HANGCHA XE Series User manual

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.

08/2023
Preface
Thank you for purchasing this XE series four-wheel lithium-ion battery forklift truck manufactured by
HANGCHA GROUP CO., LTD.
Please read this manual thoroughly to understand how to use and maintain the forklift truck safely.
The XE series lithium-ion battery forklift trucks are cost effective products developed based on
HANGCHA's "lithium-ion battery dedicated architecture" and "permanent magnet synchronous
technology". While continuing the lithium-ion battery forklift family design style, proven internal
combustion vehicle parts are adopted. The overall vehicle performance, ergonomics, reliability,
maintenance, outdoor operation capability, load capacity, etc. are optimized to meet customers' usage
scenarios for internal combustion forklift trucks. New high-performance models have been added to meet
the usage needs of different users under heavy load conditions.
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.
Relevant operators and maintenance personnel must read this manual thoroughly before using it.
Due to the constant updating and improvement of our products, the functions of your forklift may be
slightly different from the instructions in this manual.
For any queries, please contact the sales company or agent of HANGCHA GROUP CO., LTD.
○CAugust 2023, HANGCHA GROUP CO., LTD.

Contents
1. FORKLIFT TRUCK INTRODUCTION .......................................................................................... 1
1.1 OVERVIEW ..................................................................................................................................... 1
1.2 APPLICATION ENVIRONMENTS AND CONDITIONS .............................................................................. 3
1.3 DISPLAY AND CONTROLS ................................................................................................................ 4
1.4 OTHER PARTS .............................................................................................................................. 16
1.5 OPS SYSTEM ...............................................................................................................................19
1.6 NAMEPLATE AND MARKS .............................................................................................................. 21
1.7 FORKLIFT TRUCK STRUCTURE AND STABILITY ................................................................................23
2. OPERATIONS ............................................................................................................................. 27
2.1 BREAKING-IN OF A NEW TRUCK .....................................................................................................27
2.2 DAILY CHECKS AND ADJUSTMENTS .............................................................................................. 27
2.3 ADJUSTMENT AND REPLACEMENT OF THE FORKS ..........................................................................28
2.4 STARTING THE TRUCK .................................................................................................................. 29
2.5 DRIVING .......................................................................................................................................30
2.6 STEERING .................................................................................................................................... 31
2.7 BRAKING ......................................................................................................................................31
2.8 EMERGENCY STOP ....................................................................................................................... 31
2.9 LOADING,STACKING AND UNSTACKING ......................................................................................... 32
2.10 PARKING RULES ......................................................................................................................... 33
2.11 CHECKS AFTER OPERATION ........................................................................................................34
2.12 PARKING AND STORAGE ............................................................................................................. 34
3. LIFTING, TRANSPORTATION AND TOWING ..........................................................................37
3.1 LIFTING ...................................................................................................................................... 37
3.2 TRANSPORTATION ........................................................................................................................ 38
3.3 TOWING ....................................................................................................................................... 39
4. SAFETY RULES ..........................................................................................................................40
4.1 SAFETY RULES FOR DRIVING THE TRUCK ...................................................................................... 40
4.2 RULES FOR MAINTENANCE AND REPAIR ........................................................................................ 45

4.3 SAFETY RULES FOR ATTACHMENTS AND PALLETS ......................................................................... 46
4.4 SAFETY RULES FOR PARKING AND STORAGE .................................................................................46
5. LITHIUM-ION BATTERY .............................................................................................................46
5.1 INSTRUCTIONS FORSAFETY ...........................................................................................................46
5.2 INSTRUCTIONS FOR INSTALLATION ................................................................................................ 47
5.3 COMMON TERMS FOR LITHIUM-ION POWER BATTERIES .................................................................. 48
5.4 INSTRUCTIONS FOR USE ............................................................................................................... 48
5.5 EMERGENCY PLAN ........................................................................................................................51
5.6 SIZE/WEIGHT ............................................................................................................................... 52
5.7. CHARGING THE LITHIUM-ION BATTERY ......................................................................................... 54
5.8 CHARGING STEPS .........................................................................................................................59
6 REPAIR AND MAINTENANCE ....................................................................................................60
6.1 DAILY MAINTENANCE (EIGHT HOURS) ............................................................................................ 60
6.2 WEEKLY MAINTENANCE (40 HOURS) ............................................................................................. 62
6.3 EVERY ONE AND A HALF MONTH MAINTENANCE (250 HOURS) ....................................................... 64
6.4 EVERY THREE MONTH MAINTENANCE (500 HOURS) .......................................................................65
6.5 SEMI-ANNUAL MAINTENANCE (1000 HOURS) ................................................................................. 65
6.6 ANNUAL MAINTENANCE (2,000 HOURS) ........................................................................................ 66
6.7 OTHERS .......................................................................................................................................67
6.8 CHECKS AND MAINTENANCE OF THE CONTROL SYSTEM ASSEMBLIES .............................................71
7. USE, INSTALLATION AND SAFETY RULES FOR ATTACHMENTS ..................................... 72
7.1 INSTALLATION OF ATTACHMENTS .................................................................................................. 72
7.2 USE OF ATTACHMENTS .................................................................................................................73
7.3 CHECKS AND MAINTENANCE OF THE ATTACHMENTS ...................................................................... 74
8.RELEVANT SAFETY DIRECTIVES AND STANDARDS (CE MODELS) ..................................75

1
1. Forklift truck introduction
1.1 Overview
Features
1. The overall vehicle continues the XC series style with a unified design
2. The reinforced drive axle and reduction gearbox match the internal combustion vehicle mast,
steering axle, and tires.
3. The smart dashboard has a graphical interface that is simple and intuitive. It has three speed
mode options to suit different work environments.
4. Safety, comfort, and reliability have been comprehensively improved, with the overall vehicle
performance significantly higher than the original models.
5. The high-torque permanent magnet synchronous motor and high-ratio reduction gearbox
significantly improve driving speed, climbing gradient, and lifting speed.
6. The traction and lifting motors have built-in air cooling for better heat dissipation and better
overall performance. A gear reducer is introduced for the oil pump for the first time, making the
lifting motor more efficient.
7. The 80 V double permanent magnet synchronous motor system has higher power density.
Through in-depth matching of the reduction gearbox, motor, and motor controller, energy

2
consumption is reduced by 15-20% under the same conditions compared to traditional asynchronous
motor models.
8. The low center of gravity provides more stable operation.
Appearance and main parts
No.
Name
No.
Name
1
Mast
7
Rearview mirror
13

3
2
Steering wheel
8
Overhead guard
3
Load backrest
9
Driver's seat
4
Fork
10
Counterweight
5
Drive axle
11
Tow pin
6
Hood
12
Steering axle
13
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. Do not use the forklift truck
for any other purposes not mentioned in this manual as it may cause personal injury or even death, or
cause damage to the forklift truck and other property.
The forklift truck is only suitable for the specific following environments and conditions:
–The forklift truck should be used within the specified rated load.
–The forklift truck is only to be used in specific areas such as factory plants, tourist
attractions and amusement parks, etc.
–The forklift truck can be used on a flat surface indoors with sufficient load bearing capacity.
–The forklift truck can be used on driving roads with a good field of vision and the
permission of the operator.
–The forklift truck can be used at ambient temperatures of -20℃to +40℃.
–The forklift truck can be used at an altitude of ≤ 2,000 m.
–Do not drive laterally or diagonally when going uphill. When carrying cargo uphill, keep the
cargo ahead; when carrying cargo downhill, keep the operator ahead.
Please make sure to read the safety rules in this manual, which have an important impact on your
personal safety and the safety of the people and cargo on the premises.
Warning
Do not carry people.

4
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.
1.3 Display and controls
1. Steering wheel
5. Steering column
adjustment switch
9. Lift control lever
13. Multi-functional display
screen
2. Horn button
6. Ignition key switch
10. Tilt lever
14. Emergency stop switch
3. Direction lever
7. Brake pedal
11. Side shift control lever
15. Rocker switch
4. Hand brake
8. Combination light switch
12. Cup holder
16. Accelerator pedal

5
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
of the forklift truck will turn left, and the forklift truck will
turn right as it moves forward.
When the steering wheel is rotated counterclockwise,
the tail of the forklift truck will turn right, and the forklift
truck will turn left as it moves forward.
Caution
The forklift truck is equipped with a hydraulic steering mechanism. When the oil pump motor
shuts down or the oil pipeline fails, the truck cannot be steered.
The rear wheels of the forklift truck are used for steering. When steering, the user must ensure that
there are no pedestrians or barriers in the rear swing area.
[Horn button 2]
The horn button is used to warn nearby pedestrians and is located in the center of the steering wheel. The user can
sound the horn by pressing the edge of the horn button with his or her finger or pressing the center of the horn
button with his or her palm.
Direction lever [3]
The direction control lever is used to change the driving direction of the forklift
truck and is located on the left side of the steering hub column. Its operation
method is as follows:
Moving forward: When the forklift truck is stationary, the user
moves the direction control lever forward to the "F" position and
presses the accelerator pedal to make the forklift truck move forward.
Moving backward: When the forklift truck is stationary, the user
moves the direction control lever back to the "R" position, the
reversing buzzer will sound, and the user then presses the accelerator pedal to make the forklift truck
move backward.
Parking: When the forklift truck is stationary for a long time, the user moves the direction control lever to the "N"
position, and engages the parking brake to park.
Caution
The forklift truck can only be started when the direction control lever is in the "N" position.
The lever can only be shifted when the forklift truck is stationary.

6
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
the "N" position, and the user pulls the parking brake to the "locked"
position as shown in the figure, and the parking brake will be
automatically locked for parking.
Releasing the parking brake: The user keeps the parking brake button pressed, first pulls
the parking brake back forcibly, and then pushes it forward to the "release" position as shown in
the figure to complete the release of the parking brake.
Caution
Engage the parking brake before leaving
the forklift truck.
In the event of braking system failure or an
emergency, the parking brake can be engaged for
emergency braking.
Do not use the parking brake for service braking.
Steering column adjustment switch [5]
The steering column adjustment switch is used to adjust the front and rear positions of the steering wheel
and is located below the left side of the steering column.
Operating steps:
The forklift truck is in the parking state.
The user grips the steering wheel in his or her
right hand.
The user rotates the adjustment switch up by
90° with his or her left hand, at which point the
steering column is released and can be adjusted
forward and backward.
The user should adjust the position of the steering wheel, keep the right hand still, and turn
the adjustment switch down by 90° with the left hand to lock it.
The user should firmly pull the steering wheel backward and forward to ensure that the
steering column is locked tightly.
The adjustments of direction and position are completed.
Ignition key switch [6]
The ignition key switch is used to start or turn off the electrical
system of the forklift truck and is located on the right side of the

7
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
is pressed down when the key switch is turned to the "ON" position.
In this instance, there will be a fault code.
The user should restore the direction lever to the neutral position and move their foot
away from the accelerator pedal to start the truck. At this time, the fault code will disappear.
Brake pedal [7]
The brake pedal is used for braking control when driving the forklift
truck.
Caution
Emergency braking can easily cause the truck to tilt or cargo to fall,
resulting in accidents.
Combination light switch [8]
The combination light switch is used to control headlights and indicator
lights. It is located to the right of the steering column.
Operation of the indicator light:
Push
forwar
Left turn signal light
flashing
Neutral
Off
Toggle
backwa
Right turn signal light
flashing
Operation of the headlight: “√” means the switch is on.
Loca
tion
Lightin
g
Front
signal
Head
light
Width
light
√
√
√
√

8
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.
Lowering: Push the control lever forward.
Tilt lever [10]
This lever is used to tilt the mast forward and backward. It is located to
the right of the lift control lever. The speed is controlled by the angle of
the lever.
Operating steps:
Tilt forward: Push the control lever forward.
Tilt backward: Pull the control lever backward.
Caution
The multi-way valve is equipped with a forward tilt self-locking valve. Therefore when the power is off,
the mast cannot tilt forward even if the tilt lever is pushed forward.
Side shift control lever [11] (as required by attachments)
This side shift control lever is used to move the side shift frame to the left
or right. It is located to the right of the tilt lever. The speed is controlled by
the angle of the lever.
Operating steps:
Move left: Push the control lever forward.
Move right: Pull the control lever backward.
Attachment control lever (as required by attachments)
The attachment control lever refers to side shift control lever, turning control lever or other attachment
control levers, depending on the specific attachments fitted.
Cup holder [12]
A cup holder is located on the right side of the center console for holding the operator's cup.

9
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. Release the accelerator pedal to slow down the forklift
truck until it stops.

10
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. At the same time, users can change the
driver parameters through the dashboard to meet individual customization needs.
2、Main interface display
A. Running mode
H. Steering angle
B. Running hours
I. Battery level
C. Odometers
J. Safety belt
D. Low battery display
K. Driver's seat switch
E. Fault indicator light
L. Neutral indicator light
F. Working device
restriction
M. Parking indicator light
G. Speed display
N. Slow mode
Running mode [A]
There are four running modes, respectively: Mode S, mode P, and mode E (slow mode).
Mode S refers to the fast mode. In this mode, the forklift truck's acceleration, maximum
gradeability and other values are high, and the forklift truck is suitable for carrying a large
amount of cargo in a short time and climbing a slope. The power consumption of the forklift truck is highest in this
mode.
Mode P refers to the normal mode. In this mode, all indexes are slightly lower than the fast
mode, and the forklift truck is suitable for normal operating environments. This is the default
mode.
Mode E refers to the slow mode. In this mode, the maximum speed is limited, and the forklift
truck is suitable for working in crowded warehouses and narrow spaces.
Running hours [B]
When the key switch is turned on, the forklift truck running time starts counting. When the
key switch is turned off, the forklift truck running time stops counting.

11
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. After the fault is
cleared, this indicator light goes off.
Working device restriction indicator light [F]
When only 10% battery capacity remains, this icon will light up; at the same time, the lifting speed of
mast will be reduced, prompting the user to charge the battery immediately.
Vehicle speed [G]
Range is 0-30 km/h, displayed to 1 decimal place.
Steering angle [H]
Display the vehicle's left/right steering angle, unit: °
Battery level [I]
Display remaining battery capacity with a display range of 0-100% and accuracy of 1%.
It is recommended that the battery should be charged when only 30% capacity remains, otherwise its service life
will be greatly shortened.
Caution
It is important to charge the battery
on time, otherwise the battery life will
be shortened!
Safety belt [J]
Fasten the safety belt. If the safety belt is not fastened properly, the safety belt alarm indicator light
will turn on.
Driver's seat switch [K]
When the driver leaves the seat, this icon will light up. It indicates that the seat switch is turned off,
and the truck cannot move or lift. This function applies to driver’s seats fitted with a switch.
Neutral indicator light [L]
When the gear position is in neutral, the indicator light will light up.

12
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
（1）Press button 1 on the main interface to view fault information. Press
button 1 and button 2 to page up/down to view multiple fault messages.
Press button 4 to return to the main interface.
（2）Press button 2 on the main interface to switch between the three
running modes: Speed mode S, Normal mode P, and Slow mode E. The
mode indicator icon will change accordingly.
（3）Press button 3 on the main interface to view monitoring
information. Press button 1 and button 2 to page up/down to view

13
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.
（4）Press button 4 on the main interface to enter the setting page. Press
button 1 and button 2 to switch between different sub-page options.
Press button 3 to enter the selected sub-page, and press button 4 again
to return to the main interface.
6、Advanced setting page
Entering the advanced setting page requires inputting a four-digit password
first. The password input method is as follows: Use button 1
to move the cursor to the digit to be modified, use button 2 to change the
value, after all four digits are entered press button 3 to confirm.
If the password is correct, the advanced settings interface can be entered.
(1). Parameter settings interface
The parameter settings interface has 6 pages in total. 3 pages for traction
controller parameter settings, with 13 setup items. Among them, auxiliary
traction 1, auxiliary traction 2,
auxiliary traction 3 are reserved items with no function. There are 3 pages
for oil pump controller parameter settings, with 12 setup items.
Among them, auxiliary oil pump 1, auxiliary oil pump 2, auxiliary oil pump 3
are reserved items with no function.

14
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. Press button 1 to move
the cursor to the digit to be modified,
and press button 2 to change the value;
The third press of button 3 confirms the modified value, completing the
parameter modification. The interface automatically jumps back to the
previous step; press button 4 to cancel and return to the previous interface.
(2). Initialization settings interface
Press button 1 and button 2 to select the working hours and mileage
options;
Press button 3 to confirm, and the interface will automatically jump and
prompt to reset;
Press button 3 again to confirm, and the interface will automatically jump
back to the previous interface, and the stored hours/mileage data is reset;
Press button 4 to cancel and return to the previous interface.

15
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. After confirmation it will prompt "Password changed
successfully".
7、Options page
(1). Language settings
Press button 1 and button 2 to select between Chinese/English; press button 3 to
confirm, and the interface will automatically jump back and the language will
change accordingly; press button 4 to cancel and return to the previous interface.
(2). Unit settings
Press button 1 and button 2 to select between Imperial/Metric; press button 3
to confirm, and the interface will
automatically jump back and the main interface units will change accordingly;
press button 4 to cancel and return to the previous interface.

16
(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.
1.4 Other parts
Adjust the driver's seat before starting the truck to ensure that the driver can reach all operating parts; adjust the
rearview mirror to ensure that the driver can observe the rear operating environment.
Operator's seat