EP Equipment HPL152 User manual

EP EQUIPMENT CO.,LTD. is one of the
world’s leading companies manufacture,
design material handling equipment and
provide related service. With over
100,000m2plant it produces over
100,000 trucks per year, and provides
professional, effective 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.
Based on the concept of sharing
economy , EP also offer 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”.
EP EQUIPMENT CO., LTD
Address: XIAQUAN, DIPU, ANJI,
ZHEJIANG, CHINA
Tel: + 86-0571-28023920
Website: www.ep-ep.com
Email: servi[email protected]m

I
Foreword
Thanks for your purchasing our Pallet truck.
This manual is about how to use, operation and maintenance. 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 or let
the dealer know.
Notes:
1. This manual is used for operation and maintenance , the detail parameters, size
and specifications in context is only for reference , the real parameters will depend on
sale files.
2. Manual pictures for reference only, the real car shall prevail, and shall not affect the
manual use.
EP EQUIPMENT CO.,LTD
Address: XIAQUAN,DIPU,ANJI,ZHEJIANG,CHINA
Tel: [phone]
Fax: [phone]
Net: www.ep-ep.com
Email: [e-mail]
ALL RIGHT RESERVED COPYRIGHT
2019.09 1st EDITION

II
WARNING!
TO PREVENT SETIOUS RISK OF INJURY TO
YOUORSELF AND OTHERS OBSERVE THE
FOLLOWING SAFETY INSTRUCTIONS.
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,lubrication 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.

III
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.

IV
Catalog
Correct use and application....................................................................................................1
1. Truck Description................................................................................................................. 2
1.1 Application...................................................................................................................2
1.2 Assemblies..................................................................................................................3
1.2.1 Control Handle........................................................................................................ 4
1.2.3 Discharge indicator................................................................................................ 4
1.3 Identification points and data plates....................................................................... 6
1.3.1 Truck data plate...................................................................................................... 8
1.4 Standard Version Specifications..............................................................................9
1.4.1 Performance data for standard trucks.................................................................9
2. Transport and Commissioning.........................................................................................12
2.2 Using the Truck for the First Time......................................................................... 12
2.3 During brake-in........................................................................................................ 13
3.Operation............................................................................................................................. 14
3.1Safety Regulations for the Operation of Pallet Trucks........................................14
3.2 Operate and run the truck...................................................................................... 15
3.2.1 Preparing............................................................................................................... 15
3.2.2 Travel ,Steering,.Braking.....................................................................................15
3.2.3Lifting, transporting and depositing loads..........................................................16
3.2.4Parking the truck securely....................................................................................17
4.Battery Maintenance & Charging..................................................................................... 18
4.1 Lithium Battery Precautions...................................................................................18
4.2 Battery & Charger....................................................................................................19
4.3 Charging the battery................................................................................................20
4.3.1 Vehicle charging................................................................................................... 20
4.3.2 External charging................................................................................................. 21
4.4 Charge Completed.................................................................................................. 22
4.5 Charger Installation................................................................................................. 23
4.6 Maintenance & Care............................................................................................... 23
5.Pallet Truck Maintenance.................................................................................................. 24
5.1 Operational safety and environmental protection...............................................24
5.2 Maintenance Safety Regulations.......................................................................... 24
5.3 Servicing and inspection........................................................................................ 25
5.3.1Maintenance Checklist......................................................................................... 26
5.3.2 Lubrication Schedule........................................................................................... 27
5.3.3 Maintenance Instructions.................................................................................... 28
5.4 Decommissioning the industrial truck...................................................................29
5.4.1 Prior to decommissioning....................................................................................29
5.4.2 Restoring the truck to operation after decommissioning................................29
5.5Safety checks to be performed at regular intervals and following any unusual
incidents...........................................................................................................................30
5.6Final de-commissioning, disposal.......................................................................... 30

V
6.Troubleshooting.................................................................................................................. 31
Error Message................................................................................................................ 31
Lithium battery operating instructions.................................................................................35
Chapter 1 Safety Precautions...................................................................................... 36
Chapter 2 Battery Introduction and Instructions........................................................37
Chapter 3 Charging........................................................................................................38
Chapter 4 Storage..........................................................................................................39
Chapter 5 Transportation.............................................................................................. 40
Chapter 6 Common Problems and Solutions............................................................ 41
Chapter 7 Maintenance................................................................................................. 42

1
Correct use and application
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 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 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
Approval.

2
1. Truck Description
1.1 Application
The truck is designed to transport goods on level surfaces. It can lift open bottom or
diagonal board pallets as well as roll cages beyond the area of the load wheels.
Suitable environment temperature is 5°C to 40 °C.
If a long time in less than 5 ° C environment, cold storage or in the extreme conditions
of temperature and humidity changes in the use of Pallet, you must install additional
special equipment, and obtain permission from the manufacturer.

3
1.2 Assemblies
Item
Component
Item
Component
1
Control handle
6
Battery
2
Control shaft
7
Lowering lever
3
Pump
8
Fork
4
Driving wheel
9
Emergency stop switch
5
Load wheels

4
1.2.1 Control Handle
1.2.3 Discharge indicator
The LCD display (1) show battery residual capacity.
The color of the LCD (1) represent the following conditions:
Component
LCD color
Residual capacity
Standard
battery residual
capacity
Green
30-100%
Yellow
15-30%
Flashing red light
0-15%
If the controller detects a battery failure, flashes of LCD（1）represent battery failure
information until the failure is remedied. Details of failure information are shown as
below:
Under-voltage of single cell battery: The green light repeats in a cycle of flashing once
in 1 second, pausing for 2 seconds and then flashing twice, pausing for 3 seconds.
Over-voltage of single cell battery: The green light repeats in a cycle of flashing once
Item
Control / Display
Function
1
"Horn" button
Activates the horn.
2
Power switch button
Starting truck
3
Lowering lever
Pull the lowering lever and hold. The forks will be
lowered to its minimum height and stop on its own.
4
Emergency stop switch
By pressing this switch, the vehicle starts to travel
in the opposite direction
5
Drive switch
Select the required driving direction and speed.

5
in 1 second, pausing for 2 seconds and then flashing three times, pausing for 3
seconds.
Short circuit 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
1 second, pausing for 2 seconds and then flashing three times, pausing for 3 seconds.
Battery temperature is too low: The green light repeats in a cycle of flashing twice in 1
second, pausing for 2 seconds and then flashing four times, pausing for 3 seconds.
Contactor-related failures: The green light repeats in a cycle of flashing three times in
1 second, pausing for 2 seconds and then flashing four times, pausing for 3 seconds.
The yellow light flashes rapidly in 1 second when other failures happen.
When powered off, if the green light of power indicator is always on, it means that the
battery is in a balanced state, which is a normal phenomenon.
LCD (2) displays the state of charge;
The LCD (3) remain green light lit under normal,
flashing show the failure state of truck （See
section 6 Trouble shooting Error Message）.
DISPLAY
DESCRIPTION
Continuous red
Charge is charging
Continuous green
Battery charging is complete

6
1.3 Identification points and data plates
Item
Description
1
Nameplate
2
“Instructions”label
3
Emergency stop switch label
4
Anti pinch hand label
5
Charging indicator label
6
No Riding
7
Fault Indicator Label
8
LIION Logo
9
Sling Label

7

8
1.3.1 Truck data plate
For queries regarding the truck or ordering spare parts please quote the truck serial
number(3).
Item
Description
Item
Description
1
Product name
8
Battery voltage(v)
2
Model type.
9
Rated drive power(kw)
3
Series no.
10
Max battery weight(kg)
4
Manufacture date
11
Min battery weight(kg)
5
Lift height(mm)
12
Rated capacity(kg)
6
Unladen mass with battery(kg)
13
Load center(mm)
7
Unladen mass without battery(kg)

9
1.4 Standard Version Specifications
1.4.1 Performance data for standard trucks
Technical specification details in accordance with VDI2198. Technical modifications
and additions reserved.
Distinguishing mark
1.2
Model designation
HPL152
1.3
Drive unit
Battery
1.4
Operator type
Walkie
1.5
rated capacity
Q
lb.
kg
1500
1.6
Load center distance
c
in.
mm
600
1.8
Load distance
x
in.
mm
883/946
1.9
Wheelbase
y
in.
mm
1105/1168
Weight
2.1
Service weight （include battery）
lb.
kg
130
2.2
Axle loading, laden driving side/loading
side
lb.
kg
558/1172
2.3
Axle loading, unladen driving
side/loading side
lb.
kg
84/46
Types,Chassis
3.1
Tyre type driving wheels/loading
wheels
PU/ PU
3.2
Tyre size, driving wheels
（diameter×width）
in.
mm
Ф210x70
3.3
Tyre size, loading wheels
（diameter×width）
in.
mm
2x Ф78x60（Ф78x88）
3.4
Tyre size, caster wheels
（diameter×width）
in.
mm
/
3.5
Wheels, number driving，caster/loading
(x=drive wheels)
in.
mm
1x /4（1x /2）
3.6
Track width, front,driving side
b10
in.
mm
/
3.7
Track width,rear,loading side
b11
in.
mm
390
Dimensions
4.4
Lift height
h3
in.
mm
115
4.9
Height drawbar in driving position
min./max.
h14
in.
mm
638/1275
4.15
Lowered height
h13
in.
mm
80
4.19
Overall length
l1
in.
mm
1518
4.20
Length to face of forks
l2
in.
mm
381

10
4.21
Overall width
b1/ b2
in.
mm
548
4.22
Fork dimensions
s/ e/ l
in.
mm
50/150/1150
4.25
Distance between fork-arms
b5
in.
mm
540
4.32
Ground clearance, center of wheelbase
m2
in.
mm
30
4.34.
1
Aisle width for pallets 1000 × 1200
crossways
Ast
in.
mm
1612
4.34.
2
Aisle width for pallets 800 × 1200
lengthways
Ast
in.
mm
1812
4.35
Turning radius
Wa
in.
mm
1358
Performance data
5.1
Travel speed, laden/ unladen
km/
h
mp
h
km/
h
3.5/4
5.2
Lifting speed, laden/ unladen
fpm
m/ s
10mm/time
5.3
Lowering speed, laden/ unladen
fpm
m/ s
Manual
5.8
Max. gradeability, laden/unladen
%
5/10
5.10
Service brake type
Electromagnetic
Electric-engine
6.1
Drive motor rating S2 60 min
hp
kW
0.75
6.2
Lift motor rating at S3 15%
hp
kW
Manual
6.3
The maximum allowed size battery
in.
mm
Lithium-ion
Battery193x81x300
6.4
Battery voltage/nominal capacity K5
V/ Ah
24V/20Ah
6.5
Battery weight
lb.
kg
5x1
Addition data
8.1
Type of drive control
DC
10.5
Steering type
Mechanical
10.7
Sound pressure level at the driver’s ear
dB (A)
74
1）Including safety distance a = 200 mm

11
HPL152

12
2. Transport and Commissioning
2.1 Lifting the truck by crane
1.Only use crane handling equipment gear 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 ).
– 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 Using the Truck for the First 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.
•Check the hydraulic oil level.
•Install the battery if necessary (where required), do not damage battery cable.
•Charge the battery, (see "4.3 Charging the battery" ).
When the truck is parked the surface of the tyres will flatten. The flattening will
disappear after a short period of operation.
Warning!
– To 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.

13
2.3 During 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.
•Must prevent the new battery from over discharging when early used. Please
charging when remain power less than 20%.
•Perform specified preventive maintenance services carefully and completely.
•Avoid sudden stop, starts or turns.
•Oil changes and lubrication are recommended to do earlier than specified.
•Limited load is 70～80% of the rated load.