering device
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