HANGCHA XF Series, Operation Manual

Page 1: ...XF series Internal Combustion Counterbalanced 1 0t X5 5t Forklift Truck 1 5t X5 5t XF Series Internal Combustion Counterbalanced Forklift Truck OPERATION MANUAL HANGCHA GROUP CO LTD...

Page 2: ...CP D40 CP D45 CP D50 CP D55 Rated load lifting capacity kg lb 3200 7000 3650 8000 4000 9000 4500 10000 5000 11000 CE model Optional maximum lift height 6000 mm Caution Bearing Capacity Chart The chart...

Page 3: ...1 Start 35 2 Operation 35 3 Loading 36 4 Stacking 37 5 Unstacking 37 IX Various signs and labels 38 X Lifting handling and towing of the forklift truck 44 XI OPS system description 45 XII Cab and over...

Page 4: ...within the minimum range during loading and unloading operations 14 When driving on wharfs or temporary decking you should be extra careful and drive slowly 15 The driver should not stay in the truck...

Page 5: ...king operation after the forklift truck has been shut down in order to ensure your safety please carefully read and strictly implement operations related to the energy accumulator in the manual 26 Ple...

Page 6: ...hydraulic cylinder 4 Mast 5 Steering wheel 6 Overhead guard 7 Counterweight 8 Driver s seat 9 Rear wheel 10 Frame 11 Hood 12 Tilt cylinder 13 Front wheel 1 Instrumentation Diesel Engine Homepage Xinch...

Page 7: ...l show that it is within the range 40 110 Caution Stop operation immediately and reduce engine speed to cool down the engine and then stop the engine when the gauge is in the red area Check the coolan...

Page 8: ...orklift truck The light turns on for a short period after the switch is moved to the open position and the switch can be moved to the start position for starting after the light turns off Engine oil p...

Page 9: ...not fastened or loose when the driver is operating the vehicle the buzzer alarm will sound and the safety belt alarm indicator light will turn on at the same time This is to remind the driver to safe...

Page 10: ...e forklift truck until the water temperature reaches 70 Install the hazard Warning sign near the exhaust port Caution Parking regen The parking status is not suitable for heat dissipation Stay away fr...

Page 11: ...parameters the engine fault light should turn on at the same time Inhibit indicator light When the light turns on it indicates that the regen status of the engine is restricted and driving regen or p...

Page 12: ...nformation display page Homepage Key 4 Back to the homepage Press Key 1 to return to the homepage Note GCT engine fault information English will be directly displayed according to fault content B 2 Fo...

Page 13: ...ey 4 enter the advanced setting maintenance personnel password input page Back to the homepage Press Key 1 to return to the homepage 2 DPF emissions function setting page diesel engine Cancel inhibit...

Page 14: ...to be redirected to the maintenance hour reset page and reset the remaining hours to the set initial value maintenance cycle interval Back to the setting page Press Key 1 b Maintenance hour reset page...

Page 15: ...ht switch 4 Ignition key switch 5 Lifting lever 6 Tilt lever 7 Cup holder 8 Instrument 9 Rocker switch 10 Accelerator pedal 11 Brake pedal 12 Inching pedal 13 Hand brake lever 14 Steering wheel adjust...

Page 16: ...ly To turn on the headlights and the front signal light turn this switch to align the position marker on the switch handle with the corresponding symbol on the switch body Ignition key switch 4 O off...

Page 17: ...optional Accessory control lever optional This lever is used to move the side shift frame to the left or right Push forward Move left Pull back Move right The side shift speed is determined by the ti...

Page 18: ...aked The pedal can be used when the forklift truck slows down to approach cargo or conducts loading and unloading operations Caution Do not use the inching pedal excessively If the pedal is used as a...

Page 19: ...ess the brake pedal to the bottom to fully stop the truck before changing the driving direction push the lever forward to engage forward gear I pull up and push the lever forward to engage forward gea...

Page 20: ...be adjusted when the forklift truck has stopped Do not adjust the driver s seat when driving to avoid an accident For front and rear adjustment and backrest angle adjustment the handle should be pull...

Page 21: ...overhead guard Lock catch components In order to prevent the internal combustion engine hood from being opened without permission the truck is fitted with a locking hood in order to open the internal...

Page 22: ...h a hexagon bolt before moving it should be released with a socket spanner The bolt should be tightened with a socket spanner during reinstallation Water tank lid and additional water tank The additio...

Page 23: ...ck The fuel tank lid is on the left rear side of the body There is a vent in the fuel oil tank and the vent should be checked for blockages when refuelling Note Do not pour gasoline into the fuel tank...

Page 24: ...combination light from the overhead guard and take care to ensure your safety 1 Take the whole combination light to the maintenance site remove the rear lampshade and unscrew the four mounting screws...

Page 25: ...m The workplace should be provided with a fire extinguisher Do not refuel when the is engine running 5 Warm up the forklift truck until the water temperature is 70 before operation Do not open the wat...

Page 26: ...ns with poor visibility limit the speed to 1 3 of the maximum driving speed of the truck 20 The forklift truck should be driven away from LPG tanks wood paper and chemical substances the exhaust gas f...

Page 27: ...d weather conditions 23 Reverse downhill and climb facing forward when loaded The opposite applies when unloaded Do not turn on the ramp to avoid rolling over 24 Keep the engine at idle and step on th...

Page 28: ...ion Be careful not to let the forks touch the road surface to avoid damaging the fork tip and road surface 30 Know the load curves of the forklift truck and accessories and do not overload It is very...

Page 29: ...rucks with accessories like flat holding clamps cargo should be tied firmly and clamped then the multiway valve control lever should be pulled into place 39 Do not lift cargo when the forklift truck i...

Page 30: ...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 45 Use a pallet when handling small object...

Page 31: ...ll it out to check whether the oil level is between the two scale marks 5 Engine coolant quantity check Observe the coolant level in the additional water tank when the engine is cool If it is lower th...

Page 32: ...2t 2 5t forklift truck Scale value for symbol 30 is applicable to 3t 3 5t forklift truck When the mast is in the minimum position the oiling quantity is as follows 1t 1 8t forklift truck with standar...

Page 33: ...and check whether the indicator light operates normally 10 Hand brake check The truck slows down The truck brakes and stops when the hand brake lever is pulled up The truck must not swerve 11 Reversi...

Page 34: ...to the tire may cause an accident When using the air compressor as the maximum output pressure of the air compressor is higher than the specified pressure of tire the pressure setting should be adjus...

Page 35: ...gravity for loads in different shapes from boxes to boards and rectangular objects Warning Do not jump out of the truck if the forklift truck starts to roll over The forklift truck will roll over much...

Page 36: ...enter distance The horizontal distance between the center of gravity of the load on a fork and the load backrest of the fork or the front surface of the fork whichever is smaller is called the load ce...

Page 37: ...uddenly apply the brake because the forklift truck will roll over or the load will slide when a large force acts forward When the forklift truck turns a centrifugal force will be applied outwards from...

Page 38: ...the right in the position for preheating after the preheat indicator light turns off the key can be rotated to for starting After the engine is started Preheat the engine for about 5min Check the ope...

Page 39: ...Slow down step on the brake pedal to stop the truck on mechanical forklift trucks step on the clutch at the same time Pull the shift lever in the neutral position Pull up the hand brake Lower the for...

Page 40: ...s at a high level 5 Unstacking Slow down when the forklift truck approaches the place to pick up cargo Park when the forklift truck is 30cm away from the cargo Check the cargo condition Tilt the mast...

Page 41: ...amping labels 10 Antifreeze label 11 LPG label 12 Typeface label 13 Tie down point label 14 Tire pressure label 15 Diesel label 16 Gasoline label 17 Tonnage label 18 Warning label 19 Engine hood openi...

Page 42: ...pe from rubbing and damaging the lamp 1 Safety belt label and its anti tilting Warning label 5 No flushing label It is on the right leg of the right safety shelf by the engine air intake there should...

Page 43: ...r It marks Maximum weight of the LPG tank 52kg Maximum LPG pressure 2 2MPa Maximum weight borne by the support 105kg 13 Tie down point label 14 Tire pressure label 1 5t 1 8t Actual lifting capacity mm...

Page 44: ...reverse lever in neutral position and turn off key switch Do not park on a slope circumstances Repair work should be done by authorized and trained persons only W A R N I N G SERIOUS OR FATAL INJURY...

Page 45: ...ide the truck should not operate the truck to avoid an accident arising from misuse of the mast lever 23 Product nameplate 24 Lubricating system label 25 DPF Warning label The operator should carefull...

Page 46: ...truck component names 1 Description of the regen indicator light in the instrument panel 27 Emergency stop label Print location of serial number A Frame number B Mechanical environmental protection c...

Page 47: ...should not be used for long distance transport If the forklift truck is transported over a long distance it should be handled with a ship train or vehicle with load capacity of more than 5t Chock the...

Page 48: ...ift switch is not pulled to the neutral position the truck cannot be started Warning If the forklift truck is parked on a ramp you must press the brake pedal to the bottom to start the truck to protec...

Page 49: ...ks with seats provided with a safety belt protection switch after the driver first sits back on the driver s seat properly and fastens his her safety belt normal operation can be conducted Tilt the le...

Page 50: ...front glass left door right door and back door How to use the cab 1 Open the left door with the key and enter the cab 2 Close the door and ensure that the left and right doors are closed for operatio...

Page 51: ...tween the liquid level gauge and the horizontal line should be 60 unscrew the dust cover on the filling valve insert the filling valve open the intake limit valve for filling take out the filling plug...

Page 52: ...ng 3 Starting the dual fuel engine 1 Start with gasoline Shut off LPG turn on the gasoline switch for a few seconds rotate the ignition key and start the motor to run the engine with gasoline 2 Start...

Page 53: ...hut down the engine using the following methods after LPG is used Rotate the fuel changeover switch to neutral Let the engine idle until it stops Ensure that all of the remaining LPG has been used up...

Page 54: ...engine to meet the requirements of the engine under various working conditions 8 Steel cylinder 1 Functions It consists of a safety valve LPG inlet quick coupler of outlet section and corresponding fi...

Page 55: ...Fig 1 Fig 2 b Loosen the steel cylinder See the following schematic diagram for specific steps Steel belt bracket Buckle bracket Buckle and tensioner 1 Hold the tensioner with your right hand and pull...

Page 56: ...at the stop valve at the outlet end is closed 3 The steel cylinder has to be refueled at a gas station with an LPG filling permit issued by the quality and technology supervision bureau Do not refill...

Page 57: ...nd outlet stop valves 4 8 are closed 6 You should connect the forklift truck pipe joint 10 with the outlet joint 9 and fasten them 7 You should slowly open the stop valve 8 at the outlet end 8 You can...

Page 58: ...he buckle into the ratchet shaft slotting c Pull down the buckle tightly with your left hand pull out the lock catch with your forefinger middle finger and ring finger of your right hand and push up i...

Page 59: ...tight 5 The opening pressure of the safety valve has been factory set and should not be changed without permission 6 In case of any problem it must be overhauled by a qualified organization and shoul...

Page 60: ...r should not be completely depleted and the remaining gas should be no less than 0 5 of the specified filling quantity 19 Do not change the steel stamp and color mark of the steel cylinder without per...

Page 61: ...e reducing regulator must be regulated to ensure the proper air fuel ratio 6 The connections of the electric appliance switch system should be checked for oxidization and rust after being used for thr...

Page 62: ...59 WG3800 and LPG Fuel System Diagram...

Page 63: ...nd damage When batteries are provided with a lifting rope or lifting handle these should be carefully checked for security before handling do not repeatedly sway when handling to prevent the lifting r...

Page 64: ...is green 2 Disconnect the battery negative ground strap to prevent battery discharge due to additional current drain 3 When batteries cannot be removed from the truck they should be kept fully charge...

Page 65: ...tery maintenance 1 Ensure that the battery electrolyte is at the UPPER LEVEL 2 Disconnect the battery negative ground strap to prevent battery discharge due to additional current drain 3 When batterie...

Page 66: ...uipment attention should be paid to the correct connection of positive and negative electrodes to avoid fires Do not place conductive items on batteries to avoid short circuits Avoid splashing electro...

Page 67: ...rried out only after the other one is completed 4 Forklift trucks provided with accessories must not be driven when the cargo is at a high level when the cargo volume is too large do not drive the for...

Page 68: ...ase of dynamic loads check whether the working elements of accessories are normal whether the working pressure of accessories is normal and whether accessories work normally If not it is necessary to...

Page 69: ...id arm clamp bucket clamp after hanging and installation stop blocks should be welded on both sides of the joint between the upper beam of the fork arm carrier and the accessories to prevent sliding w...

Page 70: ...of operating and control elements S N Name Function 1 Handrail Installation and operation platform of control elements and placement platform for the right arm of the driver 2 Driving direction switch...

Page 71: ...ntrol lever Control the left and right movement of the forks 7 Accessory control lever Control the fourth attachment 8 Handrail locking shift Adjust the forward backward position of the handrail Strok...

Page 72: ...Notes...

Page 73: ...National customer service hotline 400 884 7888 For OVERSEAS USERS Address 666Xiangfu Road Hangzhou Zhejiang China Fax 0086 571 88926789 0086 571 88132890 ZIP 311305 Web http www hcforklift com E mail...