Related Manuals for HANGCHA XF Series
Summary of Contents for HANGCHA XF Series
- Page 1 XF series Internal Combustion Counterbalanced 1.0t-X5.5t Forklift Truck 1.5t-X5.5t XF Series Internal Combustion Counterbalanced Forklift Truck OPERATION MANUAL HANGCHA GROUP CO., LTD.
- Page 2 Note: The model tonnage number displayed below is calculated at a load center distance of 500mm. © September 2022, HANGCHA GROUP CO., LTD.
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Page 3: Table Of Contents
Contents I. Instructions for use ......................1 II. Forklift truck component names ................... 3 1. Instrumentation ..........................3 2. Controls and switches ......................... 12 3. Body and other parts ........................17 III. Safety regulations ..................... 22 IV. Daily safety checks ....................28 V. -
Page 4: Instructions For Use
I. Instructions for use In order to ensure personal and equipment safety, the driver should obey the following Precautions: 1. Only drivers with proper training and a valid license should operate the vehicle. 2. Check each control and alarm device before driving, if any damage or defects are found they should be repaired before operation. - Page 5 away with a proper carrier loader (see the vehicle handling content); if it is caused by other reasons, the truck should be towed with an appropriate vehicle; tow rope should be fixed outside the truck body when towing. Obey traffic rules when towing a truck on the highway. 22.
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Page 6: Forklift Truck Component Names
II. Forklift truck component names 3. Lifting hydraulic 1. Fork 2. Backrest 4. Mast cylinder 5. Steering wheel 6. Overhead guard 7. Counterweight 8. Driver’s seat 9. Rear wheel 10. Frame 11. Hood 12. Tilt cylinder 13. Front wheel 1. Instrumentation Key 4 Key 3 Key 2... - Page 7 Key 4 Key 3 Key 2 Key 1 GCT Engine Homepage Key 4 Key 3 Key 2 Key 1 H11/ Engine Homepage A. Instrument indicator lights Water temperature gauge Fuel gauge When the ignition key switch is in the ┃ (open) position, the water temperature gauge is active, When the ignition key switch is in the ┃...
- Page 8 position, the stopwatch will start running. The stopwatch reading will increase by one digit for every hour of operation. The light indicates the pressure of engine The stopwatch displays the cumulative working lubricating oil. hours of the forklift truck. Caution Caution After the cumulative hours reaches 100h If the light continues to turn on or flash...
- Page 9 will stop and the safety belt alarm indicator Neutral start indicator light light will turn off. Air cleaner alarm indicator light When the truck is temporarily stopped, the direction lever should be in the neutral position; at that time, the light turns on. When the light turns on, it indicates that the The truck can only be started when it is in air cleaner of the air intake system is blocked...
- Page 10 ⑥ Install the hazard Warning sign Gasoline engine / LPG engine: H1, H3 near the exhaust port. Caution Engine fuel: Gasoline Parking regen: The parking status is not suitable for heat dissipation. Stay away from inflammables and keep a safe distance from Engine fuel: LPG people.
- Page 11 SPN:3701 FMI:15 Caution When working in an environment that is not suitable for DPF regeneration, turn on the At the end of parking regen, the light will inhibit mode. After leaving, release the inhibit automatically turn off; the engine can be shut mode promptly so that active regeneration down after waiting for 2-3min until the engine can continue.
- Page 12 B. Operating instructions for instrument keys B.1 Engine fault information display page (1) Diesel engine (Kubota/Xinchai) and H11/H12 engine No faults Fault present ① Enter the engine fault information display page: Homepage=》Key 4 ② Fault query page selection: Press key 2 or key 3 again for page selection (the page selection key is not displayed when there is no fault) ③...
- Page 13 蓄电池电压 发动机转速 LPG 压力 充电效率 kg/cm A / F 点火正时 进气温度 喷射脉宽 Alpha ℃ GCT engine B.3 Setting page (1) Operations on the setting page 高级设置 保养提醒 返回 ⚫ Enter the setting page: Homepage=》Key 1 ⚫ Enter the maintenance page: Homepage=》 Key 1=》 Key 2, enter the maintenance repair page ⚫...
- Page 14 Regen: Press Key 2 and enable the DPF parking regen. Back: Press Key 1 to return to the setting page (3) Maintenance repair page a. Remaining hours query page 重置 Reset 返回 Back The remaining hours can be observed on the page Reset: Press Key 2 to be redirected to the maintenance hour reset page and reset the remaining hours to the set initial value (maintenance cycle interval).
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Page 15: Controls And Switches
2. Controls and switches Control and Switch Diagram of the 1.0T~x5.5t Forklift Truck 1. Steering wheel 2. Horn 3. Combination light switch 4. Ignition key switch 5. Lifting lever 6. Tilt lever 7. Cup holder 8. Instrument 9. Rocker switch 10. - Page 16 Steering wheel [1] To turn on the headlights and the front signal light, turn this switch to align the position marker on the switch handle with the Turn right Turn left corresponding symbol on the switch body. Controls the driving direction of the truck Ignition key switch [4] Anticlockwise rotation turns the truck to the left;...
- Page 17 interval between consecutive starts should be Move to the left 120s. Lifting lever [5] Lift Move to the right Lower This lever is used to move the side shift frame to the left or right. Push forward – Move left; Pull back – Move right This lever is used to lift or lower the forks.
- Page 18 is pressed harder, the forklift truck will be functions are added. braked. The pedal can be used when the forklift truck slows down to approach cargo or Accelerator pedal [10] conducts loading and unloading operations. Caution Do not use the inching pedal excessively. If the pedal is used as a footrest or used for a long time, it may cause overheating of the automatic transmission oil or clutch slip.
- Page 19 adjusting lever for locking. reverse gear I. Caution Caution The engine can only be started when the a. Adjust the steering wheel tilt angle after lever is in the neutral position. the forklift truck has stopped and the hand brake is engaged. Emergency power-off switch [17] b.
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Page 20: Body And Other Parts
⚫ 3. Body and other parts The seat position can be adjusted when the forklift truck has stopped. Load-backrest ⚫ Do not adjust the driver's seat The load-backrest ensures the stable loading of when driving to avoid an accident. cargos. The forklift truck must not be operated ⚫... - Page 21 Keep the safety belt fastened tightly during permission, the truck is fitted with a locking daily operation to protect yourself and reduce hood; in order to open the internal injury if the truck rolls over. combustion engine hood, the lock handle ·...
- Page 22 should be tightened with a socket spanner during reinstallation Warning The engine must be shut down during Water tank lid and additional water tank maintenance and repair under the internal The additional water tank is under the internal combustion engine hood. Take care to combustion engine hood.
- Page 23 the vent should be checked for blockages There is an opening on the lower beam of when refuelling. the fork arm carrier for loading and Note: Do not pour gasoline into the fuel tank, unloading forks. because gasoline is not used for the 4-x5.5t It is forbidden to use the fork in the open single fuel LPG truck.
- Page 24 Mirror the disassembly ones. ECU diagnosis interface A mirror is installed on the upper right of the overhead guard for observing conditions The ECU diagnosis interface of the engine is behind the truck or when reversing. under the right engine hood of the truck and is provided with a dust cover.
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Page 25: Safety Regulations
III. Safety regulations Caution The forklift may not be used underground. 1. Only trained and approved operators can It may not be used in flammable and operate the forklift truck. explosive environments. 2. Oil, water and LPG leakage, deformation and looseness should regularly... - Page 26 18. Please drive in reverse or under guidance when handling very large cargos that obstruct visibility. 19. Slow down and sound the horn when passing through crossways or other sections with poor visibility; limit the speed to 1/3 of the maximum driving speed of the truck. Warning Pay special attention to the driving direction when reversing.
- Page 27 Caution Check the road to be driven, holes, abrupt slopes, barriers, bumps, and road conditions that may cause loss of control and vibration. ·Remove rubbish, debris and foreign matter that may puncture tires and throw cargo out of balance. ·Slow down on slippery roads, do not drive on the edge of the road, and take extra care when it cannot be avoided.
- Page 28 31. The overhead guard can protect you from being hit by falling cargo. The load-backrest 27. Avoid emergency stops or driving fast ensures the stable loading of cargos. Forklifts downhill to protect cargo from falling or the without overhead guards and load-backrests truck from rolling over.
- Page 29 34. When the noise near the driver's ear is greater than 80dB, the driver should take hearing protection measures, 38. Ensure that the cargo is tied firmly and placed flat on the two forks; do not lift cargo Caution with a single fork. Rough or bumpy working surfaces and high For forklift trucks with accessories (like flat tire deformation will increase the noise level.
- Page 30 are at height. permission. 42. Do not tow a truck with a faulty engine, abnormal steering system or damaged brake system. Obey traffic rules when towing a truck on the highway. 43. Wear overalls and other personal safety protective devices, such as earplugs, safety hat, goggles, dust mask, safety shoes, anti-static clothing etc.
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Page 31: Daily Safety Checks
IV. Daily safety checks marks. 1. Leakage check: Electrolyte, hydraulic oil, cooling liquid and hydraulic transmission oil Warning Do not drive the truck if a fuel leak is found before work; start the engine only after eliminating the leakage. Check whether there is any oil leak or water leak in the engine, hydraulic pipe connectors, water tank and drive system by hand and visual inspection. - Page 32 6.Hydraulic oil tank level check Check the oil quantity in the hydraulic oil tank 1.0t-3.5t square oil scale has scales on three sides; the circled number on the top indicates the applicable model tonnage (see the figure): ○ 15 is applicable to Scale value for symbol 1t-1.8t forklift truck.
- Page 33 key switch is on. above scale “45”. 9. Indicator light check. 3t-3.5t forklift truck with standard mast Toggle the indicator light control lever and requires hydraulic oil to be added to above check whether the indicator light operates normally. scale “47” and the forklift truck with tertiary 10.
- Page 34 Slow down and step on the brake pedal; after stepping on the brake pedal, the brake light should turn on. Slow down and step on the inching pedal; check whether the inching pedal function is normal. 19. Tire check and tire pressure check. Screw the cap back on after confirming that there is no air leakage;...
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Page 35: Forklift Truck Structure And Stability
V. Forklift truck structure and stability Be aware that the structure and stability of the forklift truck are very important to safe operation. Forklift truck structure Caution The basic components of the forklift truck are the lifting device (forks and mast) and the forklift truck itself at the rear (with tires). - Page 36 · Load magnitude, weight and shape · Lift height · Tilt angle of the mast · Tire inflation pressure · Acceleration, deceleration and turning radius · Road conditions and road tilt angle · Accessories Stable center of gravity region Caution In order to make the forklift truck stable, the combined center of gravity has to be within the triangle formed by contact point of the front left and right tires and the...
- Page 37 Speed and acceleration Caution A static object should remain static without an external force. Similarly, a moving object continues to move at the same speed without an external force, which is referred to as inertia. Due to inertia, when the forklift truck starts to move forward, a force acts backwards; when the truck stops, a force acts forward.
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Page 38: Operation
VI. Operation After the engine is started Warning ① Preheat the engine for about 5min. If the forklift truck is found any damage or faults, it should not be started before ② Check the operating conditions of the repairing. engine. 1. -
Page 39: Loading
switch is in the “O” position; pull out the engine shutdown lever from the diesel forklift truck, take out the key and keep it safe. Caution ·Be careful when getting off the truck and do 15cm-20cm (6in-8in) not jump out. ·The truck should not stop on the driving route. -
Page 40: Stacking
after fork tips are clear from the cargo. ·Tilt the mast backwards in place Warning ·Do not tilt the mast when the load is lifted above 2m. ·Do not get off the truck or leave the truck when the load is at a high level. 5. -
Page 41: Various Signs And Labels
IX. Various signs and labels The 1-3.5t truck is taken as an example, the 4-x5.5t truck is similar. Emissions WAIT Inhibit Regen ≈ 30′ Back 内 燃 平 衡 重 式 叉 车 许可证号： Emissions 型号 规格 Ⅰ Ⅱ WAIT Inhibit Regen ≈... - Page 42 1. Hazard label: Stuck on the outer mast Do not stand on or under the fork arm carrier; otherwise, your safety will be at risk. 2. Lifting label: Indicates the lifting position and method of the truck. When lifting, prevent the rope from rubbing and damaging the lamp.
- Page 43 Check whether the load and the load center distance are within the allowable range of the Bearing Capacity Chart before loading. If the load shape is irregular, the heaviest part should be placed in the center of the fork and close to the load-backrest.
- Page 44 capacity is 3.0t, but if the lift height is increased or there are accessories, the rated load capacity will be decreased. 2.0t~2.5t 18. Warning 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.
- Page 45 If an attachment is installed ， the actual capacity at maximum lifting height refer to the model plate of the attachment or the rated capacities and load centers graph. HANGCHA GROUP CO.,LTD. Add: 666 Xiangfu Road, Hangzhou, Zhejiang, China (311305) 24.
- Page 46 See Chapter II of the manual; II. Forklift truck component names, 1. Description of the regen indicator light in the instrument panel. 27. Emergency stop label Print location of serial number A. Frame number B. Mechanical environmental protection code (limited to domestic market in China)
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Page 47: Lifting, Handling And Towing Of The Forklift Truck
X. Lifting, handling and towing of the forklift truck Lift the forklift truck •Tie the steel rope on the lifting hole and counterweight lifting hook at both ends of the outer mast beam firmly and lift the forklift truck with the lifting device. Warning •Do not enwind the steel rope with the overhead guard when lifting the forklift truck. -
Page 48: Ops System Description
Warning • Only attach the steel rope to the specified position. • Do not suddenly apply load on the steel rope. XI. OPS system description OPS system (limited to electric reversing hydraulic trucks) The OPS (Operator Presence Sensing) system is mainly used for safety protection, that is, when the operator is not in the correct driving position, the forklift cannot be driven and transported, thereby reducing accidents caused by misuse. - Page 49 In the event of the following conditions, the forklift truck should be stopped in a safe place and Hangcha agency should be contacted for inspection. When you are ready to start the forklift truck, and you pull the shift switch to forward gear 1 or backward gear 1, the neutral indicator light flashes.
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Page 50: Cab And Overhead Guard
XII. Cab and overhead guard Cab: Cab structure: New design, consisting of left pillar, right pillar, front glass, left door, right door and back door. How to use the cab: Open the left door with the key and enter the cab. Close the door and ensure that the left and right doors are closed for operation. -
Page 51: Precautions For Use Of The Lpg Forklift Truck
XIII. Precautions for use of the LPG forklift truck The LPG fuel system mainly consists of a steel cylinder, filter, pressure reducing regulator, and mixer. LPG enters the pressure reducing regulator from the steel cylinder through the combination valve and high-pressure pipeline via the filter. After vaporization, LPG enters the mixer and mixes with air in a certain proportion, then enters the engine cylinder for combustion and provides motive power for the forklift. - Page 52 Caution Pay special attention to the following points when the forklift truck is in use: (1) Check whether there is a gas leak in the LPG steel cylinder and pipe before driving. (2) If an LPG leak is found when the forklift truck is in use, the LPG switch should be shut off; the hydraulic valve should be closed;...
- Page 53 Caution 1. Drive the truck for at least several kilometers with gasoline every two weeks to prevent the gasoline from degrading. 2. Do not change the fuel used immediately after the engine is started; the engine should be at normal working temperature before changing the fuel. Pay special attention to the following points when the forklift truck is running on LPG: Check whether there is a gas leak in the LPG steel cylinder and pipelines before driving.
- Page 54 5. Precautions (1) If an LPG leak is found when the forklift truck is in use, the LPG switch should be turned off; the hydraulic valve should be closed; the pipe joints of device units and fasteners should be checked for looseness or leakage and promptly dealt with.
- Page 55 a. Close the outlet stop valve and loosen the outlet joint. (See Fig. 2) Fig. 1 Fig. 2 b. Loosen the steel cylinder. See the following schematic diagram for specific steps. Steel belt bracket Buckle bracket 1. Hold the tensioner with your right hand Buckle and tensioner and pull out the lock catch with your forefinger, middle finger and ring finger.
- Page 56 2. Continue 1, and push the tensioner up to 3 Continue to pull out the lock catch and pull press against the steel cylinder the entire tensioner down hard 5. Release the buckle from the side tensioner with the same method. 4.
- Page 57 end, unscrew the dust cover on the intake stop valve, insert the filling plug, open the intake stop valve for filling, and take out the filling plug when the LPG quantity reaches 80% of steel cylinder volume (when filling to 80% of rated capacity, the limit device will be automatically closed). Pull out the filling plug, screw the dust cover of the filling valve, and tighten the intake limit valve when the charge stops.
- Page 58 Steel belt fixation methods are the reverse of the disassembly steps Buckle bracket a. Hold the tensioner with your right hand and carry the buckle b. Insert the buckle into the ratchet shaft with your left hand, align with slotting the ratchet shaft slotting c.
- Page 59 e. Continue to tighten with your left hand, hold the tensioner with your right hand, f. Pull it down to press against the steel release the lock catch, and rotate the cylinder. tensioner upward and downward several times until it cannot be moved. 11.
- Page 60 (11) Steel cylinders must be refueled at gas stations with an LPG filling permit issued by the quality and technology supervision bureau. Filling without permission is prohibited. (12) When a new steel cylinder or refurbished steel cylinder is used for the first time, the filling station should conduct vacuum or nitrogen displacement treatment.
- Page 61 regulated properly. 4. The air cleaner and LPG cleaner need to be checked and cleaned frequently and should be replaced promptly in case of any damage. The air cleaner element should be cleaned frequently. 5. After assembly, debugging of the LPG forklift truck or at the end of a working day (or use of a cylinder of gas), the pressure reducing regulator must be regulated to ensure the proper air-fuel ratio.
- Page 62 WG3800 and LPG Fuel System Diagram...
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Page 63: How To Use And Maintain The Lead-Acid Battery
XIV. How to use and maintain the lead-acid battery I. Lead-acid battery and its application The battery is used as the power source to start the engine, and it is used to replace the power supply of the voltage regulator and overload generators. Light weight, low failure rate, easy to use and maintain. - Page 64 3.2 Maintenance-free batteries with power level indicator: The user needs to add some water and liquid during use. 3.2.1 Battery inspection When the battery capacity status is normal and the electrolyte density reaches the standard, the observation window shows green. When the battery capacity is insufficient, and the density of the electrolyte is reduced, the observation window is white.
- Page 65 Check and confirm whether the liquid level is between "UPPER LEVEL" and "LOWER LEVEL" 1: "UPPER LEVEL" 2: "LOWER LEVEL" If the liquid level is at or lower than “Lower Level”, distilled water should be added. When the electrolyte level is found to be seriously insufficient, the case should be carefully checked for cracking, leakage or battery failure.
- Page 66 Caution ·It is only safe to charge batteries in open areas. Do not charge batteries in a poorly ventilated garage or enclosed room. ·Do not charge batteries when the engine is running. All accessories must be turned off. V. Precautions for using batteries Batteries can produce explosive gases, the electrolyte is corrosive, and batteries can generate enough current to burn your skin.
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Page 67: Use, Installation And Safety Rules For Accessories
XV. Use, installation and safety rules for accessories Hangcha selects accessories, such as the flat clamp, rotating clamp, roll clamp, string rod, side shifter and others in accordance with ISO2328 Fork Lift Trucks-Hook-on Type Fork Arms and Fork Carriers- Mounting Dimensions. - Page 68 (9) It is prohibited to use accessories for unsuitable purposes, do not exceed the normal scope of work of accessories. (10) When accessories are faulty, they should not be used until the fault has been eliminated. The following inspection and maintenance should be carried out frequently (1) Check whether the spacing between the lower beams of the forks of the forklift truck and the lower hooks of accessories conform to the requirements of accessory manual.
- Page 69 of the fork arm carrier is less than 50mm; otherwise, it will affect the lateral stability of the forklift truck. 5. For accessories with a rotation function (roll clamp, soft clamp, multi-purpose rigid arm clamp, bucket clamp) after hanging and installation, stop blocks should be welded on both sides of the joint between the upper beam of the fork arm carrier and the accessories to prevent sliding when operating them.
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Page 70: Optional Configuration Of Driver's Seat Handrail For Fingertip Control
XVI. Optional configuration of driver's seat handrail for fingertip control 1. Description of operating and control elements Name Function Installation and operation platform of control elements and Handrail placement platform for the right arm of the driver Driving direction switch Select the driving direction or neutral position Horn button Trigger Warning sound signal... - Page 71 Name Function Lift control lever Lift and lower the control mast Tilt the control lever The control mast tilts forward and backward Side shift control lever Control the left and right movement of the forks Accessory control lever Control the fourth attachment Adjust the forward/backward position of the handrail (Stroke Handrail locking shift 110mm)
- Page 72 Notes...
- Page 73 HANGCHA GROUP CO., LTD. National customer service hotline: 400-884-7888 For: OVERSEAS USERS ■Address: 666Xiangfu Road, Hangzhou,Zhejiang, China ■Fax: 0086-571-88926789 0086-571-88132890■ ZIP:311305 ■Web: http://www.hcforklift.com■E-mail: sales@hcforklift.com...