EP Equipment J1HD User manual

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Part No.508000003143
V1 10/2019

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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
Fax: + 86-0571-28035616
Website: www.ep-ep.com
Email: servi[email protected]m

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Foreword
Thanks for purchasing our task support vehicle.
The present original operating instructions are designed to provide sufficient
instruction for the safe operation and maintenance of the truck.Please be sure to read
this operator manual carefully if you are operator or are in charge of the truck,before
you operate and service the truck. Only in this way can you protect yourself and make
the truck play a role as much as possible.
Our trucks are subject to ongoing development, so maybe there are some
differences between your product and the description in this manual. And the operator
manual details will be different because of customer's special requirements.
If you have any questions ,please keep in touch with the sales department of
Equipment 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.
Warning!
The truck can only be used indoors !
EP EQUIPMENT CO.,LTD.
Address: XIAQUAN,DIPU,ANJI,ZHEJIANG,CHINA
Tel:[phone]
Fax:[phone]
Net:www.ep-ep.com
Email:[e-mail]
2019.10 1st EDITION

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WARNING!
TO PREVENT SETIOUS RISK OF INJURY TO
YOUORSELF AND OTHERS OBSERVE THE
FOLLOWING SAFETY INSTRUCTIONS.
These trucks 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 operator position.
– Press the emergency brake switch .
– 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. 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

III
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 Truck Assemblies...................................................................................................................3
1.3 Standard Version Specifications............................................................................................5
1.4 Identification points.............................................................................................................. 8
2. Commissioning....................................................................................................... 10
2.1 Using the truck for the First Time....................................................................................... 10
2.2 During brake-in....................................................................................................................10
3.Operation................................................................................................................. 11
3.1 Safety Regulations for the Operation of trucks.................................................................. 11
3.2 Controls and Displays..........................................................................................................12
3.2.1 Control panel controls and displays.........................................................................12
3.2.2 Display unit controls and displays............................................................................14
3.3 Run the truck.......................................................................................................................17
3.4 Industrial Truck Operation.................................................................................................. 18
3.4.1 Safety regulations for truck operation.....................................................................18
3.4.2 Travel, Steering, Braking.......................................................................................... 18
3.4.3 Lifting - Lowering..................................................................................................... 20
3.4.4 Order picking and placing load units....................................................................... 22
3.5 Parking the truck securely...................................................................................................23
4.Battery Maintenance & Charging......................................................................... 25
4.1 Safety regulations for handling acid batteries....................................................................25
4.2 Battery type & dimension...................................................................................................25
4.3Charging the battery............................................................................................................ 26
4.4 Battery removal and installation.........................................................................................26
4.5 Battery maintenance...........................................................................................................27
5. Maintenance............................................................................................................28
5.1 Operational safety and environmental protection.............................................................28
5.2 Maintenance Safety Regulations........................................................................................ 28
5.3 Servicing and inspection..................................................................................................... 29
5.3.1 Maintenance Checklist............................................................................................ 30
5.3.2 Lubrication Schedule............................................................................................... 32
5.3.3 Maintenance Instructions........................................................................................33
5.3.4 Recommissioning..................................................................................................... 34
5.4 Decommissioning the truck................................................................................................ 35
5.4.1Prior to decommissioning.........................................................................................35
5.4.2 Restoring the truck to operation after decommissioning.......................................35
5.5 Safety checks to be performed at regular intervals and following any unusual incidents 36
5.6 Final de-commissioning, disposal....................................................................................... 36
6.Troubleshooting.......................................................................................................37
6.1 Error Message..................................................................................................................... 38

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6.1.1 Traction Controller (COMBIAC0 _MASTER uc)........................................................ 38
6.1.2 Traction Controller (COMBIAC0_SLAVE uc)............................................................. 69
6.1.3 Steering Controller (EPS-AC0)..................................................................................75

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Correct use and Application
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
supplied with the truck. The guidelines is an important component of these operating
instructions and must be observed. Your country's relevant laws and regulations is not
affected.
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 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 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 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.
Adding accessories
The mounting or installation of additional equipment which affects or enhances the
performance of the truck requires the written permission of the manufacturer. Local
authority approval may also need to be obtained.
Local authority approval does not however constitute the manufacturer’s approval.

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1. Truck Description
1.1 Application
The J1HD is an electric truck.The J1HD is designed to transport and pick goods on
level surfaces.Loads can be stacked,unstacked and transported over long distances.
The capacity can be obtained from the data plate.
Warning!
The truck can only be used indoors !

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1.2 Truck Assemblies
Item
Component
Item
Component
1
Control panel
11
Battery
2
Load handler
12
Dead man switch
3
Warning lamp
13
Height-adjustable operator position
4
Cover
14
Load wheel
5
Controller
15
Gates
6
Balance wheel
16
Pallet
7
Frame
17
Mast
8
Drive wheel
18
Blue lamp
9
Hydraulic pump
19
White lamp
10
Battery baffle

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Safety mechanisms: An enclosed truck geometry with rounded edges ensures safe
handling of the truck. Pressing the Emergency brake switch disconnects all
electrical functions in hazardous situations.Gates on either side of the cab interrupt all
truck operations as soon as they are opened.When you start up the truck the drive
pedal must be applied.
Drive: The entire drive unit is enclosed in the truck chassis.
The electronic traction controller ensures the smooth rotation of the drive motor and
as a result smooth driving, powerful acceleration.
Brake system: The operator can brake gently and wear-free by pulling back the
travel control button.The electromagnetic spring pressure brake acting on the drive
motor serves as both parking and handbrake.
Steering system:Extremely smooth steering with three phase drive system.The
steering wheel is integrated in the control panel. The position of the steered drive
wheel is shown in the control panel display unit. The maximum steer angle is

90°.
Controls and Displays：The functions are activated via ergonomic thumb movement
to ensure fatigue-free operation without stressing the wrists; sensitive application of
travel and hydraulic movements to spare and position the goods precisely.Driver's
display unit for all important driver information such as steering wheel position,overall
lift, truck status reports (e.g. faults), battery capacity and time etc..
Hydraulic system ：All hydraulic operations are controlled by a sturdy,
maintenance-free AC motor with no wear parts and with a flanged low emission gear
pump.Oil is distributed via magnetic switch valves. The varying oil requirements are
controlled by the speed of the motor.
Electrical system:Standard electronic drive, lift and steering control system.The
electronic drive control enables plugging when changing direction.
For controls options see chapter three.

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1.3 Standard Version Specifications
Technical specification details in accordance with VDI2198. Technical modifications
and additions reserved.
Unit
Distinguishing mark
1.1
Manufacturer
EP
EP
1.2
Model designation
J1HD(4110)
J1HD(5330)
1.3
Drive unit
Electrics
Electrics
1.4
Operator type
standing
standing
1.5
rated capacity on front platform
Q1
Kg
Δ318
Δ318
rated capacity on behind platform
Q2
Kg
137
137
rated capacity on standing platform
Q3
Kg
136
136
1.9
Wheelbase
y
mm
1300
1300
Weight
2.1
Service weight （include battery）
kg
1440
1630
2.2
Axle loading, laden driving side/loading
side
kg
740/1100
780/1220
2.3
Axle loading, unladen driving
side/loading side
kg
520/820
540/990
Types,Chassis
3.1
Tyre type, Driving wheels/Loading wheels
polyurethane
/polyurethane
polyurethane
/polyurethane
3.2
Tyre size, driving wheels
（Diameter×Width）
mm
Φ260*125
Φ260*125
3.3
Tyre size, loading wheels
（Diameter×Width）
mm
Φ204*76
Φ204*76
3.4
Tyre size, caster wheels（diameter×width）
mm
Φ74*48
Φ74*48
3.5
Wheels, number driving，caster/loading
(x=drive wheels)
mm
1x,2/2
1x,2/2
Dimensions
4.2
Height, mast lowered
h1
mm
2120
2250
4.8
Seat height/standing height)
h7
mm
250
250
4.14
Stand height, elevated
h12
mm
4110
5330
4.19
Overall length
L1
mm
1685
1685
4.21
Overall width
b1/b2
mm
914
914
4.32
Ground clearance, center of wheelbase
m2
mm
50
50
4.33
front cargo platform width
B0×L2
mm
900×700
900×700
4.34
initial height of front cargo platform
h2
mm
1082
1082
4.35
Control handle height
h5
mm
1010
1010

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4.36
behind platform width
L4×B1
mm
346×714
346×714
4.37
Overall length platform launch
L3
mm
2000
2000
4.38
The channel width
Ast
mm
2260
2260
4.39
Turning radius
Wa
mm
1600
1600
Performance data
5.1
drive speed, laden/unladen
km/ h
10.5
10.5
drive speed, laden/unladen
km/ h
5
5
drive speed, laden/unladen
km/ h
3.2
3.2
drive speed, laden/unladen
km/ h
1.6
1.6
5.2
Lifting speed, laden/ unladen
m/ s
0.20/0.28
0.20/0.28
5.3
Lowering speed, laden/ unladen)
m/ s
0.35/0.30
0.35/0.30
5.8
Max. gradeability, laden/unladen
%
0
0
5.10
Service brake type
Electromagnetic
Electromagnetic
Electric-engine
6.1
Drive motor rating S2 60 min
kW
4
4
6.2
Lift motor rating at S3 15%
kW
4
4
6.3
The maximum allowed size battery
mm
300x840x670
300x840x670
6.4
Battery voltage/nominal capacity K20
V/ Ah
48V/360AH
48V/360AH
6.5
Battery weight
kg
300
300
Addition data
8.1
Type of drive unit
AC
AC
10.5
Steering type
Electronic
Electronic
10.7
Sound pressure level at the driver’s ear
dB (A)
74
74
1）Including safety distance a = 200mm

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J1HD

8
1.4 Identification points

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Item
Description
1
Sling label
2
Information sign "Never standing"
3
Operator warning decal
4
Emergency Lowering label
5
AC Power Decal
6
“Never put your hands in inner and outer mast.“ warning
7
Nameplate
8
Operator danger decal
9
Key Switch decal
10
Lift Lower Horn decal
11
Forward/Reverse travel
12
Power shut off
13
Foot pedal label
14
Operator caution decal

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2. Commissioning
2.1 Using the truck for the First Time
Only operate the truck with battery current.
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), (see "4.4 Battery removal and
installation" on page 23) do not damage battery cable.
•Charge the battery, (see "4.3 Charging the battery" on page 23).
When the truck is parked the surface of the tyres will flatten. The flattening will
disappear after a short period of operation.
2.2 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.

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3.Operation
3.1 Safety Regulations for the Operation of trucks
Driver authorization: The 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 authorized to operate the truck by the proprietor or his
representative.
Driver’s rights, obligations and 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.
Unauthorized Use of truck: The driver is responsible for the truck during the time it
is in use. He shall prevent unauthorized 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 truck. trucks not safe for operation (e.g. wheel or brake problems) must
not be used until they have been rectified.
Repairs: The driver must not carry out any repairs or alterations to the truck without
the necessary training and authorization to do so. The driver must never disable or
adjust safety mechanisms or switches.
Hazardous 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 lowering operating equipment.
·Unauthorized persons must be kept away from the hazardous area.
·Where there is anger to personnel, a warning must be sounded with sufficient
notice.
·If unauthorized personnel are still within the hazardous area the truck shall be
brought to a halt immediately.
Safety Devices and Warning Signs: Safety devices, warning signs and warning
instructions shall be strictly observed.

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3.2 Controls and Displays
3.2.1 Control panel controls and displays

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Item
Control / Display
Function
1
Steering wheel
Steers the truck in the required direction.
2
Display unit
Operating information and warning message display.
3
"Lifting" button
Lift the operator position.
4
"Lowering" button
Lower the operator position.
5
"Horn" button
Activates the horn.
6
Emergency stop switch
Disconnects the supply current, deactivates all electrical
functions, causing the truck to brake automatically.
7
Travel switch
Select the required driving direction.
8
Key switch
Switches control current on and off. Removing the key prevents
the truck from being switched on by unauthorized personnel.
9
White lamp button
Control white light lights on and off.