Ep equipment Ept20-20ra User manual

Foreword

Thanks for your purchasing our forklift truck.

This manual is about how to use, operation and maintenance EPT20-20WA.

Please operator and whom in charge of the truck must read the manual carefully

before operate the truck.

We have the right to improve the truck, maybe there are some difference between

your product and the description in this manual.

If you have any questions please keep in touch with the sales department of E-P

Equipment or let the dealer know.

EP EQUIPMENT

EQUIPMENT

EQUIPMENT CO.,LTD.

CO.,LTD.

Address:

Address: XIAQUAN,DIPU,ANJI,ZHEJIANG,CHINA

XIAQUAN,DIPU,ANJI,ZHEJIANG,CHINA

Tel:

Tel: 86-572-5333300

86-572-5333300

Fax:

Fax: 86-572-5333303

86-572-5333303

Net:

Net: www.ep-ep.com

www.ep-ep.com

Email:

Email: ki[email protected]

kin[email protected]

ALL

ALL RIGHT

RIGHT

RIGHT RESERVED

RESERVED

RESERVED COPYRIGHT

201

201 1

1 .

. 3

3 1

EDITION

WARNING

WARNING !

TO PREVENT

PREVENT

PREVENT SETIOUS

SETIOUS

SETIOUS RISK

RISK

RISK OF

OF INJURY

INJURY

INJURY TO

YOUORSELF

YOUORSELF AND

AND

AND OTHERS

OTHERS

OTHERS OBSERVE

OBSERVE

OBSERVE THE

THE

FOLLOWING

FOLLOWING SAFETY

SAFETY

SAFETY INSTRUC

INSTRUC

INSTRUC T

T IONS.

IONS.

These truck may become hazardous if adequate maintenance is neglected. Therefore,

adequate maintenance facilities, trained personnel and procedures should be

provided.

Maintenance and inspection shall be performed in conformance with the following

practices:

1. A scheduled planned maintenance,lu brication and inspection system should be

followed.

2. Only qualified and authorized personnel shall be permitted to maintain, repair,

adjust, and inspect truck.

3. Before leaving the truck:

– Do not park the truck on an incline.

– Fully lower the load forks.

– Set the key switch to the " OFF " position and remove the key.

4. Before starting to operate truck:

– Be in operating position

– Place directional control in neutral

– Before operating truck, check functions of lift systems, directional control,speed

control,steering, warning devices and brakes.

5. Avoid fire hazards and have fire protection equipment present. Do not use open

flame to check lever, or for leakage of electrolyte and fluids or oil. Do not use open

pans of fuel or flammable cleaning fluids for cleaning parts.

6. Brakes,steering mechanisms, control mechanisms,guards and safety devices shall

be inspected regularly and maintained in legible condition.

7. Capacity, operation and maintenance instruction plates or decals shall be

maintained in legible condition.

8. All parts of lift mechanisms shall be inspected to maintain them in safe operating

condition.

9. All hydraulic systems shall be regularly inspected and maintained in conformance

with good practice. Cylinders, valves and other similar parts shall be checked to

assure that "drift" has not developed to the extent that it would create a hazard.

10. Truck shall be kept in a clean condition to minimize fire hazards facilitate

detection of loose or detective parts.

11. Modifications and additions which affect capacity and safe truck operation shall

not be performed by the customer or user without manufacturers prior written

approval. Capacity, operation and maintenance plates or decals shall be changed

accordingly.

Catalog

Correct

Correct use

use

use and

and

and application

application

application ........................................................................................... 1

1. Truck

Truck

Truck Description

Description

Description ......................................................................................................... 2

1.1Application .............................................................................................................. 2

1.2 Assemblies ............................................................................................................. 3

1.2.1Control Handle ............................................................................................. 4

1.2.2Key switch .................................................................................................... 4

1.2.3Battery discharge indicator ......................................................................... 5

1.2.4Emergency brake switch ............................................................................. 5

1.3 Identification points and data plates .................................................................... 6

1.3.1Truck data plate ........................................................................................... 7

1.4.Standard Version Specifications .......................................................................... 7

1.4.1Performance data for standard trucks ....................................................... 8

1.4.2Dimensions ................................................................................................... 9

2.Transport

2.Transport and

and

and Commissioning

Commissioning

Commissioning ................................................................................. 11

2.1Transport ............................................................................................................... 11

2.2Using the Truck for the First Time .......................................................................

2.3During brake-in ..................................................................................................... 12

3.Operation

3.Operation ...................................................................................................................... 13

3.1Safety Regulations for the Operation of Forklift Trucks .................................... 13

3.2 Operate and run the truck .................................................................................. 14

3.2.1 Preparing ................................................................................................... 14

3.2.2 Travel ......................................................................................................... 14

3.3.3Lifting, transporting and depositing loads ................................................ 16

3.3.4Parking the truck securely ........................................................................ 17

4.Battery

4.Battery Maintenance

Maintenance

Maintenance &

& Charging

Charging

Charging ............................................................................. 18

4.1 Safety regulations for handling acid batteries .................................................. 18

4.2 Battery type & dimension ................................................................................... 18

4.3Charging the battery ............................................................................................ 19

4.3.1Exposing the battery .................................................................................. 19

4.3.2 Charging .................................................................................................... 19

4.4Battery removal and installation .......................................................................... 20

4.5Battery maintenance ............................................................................................ 20

4.6Battery Disposal ................................................................................................... 21

5.Forklift

5.Forklift Truck

Truck

Truck Maintenance

Maintenance

Maintenance ........................................................................................ 22

5.1Operational safety and environmental protection .............................................. 22

5.2Maintenance Safety Regulations ........................................................................ 22

5.3Servicing and inspection ..................................................................................... 24

5.3.1Maintenance Checklist .............................................................................. 25

5.3.2 Lubrication Schedule ................................................................................ 27

5.3.3 Maintenance Instructions ......................................................................... 28

5.4Decommissioning the industrial truck ................................................................. 30

5.4.1Prior to decommissioning .......................................................................... 30

5.4.2 Restoring the truck to operation after decommissioning ....................... 31

5.5Safety checks to be performed at regular intervals and following any unusual

incidents ..................................................................................................................... 31

5.6Final de-commissioning, disposal ....................................................................... 32

6.Troubleshooting

6.Troubleshooting .......................................................................................................... 33

Correct

Correct use

use

use and

and

and application

application

The “ Guidelines for the Correct Use and Application of Industrial Trucks ” (VDMA) are

supplied with the truck. The guidelines form part of these operating instructions and

must be observed. National regulations apply in full.

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 serviced in accordance with the present instructions.

Any other type of use is beyond the scope of application and can result in damage to

personnel, the truck or property. In particular, avoid overloading the truck with loads

which are too heavy or placed on one side. The data plate attached to the truck or the

load diagram are binding for the maximum load capacity. The industrial truck must not

be used in fire or explosion endangered areas, or areas threatened by corrosion or

excessive dust.

Proprietor

Proprietor responsibilities

responsibilities

For the purposes of the present operator manual the “ proprietor ” is defined as any

natural or legal person who either uses the industrial truck himself, or on whose behalf

it is used. In special cases (e.g. leasing or renting) the proprietor is considered the

person who, in accordance with existing contractual agreements between the owner

and user of the industrial truck, is charged with operational duties.

The proprietor must ensure that the truck is used only for the purpose it is intended for

and that danger to life and limb of the user and third parties are excluded.

Furthermore, accident prevention regulations, safety regulations and operating,

servicing and repair guidelines must be followed. The proprietor must ensure that all

truck users have read and understood this operator manual.

Failure to comply with the operator manual shall invalidate the warranty. The same

applies if improper work is carried out on the truck by the customer or third parties

without the permission of the manufacturer ’ s customer service department.

Attaching

Attaching accessories

accessories

The mounting or installation of additional equipment which affects or supplements the

performance of the industrial truck requires the written permission of the manufacturer.

In some cases, local authority approval shall be required.

Approval of the local authorities however does not constitute the manufacturer ’ s

A pproval.

1. Truck

Truck

Truck Description

Description

1.1Application

The truck is a tiller operated electric pallet truck with a folding operator platform and

side arms.

The truck is designed for lifting and transporting goods on a level surface. The truck

can pick up, outside the load wheel area, open bottom or diagonal board pallets as

well as roll cages . The capacity of the truck is shown on the data plate or the data

capacity plate Qmax.

1.2

1.2 Assemblies

Assemblies

Item Description Item Description

1 Travel switch 7 Caster wheel

2 Tiller 8 Drive wheel

3 Key switch 9 Pressure sensitive mat

4 Battery discharge indicator 10 Folding operator platform

5 Emergency brake swi t ch 11 Ram protection

6 Side arm

1.2.1Control

1.2.1Control Handle

Handle

1. 2.

2. 2

2 Key

Key

Key switch

switch

Switches control current on and off.

Removing the key prevents the truck from being switched on by unauthorised

personnel.

“ Lower ” button Lowers load forks.

1 2

“ Lift ” button Raises load forks.

1 3

Travel switch Controls the driving speed and direction

1 4

Warning signal

button

Triggers a warning signal.

1 5

Collision safety

switch

Safety function which, when activated, forces the truck to

reverse until the switch restored to neutral.

1.2.3

1.2.3 Battery

Battery

Battery discharge

discharge

discharge indicator

indicator

The LEDs (1) represent battery residual

capacity, The LCD (2) displays the

operating hours

Battery

Battery Discharge

Discharge

Discharge Indicator

Indicator

Indicator (1)

(1)

When the truck has been released via

the key switch, the battery charge

status is displayed.

The colours of the LEDs (1) represent

the following conditions:

LED colour value

Green Standard battery residual capacity 70-100%

Orange Standard battery residual capacity 50-60%

Flashing Red Standard battery residual capacity 0-20%

Battery Discharge for 70%, A flashing red show on storage battery charge warning.

Battery Discharge for 80%, Two flashing reds show on battery charge used up

warning , Lifting is now inhibited. The battery must be charged.

Operating

Operating hours

hours

hours display

display

Display range between 0.0 and 99,999.0 hours. Travel and lifting are logged. This is a

backlit display .

Power

Power up

up test

test

On power up the display shows:

– the operating hours

– the charge status

1.2.4

1.2.4 Emergency

Emergency

Emergency brake

brake

brake swi

swi

swi t

t ch

The supply current is interrupted, all electrical functions are deactivated and the truck

is automatically braked.

1.3

1.3 Identification

Identification

Identification points

points

points and

and

and data

data

data plates

plates

Item

Description

1 Logo decal

Decal hook-up caution

Hook decal

Plate data

Decal operation warning

AC power decal

1.3.1

1.3.1 Truck

Truck

Truck data

data

data plate

plate

Item Description Item Description

1 Manufacturer 6 Fork length （mm ）

2 Model name 7 (Recommendation) Battery capacity （Ah ）

3 Type 8 Net weight w.o. battery

（

）

4 Rated capacity （kg ）9 Serial no.

5 Fork width(mm)

For queries regarding the truck or ordering spare parts always quote the truck

serial number ( 9 ).

MODEL

MODEL NUMBER

NUMBER

NUMBER EXAMPLE

EXAMPLE

EPT

EPT 20

20 –

–

– 20

20 R

R A

Electric pallet truck AC Power

Walk

Capacity: 20 = 20 00 kg

1.4.Standard

1.4.Standard Version

Version

Version Specifications

Specifications

Technical specification details in accordance with VDI 2198. Technical modifications

and additions reserved.

1.4.1

1.4.1 Performance

Performance

Performance data

data

data for

for

for standard

standard

standard trucks

trucks

Item Description parameter Unit

Load capacity 2000 kg

Load center 600 mm

Travel speed

laden

7.5

km/h

unladen

8.5

km/h

Lifting speed

laden

0.056

m/s

unladen

0.060

m/s

Lowering speed

laden

0.057

m/s

unladen

0.057

m/s

Maximum

gradeability S

5 min.

laden

unladen

Service brake Electromagnetic

Service weight Incl. battery

670

Axle loading, laden

operator/load side

1066/ 1604

Axle loading, unladen operator/load side

546/ 124

Motor rating power

Drive

1.5

Lift

2.2

Tyre type PU/PU

Tyre size, operator side

Ф 230 × 75

Tyre size, load side

2 × Ф 85 × 70

Balance wheels (dimensions)

Ф 130 × 60

Battery

Type Industry battery

voltage/ rated capacity

24/210

V/Ah

weight 190 kg

Sound level at operator's ear 74 dB(A)

1.4.2Dimensions

Item Description parameter Unit

X Load distance (Raised/ Lowered) 916/ 982 937/ 1003 mm

Y Wheelbase 1420 1440 mm

h3 Lift height 125 mm

b11 Tread load side 370/ 515 mm

h13 Fork height lowered 85 mm

h14

Height of tiller arm in operating

position

min

1150

max

1470

Overall length 1860 1930

l2 Length to face of forks

710

b1 Overall width

730

Fork dimensions

T hickness

55 55

e W idth

170 170

l L ength

1150 1220

b5 Fork spread 540/ 685 mm

m2 Ground clearance

Wa Outer turning radius 1700 1725 mm

Ast Aisle width

1000 × 1200 pallet crossways

2400

800 × 1200 pallet lengthways

2263

2. Transport

Transport

Transport and

and

and Commissioning

Commissioning

2.1

2.1 Transport

Transport

Lifting

Lifting the

the

the truck

truck

truck by

by crane

crane

There are two way to pack the truck: one

is use a stock, the other is use a box. The

way to pick up depend on transport.

1. Only use crane handling equipment

ge ar with sufficient capacity.

2. Loading weight > net weight of truck (+

battery weight for electric trucks). Loading

weight not only net weight of truck but

also the stock or the box.

3. Stock (box) should be big enough and

strong enough to bear hole truck.

– Park the truck securely . (see 3.2.4

Parking the truck securely on page 17 ).

–Make sure forks are positioned properly

for the pallet. Move forward slowly to

insert forks into the pallet as far as

possible and then stop the truck.

2.2

2.2 Using

Using

Using the

the

the Truck

Truck

Truck for

for

for the

the

the First

First

First Time

Time

Only operate the truck with battery current. Rectified AC current will damage the

electronic components. Cable connections to the battery (tow leads) must be less

than 6 m .

Preparing the truck for operation after delivery or transport

Procedure

–Check the equipment is complete.

–Che ck the hydraulic oil level.

–Install the battery if necessary (where required) , (see " 4.4 Battery removal and

installation" on page 20 ) do not damage battery cable .

–Charge the battery, (see " 4.3 Charging the battery" on page 19 ).

When the truck is parked the surface of the tyres will flatten. The flattening will

disappear after a short period of operation.

Warning

Warning !

–

avoid break the fork be hurt when you move the truck to stock.

–In order to keep the truck out of be scraped,please move the truck void in

void and flat place.

– when you lowering the stock advert status of the place to avoid collapse.

2.3During

2.3During brake-in

brake-in

We recommended operating the machine under light load conditions for the first stage

of operation to get the most from it. Especially the requirements given below should

be observed while the machine is in a stage of 100 hours of operation.

1. Must prevent the new battery from over discharging when early used. Please

charging when remain power less than 20%.

2. Perform specified preventive maintenance services carefully and c . ompletely.

3. Avoid sudden stop, starts or turns.

4. Oil changes and lubrication are recommended to do earlier than specified.

5. Limited load is 70 ～80% of the rated load.

3. Operation

Operation

3.1Safety

3.1Safety Regulations

Regulations

Regulations for

for

for the

the

the Operation

Operation

Operation of

of Forklift

Forklift

Forklift Trucks

Trucks

Driver

Driver authori

authori

authori s

s ation:

ation:

ation: The forklift truck may only be used by suitably trained

personnel, who have demonstrated to the proprietor or his representative that they

can drive and handle loads and have been authorised to operate the truck by the

proprietor or his representative.

Driver

Driver ’

’

’ s

s rights,

rights,

rights, obligations

obligations

obligations and

and

and responsibilities:

responsibilities:

responsibilities: The driver must be informed of

his duties and responsibilities and be instructed in the operation of the truck and

shall be familiar with the operator manual . The driver shall be afforded all due rights .

Safety shoes must be worn with pedestrian operated trucks.

Unauthorised

Unauthorised Use

Use

Use of

of Truck:

Truck:

Truck: The driver is responsible for the truck during the time it

is in use. He shall prevent unauthorised persons from driving or operating the truck. It

is forbidden to carry passengers or lift personnel.

Damage and Faults: The supervisor must be immediately informed of any damage or

faults to the forklift truck. Trucks not safe for operation (e.g. wheel or brake problems)

must not be used until they have been rectified.

Repairs:

Repairs: The driver must not carry out any repairs or alterations to the forklift truck

without the necessary training and authorisation to do so. The driver must never

disable or adjust safety mechanisms or switches.

Hazardous

Hazardous area:

area:

area: A hazardous area is defined 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 owering operating equipment.

Unauthorised persons must be kept away from the hazardous area.

Where there is anger to personnel, a warning must be sounded with sufficient notice.

If u nauthorised personnel are still within the hazardous area the truck shall be brought

to a halt immediately.

Safety

Safety Devices

Devices

Devices and

and

and Warning

Warning

Warning Signs:

Signs:

Signs: Safety devices, warning signs and warning

instructions shall be strictly observed.

3.2

3.2 Operate

Operate

Operate and

and

and run

run

run the

the

the truck

truck

3.2.1

3.2.1 P

P reparing

reparing

Before the truck can be commissioned, operated or a load unit lifted, the driver must

ensure that there is nobody within the hazardous area.

Checks

Checks and

and

and operations

operations

operations to

to be

be performed

performed

performed before

before

before starting

starting

starting daily

daily

daily work

work

– Visually inspect the entire truck (in particular wheels and load handler) for obvious

damage.

– Visually inspect the battery attachment and cable connections.

Switching

Switching on

on the

the

the truck

truck

– Make sure the swi t ch is depres sed .

– Insert the key in the key switch and turn it to the right as far as it will go ( position

“ ON ” )

– Test the warning button .

The truck is now operational.

The battery discharge indicator indicates the existing battery charge status.

– Test the braking operation of the tiller .

3.2.2

3.2.2 Travel

Travel

We distinguish between two travel modes:

Truck with a folding operator platform and moving tiller.

Do not reach between the operator platform and the truck panel when you fold up the

platform.

– Pedestrian mode:

Push the side arms in, fold up the operator platform (1). The truck can only be

operated at the reduced travel speed.

– Rider mode:

Push the side arms out, fold down the operator platform (1). The truck can be

operated at maximum speed.

General:

– Set the tiller (5) to the travel zone (F).

– Turn the controller (4) to the required direction (fwd. or rev.).

If the side arms are not folded out,the truck can only be operated at reduced speed.

Do not drive the truck unless the panels are closed and properly locked.When

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