HANGCHA XC Series Operation And Maintenance Manual Download Page 2

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Foreword

Thank you very much for purchasing lithium battery counterbalanced forklift truck of Hangcha

Group.

Before using the truck, relative persons must read and understand the manual, get to know how to

safely operate and maintain the truck.

XC series four-wheel lithium battery counterbalanced forklift truck is a new product with small

turning radius, attractive design, compact structure, small size, low centre of gravity, good stability

and superior performance.

This manual is about the brief introduction and correct operation of the XC series four-wheel lithium

battery counterbalanced forklift truck, which will tell you how to operate safely and maintain

preventively. Relevant operator and maintainer must read this manual before operation.

Because of the update and improvements of our products, there may be some differences between

this operation manual contents and your forklift truck.

Please contact the sales company or agent of Hangcha Group in case of anything unclear.

This series of forklifts have passed CE certification.

Model

Traction

motor

controller

Pump motor

controller

Traction motor

Pump motor

Rated capacity (t) / Load

center (mm)

CPD15-XD4-SI16

ACS80M-

330C-35P

ACS80M-

330C-35P

XIPD150-130000-

000

XIPD150-621000-

G00

1.5/ 500

CPD18-XD4-SI16

1.8/ 500

CPD20-XD4-SI21

ACS80M-

330C-35P

ACS80M-

330C-23P

AIP252-130000-

000

XIPD352-621000-

000

2.0/ 500

CPD25-XD4-SI21

2.5 / 500

CPD30-XD4-SI21

ACS80L-

440C-35P

ACS80M-

330C-23P

3.0 / 500

CPD35-XD4-SI21

3.5 / 500

CPD20-XD4-SI25

ACS80L-

440C-35P

ACS80M-

330C-35P

JP308-130000-

000

JP452-622000-

G01

2.0/500

CPD20-XD4-SI26

XIPD351-130000-

000

CPD25-XD4-SI25

ACS80L-

440C-35P

ACS80M-

330C-35P

JP308-130000-

000

JP452-622000-

G01

2.5/500

CPD25-XD4-SI26

XIPD351-130000-

000

CPD30-XD4-SI25

ACS80XL-

550C-35P

ACS80L-

440C-35P

JP308-130000-

000

JP452-622000-

G01

3.0/500

CPD30-XD4-SI26

XIPD351-130000-

000

CPD35-XD4-SI25

ACS80XL-

550C-35P

ACS80L-

440C-35P

JP308-130000-

000

JP452-622000-

G01

3.5 /500

CPD35-XD4-SI26

XIPD351-130000-

000

CPD40-XD4-SI28

ACS80XL-

550C-35P

ACS80XL-

550C-35P

XIPD500-130000-

000

XIPD500-

621000-000

4.0 /500

CPD45-XD4-SI28

4.5/500

CPD50-XXD4-SI28

4.99/500

CPD50-XD4-SI28

5.0 /600

Summary of Contents for XC Series

Page 1: ...0 35 XD4 SI21 CPD20 25 30 35 XD4 SI25 CPD20 25 30 35 XD4 SI26 CPD40 45 50 XD4 SI28 CPD50 XXD4 SI28 CPD15 18 XD6 SI16 CPD20 25 30 35 XD6 SI21 CPD20 25 30 35 XD6 SI26 CPD40 45 50 XD6 SI28 CPD50 XXD6 SI2...

Page 2: ...of anything unclear This series of forklifts have passed CE certification Model Traction motor controller Pump motor controller Traction motor Pump motor Rated capacity t Load center mm CPD15 XD4 SI1...

Page 3: ...D35 XD6 SI26 3 5 500 CPD40 XD6 SI28 ACS80L60 C35T ACS80L50 C35T XIPD500 130000 000 XIPD500 621000 000 4 0 500 CPD45 XD6 SI28 4 5 500 CPD50 XXD6 SI28 4 99 500 CPD50 XD6 SI28 5 0 600 Warning In order to...

Page 4: ...NG LABEL 37 1 12 STRUCTURE AND STABILITY OF TRUCK 39 2 SAFETY INSTRUCTIONS 43 3 OPERATION AND SAFETY PRECAUTIONS FOR THE ELECTRIC FORKLIFT LITHIUM BATTERY 50 4 TRUCK LIFTING CARRYING AND TOWING 53 4 1...

Page 5: ...TALL AND SAFETY RULES OF ATTACHMENT 85 7 1 ATTACHMENT INSTALL 85 7 2 ATTACHMENT USE 85 7 3 ATTACHMENT CHECK AND MAINTENANCE 86 8 RELATED SAFETY INSTRUCTION AND STANDARD FOR TRUCKS EXPORTING TO EUROPE...

Page 6: ...ol system Ergonomic large operating space Hydraulic system Adopted high power oil pump motor and working oil pump greatly improves the lifting speed Electrical system 80V battery pack provides super p...

Page 7: ...e road with good vision and equipment use license Approved working site temperature is 5 40 Altitude should not over 2000m Max gradability when driving with full load is 18 It is prohibited to travel...

Page 8: ...r mast 4 Outer mast 5 Steering wheel 6 Overhead guard 7 Counterweight 8 Seat 9 Rear wheel steering wheel 10 Frame 11 Hood 12 Tilting cylinder 13 Front wheel drive wheel 14 Lithium battery side door 15...

Page 9: ...n light switch 4 Key switch 5 Lift lever 6 Tilt lever 7 Cup holder 8 Emergency stop button 9 Rocker switch 10 Accelerator pedal 11 Brake pedal 12 Hand brake handle 13 Steering wheel adjustment switch...

Page 10: ...n button 2 Press the horn button in the center of the steering wheel and the horn will sound Combination lights 3 The combination lights include turn signal lights and light switch Turn signal Push or...

Page 11: ...is depressed the forklift will not start when the key 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 position...

Page 12: ...ency stop button 8 Turn the power on or off In case of emergency press the red mushroom button to cut off the main power of the vehicle No walking turning lifting Caution Do not use the emergency stop...

Page 13: ...al the fault will disappear Brake pedal 11 Depressing the brake pedal will slow down or stop the forklift Release the pedal and the vehicle runs Caution Avoid sudden braking Sudden braking can easily...

Page 14: ...ward N Neutral R Reverse Before changing the direction of travel depress the brake pedal to bring the vehicle to a complete stop then shift the handle forward to a forward gear If you need to go backw...

Page 15: ...els back Caution If press the direction switch to opposite direction during truck running the electric braking works to decelerate the forklift After stop the truck moves to another direction If the d...

Page 16: ...relative to the mast Attachment switch Apply when installing the attachment with the fourth valve Push and pull this switch can realise the attachment function Horn button Press this button when a rem...

Page 17: ...12 Adjust armrest height Turn upward release the armrest and vertically move it to proper position turn downward lock the armrest...

Page 18: ...13 1 5 Display meter 1 5 1 Multifunction display screen Located in the top right corner of the overhead guard...

Page 19: ...battery level is lower than or equal to 20 F Menu M Neutral light Lights up when the vehicle is in neutral G The number shows the current cumulative working time of the vehicle and the 5 digit displa...

Page 20: ...ction key 3 Function key 4 Function key 5 Combination key Icon Name Function Up In the main interface press the up and down at the same time to view the instrument information including the instrument...

Page 21: ...p switch status 14 Attachment switch Attachment switch status 2 Operate monitor operator administrator Monitoring value cannot be changed OPERATE MONITOR 1 Start up working time Key switch on timing 2...

Page 22: ...urrent effective value of traction motor phase current Arms 2 Pump motor phase current Current effective value of pump motor phase current Arms 3 Left drive wheel phase current Current effective value...

Page 23: ...imit 15 Fan on temperature 0 1 16 Fan off temperature 0 1 17 Hill holding time ms 18 SPE maximum speed RPM 6 Pump set administrator P M SET 1 Pump maximum speed RPM 2 Lift acceleration 3 Maximum lift...

Page 24: ...set administrator BDI SET 1 Battery capacity 2 Battery voltage RO 0 01V 3 Reset voltage value option 4 Reset voltage value 0 01V 5 Full voltage value option 6 Full voltage value 0 01V 7 Empty voltage...

Page 25: ...reaches the value the instrument sounds an alarm the traction speed is halved and the oil pump is prohibited from lifting 8 Steering set administrator STEER SET 1 Speed limit function activated 2 spee...

Page 26: ...ered twice 2 Set administrator password Administrator level password setting 3 Language settings Chinese and English language selection 4 Parameter save Write the value as 1 save the parameter modific...

Page 27: ...22 11 Steering electric control software version 12 SIM card information Display the ICCID number of the SIM card 13 Unit switching Switch between speed unit km h and MPH...

Page 28: ...ode P mode power mode is used for long distance transport situations that require greater power or speed E mode economic mode all parameters are optimized power saving suitable for long term work on a...

Page 29: ...charge the lithium battery as soon as possible Seat switch indicator J This lamp illuminates whenever the driver leaves the seat indicating that the seat switch is OFF At this time the vehicle cannot...

Page 30: ...evious interface Press to view running monitoring The picture shows the monitoring content check the working condition of the forklift and 0 displayed in total voltage too high total voltage serious u...

Page 31: ...g port a Press the latch to open the side door b The lithium battery charging port is visible and the charging port is covered with a cover Open the cover to see the charging port Lithium battery char...

Page 32: ...um 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 For the removal...

Page 33: ...he forklift without the load bracket It is forbidden to disassemble and modify the load bracket Seat 1 Weight adjustment lever 2 Forward and rearward adjustment lever 3 Backrest angle adjustment lever...

Page 34: ...ot be familiar with it One kind of seat it needs to press the white circular button with the words press to release by one hand then the belt can be pulled out by the other hand and inserted into the...

Page 35: ...onents To avoid opening the hood arbitrarily a lock assembly is set here To open the hood you must first pull the handle of the lock assembly And then the cover is released Air spring When opening the...

Page 36: ...machine centerline and fork stoppers should always be locked The lower beams of the fork carriage have an opening section to load or unload forks Do not set the forks over the opening Check the bolt a...

Page 37: ...or s need the tilting angle of steering column is adjustable Pull the lever upward the steering column is released push downward and locked Brake fluid reservoir The brake oil cup is installed in the...

Page 38: ...little to make sure the fork locating pin get in the slot of fork carriage Fork distance is adjusted Caution Fork locating pin must be locked keep in the slot of fork carriage otherwise forks are eas...

Page 39: ...hen back the truck Fork assemble Place forks on the ground against the truck lower the fork carriage to the lowest drive the truck forward slowly aim at the upper and lower slot of fork and the upper...

Page 40: ...n the driver leaves the seat or the safety belt is released if equip with safety belt protection switch over 1 second working stops automatically and the instrument displayed seat indicator light ligh...

Page 41: ...OPS will cut off the drive power and make the truck slip In order to avoid this accident the driver must sit correctly when operating on the uphill Fork locking function after power off This function...

Page 42: ...h symbol No Description 1 Product nameplate located on the upper left of the instrument stand 2 Warning labels Measures to be taken when the forklift rolls over 3 Danger label It is strictly forbidden...

Page 43: ...er 11 Fuse label Only use the specified fuse 12 Hydraulic oil filler port 13 Load curve label 14 Manufacturer s logo 15 Tie down point label Tie down point when dragging 16 Tire pressure label optiona...

Page 44: ...The relationship between the forklift s centre of gravity and the load s centre of gravity is very important to maintaining the operation of the forklift Caution Load center The forklift handles loads...

Page 45: ...decreases Caution Gravity and 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 f...

Page 46: ...d If the combined CoG moves out of the stability triangle the forklift will tip over in the direction that the combined CoG has moved Caution the load capability chart This graph shows the relationshi...

Page 47: ...braking is dangerous because it generates a large forward force that will cause the forklift to tip over or the load to slide off When the forklift turns a corner a centrifugal force is exerted outwar...

Page 48: ...battery when checking it Pay attention to safety in case of high level maintenance such as mast front and rear lights etc to prevent pinching or slipping Be careful do not be scalded when inspecting...

Page 49: ...est 9 Never attempt to work the controls unless property seated Before starting the vehicle adjust the seat position to facilitate hand and foot control 10 Before starting up make sure that The seat b...

Page 50: ...on work 15 Keep your head hands arms feet and legs in the cab and do not extend them for any reason 16 Pallets and skids should be strong enough to bear the weight of the load Never use damaged or def...

Page 51: ...when driving around corners or along narrow aisles and be aware of other people 23 Try to reduce the front tilting angle when stacking goods you can only tilt forward when the goods are higher than t...

Page 52: ...n operating a loaded forklift reverse downhill and climb forward When operating an unloaded forklift reverse uphill and go downhill Do not turn on ramps to avoid tipping over 30 Goods are not allowed...

Page 53: ...dable be sure to block the wheels Lower the forks to the floor and tilt slightly forward Turn off the key switch and remove the key Disconnect the battery plug Park the forklift away from naked flames...

Page 54: ...refrigerator when power off 40 Maintain 3 point contact with the vehicle when getting on and off When getting on and off the vehicle always keep one hand and both feet in contact with the vehicle or...

Page 55: ...a normal phenomenon and the performance will recover when the ambient temperature rises 8 Unauthorized modification or dissection of the battery system and battery box is prohibited to avoid danger No...

Page 56: ...If smoke or fire occurs stop the vehicle turn off the power supply and use a water based fire extinguisher to put out the fire under the condition of ensuring the safety of personnel 18 Charge in a we...

Page 57: ...arging voltage charging current charging time and charging failure information 7 The charger will automatically stop charging after fully charged output voltage and output current on the meter is 0 pr...

Page 58: ...al parts are exposed to the outside to avoid short circuits The diagnostic port is free of dust and wrapped or covered 4 Truck lifting carrying and towing 4 1 Lifting Securely fasten wire ropes to the...

Page 59: ...d Fully tilt the mast backward when lifting When assembling lifting tool notice that the lifting tool will not touch forklift part or overhead guard when lifting Do not lift a forklift by its cab fram...

Page 60: ...needs to be transported over a long distance should be transported in a ship train or a truck having a load capacity over 5T Steps Park the forklift on the lorry or trailer and apply the parking brake...

Page 61: ...ng pin 13 in the lower counterweight is only used for the following occasions Forklift malfunctions on the working road and move the truck urgently Use when forklift gets into trouble and cannot drive...

Page 62: ...ensure that the low voltage connectors of the battery system are disconnected from the vehicle components Pay attention to safety protection when connecting the power high voltage to prevent the inst...

Page 63: ...regarded as the battery entering an overcharged state 3 7 Explosion The battery case is ruptured and solid matter inside is rushing out of the battery making a sound 3 8 Fire An open flame emerges fro...

Page 64: ...er abnormal conditions 5 3 Connector maintenance When the power is off check whether the connectors are loose damaged or other abnormal conditions 5 4 Status detection Observe the battery system volta...

Page 65: ...20 160 432 Allowable heaviest kg 380 380 175 Warning The weight and dimension of the battery have a great impact on the stability and carrying capacity of the vehicle s operation When installing or re...

Page 66: ...um battery forklifts can be equipped with two kinds of chargers 1 Titan intelligent charger 2 Shineng charger 5 8 1 Titan intelligent charger Operating Instructions of SLC 80200 Intelligent Charger To...

Page 67: ...ired for control operations and the default password is 123456 Click the power on icon switch the charging control to on or off Click the purple part of the charging status information bar to enter th...

Page 68: ...de 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 Password input interface E...

Page 69: ...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 corre...

Page 70: ...nge are related to the 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 conve...

Page 71: ...ors 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 indicator lights up in gr...

Page 72: ...t is the Yida plug and the output is the charging gun Warning PE protection earth must be connected otherwise it may threaten the safety of life Instructions 1 Precautions a Before the charger is turn...

Page 73: ...lines cannot be connected at the same time Power on Check whether the AC fan wind direction is correct after the power is on The touch screen can be turned on normally communication with the charging...

Page 74: ...p button Display screen 3 Remove the charging gun press the button lock before pulling it out Check the charging gun make sure no water or debris on each port or metal terminal damaged or influenced b...

Page 75: ...will automatically stop charging after fully charged output voltage and output current on the meter is 0 press the pause button and then press charging gun lock and pull the charging gun out If it nee...

Page 76: ...ection voltage 2 2V Overcharge release voltage 3 67V Overtemperature protection temperature 60 Undervoltage release voltage 2 8V Overdischarge release voltage 2 6V 3 In the process of using the batter...

Page 77: ...bove 10 before operating the vehicle 6 Do not disassemble the battery box under any circumstances 7 It is forbidden to fall and it is strictly forbidden to knock the battery pack etc 8 It is forbidden...

Page 78: ...Disassemble the battery check whether the circuit is broken check whether the solder joints are falling off and repair the damaged area according to the situation 2 The protective plate does not work...

Page 79: ...es 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 Park a...

Page 80: ...esting lights and checking operating performance before checking the electrical system turn off the key switch and disconnect the battery plug Before operating the vehicle the operator should be famil...

Page 81: ...Check the steering system function Check if the brake pedal functions properly Check the accelerator pedal Depress the accelerator pedal change with the stroke the acceleration is strong and weak and...

Page 82: ...compressor is higher than the specified pressure of tire otherwise it may cause severe accidents Tire pressure adopts new standard GB T2982 2001 Model Front wheel Rear wheel 1 5t 1 8t 0 79 MPa 1 0 MPa...

Page 83: ...sting screw on the rod tip Twist clockwise to increase the operating force twist anti clockwise to reduce it Ensure that the hand brake handle is tightened and then loosened to return to the original...

Page 84: ...heck mast and fork Forks are not cracked or bent and that they are firmly and correctly installed in the fork carriage Check the oil cylinder and pipeline for leakage Check that the rollers turn condi...

Page 85: ...ou find anything weird or wrong Report problems to your supervisor You can obtain the Table of Periodic Maintenance and Lubrication Cycles from the dealer If it is used properly the checklist can remi...

Page 86: ...e driven and lifted during this time If the direction switch or accelerator pedal or lift switch etc is operated during this period a fault code will appear in the screen and the fault indicator will...

Page 87: ...rking Decelerate then depress the brake pedal until the vehicle stops Get the shift lever in neutral Apply the hand brake Lower the forks to the floor and tilt the mast all the way forward Turn the ke...

Page 88: ...rming that the fork tip has left the cargo lower the fork to a position 15cm 20cm above the ground The mast is tilted back into place Caution Slow down the forklift in the following situations When tu...

Page 89: ...Check before parking Stop the vehicle Fully lower the mast Set the direction switch to zero or neutral Apply the handbrake Turn off the power with the key switch press the emergency stop switch to cut...

Page 90: ...along the forklift frame during use After the attachment is mounted the upper hook stopper should be embedded in the gap of the upper beam so that the offset between the centerline of the attachment...

Page 91: ...external force when the attachment is working it is forbidden to use the attachment for improper occasions and it must not exceed the normal working range of the attachment It is forbidden to use the...

Page 92: ...1 2010 EN13059 2002 A1 2008 and their harmonious standards Main safety factor will be according with DIRECTIVE 2006 42 EC OF THE EUROPEAN PAMENT AND OF THE COUNCIL and EN ISO 3691 1 2015 ISO TS 3691 7...

Page 93: ...g General Manager We declare that the machinery Wir erkl ren hiermit dass die Maschine product name Electric Forklift Truck Produktbezeichnung commercial name Handelsbezeichnung function Funktion mode...

Page 94: ...89 Maintenance record Date Service content Serviceman...

Page 95: ...7 0571 85131772 311305 http www zjhc cn sales zjhc cn Address For OVERSEAS USERS Address 666 Xiangfu Road Lin an Economic Development Zone Zhejiang China Fax 0086 571 88926789 0086 571 88132890 ZIP 31...

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HANGCHA XC Series, Operation And Maintenance Manual

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