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Table of Contents
Related Manuals for HANGCHA XE Series
Summary of Contents for HANGCHA XE Series
- Page 1 XE Series XE Series Four-wheel Lithium-ion Battery Forklift Truck CPD15/18/20/25/30/35/38-38-XEY2-SI CPD20-XEXY2-SI CPD30/35/38-XEY2H1-SI CPD20/25/30/35/38-XEY2H-SI CPD40/45/50-XEY2-SI CPD50-XEXY2-SI OPERATION AND MAINTENANCE MANUAL HANGCHA GROUP CO., LTD.
- Page 2 This manual provides instructions on how to use the 1.5 t to 5.0 t XE series four-wheel battery forklift truck correctly, instructing you on how to perform the safety operation and preventive maintenance.
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Page 3: Table Of Contents
Contents 1. FORKLIFT TRUCK INTRODUCTION ..................1 1.1 O ............................. 1 VERVIEW 1.2 A ................3 PPLICATION ENVIRONMENTS AND CONDITIONS 1.3 D ........................ 4 ISPLAY AND CONTROLS 1.4 O ..........................16 THER PARTS 1.5 OPS ..........................19 SYSTEM 1.6 N ......................21 AMEPLATE AND ARKS 1.7 F... - Page 4 4.3 S ................. 46 AFETY RULES FOR ATTACHMENTS AND PALLETS 4.4 S .................46 AFETY RULES FOR PARKING AND STORAGE 5. LITHIUM-ION BATTERY ......................46 5.1 I ......................46 NSTRUCTIONS FORSAFETY 5.2 I ....................47 NSTRUCTIONS FOR INSTALLATION 5.3 C ..............48 OMMON TERMS FOR LITHIUM ION POWER BATTERIES 5.4 I .......................
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Page 5: Forklift Truck Introduction
1. Forklift truck introduction 1.1 Overview Features The overall vehicle continues the XC series style with a unified design The reinforced drive axle and reduction gearbox match the internal combustion vehicle mast, steering axle, and tires. The smart dashboard has a graphical interface that is simple and intuitive. It has three speed mode options to suit different work environments. - Page 6 consumption is reduced by 15-20% under the same conditions compared to traditional asynchronous motor models. The low center of gravity provides more stable operation. Appearance and main parts Name Name Mast Rearview mirror...
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Page 7: Application Environments And Conditions
Steering wheel Overhead guard Load backrest Driver's seat Fork Counterweight Drive axle Tow pin Hood Steering axle Marking positions for frame S/N 1.2 Application environments and conditions The forklift truck in this manual is only intended for lifting/lowering or handling cargo. Users must operate and maintain the forklift truck according to this manual. -
Page 8: Display And Controls
Do not overload. Do not push or pull the cargo. Do not use non-explosion-proof forklift trucks in flammable and explosive environments. Do not use forklift trucks not specially designed for cold storage warehouses in cold storage warehouses. - Page 9 Steering wheel [1] The steering wheel is used to control the driving direction of the forklift truck and is located in the middle of the center console. Its operation method is as follows: When the steering wheel is rotated clockwise, the tail ...
- Page 10 Parking brake [4] The parking brake is used for forklift truck parking and is located to the left of the center console. Its operation method is as follows: Parking state: After the forklift truck has stopped, the lever is in ...
- Page 11 steering hub column. Pull the key out of the lock switch to ensure that the truck cannot be started accidentally. The key switch has two functional positions: on/off; first, set the shift lever to neutral, release the accelerator pedal, and then turn the key clockwise to the "ON" position. Caution The forklift truck will not start if the direction lever is not in neutral or the accelerator pedal ...
- Page 12 Lift control lever [9] This lever is located in the right side of the center console and is used to lift or lower the forks. The lifting or lowering speed is controlled by the angle of the control lever. Operating steps: Lifting: Pull the control lever backward.
- Page 13 Emergency stop switch [14] Turns the power on or off. In an emergency, press the red mushroom-shaped button to cut off the main vehicle power. Traveling, steering and lifting actions will be disabled. Accelerator pedal [16] The accelerator pedal is used to control the driving speed. Press the pedal to start the forklift truck. Controls the speed according to the angle at which the pedal is pressed.
- Page 14 Multi-function display [13] 1、An introduction to the instrumentation functions The XE series forklift truck's smart dashboard is an on-board color screen dashboard integrated with the CAN bus. It can display vehicle speed, battery level, working hours, total mileage, Chinese/English display, password protection, fault codes, drive and lithium-ion battery monitoring information, etc.
- Page 15 Low battery display [D] When the battery level is less than 20% of the battery capacity, this indicator light will light up; When the battery level is higher than 20% of the battery capacity, this indicator light goes off. Fault indicator light [E] When an electrical system fault occurs, this indicator light stays on constantly.
- Page 16 Parking indicator light [M] When the hand brake is engaged, this icon will light up. Tortoise speed mode [N] When the forklift truck is running in low-speed mode (Mode SPE), this indicator light will light up. 3、Instrument buttons 4、Power on interface 5、Main menu Press button 1 on the main interface to view fault information.
- Page 17 traction controller, auxiliary traction controller (reserved), oil pump controller, auxiliary oil pump controller (reserved), and lithium-ion battery monitoring information. Press button 4 to return to the main interface. Press button 4 on the main interface to enter the setting page. Press （4）...
- Page 18 The first press of button 3 selects the current page, and the right button prompt information changes automatically. Press button 1 and button 2 to select the setting item under the current sub-page; The second press of button 3 selects the current setting item, and the right button prompt information changes automatically.
- Page 19 Note: The working hours on the current main interface are controller forwarded data and cannot be reset through the dashboard. It is a reserved function. (3). User password settings interface To change the password, the original password must be entered first, then enter the new password.
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Page 20: Other Parts
(3). Start-up interface settings Press button 1 and button 2 to select HANGCHA Logo/No Power On Screen options; press button 3 to confirm, and the interface will automatically jump back and the power on screen will change accordingly; press button 4 to cancel and return to the previous interface. - Page 21 1: Forward and backward adjustment handle for the driver's seat 2: Backrest angle adjustment handle 3: Safety belt Adjustment of the position of driver's seat Operating steps: The driver sits on the seat. Pull the driver's seat position adjustment lever in the ...
- Page 22 For front and rear adjustment and backrest angle adjustment, the handle should be pulled in place to ensure that the structure is completely disengaged before adjustment. After adjustment, the levers should return to the locked position. Ensure that all the components are ...
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Page 23: Ops System
1.5 OPS system The OPS (Operator Presence Sensing) system is a safety protection system that senses whether the driver is sitting in the seat correctly with a sensor mounted in the driver's seat. If the driver is not sitting in the driver's seat correctly, the driving force will be cut off and all handling operations will be stopped. - Page 24 OPS function exception handling 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. a. After the driver leaves the seat, the seat switch indicator light “...
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Page 25: Nameplate And Marks
1.6 Nameplate and Marks 载 荷 曲 线 图 RATED CAPACITIES AND LOAD CENTRES GRAPH 公斤(kg) 起升高度≤3m 3000 额 2500 定 2000 1500 载 1000 荷 重 毫米(mm) 1100 量 载 荷 重 心 位 置 LOAD CENTRE POSITION 轮 胎 气 压 前轮... - Page 26 Name HC label Mast warning label (one for each mast): Do not stand on forks or stand under raised forks Safety belt label Warning label Lithium-ion battery label Typeface label Tonnage label Left, right labels Tie-down point label Tire pressure label Typeface label Load curve label Engine hood opening label...
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Page 27: Forklift Truck Structure And Stability
Forklift truck structure and stability Prevent the truck from rolling over! Be aware that the structure and stability of the forklift truck are very important to safe operation. Forklift truck Caution structure 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 28 truck. When the forklift truck is unloaded, the center of gravity remains unchanged; when it is loaded, the center of gravity is formed by the combined center of gravity of the forklift truck and the load. The center of gravity of the load is determined by whether the mast is tilted forward or backward or whether it is lifted or lowered, thus the combined center of gravity can change.
- Page 29 Stable center of Caution gravity region 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 midpoint of the rear axle. If the combined center of gravity is on the rear axle, the two front tires will form a fulcrum and the forklift truck will tilt forward.
- Page 30 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. It is dangerous to suddenly apply the brake, because the forklift truck will roll over or the load will slide when a large force acts forward.
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Page 31: Operations
2. Operations 2.1 Breaking-in of a new truck To ensure the safety operation of the forklift truck, The forklift truck should be operated under low the operator must check and adjust the forklift load in the initial stages after it is put into use, truck before driving it. -
Page 32: Adjustment And Replacement Of The Forks
pulled out quickly. both directions and check whether the wheel position is displayed on the instrumentation. – Adjust the tilt angle of the steering – Check hydraulic functions column. lift/lowering, tilt and attachments. – Adjust the field of vision in the rearview –... -
Page 33: Starting The Truck
carrier. beam of the fork arm carrier for loading - The fork clearance is adjusted. and unloading forks. Do not fasten the fork in the open position of the fork arm carrier to prevent the fork from falling off from the open position. -
Page 34: Driving
during this time. If the operator operates Warning the direction switch, accelerator pedal or If the forklift truck has any damage the lifting switch during this period, a or faults, it should not be started before fault message will appear in the display repairing. -
Page 35: Steering
Caution 2.7 Braking During driving, if the direction switch is switched to the opposite driving ─ Decelerate and depress the brake pedal direction, the forklift truck will be braked to stop the forklift truck. until the forklift starts to move in the ─... -
Page 36: Loading, Stacking And Unstacking
Pull up the emergency stop switch again when starting next time. Warning The emergency stop switch should only be used in dangerous situations during driving. The emergency stop switch must not be used for service braking. 2.9 Loading, stacking and unstacking Loading ─... -
Page 37: Parking Rules
that the cargo is above the unloading site and ─ Tilt the mast forward to the fork level confirm that the cargo is safe and in place. and lift the forks to the position of pallet or ─ Conduct the necessary lifting and tilting crosstie. -
Page 38: Checks After Operation
– – Lower the mast completely and tilt it Check the electrolyte level. forward. – If the fork did not lift to the maximum – Turn the key to the "0" position and height during the operation on that day, the remove it from the switch. - Page 39 storage warehouse should not be turned off – Run the forklift truck once a week. Lift and parked inside the warehouse. the forks to maximum height several times. Long-term storage – Check the specific gravity and level of Carry out the following maintenance and checks in electrolyte once a month.
- Page 40 truck and connect the battery leads. Carefully carry out pre-start inspection to check the starting, forward, reverse, steering, lifting, lowering, front and rear tilting functions of the forklift truck.
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Page 41: Lifting, Transportation And Towing
3. Lifting, transportation and towing 3.1 Lifting Tie the steel rope on the lifting hole and counterweight lifting hole at both ends of the beam of outer mast firmly and lift the forklift truck with the lifting device. The wire rope connected with one end of counterweight should be passed through the gap in the overhead guard, to avoid placing any strain on the overhead guard. -
Page 42: Transportation
3.2 Transportation The forklift truck can be used for loading and unloading and short distance transport, but should not be used for long distance transport. If the forklift truck is transported over a long distance, it should be carried with a ship, train or vehicle with load capacity of more than 5 tons such as a truck and trailer. Operating steps: –... -
Page 43: Towing
3.3 Towing Do not routinely use the forklift truck for towing or being towed. The tow pin under the counterweight is only to be used in the following situations: – To urgently move the forklift truck if it suddenly breaks down on the working road. –... -
Page 44: Safety Rules
4. Safety rules should stop the truck immediately, hang the "Danger" or "Fault" sign, pull out the key and 4.1 Safety rules for driving the truck report to the management. The truck should not Only trained and approved operators can be used until all faults are eliminated. - Page 45 Do not get on or off the forklift truck when it – No people should be around the forklift is running. Safety pedals are installed on both truck. sides of the body, hand-guards are installed on – Do not depress the accelerator pedal or the left side of the overhead guard, and the operate the lift control lever or tilt control operator must always face the forklift when...
- Page 46 accessories. Do not use people as additional counterweight. Do not stretch your head or body between Do not use a mobile phone or other the mast and the overhead guard. You may be electronic products while driving. Focus on the injured if your head or body is trapped.
- Page 47 operator must be familiar with the meaning of his hands, flags, whistles or other signals. When the forklift truck is used for carrying cargo in large lengths such as wood, pipes and oversized items, or attachments of the forklift truck could be extended, the operator must pay full attention to It is dangerous to lift the forks when driving the front and keep an eye on other people when...
- Page 48 forks; when cargo is not aligned, or when the pallet jack turns or crosses uneven surfaces, the cargo may easily fall off. The possibility of rollover is also increased. Do not lift cargo when the forklift truck is on a slope and avoid loading and unloading operations on ramps.
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Page 49: Rules For Maintenance And Repair
3. Improper maintenance can cause serious – During maintenance at height (such as accidents and shorten the service life of forklift the mast, front light and back light), take care trucks. For safe operation, please contact Hangcha... -
Page 50: Safety Rules For Attachments And Pallets
Hangcha 5. Lithium-ion Battery dealers or agents. Do not refit the attachments 5.1 Instructions forsafety... -
Page 51: Instructions For Installation
shock. Before installing the battery system, make sure that the low-voltage plug-in of the battery system is disconnected from the truck. When connecting the high-voltage system, pay attention to safety 5.1.2 Maintenance personnel must have a protection to prevent an electric shock during electrician license issued... -
Page 52: Common Terms For Lithium - Ion Power Batteries
5.3.7 Explosion: The battery housing is broken and 5.3 Common terms for lithium-ion solid material is flushed out of the battery with an power batteries explosive sound. 5.3.1 Battery system 5.3.8 Fire: Open fire comes out of the battery The battery system is an energy storage device shell. - Page 53 charger display while charging to ensure that all during operation of the vehicle. parameters are in the normal range. （4）In the event of a fault alarm during charging, Caution both the battery system and charger will stop When the ambient temperature is low, the ...
- Page 54 (3) Do not place any foreign objects and tools on the lithium-ion battery to prevent short circuits. (4) Battery packs of different brands, different capacities or different types should not be used together. (5) If there is a large amount of dust or other foreign objects on the top cover and posts of the battery pack, use compressed air or dry cloth to clean them promptly, rather than water or a wet...
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Page 55: Emergency Plan
a. If there is any smoke or burning in the external 5.5 Emergency plan wire, use a carbon dioxide or dry powder fire 5.5.1 Severe abnormalities: extinguisher for fire-fighting. During use, users should be familiar with safety b. If there is any smoke from the battery, use a precautions should carry... -
Page 56: Size/Weight
5.6 Size/Weight Item CPD15-XEY2-SI CPD18-XEY2-SI CPD20-XEXY2-SI Model DQ-EB4080160A0-C128 DQ-EB4080160A0-C128 DQ-EB4080160A0-C128 Length (L) 1014 1014 1014 Width (W) Height (H) Rated capacity Rated voltage 77.28 77.28 77.28 Item CPD20-XEY2-SI CPD25-XEY2-SI Model DQ-EB0080230A0-C111 DQ-EB0080230A0-C111 Length (L) 1074 1074 Width (W) Height (H) Rated Rated 76.8... - Page 57 Item CPD20-XEY2H-SI CPD25-XEY2H-SI Model DQ-EB2080304A0-C112 DQ-EB2080304A0-C112 Length (L) 1074 1074 Width (W) Height (H) Rated Rated 76.8 76.8 Item CPD38-XEY2H-SI CPD35-XEY2H-SI CPD30-XEY2H-SI Model DQ-EB2080304A0-C121 DQ-EB2080304A0-C121 DQ-EB2080304A0-C121 Length (L) 1074 1074 1074 Width (W) Height (H) Rated capacity Rated voltage 76.8 76.8 76.8 Item...
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Page 58: Charging The Lithium-Ion Battery
5.7. Charging the lithium-ion battery YLCHD-80V65A-00 charger 1. Appearance and structure The product dimensions and weight are shown in the table below Installation Model Weight (kg) L×W×H (mm) Cooling method position 48 V 100 A 525×455×260 Forced air cooling Indoor 80 V 65 A 525×455×260 Forced air cooling... - Page 59 2. Electrical parameters Model 48 V 100 A 80 V 65 A AC380 V ± 15% AC380 V ± 15% Rated input voltage Three-phase four-wire voltage Three-phase four-wire voltage Input grid frequency 50/60 Hz 50/60 Hz Power factor ≥ 0.99 ≥...
- Page 60 2) Inspect the charger before charging to ensure correct wiring and no faults or abnormalities. 3) Confirm the battery voltage and capacity match the charger. (Refer to charger specs and battery specs). 4) Before charging, connect the charger output plug to the truck battery socket, and then connect the charger input plug to the power socket.
- Page 61 Voltage: Battery current voltage value Charging time: Accumulated charging time Total current: Charger max output current value when operating 10) After charging is complete the indicator light stays on and the screen displays charging completed. Disconnect the charger's AC circuit breaker, unplug the AC input connector, and then unplug the battery connector.
- Page 62 Other faults Abnormal current Abnormal voltage...
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Page 63: Charging Steps
5.8 Charging steps 1. Park the truck at the charging pile according to damaged or affected by rust or corrosion. regulations and turn off the key switch, i.e., power off the truck. 2. Turn off the charger input master switch, make sure the emergency stop switch is disconnected, the charger starts automatically, the power indicator light turns on and the display interface... -
Page 64: Repair And Maintenance
buckle to take out the charger. 7. Replace the charging gun on the charger and turn off the charger input master switch. 8. Put the charging covers of the lithium-ion battery and forklift truck back in place. 6 Repair and maintenance 6.1 Daily maintenance (eight hours) It also serves as a pre-operation check. - Page 65 key switch is on. 6. Indicator light check Toggle the indicator light control lever and check whether the indicator light operates normally. The height of the liquid level on the dipstick corresponding to the different mast lifting heights: "30" refers to the hydraulic level when the lifting 7.
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Page 66: Weekly Maintenance (40 Hours)
both directions and check whether the wheel position is displayed on the instrumentation. 16. Check the driver's seat switch When the driver is not sitting in the driver's seat correctly, the driver's seat switch indicator light on the instrument will light up and the hydraulic functions will be disabled. - Page 67 B) In order to ease the forklift truck operation, apply a layer of grease to the contact surface of the lifting guide wheel and the inner & outer mast. Warnings When applying grease, park the forklift on a flat road, turn off the engine and engage the hand brake.
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Page 68: Every One And A Half Month Maintenance (250 Hours )
– Adjust the pedal height: Adjust the stop bolts so that the distance between the middle point of the upper surface of the pedal and the front bottom base is 115 mm - 125 mm. – Adjust the length of the brake master cylinder push rod so that the idle stroke of Driving wheel (front wheel) the pedal is 1 mm - 3 mm. -
Page 69: Every Three Month Maintenance (500 Hours )
cylinder for any leaks or damage 3. Change drive axle gear oil 6.5 Semi-annual maintenance (1000 The gear oil should be replaced after 250 hours of use for the first time, and then replaced once hours) every 2000 hours. Park the forklift on horizontal ground. Add the following maintenance items in addition 1) Remove the oil drain plug and drain the to every three-month maintenance. -
Page 70: Annual Maintenance (2,000 Hours )
new brake fluid as the level drops. bearing, and then change the grease. 2. Change the rear wheel bearing lubricating Caution grease Refer to the content on the steering axle in the Prevent dust and water from mixing with the brake fluid when adding it. -
Page 71: Others
times, and tilt the mast forward/backward 3 - 3) Place wooden blocks behind the rear wheels 5 times. to prevent the forklift truck from moving; 4) Loosen each wheel nut 1 - 2 turns Refill it with hydraulic oil to the specified line. counterclockwise. - Page 72 4) Loosen the nuts on the wheel 1 - 2 turns counterclockwise. Warning Do not remove the nuts until the rear wheels are lifted off the ground. 5) Slowly lift the forklift truck with a jack until the rear wheels are completely off the ground. Place wooden blocks on each rear side of the forklift frame to support the forklift as shown in the diagram.
- Page 74 2. Fuse (1) Before replacing any defective fuse or relay, please investigate the cause of failure. Replace the fuse with a new one of the correct specification. Check and replace the fuse Operating steps: – Park the forklift truck according to rules and regulations.
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Page 75: Checks And Maintenance Of The Control System Assemblies
6.8 Checks and maintenance of the control system assemblies Operating steps: – Park the forklift truck according to rules and regulations. – Open the right door and unplug the battery. – Open the cover of the counterweight. Check, replace and adjust components of the control system assemblies when they are exposed. -
Page 76: Use, Installation And Safety Rules For Attachments
7. Use, installation and safety rules for attachments We select the accessories, such as the side shifter, fork positioner, rotator, push-puller and string rod, etc., in accordance with international standard ISO2328: Forklift trucks - Hook-on type fork arms and fork arm carriages - Mounting dimensions. -
Page 77: Use Of Attachments
operating them. – When accessories with lower hook positioning are installed, the joint spacing between the lower hook and the lower beam of the fork arm carrier should be adjusted appropriately. 7.2 Use of attachments – Become familiar with the relevant content on the nameplate of the forklift truck, read the relevant operation manual carefully before use (especially the user manual and installation manual of the professional accessory company), and be trained and qualified to operate the forklift truck accessories. -
Page 78: Checks And Maintenance Of The Attachments
7.3 Checks and maintenance of the attachments – 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 the accessory manual. – Check whether the upper hook is properly embedded in the groove of the fork arm carrier of the forklift truck. -
Page 79: Relevant Safety Directives And Standards (Ce Models)
8.Relevant safety directives and standards (CE models) The CE certification models meet the following directives and standards: Machinery Directive 2006/42/EC (The European Council of the Laws of the Member States concerning Machinery), Noise Directive 2000/14/EC (Directive of the Laws of the Member States concerning Outdoor Equipment Noise Radiation), EN ISO 12100:2010 (Safety of machinery —... - Page 80 DECLARATION OF CONFORMITY EG-KONFORMITÄTSERKLÄRUNG Business name of the manufacturer: Hangcha Group Co., Ltd. Firmenbezeichnung des Herstellers: Full address of the manufacturer: 666 Xiangfu Road, Lin'an District, Hangzhou City, Zhejiang Province 311305, P.R. China Vollständige Adresse des Herstellers: Name and address of the person (established in the Community) compiled the technical file:...
- Page 81 Maintenance Record Sheet Maintenance Date Maintenance content personnel...
- Page 82 HANGCHA GROUP CO., LTD. ■ Address For: OVERSEAS USERS ■ Address: 666 Xiangfu Road, Lin'an Economic Development Zone, Zhejiang, China ■ Fax: 0086-571-88926789 0086-571-88132890 ■ ZIP:311305 ■ Web: http://www.hcforklift.com ■ E-mail: sales@hcforklift.com...