HANGCHA XC Series Operation And Maintenance Manual
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HANGCHA XC Series Operation And Maintenance Manual

3-wheel lithium-ion battery forklift
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3-Wheel Lithium-ion
Battery Forklift
OPERATION AND
MAINTENANCE
MANUAL
Original Instruction
HANGCHA GROUP CO., LTD.
06/2023
XC
CPDS13/15/16/18/20-XCD4-SI
CPDS13/15/16/18/20-XCD6-SI
CPDS13/15/16/18/20-XCD8B-SI
CPDS13/15/16/18/20-XCD8G-SI
CPDS13/15/16/18/20-XCC2G-SI
Series

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  • Page 1 Series CPDS13/15/16/18/20-XCD4-SI 3-Wheel Lithium-ion CPDS13/15/16/18/20-XCD6-SI CPDS13/15/16/18/20-XCD8B-SI Battery Forklift CPDS13/15/16/18/20-XCD8G-SI CPDS13/15/16/18/20-XCC2G-SI OPERATION AND MAINTENANCE MANUAL Original Instruction HANGCHA GROUP CO., LTD. 06/2023...
  • Page 2 This manual provides instructions on how to use the XC series 3-wheel lithium-ion battery counterbalanced forklift, operators and maintenance personnel must read it before use.

  • Page 3: Table Of Contents

    Content Preface 1. Overview ........................ 1 2. Appearance and main parts ..................3 3. Instrument and operating parts ................4 3.1 Multifunction display screen ................5 3.2 Operating parts .....................13 3.3 Lithium battery replacement and installation ..........20 3.4 Others ......................20 4.
  • Page 4 17.1 Attachment install ...................77 17.2 Attachment use ..................77 17.3 Attachment check and maintenance ............78...

  • Page 5: Overview

    1. Overview The forklifts described in this manual are only suitable for loading and unloading and transporting goods over short distances. It must be used, operated and maintained according to the information in this manual. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment or property.
  • Page 6 Warning It is prohibited to use this forklift in explosion-proof places.  Operating rules: － Lift and lower cargo. － Transport the lowered cargo. － Do not move the forklift truck when goods are lifted above 500mm. － When running with goods in two layers, the lifting height of the mast must not exceed 1500mm.

  • Page 7: Appearance And Main Parts

    2. Appearance and main parts 1. Fork 2. Backrest 3. mast 4. Overhead guard Driver’ s seat 6. Rear cover 8. Rear wheel (steering 9. Front wheel (driving Counterweight wheel) wheel)

  • Page 8: Instrument And Operating Parts

    3. Instrument and operating parts Accelerator 2. Brake pedal 3. Hand brake Steering Driving pedal column stop direction lever handle 6. Steering wheel 7. Horn switch Combination 9. Lifting lever 10. Tilt lever light switch Sideshift Accessory Adjusting 14. Cup holder 15.

  • Page 9: Multifunction Display Screen

    3.1 Multifunction display screen Display Display Current battery capacity Body control shortcut menu Whether the vehicle is in a forward or Handbrake light: Lights up when the reverse state, it is not displayed when driver operates the handbrake in neutral Current three working modes: "S", "P", Seat light: Lights up when the driver "E"...
  • Page 10 Menu Icon Name Function Move the cursor up, or increase the selected number by 1; switch S mode (turtle speed mode) in the main interface; Move the cursor to the left; switch the P mode in the main Left interface; Move the cursor to the right;...
  • Page 11 Menu structure introduction Menu Description Remark Switch monitor --------------------------------------------------------( operator, administrator ) Monitoring value, cannot be changed SW MONITOR Seat switch Seat switch status Forward gear switch Forward gear switch status Reverse gear switch Reverse gear switch status Foot brake switch Brake pedal status Accelerator pedal...
  • Page 12 Pump motor Current pump motor temperature temperature Pump drive Current pump drive temperature temperature Left drive wheel Current left drive wheel motor motor temperature temperature Left drive wheel Current left drive wheel drive drive temperature temperature Pump control pump control output percentage percentage...
  • Page 13 maximum acceleration High acceleration activation acceleration activation High acceleration error acceleration error Reversing speed limit Fan on temperature *0.1℃ Fan off temperature *0.1℃ Hill-holding time maximum speed ( administrator )P.M. SET 6. Pump set Pump maximum speed Lift acceleration Maximum lift speed Steering idle speed Assist value at idle speed Maximum tilt speed...
  • Page 14 High lift error Low lift error 7. Battery set-------------------------------------------------------------------( administrator ) BDI SET Battery capacity Battery voltage RO，0.01V Reset voltage value option Reset voltage value 0.01V Full voltage value option Full voltage value 0.01V Empty voltage value option Empty voltage value 0.01V Battery drop...
  • Page 15 8. Steering set ( administrator ) STEER SET Speed limit function activated speed limit ratio High analog activation analog activation High analog error Low analog error High analog dead zone analog dead zone Start angle Speed limit angle Potentiometer value 9.
  • Page 16 Parameter save Write the value as 1, save the parameter modification Parameter recovery Write value as 1, restore to default value Instrument 0~100，100 is the maximum brightness brightness adjustment Speed display Change speed to integer or decimal Instrument software version Traction electric control...

  • Page 17: Operating Parts

    3.2 Operating parts the accelerator pedal is depressed, the forklift will not start when the key Steering wheel switch is turned to ON. At this point a fault code will be  displayed, which is perfectly normal. Return the direction lever to the neutral ...
  • Page 18 be on and the instrument panel will Warning display an error which will disappear If the forklift truck must be parked  when the direction lever is pushed into on a ramp, solid wedge blocks must be the neutral position. used to support the wheels.
  • Page 19 Accelerator pedal ×: ON Stepless regulation for the driving speed of the Conta Lightin Front forklift. Head Width signal Slowly depress the accelerator pedal, the drive light light Sign Sign light motor will start running and the forklift will move off. According to the pedaling force on ×...
  • Page 20 It is used for forward and backward tilting of the mast. Push——tilt forward; Fork locating pins are used for adjusting the Pull——tilt backward fork space. Pull up it, turn 180° and shift the The tilting speed is controlled by tilting angle forks to the desired position.
  • Page 21 lower beams and gaps of the fork arm, lift the fork arm slowly, and adjust the position of the forks. Step and handrail for getting on and off the truck The body is provided with a step for getting on and off the truck on both sides;...
  • Page 22 Brake fluid reservoir The hydraulic oil filling port is located on the left side of forklift frame and hydraulic oil can be added by opening the left battery side plate. Brake fluid reservoir is located under the front Replenish with clean hydraulic oil through the chassis.
  • Page 23 Charging port structure and side cover Use your finger to press the button down and then the handle will pop out. Pull the handle to The charging cover assembly is held in place with a magnet, which is easy to open for open the right-side door.

  • Page 24: Lithium Battery Replacement And Installation

    To insert or pull out, press the lock button (6) on the charging gun head. 3.3 Lithium battery replacement and installation The lithium battery sinks at the bottom of the vehicle body, and the side is fastened by a protective rod. Rely on the weight to sit on the frame.
  • Page 25 Turn the adjustment knob located on the right side of the seat to adjust the backrest to the desired angle. Loosen the knob to adjust the backrest. Driver's seat Caution Adjustment of the driver's seat Do not tilt the backrest too ...
  • Page 26 release) by one hand, then the belt can be including anchor points;  Failure of belt buckle or traction device; pulled out by the other hand and inserted into  Loose thread. the socket. If abnormal condition occurs, please change a You may also meet another seat: the belt box is adjustable.
  • Page 27 open the cover at this time. Pedal and handrail for getting on and off the truck There equips with pedals for getting on and off the truck on both side of the truck, and handrail on left leg of overhead guard. Always face the forklift when getting on and off.
  • Page 28 Measures taken special circumstances: – Fasten the seat belt and sit in the seat. – Do not jump out of the forklift. – Lean your body forward, grip the steering wheel with both hands and support your body with both feet.

  • Page 29: Operator Presence Sensing

    4. Operator Presence Sensing OPS (Operator Presence Sensing) system is a safeguard system that installs a sensor in the driver seat to sense if the driver sits on the seat correctly. If the driver does not sit on the seat correctly, driving force is cut off, meanwhile, all loading and unloading operations will be stopped.
  • Page 30 OPS in the startup state. OPS abnormal function handling Park the truck in safe place and contact Hangcha agency to check if any below condition is occurred. a. after the driver leaves the seat, the seat indicator light does not light up;...

  • Page 31: Safety Instructions

    5. Safety instructions During maintenance at height (such – as the mast, front light and back light), Only trained and approved operators can take care to avoid getting trapped and operate the forklift truck. slipping Take care to avoid getting burnt when –...
  • Page 32 trucks are designed for: temperature: control lever before powering on. Maintain stable accurate -20℃ to 50℃; wind speed: no more than – operation; sudden stops and sharp turns 5m/s; relative air humidity: no more than should be avoided. Truck rollover may 90% (temperature: 20℃).
  • Page 33 22. The stacking height of cargo should not 17. Various attachments are provided from exceed that of the load-backrest; if this cannot HANGCHA for the user, such as rotating be avoided, the cargo should be fixed securely. clamps, flat holding clamps, side shift forks, Please drive in reverse or under guidance and booms, which are to be used exclusively.
  • Page 34 possible when stacking for unloading; when Slow down and sound the horn when – the height of cargo is slightly higher or lower passing through crossroads or other than that of the stacking layer, cargo can tilt sections with poor visibility. forward.
  • Page 35 the forklift truck turns or crosses uneven surfaces, the cargo may easily fall off. The possibility of rollover is also increased. 34. Pull up the hand brake when parking on a flat road; if the truck has to be stopped on a 31.
  • Page 36 is generally installed on the rear leg of the safety frame for easy access. The driver and management personnel should be familiar with the position and operation of the fire extinguisher. 38. Use a pallet when handling small objects and do not place them on the forks directly. 39.

  • Page 37: Transportation, Lifting And Towing Of Forklift Trucks

    6. Transportation, lifting and towing of forklift trucks 6.1 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 5t.

  • Page 38: Towing

    6.3 Towing Towing steps 1.Place the driving direction lever in neutral. 2.Turn off the key switch, press the red emergency switch button and unplug the power supply. 3.Release the hand brake handle. 4.Tie the towing wire rope to the tow pin or welding post behind the counterweight to tow the forklift.

  • Page 39: Structure And Stability Of Truck

    7. Structure and stability of truck Prevent the forklift to turn over! It is very important for operator to know the truck’s structure and relationship between load and stability. The structure of Caution the truck The forklift truck essentially consists of the lifting device (forks and mast) and the truck itself (with tires).
  • Page 40 Gravity and Caution stability Forklift stability depends on the common centre of gravity of the forklift. When the forklift is unloaded, the centre of gravity (CoG) remains unchanged. When the forklift is loaded, the centre of gravity is formed by the combined centre of gravity of the forklift and load.
  • Page 41 Speed and Caution acceleration A stationary object will remain stationary unless an external force acts on it. Similarly, in the absence of an external force, a moving object will continue moving at the same speed. This is inertia. Due to inertia, a rearward force is exerted when the forklift starts moving, and a forward force is exerted when the forklift stops moving.

  • Page 42: During Running-In

    8. During running-in New forklifts should run under low load in the initial stage of being put into use. In particular the following requirements should be met within the first 100 hours of operation: Battery over discharge must be prevented during initial use. –...

  • Page 43: Daily Maintenance

    9. Daily maintenance sluggishness or jamming. The correct braking distance at no load is Careful and thorough maintenance keeps the 2.5m. forklift in good working condition. Ensure the Adjust the pedal height: Adjust the brake light forklift safety, that is, ensure your work and switch so that the distance between the middle personal safety.
  • Page 44 The level should be within the scale range dipstick, place an oil container under the frame, between “MAX” and “MIN”, if the level is remove the drain plug, and drain out the old insufficient, please top it up and check whether oil.
  • Page 45 Check the rotation of the rollers. – Check whether there are cracks or – deformation in the mast. Manipulate the lifting, tilting, and – metal handle to check whether the mast works normally and whether there is any abnormal noise. 14.

  • Page 46: Forklift Operations

    10. Forklift operations 10.4 Braking The braking methods include service braking 10.1 Starting and parking braking. Service braking: When it is necessary to slow Release the emergency stop down or stop the forklift, please depress the button and rotate it clockwise, the foot brake.

  • Page 47: Forklift Loading

    10.6 Forklift loading Do not get off or leave the forklift  truck when the load is at a high level. Loading steps. Decelerate forklift, drive 10.7 Forklift unloading close to the cargo pallet and adjust the fork spacing. Unloading steps: Position mast vertically,...

  • Page 48: Storage

    11. Storage and should be strong enough to support the weight of the forklift 11.1 Daily storage truck. Park the forklift at the designated –  Do not use blocks higher than 300 place and use wedge blocks to support mm (11.81 inches) the wheels.

  • Page 49: Lithium Battery

    12.Lithium battery Before installing the battery system, ensure that the low-voltage connectors of the battery system are disconnected from the vehicle 12.1Safety notice components. Pay attention to safety protection when connecting the power high voltage to 1.1 It is strictly forbidden to touch the positive prevent the installer from getting electric shock and negative poles of the battery box with both during the installation process.

  • Page 50: Usage Notice

    The capacity value stated by the manufacturer charge it as soon as possible. that the battery can provide in a fully charged 4.3 Charging instructions, please charge in state under specified conditions. time if the battery system SOC is lower than 3.5 Overdischarge 20%.

  • Page 51: Emergency Plan

    conditions. overheating, high current discharge, etc.). 5.3 Connector maintenance: When the power During charging and using, the abnormal is off, check whether the connectors are loose, conditions that may occur in the power battery damaged or other abnormal conditions. system: battery system local...

  • Page 52: Lithium-Ion Battery Parameters (Catl Standard Configuration)

    12.7 Lithium-ion battery parameters (CATL standard configuration) Item 1.3t-1.8t 2.0t Length (L) Width (W) Height (H) 489.2 Min. weight Rated capacity Rated voltage 77.28 80.5...

  • Page 53: Charging Of Lithium Batteries

    12.8 Charging of lithium batteries This lithium battery forklifts can be equipped with two kinds of chargers: Titan intelligent charger; Titan intelligent charger Operating Instructions of SLC-80200 Intelligent Charger Touch screen display interface Start-up interface Home page Click the icon: , enter the help interface.
  • Page 54 Help interface Click the icon: , return to the main interface. Click the reservation icon to set the time of the appointment mode, and the password is 123456. Click the icon: , enter the password input interface. After the password is entered correctly, it will enter the factory parameter setting interface.
  • Page 55 Password change interface Enter in sequence according to the prompts: the old password of the user, the new password for the first time, and the new password for the second time. Click the icon: , if the old password is entered correctly, and the new password entered for the first time is the same as the new password entered for the second time, the modification is successful;...
  • Page 56 machine hardware and cannot be modified arbitrarily after factory setting. If the above parameters need to be modified, please consult the manufacturer. The charger number is convenient for users to distinguish, and users can set it at will. The debugging interface is for factory debugging, and users cannot operate it at will.
  • Page 57 Charging steps： 1. Select "On" charge control mode. The "CAN" and "485" indicators light green. 2. The DC charging gun is connected to the battery normally. 3. It starts charging when "residual capacity" is less than "allowable charging SOC limit". 4.The "Battery"...
  • Page 58 the battery switch under the condition of output current, except in case of emergency. Operation flow chart Power on self test：Make sure that AC input zero wire and DC output positive and negative electrode wiring are correct, and that there is no short circuit in input and output; The input voltage and frequency are normal;...

  • Page 59: Charging Procedures

    12.9 Charging procedures 1.Stop the truck, turn off the key switch, and the truck is disconnected. 2.Pull the pedals on the four wheels of the charger tray upward, pull the charger to the proper charging position, and depress the four pedals to prevent the charger from moving.
  • Page 60 charging without being fully charged, first press the pause button, wait until the charge current is reduced to 0A, and then press charging gun lock and pull the charging gun out. 8.Insert the charging gun to the charger lay-down position, and pull down the charger main input valve.

  • Page 61: Common Faults And Solutions Of Batteries

    12.10 Common faults and solutions of batteries The voltage is too low after the battery is fully charged 1. The battery has been stored out of use for a long time and has not been maintained in accordance with the regulations. Solution: Just charge the battery. 2.
  • Page 62 b. There is an abnormal odor anywhere in the battery system. c. Any part of the battery system smokes and catches fire. 2. Emergency measures in case of smoke or fire in the battery system during use, if smoke or open fire occurs in the battery system during use, it shall be handled in the following order: a.

  • Page 63: Maintenance

    Inspection and maintenance are often easily overlooked. Early detection enables problems to – be settled in a timely manner. Use original Hangcha Group spare parts. – Do not use different types of oil when changing or topping up oil. –...

  • Page 64: Regular Maintenance Schedule

    13.1 Regular maintenance schedule 〇 — check, correct, adjust ×— replace Lithium battery Every 3 Every 6 Daily Weekly Monthly Item Service required Tool months months (8h) (40h) (166h) (500h) (1000h) Lithium battery installation 〇 〇 〇 〇 〇 fastening Lithium battery charging...
  • Page 65 Controller Every 3 Every 6 Daily Weekly Monthly Annually Item Service required Tool months months (8h) (40h) (166h) (2000h) (500h) (1000h) Check condition of 〇 〇 〇 contacts Check mechanical 〇 〇 〇 movement contactors Check pedal 〇 〇 〇 microswitches functioning properly Check condition of...
  • Page 66 Check tightness of the bolts in the joints 〇 〇 〇 〇 of the vehicle frame Torqu Check tightening torque 〇 〇 〇 〇 〇 〇 wrenc of the hub bolts Wheels (Front, Rear Wheels) Every 3 Every 6 Daily Weekly Monthly Annually...
  • Page 67 Check lubrication of the axle bearing shaft 〇 〇 〇 change lubricating oil Check operation of the 〇 〇 〇 〇 〇 〇 steering cylinder Check steering cylinder 〇 〇 〇 〇 〇 〇 for any leakage Check engagement 〇 〇...
  • Page 68 Braking system Every 3 Every 6 Daily Weekly Monthly Annually Item Service required Tool months months (8h) (40h) (166h) (2000h) (500h) (1000h) Free play Ruler 〇 〇 〇 〇 〇 〇 Pedal stroke 〇 〇 〇 〇 〇 〇 Operation 〇...
  • Page 69 Hydraulic system Every 3 Every 6 Service Daily Weekly Monthly Annually Item Tool months months required (8h) (40h) (166h) (2000h) (500h) (1000h) × Check oil level, × 〇 〇 〇 〇 First change oil Clean oil filter, 〇 〇 replace Clear foreign 〇...
  • Page 70 Lifting system Every 3 Every 6 Daily Weekly Monthly Annually Item Service required Tool months months (8h) (40h) (166h) (2000h) (500h) (1000h) Check chain tension, check 〇 〇 〇 〇 〇 〇 deformation, damage and corrosion Lubricate chain 〇 〇 〇...
  • Page 71 Looseness lift Testing cylinder piston rod Testing hamme 〇 〇 head bolts and plate hammer bolts Cracking damage rollers, 〇 〇 〇 〇 roller shafts welding parts Others Every 3 Every 6 Daily Weekly Monthly Annually Item Service required Tool months months (8h)

  • Page 72: Replace The Key Safe Parts Termly

    13.2 Replace the key safe parts termly Some parts are difficult to find damage or damage through regular maintenance. In order to – fully improve the safety, users should regularly replace the parts according to the following table. If these parts are abnormal before the replacing time, they should be replaced immediately. –...
  • Page 73 Industrial Battery terminal vaseline Automotive general Lubricating purpose lithium-based grease grease Drive axle oil plug ports: Letter “B” refers to the gear oil filling plug port, each gear box oil reservoir is about 0.35L. Figure “2” and “3” oil plug ports are the oil level observation ports, and the oil should be added until it flows out of the No.

  • Page 74: Main Technical Performance Parameter Table

    14. Main technical performance parameter table Item Rated load capacity 1300 1500 1600 1800 2000 Load center distance Lifting height 3000 3000 3000 3000 3000 Free lift height Mast max. tilting angle(F/R) (°) Max. travelling speed km/h 16/16 16/16 16/16 16/16 15/15 （Unladen/Laded）...
  • Page 75 Item Rated load capacity 1300 1500 1600 1800 2000 Load center distance Lifting height 3000 3000 3000 3000 3000 Free lift height Mast max. tilting angle(F/R) (°) Max. travelling speed km/h 16/16 16/16 16/16 16/16 15/15 （Unladen/Laded） Max. lifting speed mm/s 450/600 430/550 450/600...
  • Page 76 Item Rated load capacity 1300 1500 1600 1800 2000 Load center distance Lifting height 3000 3000 3000 3000 3000 Free lift height Mast max. tilting angle(F/R) (°) Max. travelling speed km/h 16/16 16/16 16/16 16/16 15/15 （Unladen/Laded） Max. lifting speed mm/s 450/600 430/550 450/600...
  • Page 77 Item Rated load capacity 1300 1500 1600 1800 2000 Load center distance Lifting height 3000 3000 3000 3000 3000 Free lift height Mast max. tilting angle(F/R) (°) Max. travelling speed km/h 16/16 16/16 16/16 16/16 15/15 （Unladen/Laded） Max. lifting speed mm/s 450/600 450/600...

  • Page 78: Signs/Labels

    15. Signs/labels Warning and guidance signs/labels, e.g. Warning labels, load curves and product nameplates, must be clearly readable and replaced when necessary. WARNING Fasten Seatblet If Truck Tips Over Do Not Jump! Lean Forward Hold Tight Brace Feet Lean Away From Impact 起吊方法...
  • Page 79 Emergency stop label: the position of emergency stop button Hydraulic oil label Engine hood opening label Lithium-ion battery label Tonnage label Brake fluid sign Fuse label Tie-down point label: the tie-down point for towing forklift trucks Counterweight label...

  • Page 80: Bolts Tightening Torque Table

    16. Bolts Tightening Torque Table Unit:N·m Grade Nominal Diameter 4～5 5～7 6～8 9～12 10～12 12～15 14～18 22～29 20～25 25～31 29～39 44～58 35～44 44～54 49～64 76～107 54～69 69～88 83～98 121～162 88～108 108～137 127～157 189～252 118～147 147～186 176～216 260～347 167～206 206～265 245～314 369～492 225～284 284～343...

  • Page 81: The Use, Install And Safety Rules Of Attachment

    17. The use, install and safety rules of attachment HANGCHA will choose attachment that in accordance with International standard ISO2328 Forklift pothook fork and installation size of carriage, such as sideshifters, fork positioner, rotator, push/pull and coil boom ect. sideshifter...
  • Page 82 rotator, it is forbidden to perform two actions at the same time, and only after one action is completed, another action can be performed. Forklifts equipped with attachments are strictly prohibited from driving in a high cargo position; – when the volume of the cargo is too large, it is forbidden to drive the forklift forward; when transporting cargo, ensure that the bottom of the cargo is 300mm off the ground and the mast is tilted backwards.
  • Page 83 18 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: The results meet the requirements of Directive 2006/42/EC of the European Parliament and of the council on the approximation of the laws of the Member States relating to machinery、2000/14/EC of the European Parliament and of the council on the approximation of the laws of the Member States relating to the noise emission in the environment by equipment for use outdoors 、...
  • Page 84 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 85 Maintenance record Date Service content Serviceman...
  • Page 86 杭叉集团股份有限公司 HANGCHA GROUP CO., LTD. 全国客服热线：400-884-7888 ■ 地址：中国浙江省杭州市临安区相府路 666 号 ■ 电话：0571-88926666（总机号）85191117 ■ 传真：0571-85131772 ■ 邮编：311305 ■ 网站：http://www.zjhc.cn ■ 电子邮件：sales@zjhc.cn ■ Address For: OVERSEAS USERS ■ Address: 666 Xiangfu Road, Hangzhou, Zhejiang, China ■ Fax: 0086-571-88926789 0086-571-88132890 ■ ZIP:311305 ■ Web: http://www.hcforklift.com...

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