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HANGCHA XF Series User Manual

HANGCHA XF Series
142 pages
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XF series
OPERATION MANUAL
1.0t-X5.5T XF series Internal Combustion
Counterbalanced Forklift Truck
Operational and
Maintenance Manual
Original Instruction
HANGCHA GROUP CO., LTD
04/2018

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HANGCHA XF Series Specifications

General IconGeneral
TransmissionAutomatic
ModelXF Series
Load Capacity1.0 - 3.5 tons
Mast TypeDuplex, Triplex (various lift heights available)
Lifting Height3000 - 6000 mm
Tire TypeSolid/Pneumatic

Summary

Foreword

General Rules

Name of Main Parts or Component

Instruments

Details on forklift gauges, indicators, and warning lights.

Controls and Switches

Identification and function of steering wheel, levers, pedals, and switches.

Truck Body and Components

Description of key structural parts like the hood, overhead guard, seat, and cabin.

Safety Rules

Maintenance

Daily Maintenance (8 Hours)

Pre-operation checks: fluid leaks, appearance, fuel, oil, coolant, tires.

Weekly Maintenance (40 Hours)

Air cleaner maintenance and other checks based on daily maintenance.

Monthly Maintenance (166 Hours)

Engine oil/filter change, tilt cylinder lubrication, gear oil check, transmission oil filter change.

Semi-Annual Maintenance (1000 Hours)

Brake fluid change, steering wheel lock lubrication, hydraulic oil change, filter replacement.

Annual Maintenance (2000 Hours)

Engine coolant replacement, wheel bearing grease change, steering axle gear oil change.

Others

Maintenance on fuses, relays, and tire changes.

Structure and Stability of Truck

Understanding Truck Structure and Load Stability

Key structural elements and how load, center of gravity affect stability.

Factors Affecting Forklift Stability

Load center, mast tilt, tire pressure, speed, and surface conditions impact stability.

Load Capacity and Center Distance

Relationship between maximum load and load center distance specified on load chart.

Operation

Start-up

Procedures for starting diesel and gasoline engines, including preheating and warm-up.

Travel

Steps for safe travel: steering, fork positioning, checking surroundings, and gear shifting.

Pick up

How to pick up loads: fork adjustment, positioning, and inserting into pallet.

Stacking Load

Procedure for stacking loads: approaching, positioning, and lowering the load.

Remove Load

Steps for safely removing loads: approaching, positioning forks, and backing away.

Parking

Parking Daily

Daily parking procedure: positioning, neutral shift, parking brake, engine shutdown.

Park the Truck for a Long Time

Procedure for long-term parking: blocking wheels, removing battery, applying rust-preventive oil.

Running After Storing for a Long Time

Steps to safely resume operation after extended storage: removing rust oil, draining oil, checking parts.

Maintenance

Preventive Maintenance Schedule

Schedules for engine, LPG, and drive system maintenance based on operating hours.

Torque Specifications

Table of torque values for various bolt sizes and grades.

Periodic Replacement of Key Safe Parts

Service life and replacement schedule for critical safety components like hoses and seals.

Table for the Oil Used in the Truck

Recommended oils and their capacities for different forklift models and components.

Lubrication System Drawing

Diagram showing lubrication points and recommended lubricants for various truck parts.

Labels: Stick Various Nameplate and Mark at Different Position of the Truck

Label Descriptions and Locations

Diagram showing label positions on the forklift, with numbered references.

Safety and Warning Labels

Identification of danger, hang, tonnage, and hood open labels with visual examples.

Operational and Identification Labels

Details on diesel, gasoline, hang, operate, nameplate, and load curve labels.

System and Warning Labels

Information on lubrication system, no washing, danger, and hydraulic oil labels.

Danger and Compliance Labels

Descriptions of danger, hand injury risk, antifreeze, horn, and safety belt labels.

Tire Pressure, CE, and LPG Labels

Information on tire pressure, CE marking, LPG, and emergency stop labels.

Truck Transporting, Lifting, Towing

Hoist the Truck

Instructions for safely hoisting the forklift using wire ropes and lifting devices.

Transporting

Guidelines for short-distance transportation and securing the forklift on ships, trains, or lorries.

Towing

Procedure for towing a damaged truck, including using the towing rod and safety precautions.

Model Meaning

Main Technical Performance Parameter

Cab and Overhead Guard

Cabin Structure and Operation

Details on cabin construction, door operation, and glass movement.

Cabin and Overhead Guard Disassembly

Procedure for safely dismantling cabin parts and the overhead guard assembly.

Operation and Notice About LPG Forklift

LPG Fueling and Replace

Instructions for refueling LPG cylinders and replacing them safely.

The Operation of Dual Fuel Switch

How to switch between gasoline and LPG fuel sources on dual-fuel forklifts.

Starting the Engine

Procedures for starting the engine using gasoline or LPG fuel.

Change Fuel During the Engine Runs

Safe methods for switching fuel types while the engine is running or stopped.

Attentions

Important safety notes for LPG operation, including leakage checks and temperature management.

Press Reducing Regulator

Function and operation of the press reducing regulator for LPG systems.

Mixer

Role of the mixer in combining LPG and air for engine combustion.

Cylinder

Function, parameters, and replacement procedures for LPG cylinders.

Procedure for Replacing LPG Cylinder

Step-by-step guide for safely replacing LPG cylinders, including handling and fixing.

Cylinder Fixed Way

Methods for securely fixing LPG cylinders using metal belt and buckle belt brackets.

Notice During Usage

Precautions for LPG usage, charging, storage, and maintenance of the system.

Service & Maintenance

Maintenance guidelines for the LPG system, including cleaning filters and checking connections.

Operational Method of Lead Acid Battery

Battery Storage, Transport, and Checks

Safe practices for storing, transporting, and inspecting lead-acid batteries.

Battery Maintenance and Recharging

Procedures for maintaining, recharging, and safety measures during recharging.

Use, Installation and Safety Rules of Attachment

Attachment Use

Guidelines for using attachments: understanding capacity, operating methods, and safety rules.

Attachment Assembly

Procedures for safely assembling attachments, ensuring correct fit and stability.

Description of OPS System

Operator Presence Sensing (OPS) System Function

How the OPS system ensures operator presence and prevents operation when unsafe.

OPS System Abnormalities and Troubleshooting

Identifying and addressing issues with the OPS controller, including alarms and indicator lights.

Relevant Safety Command and Standard

Maintenance Record

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