EP Equipment CPD15/18/20FVD8(-C) User manual

Part No.508000004049
V3 10/2022
CPD15/18/20FVD8(-C)
CPD15/18/20/25F8/18F8-H
Operation Manual
CPD18/20FVL
Electric forklift truck

EP EQUIPMENT CO.,LTD. is one of the world’s
leading companies manufacture, which design
material handling equipment and provide related
service. With over 100,000 square metres plant
it produces over 100,000 trucks per year, and
provides professional, e󰀨ective and optimized
material handling solutions worldwide, until now
it has developed three major kinds of business:
Material handling equipment: Focus
on electric forklift and warehouse
equipment
OEM parts: Global parts supply
Imow industry,online: One-stop
industrial products supply
Guided by our customer-oriented concept, EP
has developed service centers in more than 30
countries around the world, from which customers
are able to receive timely local service. Moreover,
95% of warranty parts can be shipped out within
24 hours 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.
•
•
•
EP EQUIPMENT CO., LTD
Address: No.1 Xiaquan Village, Lingfeng
Street, Anji, Huzhou, Zhejiang
Tel: + 86-0571-28023920
Website: www.ep-ep.com
Email: [email protected]
EP Equipment Group
Alsembergsesteenweg 454A, 1653 Dworp,
Belgium
Tel: [phone]
E-Mail: [email protected]
Based on the concept of sharing economy, EP
also o󰀨er rental service for various logistics
equipment. Adhering to the idea “Making the
leasing of logistic equipment more simple”, EP
is devoted to providing customized one-stop
leasing solutions for our customers with our
high quality, reasonable price and prompt rental
service.
EP’s mission&vision is “ Let more people apply
the electrical material handling equipment to
relieve the intensity of labour” and “Let’s grow
together”.

Foreword
The present operation manual is designed to provide su󰀩cient instructions for the safe operation of
the industrial truck. The information is provided clearly and concisely.
Our trucks are under ongoing development. EP reserves the right to alter the design, equipment
and technical features of the system. No guarantee of particular features of the truck should
therefore be assumed from the present operation manual.
Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following graphics:
Means that failure to comply can cause risk to life and/or major damage to property.
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 Instruction.
WARNING
CAUTION
DANGER
i
NOTE
Internet address and QR code of Parts
manual
By entering the address http://www.ep-care.com
in a web browser or by
scanning the QR code, Login after registration,
Select “Parts purchase"
function and input part number or model name to
nd the truck.
NOTE:After registration, please send email to
info@ ep-care.com to activate your account
ALL RIGHTS RESERVED
2022.10 02st EDITION
The manufacturer uses the conformity mark-
ing to document the conformity of the industri-
al truck with the relevant directives at the time
of placing on the market:
● CE: in the European Union (EU)
● UKCA: in the United Kingdom (UK)
The conformity marking is applied to the
nameplate. A declaration of conformity is is-
sued for the EU and UK markets.
An unauthorised structural change or addition
to the industrial truck can compromise safety,
thus invalidating the declaration of conformity.

Declaration
EP EQUIPMENT CO., LTD.
Address: No.1 Xiaquan Village, Lingfeng Street, Anji, Huzhou, Zhejiang
We declare that the machine
Industrial truck type: corresponding to these this operation manual
Model: corresponding to these this operation manual
Serial No.: corresponding to these this operation manual
Fullls all the relevant provisions of Directives
− "Machinery Directive 2006/42/EC" 1)
− "EU directive 2014/30/EU"1)
− "Supply of Machinery Safety Regulations 2008( 2008 No. 1597)" 2)
− "Electromagnetic Compatibility Regulations 2016 (SI 2016 No.1091)2)
Personnel authorised to compile the technical documents:
See EC/EU Declaration of Conformity
EP EQUIPMENT CO., LTD.
1) For the markets of the European Union, the EU candidate countries, the EFTA States and
Switzerland.
2) For the United Kingdom market.
The declaration shown explains the conformity with the provisions of the EC Machinery Directive
2006/42/EC and the Supply of Machinery Safety Regulation 2008, 2008 No. 1597.The declaration
shown explains the conformity with the provisions of EU directive 2014/30/EU(Electromagnetic
Compatibility - EMC) and Electromagnetic Compatibility Regulations 2016, SI 2016 No.1091.
An unauthorised structural change or addition to the industrial truck can compromise safety, thus
invalidating the declaration of conformity.
Legal requirements for marketing

Table of contents
A Introduction...........................................................................................................................A1
1.1 Intended use.......................................................................................................................A2
1.2 Improper use .....................................................................................................................A3
1.3 Forklift truck handover .......................................................................................................A3
B Truck description ...................................................................................................................B1
1.1 Application ..........................................................................................................................B1
1.2 Truck Assemblies ...............................................................................................................B2
1.2.1 Display(1) .......................................................................................................................B6
1.2.1 Display(2) .......................................................................................................................B6
1.2.2 Controls ........................................................................................................................B15
1.2.3 Components .................................................................................................................B20
1.2.4 Cover and Seat..............................................................................................................B22
1.3 Standard version specications........................................................................................B26
1.3.1Performance data for standard truck..............................................................................B26
1.3.2 Dimensions....................................................................................................................B37
1.4 Identication points .........................................................................................................B41
1.5 Truck data plate ...............................................................................................................B42
1.6 The load capability chart ..................................................................................................B43
C Safety...................................................................................................................................C1
1.1 Before operation.................................................................................................................C1
1.2 Safety ................................................................................................................................C1
1.3 Battery Safety.....................................................................................................................C9
1.4 Related Safety Instruction and Standard(For CE) .............................................................C9
D Transport and commissioning ..............................................................................................D1
1.1 transport .............................................................................................................................D1
1.2 Use a hoist to lift the truck ..................................................................................................D1
1.3 The structure and stability of truck......................................................................................D3
1.4 Using the truck for the rst time..........................................................................................D6
1.5 During running-in................................................................................................................D6
E Operation .............................................................................................................................E1
1.1 Checks and operations to be performed before starting daily work ...................................E1
1.1.1 Switching on the truck .....................................................................................................E2
1.2 Driving, Steering, Braking ...................................................................................................E2
1.3 Loading...............................................................................................................................E3
1.4 Parking the truck securely ..................................................................................................E6
1.5 Operator daily checklist ......................................................................................................E7
1.6 Operator daily checklist ......................................................................................................E8
F Battery Maintenance & Charging & Replacement................................................................F1
1.1 Battery type & dimension....................................................................................................F1
1.2 Charging the battery...........................................................................................................F2
1.3 Battery removal and installation .........................................................................................F6
1.4 Battery removal and installation .........................................................................................F6
G Truck maintenance .............................................................................................................G1
1.1 Operational safety and environmental protection...............................................................G1
1.2 Maintenance safety regulations..........................................................................................G1
1.3 Servicing and inspection.....................................................................................................G2
1.3.1Maintenance checklist ......................................................................................................G3
1.3.2 Lubrication points ............................................................................................................G6
1.4 Maintenance instructions..................................................................................................G10
1.4.1 Steering wheels removal and installation ......................................................................G10
Pg.

1.4.2 Drive wheels removal and installation ...........................................................................G11
1.4.3 Check the gear or drive axle oil level.............................................................................G13
1.4.4 Check the hydraulic oil level..........................................................................................G14
1.4.5 Check the electrical fuses..............................................................................................G14
1.5 Decommissioning the trucks.........................................................................................G15
1.5.1 Prior to decommissioning ..............................................................................................G15
1.5.2 Restoring the truck to operation after decommissioning ...............................................G15
1.6 Final decommissioning, disposal....................................................................................G15
H Troubleshooting ..............................................................................................................H1
Appendix 1.............................................................................................................................. I1
1 Lead-acid battery operating instructions .......................................................................... I2
1.1 Safety and warning............................................................................................................I2
1.2 Use of Battery....................................................................................................................I3
1.2.1 Pre-use Checks..............................................................................................................I3
1.2.2 Discharging.....................................................................................................................I3
1.2.3 Charging........................................................................................................................ I3
1.2.4 Temperature .................................................................................................................. I4
1.3 Maintenance & Care......................................................................................................... I4
1.3.1 Daily Maintenance......................................................................................................... I4
1.3.2 Weekly Maintenance .................................................................................................... I4
1.3.3 Monthly Maintenance ................................................................................................... I5
1.3.4 Care .............................................................................................................................. I6
1.4 Storage ............................................................................................................................ I6
1.5 Troubleshooting ............................................................................................................... I6
Appendix 2.............................................................................................................................. J1
I Lithium battery operating instructions ............................................................................... J2
1.1 Lithium battery use and maintenance manual...................................................................J2
1.2 Safety and warning............................................................................................................J3
1.3 Hazard of faulty or discarded battery.................................................................................J5
1.4 Instructions ........................................................................................................................J6
1.4.1 Battery indicator..............................................................................................................J6
1.4.2 Lithium Battery Nameplate .............................................................................................J8
1.4.3 Charging........................................................................................................................ J9
1.5 Storage............................................................................................................................. J10
1.6 Transportation................................................................................................................... J10
1.7 Instructions for disposal.................................................................................................... J11
1.8 Common Problems and Solutions ................................................................................... J12
1.9 Service ............................................................................................................................. J13
Table of contents

REV. 09/2022
1A
A Introduction
The truck described in the present operator manual is an industrial truck designed for lifting and
transporting load units.
It must be used, operated and maintained according to the information in this operation manual.
Any other uses are outside the design envelope and can lead to injury to persons or damage to
equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads
must be avoided. The max. admissible load to be picked up is indicated on the nameplate or load
diagram label shown on the truck. The truck has been passed CE certication.
Duties of the user
For the purposes of the present operating instructions, the operating company is dened as any
natural or legal person who either uses the truck himself, or on whose behalf it is used. In special
cases (e.g. leasing or renting). the operating company is considered to be the person who is to
carry out the specified operational duties in accordance with existing contractual agreements
between the owner and operator of the industrial truck.
The operating company must ensure that the truck is used only for its intended purpose and that
dangers to the health and safety of the operator and third parties are prevented. Further more,
accident prevention regulations, safety regulations and operating, servicing and repair guidelines
must be followed. The operating company must ensure that all operator have read and understood
these operating instructions.
Mounting of attachments
The mounting or installation of any attachments which will interfere with, or supplement, the
functions of the truck is permitted only after written approval by the manufacturer has been
obtained. If necessary, the approval of local authorities has to be obtained. Any approval obtained
from local authorities does not, however, make the approval by the manufacturer unnecessary.
Check that loads are handled safely before commissioning a truck with attachments. It may be
necessary to make adjustments, depending on the type of attachment, e.g. to pressure settings or
adjusting stops and operating speeds.
Modication
Unauthorized modication to the truck can result in injury or death.
Can 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
every possible.
Exception:Only in the event that the truck manufacturer is no longer in business and there is no
successor in the interest to the business, may the user arrange for a modication or alteration to a
powered industrial truck, provided, however, that the user

REV. 09/2022 2A
Intended use
The industrial truck is used for moving and lifting the loads indicated on the capacity rating
plate.
Damages and other defects to industrial trucks or to attachments must be reported to the
supervisor immediately. Industrial trucks and attachments which are not safe to operate
may not be used until they have been properly repaired.
Safety installations and switches may not be removed or rendered unusable. Specied settings
may only be changed with the approval of the manufacturer.
Only the areas approved by the operating company or its representative may be used for
transportation purposes. Loads may only be deposited or stored at the intended places.
Inclines used by industrial trucks shall not exceed the limits specied by the manufacturer
and must have an adequately rough surface.
Danger points on driving lanes or routes shall be secured or marked by the customary road
tra󰀩c signs and by additional warning signs, if necessary.
Driving routes shall be su󰀩ciently paved, level and free of objects. Drain channels and
railways crossings, etc., shall be levelled and, if necessary, covered with ramps in such a way
that they can be driven over without bumps as far as possible.
The EU Directive 89/654/EEC (Minimum Regulations for Health and Safety for the workplace)
shall be observed. The respective national regulations apply for non-EU countries.
1.1
•
•
•
•
•
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•
Safety devices and warning labels
The safety devices, warning signs and warning instructions in the present operating instructions
must be strictly observed.
Hazardous area: A hazardous area is dened as the area in which a person is at risk due to
truck movement, lifting operations, the load handler (e.g. forks or attachments) or the load
itself. This also includes areas which can be reached by falling loads or lowering operating
equipment. Unauthorized persons must be kept away from the hazardous area.
Where there is danger to personnel, a warning must be sounded with su󰀩cient notice.
Give a warning signal with plenty of time for people to leave.
If unauthorized personnel are still within the hazardous area stop the truck immediately.
a) arranges for the modication or alteration to be designed, tested and
implemented by an engineer(s) expert in industrial trucks and their safety.
b)maintains a permanent record of the design, test(s) and implementation of the modication or
alteration.
c) approves and makes appropriate changes to the capacity plate(s), decals, tags and
instruction handbook.
d) affixes a permanent and readily visible label to the truck stating the manner in which the
truck has been modied or altered, together with the date of the modication or alteration and
the name and address of the organization that accomplished those tasks.

REV. 09/2022
3A
Schematic views1.4
View of functions and operations
This documentation explains the (usually
sequential) chain of certain functions
or operations. Schematic diagrams of a
counterbalance truck are used to illustrate
these procedures.
i
NOTE
These schematic diagrams are not
representative of the structural state of
the documented truck. The diagrams are
used solely for the purpose of clarifying
procedures.
Improper use
The operating company or driver, and not the manufacturer, is liable if the truck is used in a
manner that is not permitted. The following list is exemplary and is not intended to be
exhaustive.
1.2
Do not stack loads or turn when driving on a ramp.
Never park the truck in a place that may obstruct re extinguishers, re escapes or aisles.
Do not leave the truck unattended when the load is raised.
Do not stand on the fork arms when raised.
Do not increase the truck's load capacity, e.g. by attaching an additional weight.
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•
To avoid the inconvenience of making a claim after use, check the forklift truck is in perfect
condition and repair, and conrm your satisfaction with the vehicle on the manufacturer's
product qualication certicate upon handover.
Forklift truck handover1.3
When driving on public roads, the corresponding regulations must be observed, as well as
country-specic restrictions for winter road conditions.
The operating company is responsible for adequate re protection in the vicinity of the
industrial truck.
Industrial trucks may only be used to tow trailers if they are intended for this purpose by the
manufacturer . The maximum towed load specied in the operating instructions for unbraked
or braked trailers must not be exceeded. The towing industrial truck must be operated in such
away that safe driving and braking of the towed vehicle is ensured for all driving movements.
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•

REV. 09/2022
1
B
B Truck Description
Application
It is a four-wheel electric sit-down counterbalanced truck. It is battery-powered truck. With
maximum economic e󰀩ciency, safety and driving comfort. These trucks are equipped with lead-
acid battery For F8 and FVD8. The FVL series are equipped with lithium-ion battery. Customer
can choose attachments randomly. It also o󰀨ers option of manufacturer’s latest telematics and
provides the following features to facilitate your feet management:
• Truck location in real-time
• Reports of truck usages and diagnosis
• Li-ion battery condition analytics
• Updates on card access registration
1.1
WARNING
Extreme conditions
• Special equipment and authorisation are required if the truck is to be constantly used in
extreme conditions, especially in dusty or corrosive atmospheres.
• The truck is not authorised for use in areas at risk of explosion.
• In adverse weather conditions (thunder, lightning) the industrial truck must not be operated
outside or in endangered areas.
for FVL
i
NOTE
i
NOTE
Lithium-ion battery working temperature is divided into charging temperature requirement and
discharging temperature requirement:
The charging temperature range is 0°C-40°C. A high-rate recharging operation below 0°C may
lead to battery damage, so we recommend charging temperature range is 5°C-40°C;
The discharging temperature range is -20°C-55°C. If used in low temperature°C-20°C-0°C,
battery discharge capacity will be smaller compared with the one in normal temperature
condition, which is normal; battery used between 40°C-60°C in the long run will accelerate the
aging of the internal material. It may shorten the service life of battery, so not recommended.
So we recommend working temperature is 0°C-40°C.
• Used in specied area as factory, tourist attraction and recreation place.
• Indoor and outdoor use.
• The truck’s max operation altitude is up to 2000m.
• The lowest environment temperature under normal outdoor conditions when operation
-20℃.
• Average environment temperature under continuous operating condition +25℃.
• The highest environment temperature in the short term (≤1h) +40℃.
• The lowest environment temperature under normal indoor conditions when operation +5℃.
• Do not negotiate inclines crosswise or at an angle. Transporting loads downhill.
• If you must travel on an incline, the gradients should be below A% at full load, or below
B% without a load. (For the value of A and B, refer to the gradeability in Standard Version
Specications)
It’s prohibited to use the truck in the area of the explosion.
Special equipment and authorisation are required if the truck is to be used in extreme
conditions (e.g. cold stores). We recommend with special measures for the truck or buy cold
store truck. If in doubt, contact the manufacturer's customer service department.

REV. 09/2022 2B
Truck Assemblies1.2
1 Drive wheel
2 Battery behind panel
3 Chassis
4 Counterweight
5 Steering wheel
6 Driver's seat
7 Warning light
8 Combination light
9 Overhead guard
10 Mast
11 Headlight
12 Cab
13 Fork
Fig3625-00011OM
FVD8/F8

REV. 09/2022
3
B
14 Seat 22 Tilting lever
15 Steering wheel 23 Emergency stop switch
16 Key switch 24 Attachment lever
17 Combined lamp switch 25 Side lever
18 Steering column tilting angle
adjuster 26 Accelerator pedal
19 Display 27 Brake pedal
20 Caution light switch 28 Travel combination switch
21 Lifting lever
Fig3625-00012OM
FVD8/F8

REV. 09/2022 4B
1 Drive wheel
2 Chassis
3 Counterweight
4 Steering wheel
5Towing pin
6 Driver's seat
7 Rear combination light
8 Warning light
9 Overhead guard
10 Mast
11 Headlight
12 Forks
1
2
3
4
6
7
8
9
10
11
12
5
FVL

REV. 09/2022
5
B
16
20
21
24
23
25
19
17
15
27
18
28
26
22
15 Steering wheel 23 Attachment lever
16 Key switch 24 Side lever
17 Combined lamp switch 25 Accelerator pedal
18 Steering column tilting angle
adjuster 26 Brake pedal
19 Display 27 Travel combination switch
20 Lifting lever 28 Hand brake lever
21 Tilting lever
22 Emergency stop switch
FVL

REV. 09/2022 6B
Display(1)
1.2.1
AKEY BOARD BUTTION:ENTER Save all changing
BKEY BOARD BUTTION:ROLL UP Change the digit marked by cursor
CKEY BOARD BUTTION:ROLL DOWN Change the digit marked by cursor
DKEY BOARD BUTTION:SET UP Shift cursor on previous digit
EKEY BOARD BUTTION:SET DOWN Shift cursor on following digit
FKEY BOARD BUTTION:OUT Cancel all changing
3218-00004OM
When turn on the key switch, the system will self-
diagnose, the lights will be on one by one. After
self-diagnose, Battery dischage indicator will
display its remaining capacity.
Fig0000-00060OM
Fig0000-00059OM
Red Orange Green
10.2Km/h
Red Orange Green
It displays vehicle travelling speed in normal
work.
1
2
3
Travel speed display(1)
Battery power display(2)
Battery dischage indicator(3)
It displays the remaining battery capacity. The
residual capacity is reduced with the reducing of
cell numbers. When the residual power is less
than 10%, the low battery indicator illuminates.
F8

REV. 09/2022
7
B
Low battery indicator
The default system parameter setting
residual power is below 10%, this lamp
will illuminate. Charge timely after the
lamp illuminates.
Fault indicator
In the event of a controller failure or
operating error, this lamp will illuminate
and a fault code will be displayed on the
instrument.
Parking brake indicator
This lamp illuminates whenever the
parking brake is applied.
Power indicator
The lamp illuminates when power supply
is OK only
Parking brake warning
This indicator is useless to electric truck.
The meanings of indicators:
Fig0000-00061OM
Fig0000-00062OM
Fig0000-00063OM
Fig0000-00064OM
Fig0000-00065OM
At the same time low power protection
function is activated, it means the truck can
only travel, but can't lift.
CAUTION
NOTE
After eliminate the faults, please restart
the truck.
i
Too low battery power will inuence the
service life of the battery. Charge the
battery when the capacity less than 20％.
CAUTION

REV. 09/2022 8B
Seat indicator
This lamp illuminates whenever the driver
leaves the seat, indicating that the seat
switch is OFF. At this point, the vehicle
cannot move or lift. This feature requires the
seat to be tted with OPS.
Fig0000-00066OM
Start the truck, the top right corner of the
instrument displays the accumulated service
hour,
and then it displays the steering angle after
several seconds.
Service hour display
Steering angle display
The arrow pointed cursor position indicates
the steering angle. The cursor in the middle
position of the steering angle, indicates the
steering angle is 0;
cursor in the left position, indicates turning
left, on the contrary, indicates turning
right. Compared to the middle position,
the steering angle turns greater with the
increasing of the cell numbers.
Fault code display
In the event of a controller failure or
operating error, the instrument displays fault,
and the indicator illuminates.

REV. 09/2022
9
B
Display (2)1.2.1
BATTERY DISCHARGE INDICATOR
RED-ORANGE-GREEN
(5) KEY BOARD BUTTON: OUT
(4) KEY BOARD BUTTON: SET DOWN
(3) KEY BOARD BUTTON: SET UP
(2) KEY BOARD BUTTON: ROLL DOWN
(1) KEY BOARD BUTTON: ROLL UP
(*) KEY BOARD BUTTON: ENTER
Fig0000-00144OM
FVD8/FVL

REV. 09/2022 10B
PERFORMANCE
CHOICE#1#2
The display sends the
chosen performance
to traction and pump
controllers via can; they will
manage this information.
SERVICE MENU
It is possible to scroll items of
service menu by using buttons
and 2. These submenus are
ZAPI CONTROLLERS and
DIS00-UP DISPLAY.Push
button* to enter the desired
menu.
DIS00-UP SOFTWARE
The display will show some
parameter of the display. You
can adjust them by the button.
BUTTON 0*= ENTER/OK
BUTTON1= ROLL UP
BUTTON2= ROLL DOWN
BUTTON3= SET UP
BUTTON4 = SET DOWN
BUTTON5= OUT
ZAPI CONSOLE
The display will act like a
ZAPI can conslole.
BUTTON 0*= ENTER/OK
BUTTON1= ROLL UP
BUTTON2= ROLL DOWN
BUTTON3= SET UP
BUTTON4 = SET DOWN
BUTTON5= OUT
MAIN PAGE WITH OR WITHOUT
ALARMS
If there are no alarms, the main page shows
battery charge, traction hour meter and
truck speed. If alarm are persent the main
page shows alarm code and node number
where alarm has occurred.
START
** Button5
PASSWOERD
REQUEST
password
Fig0000-00185OM

REV. 09/2022
11
B
DIS00-UP display doesn’t calculate the remaining capacity of the battery. It just reads the battery
information from the controller and shows the percentage with twenty grids.
If the battery is fully charged and the controller veries the capacity of battery is 100%, the display
will show twenty grids as 100%.
If the battery is not fully charged or used for several times, the controller veries the percent of the
battery capacity. And the display will show the percent by grids. Each grid means 5% of the battery
capacity.
When the controller verify the remaining capacity of the battery is nearly empty, the display will
show just one grid. And this grid will keep blinking.
Battery Indicator【1】
Fig0000-00230OM
Fig0000-00231OM
Fig0000-00232OM
Fig0000-00233OM
1 2
3
4