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