EP Equipment EPL153, Operation Manual

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Page 2: ...ours after been ordered Through our online after sales service system customers can process their warranty claims order spare parts and consult the operation manuals maintenance materials and spare parts catalogs With business all over the world EP has thousands of employees and hundreds of agents worldwide to provide our global customers with prompt local service Based on the concept of sharing e...

Page 3: ...ted by the following graphics Please strictly adhere to these safety instructions to avoid personal injury or major damage to equipment Please pay attention to the important safety instructions Pay attention to Instructions EP EQUIPMENT CO LTD Address XIAQUAN DIPU ANJI ZHEJIANG CHINA Tel 86 571 28023920 Website www ep ep com Email info ep care com ALL RIGHTS RESERVED 2019 10 2st EDITION Internet a...

Page 4: ... by means of the EC EU Declaration of Conformity and the relevant certification label on the nameplate The industrial truck is supplied with the EC EU Declaration of Conformity document This declaration proves that this truck complies with the requirements of the EC Machinery Directive Unauthorised modification or additional installation of equipment to the structure of the industrial truck may affe...

Page 5: ...sing the truck for the first time D2 1 4 Break in period precautions D2 E Operation E1 1 1 Safety regulations for the operation of pallet trucks E1 1 2 Operate and run the truck E1 1 2 1 Turning the truck on and off E1 1 2 2 Driving steering braking E2 1 2 3 Loading E3 1 3 Raising and lowering the forks E5 1 4 Parking the truck securely E5 1 5 Using the truck on a slope E6 1 5 1 Starting on a slop...

Page 6: ...intenance and repairs G6 1 4 2 Remove the cover G6 1 4 3 How to add oil G7 1 4 4 How to add grease G7 1 4 5 Checking the fuses G7 1 4 6 Recommissioning G8 1 5 Decommissioning the industrial truck G8 1 5 1 Prior to decommissioning G8 1 5 2 Restoring the truck to operation after decommissioning G8 1 6 Safety checks to be performed at regular intervals and following any unusual incidents G9 1 7 Final...

Page 7: ... is not abused and only used within its design scope and that all danger to the operator or third parties is avoided In addition to this it must be ensured that the relevant accident prevention regulations and other safety related provisions as well as the operating servicing and maintenance guidelines are observed The user must also ensure that all persons operating the truck have read and unders...

Page 8: ...or being unaware of the basic safe operating practices of the truck The following basic safe operating practices must be observed to ensure the safety of operators and others Never operate the truck in environments with s potentially explosive atmosphere Never carry passengers Do not overload the truck by exceeding the rated load indicated on the load designation plate Overloading can affect braki...

Page 9: ...e the truck at altitudes not exceeding 2000 meters The walking lifting and lowering devices harnesses and components are IP55 dust and water resistant Trucks can only be operated in adequately illuminated working areas to avoid injuries In case of insufficient light an additional lighting equipment is needed to ensure that the driver can see properly If you must travel on an incline the gradients ...

Page 10: ...REV 10 2019 2 B 1 Control handle 8 Forks 2 Controller 9 Key switch 3 Lift cylinder 10 Emergency stop switch 4 Driving wheel 5 Charger 6 Battery 7 Load wheels 1 2 Truck assemblies ...

Page 11: ...Pull the lowering lever and hold The forks will be lowered to its minimum height and stop on its own 4 Emergency reverse switch By pressing this switch the vehicle starts to travel in the opposite direction 5 Drive switch Select the required driving direction and speed 6 Creep speed switch Keep the handle in the vertical state and press creep speed switch and drive switch at the same time then the...

Page 12: ...rent When pulling out the key switch the control current of the truck will be interrupted When inserting the key switch the control current of the truck will be connected Pulling out the key switch of a truck before leaving can prevent the truck from starting accidentally Key switch Charging indicator 1 2 3 Component LCD color Residual capacity Standard battery residual capacity Green 30 100 Conti...

Page 13: ...it protection The green light repeats in a cycle of flashing once in 1 second pausing for 2 seconds and then flashing four times pausing for 3 seconds Over current protection The green light repeats in a cycle of flashing once in 1 second pausing for 2 seconds and then flashing five times pausing for 3 seconds Battery temperature is too high The green light repeats in a cycle of flashing twice in ...

Page 14: ...e label 3 Charging trouble light label 10 Anti pinch hand label 5 Instructions label 11 Sling label 6 Charging indicator label 12 Hydraulic oil label 7 Lithium ion label 13 Function label 8 No riding label 1 3 100 15 30 15 30 100 100 15 30 15 30 100 码 2 3 5 6 7 8 9 13 10 Right Front Back Top Back Top 11 12 ...

Page 15: ... serial number Item Description Item Description 1 MODEL TYPE 8 BATTERY VOLTAGE 2 SERIAL NO 9 MAX BATTERY WEIGHT 3 MANUFACTURE DATE 10 MIN BATTERY WEIGHT 4 RATED CAPACITY 11 UNLADEN MASS WITHOUT BATTERY 5 LOAD CENTER 12 UNLADEN MASS WITH BATTERY 6 LIFT HEIGHT 7 RATED DRIVE POWER 1 3 1 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 16: ... r a b w a r d t h g i e H 9 4 14 in mm 750 1190 h t h g i e h d e r e w o L 5 1 4 13 in mm 80 l h t g n e l l l a r e v O 9 1 4 1 in mm 1550 l s k r o f f o e c a f o t h t g n e L 0 2 4 2 in mm 400 4 21 Overall width b1 b2 in mm 560 685 0 5 1 1 x 0 5 1 x 0 5 m m n i l e s s n o i s n e m i d k r o F 2 2 4 b s m r a k r o f n e e w t e b e c n a t s i D 5 2 4 5 in mm 560 685 m e s a b l e e h w f...

Page 17: ...REV 10 2019 9 B 1 4 2 Dimensions ...

Page 18: ...ould occur it must be reported immediately WARNING Unauthorized modifications to the truck can result in injury or death Do not remove disable or modify any safeguards or other safety devices These include any alarms lights mirrors overhead guards and load backrest extensions If present an overhead guard is intended to provide protection to the operator from falling objects but cannot protect from...

Page 19: ...he forks upgrade to maintain control when travelling up or down an incline with a loaded truck Keep the forks downgrade when travelling up or down an incline with an empty truck R Tip over will occur if you turn while travelling on a ramp or travel at an angle other than straight up or straight down a ramp Never turn on an incline or ramp either loaded or unloaded Travel straight up or straight do...

Page 20: ...d contacts the eyes seek medical attention at once Clean spilled battery acid immediately with large amounts of water Remove any metal rings bracelets bands or other jewelry before working with or near batteries or electrical components Never expose batteries to open flame or sparks Areas in which batteries are stored or charged must be well ventilated to prevent concentration of explosive gases If...

Page 21: ...peration at the planned usage location under the electromagnetic interference conditions to be expected there An EMC test thus firstly measures the electro magnetic interference emitted by the truck and secondly checks it for sufficient resistance to electromagnetic interference with reference to the planned usage location A number of electrical measures are taken to ensure the electromagnetic compa...

Page 22: ...prescribed steps and park the vehicle correctly Make sure the forks are aligned with the pallet move slowly and stop after insertingthe forks as far into the pallet as possible CAUTION Operate on open level ground and pay attention to ground conditions when lifting and lowering the palletto prevent the truck from tipping When transporting the truck make sure it is fully secured and take precaution...

Page 23: ...on Check control handle pivot Check operating controls Break in period precautions Fasten wheel screws again at 50 hours of operation Within the first 100 hours in particular the following requirements should also be met Excessive discharge of a new battery during initial use must be prevented It should generally be charged promptly when at 20 The specified preventive maintenance must be done thorou...

Page 24: ...wed to perform any repairs or modifications on the fork lift truck Under no circumstances must the driver change the setting of switches or safety installations or render them ineffective Danger area A danger area is considered to be the area within which persons are endangered by the travelling or lifting movements of the fork lift truck or its load lifting devices e g fork or attachments or by t...

Page 25: ...ore operating the truck Tilt the control shaft into the driving range M and set the controller to the desired direction V or R Steering Steering the truck is done using the control handle Manually moving it to the left or right will swivel the drive wheel The truck then turns in forward or reverse according to the handle direction Emergency stop Push the emergency stop switch All of the electrical...

Page 26: ...e truck s nameplate Ensure that the load is stable and uniform to prevent any partial spillage Check that the width of the load is compatible with the width of the forks If the control handle moves slowly or not at all to the upper brake zone the truck must be taken out of service until the cause of this fault is be rectified Replace the gas pressure spring if necessary WARNING WARNING 1 2 3 Count...

Page 27: ...a few centimeters above its support Back the truck away from the stack or any neighbouring loads gently and in a straight line Transporting loads Always carry loads in the forward direction of travel R in order to have the best visibility When carrying a load on a slope always ascend or descend with the load uphill Never drive sideways across a slope or perform a U turn Reverse travel V is to be u...

Page 28: ... must make sure that it has been correctly stowed and does not exceed the truck s capacity Make sure long loads are stable supported by the forks WARNING 1 3 Parking the truck securely Lowering the forks Press emergency stop switch Remove the key It is forbidden to park on the slope for a long time 1 4 Unloading Carefully drive the truck to the desired location Carefully drive the truck to the unl...

Page 29: ...ys be forwards with the load uphill Without a load it is recommended to descend slopes forwards In all cases travel at a very low speed and brake very gradually Risk to life and or risk of major equipment damage Never park the truck on a slope Never make a U turn or take shortcuts on a slope On a slope the operator must drive very slowly i 1 5 DANGER Starting on a slope If you have to stop and the...

Page 30: ...has sufficient capacity to carry the weight of the truck Refer to the truck data plate for truck weight If a battery is installed its weight must be added to the truck weight listed on the data plate Switch the truck off and press the emergency stop button Attach lifting equipment to the holes in each side of the chassis Attach lifting equipment to the fork tips to keep the truck approximately hori...

Page 31: ...rol handle pivot Check the pivot point where the control handle attaches to the chassis for smooth operation by moving the handle through its entire range Check operating controls Returnspring Pull the control handle down into its operating range and release it It should return to the vertical position under spring tension Brake interlock handle Operate the truck in forward or reverse Move the con...

Page 32: ...emark Check for fluid leakage Check forks and chassis Check battery connector Check decal condition Check control handle pivot Check operating controls Check the load wheels Check the drive wheels Check electro magnetic brake function Check horn function Check Forward and reverse travel function Check lift and lower function ...

Page 33: ...s are maintenance free Battery type dimension as follow Tuck type Voltage Rated capacity V AH Dimension mm Charger A Charging time h Internal EPL153 24 20 230 260 85 10A 2 1 1 1 2 DANGER Charging the battery Safety regulations for charging the battery Before charging check all cables and plug connections for visible signs of damage Before start and finish charging make sure power is turn OFF It is...

Page 34: ...s battery cable c Unscrew eight screws 2 remove the battery 1 A fully charged battery will provide approximately 3 hours of continuous use Capacity will be reduced when used in low temperature environments Storage If batteries are taken out of service for a lengthy period they should be stored in the fully charged condition in a dry frost free room If the battery is not used for an extended period...

Page 35: ...40 C Avoid the battery becoming corroded by water or corrosive liquid Keep the battery away from all fire sources heat sources and flammable or explosivematerials Storage We recommend that batteries are stored at a height between 60 and 120 cm Store the battery in a dry place at a temperaturebetween 0 and 40 to preserve its service life This area must not be hermetically sealed to allow air renewa...

Page 36: ...tery Transporting only the lithium battery A class 9 danger label must be affixed to the packaging for transport It is different if the battery is transported on its own or in a truck An example of a label appears in this supplement Refer to the latest current regulations before dispatch as the information might have changed since this supplement was written Special documents must be sent with the...

Page 37: ... inspection procedures and simple maintenance checks e g checking the hydraulic oil level or checking the fluid level in the battery may be performed by operators This does not require training as described above Lifting and jacking up When a fork truck is to be lifted the lifting gear must only be secured to the points specially provided for this purpose When the truck is to be jacked up suitable...

Page 38: ...ation under normal operating conditions They must be reduced accordingly if the truck is to be used in conditions of extreme dust temperature fluctuations or multiple shifts The following maintenance checklist states the tasks and intervals after which they should be carried out Maintenance intervals are defined as W Every 50 service hours at least weekly A Every 250 operating hours B Every 500 op...

Page 39: ...k the transmission for noise and leakage Check travel mechanism adjust and lubricate if necessary Check control handle lifts back to braking position Check wheels for wear and damage Check wheel bearings and attachments Truck frame Check truck frame for damage Hydraulic operation Test hydraulic system Check that hose and pipe lines and their connections are secure check for leaks and damage Check ...

Page 40: ... or adding lubricant use clean containers It is strictly forbidden to mix different types and specifications of lubricants with each other except for those can be mixed under clear statement Lubricant CAUTION The use and disposal of lubricants must be carried out in strict accordance with the manufacturer s regulations Hydraulic oil injection nozzle Sliding surface Grease ...

Page 41: ...draulic System Low temperature anti wear hydraulic oil cold storage L HV32 B Multi purpose grease Polylub GA352P Appropriate amount Sliding surface See Table 1 C Grease MoS2 100 grams Gearbox Table 1 Sliding Surface Lubrication Table Code Position L1 Steering shaft L2 Drive Wheel L3 Load Wheel L4 Long Shaft B L4 L1 L2 L3 ...

Page 42: ...ark the truck securely See Parking the truck securely Remove the key to prevent the truck from accidentally starting When working under a raised lift truck secure it to prevent it from tipping or sliding away Remove the cover Unscrew the four screws 1 remove cover 2 Unscrew the four screws 3 remove driving cover 4 Rotate the handle 90 degrees unscrew the four screws 6 remove the hydraulic cover 5 ...

Page 43: ...se 5A installed on main harness If necessary replace it with fuse that match the parameters specified in the table below Item To protect Rating 1 Wire harness 5A WARNING How to add oil It is necessary to add hydraulic oil when you heard explosion sound from pipe during lifting Prepare the truck for maintenance and repairs See Maintenance Instructions Remove the hydraulic cover See Section1 4 2 Add...

Page 44: ...grease to the terminals Spay all exposed electrical contacts with a suitable contact spray Charge the battery every two months to avoid depletion of the battery through self discharger Restoring the truck to operation after decommissioning Thoroughly clean the fork truck Clean the battery Grease the pole screws using pole grease and reconnect the battery Recharge the battery Check if the hydraulic...

Page 45: ...t 2 inspections The owner is responsible for ensuring that faults are immediately rectified A test plate is attached to the truck as proof that it has passed the safety inspection This plate indicates the due date for the next inspection Final decommissioning disposal Final proper decommissioning or disposal of the truck must be performed in accordance with the regulations of the country of applic...

Page 46: ...operational Hydraulic oil level too low Faulty fuse Charging the battery Carry out all measures listed under Truck does not start Check the hydraulic oil level Check fuses Controller Error Message The error message can be obtained in two ways 1 By reading the appropriate display on the hand held unit 2 By observing the fault codes issued by the LED 1 fault indicator Handheld Unit Diagnostics The f...

Page 47: ... wire s broken or shorted 2 Broken speed limit pot 1 4 UNDER VOLTAGE FAULT battery voltage too low 1 Battery voltage 17 volts 2 Bad connection at battery or controller 1 5 OVER VOLTAGE FAULT battery voltage too high 1 Battery voltage 31 volts 2 Vehicle operating with charger attached 3 I n t e r m i t t e n t b a t t e r y connection 2 1 MAIN OFF FAULT main contactor driver Off fault 1 Main contac...

Page 48: ...Off fault 1 Electromagnetic brake driver open 2 Electromagnetic brake coil shorted 3 5 HPD FAULT HPD High Pedal Disable 1 Improper sequence of throttle and KSI push or inhibit inputs 2 Misadjusted throttle pot 4 1 CURRENT SENSE FAULT current sense out of range 1 Short in motor or in motor wiring 2 Controller failure 4 2 HARDWARE FAILSAFE motor voltage out of range 1 Motor voltage does not correspo...