ep CQD12R User manual

I

I
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

II
Foreword
Thanks for purchasing our reach trucks.
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 E-P
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.
3.Manual pictures only sign for one of the models in this series models.
COPYRIGHT OF THESE OPERATING INSTRUCYIONS REMAINS
WITH EP CO.,LTD
OM3316 12.15

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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 load forks.
– 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

IV
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.

V
Catalog
Correct use and Application............................................................................................... 1
1. Truck Description..............................................................................................................2
1.1Application.................................................................................................................. 2
1.2 Truck Assemblies..................................................................................................... 3
1.3 Standard Version Specifications............................................................................ 5
1.3.1 Performance data for standard trucks.......................................................5
1.3.2 Dimensions....................................................................................................5
1.4 Identification points and data plates.................................................................... 10
1.4.1 Truck data plate..........................................................................................12
1.4.2 Capacity chart............................................................................................. 12
2. Commissioning................................................................................................................13
2.1 Using the truck for the First Time.........................................................................13
2.2 During brake-in....................................................................................................... 13
3.Operation............................................................................................................................14
3.1 Safety Regulations for the Operation of trucks..................................................14
3.2 Controls and Displays............................................................................................15
3.2.1 Control panel controls and displays........................................................ 15
3.2.2 Display unit controls and displays........................................................... 17
3.3 Run the truck...........................................................................................................18
3.3.1 Checking and Preparing............................................................................18
3.3.2 Adjusting the driver’s seat.........................................................................18
3.3.3 Adjusting the steering wheel.....................................................................19
3.3.4 To prepare the truck for operation........................................................... 19
3.4 Industrial Truck Operation.....................................................................................20
3.4.1 Safety regulations for truck operation..................................................... 20
3.4.2 Travel, Steering, Braking...........................................................................21
3.4.3 Lifting and depositing loads...................................................................... 22
3.5 Parking the truck securely.....................................................................................24
4.Battery Maintenance & Charging................................................................................. 25
4.1 Safety regulations for handling acid batteries....................................................25
4.2 Battery type & dimension...................................................................................... 25
4.3 Exposing the battery.............................................................................................. 26
4.4 Charging the battery.............................................................................................. 27
4.5 Battery removal and installation...........................................................................27
4.6 Battery maintenance.............................................................................................. 28

VI
5.Truck Maintenance...........................................................................................................29
5.1 Operational safety and environmental protection..............................................29
5.2 Maintenance Safety Regulations......................................................................... 29
5.3 Servicing and inspection....................................................................................... 30
5.3.1 Maintenance Checklist.............................................................................. 31
5.3.2 Lubrication Schedule................................................................................. 33
5.3.3 Maintenance Instructions.......................................................................... 34
5.4 Decommissioning the truck...................................................................................36
5.4.1 Prior to decommissioning..........................................................................36
5.4.2 Restoring the truck to operation after decommissioning......................36
5.5 Safety checks to be performed at regular intervals and following
any unusual incidents...........................................................................................37
5.6 Final de-commissioning, disposal........................................................................37
6.Troubleshooting............................................................................................................... 38

1
Correct use and Application
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.

2
1. Truck Description
1.1Application
The series is a three wheel electric side seat, clear view reach truck. It is designed for
internal and external use to lift and transport goods. Open bottom pallets
or pallets with transverse boards can be lifted inside or outside the area of the load
wheels or roll cage. Loads can be stacked, unstacked and transported over long
distances.
The capacity can be obtained from the data plate.

3
1.2 Truck Assemblies
Item
Component
Item
Component
1
Mast
8
Tank
2
Overhead guard
9
Drive wheel
3
Free lift cylinder
10
Driver's seat
4
Controller
11
Drive pedal
5
Load wheel
12
Accelerator pedal
6
Outriggers
13
Star-shaped handle
7
Battery
14
Control panel

4
Safety mechanisms: An enclosed truck geometry with rounded edges ensures safe
handling of the truck. The driver is protected by the overhead guard (2). Pressing the
Emergency brake switch disconnects all electrical functions in hazardous
situations.The drive wheel (9) and the load wheels (5) are protected by a solid skirt.
Line brake safety devices in the lift cylinders limit the load lowering speed in the event
of a hydraulic system failure.
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 braking system consists of three independent braking
systems.The truck can be braked gently and wear-free by switching to the opposite
travel direction.In addition, the truck can be braked via a brake pedal which acts on
the hydraulic brake shoes in the load wheels.The truck can be braked by taking your
foot off the drive pedal(coasting brake).
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°.
Operator position: The driver’s position is ergonomically designed with ample
legroom. The driver's seat and steering arm can be adjusted to suit the driver.
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:Highly efficient three phase technology with energy retention for
the drive and lift motors provides high travel and lift speeds and better use of energy.
Mast support: The mast support is mounted on support rollers. A single telescopic
reach cylinder extends and retracts the support.
For controls options see chapter three.

5
1.3 Standard Version Specifications
Technical specification details in accordance with VDI2198. Technical modifications
and additions reserved.
1.3.1 Performance data for standard trucks
Item
Description
CQD12R/RF
Unit
Drive unit
Battery
Operator type
Seated
Q
Load capacity
2645
lb.
c
Load center
23.6
in.
Travel speed, laden/ unladen
5.0/5.2
mph
Lifting speed, laden/ unladen
51.2/79.6
fpm
Lowering speed, laden/ unladen
69.65/53.7
fpm
Reach speed, laden/ unladen
19.9/19.9
fpm
Max. gradeability, laden/unladen
8/10
%
Service weight （include battery）
SEE Form 2
lb.
Axle loading, fork advanced, unladen driving
side/loading side
2264/2171
lb.
Axle loading, fork retracted, unladen driving
side/loading side
2828/1020
lb.
Axle loading, fork advanced, laden driving
side/loading side
862/6333
lb.
Axle loading, fork retracted, laden driving
side/loading side
2590/4605
lb.
Drive motor rating S2 60 min.
5.3
hp
Lift motor rating at S3 15%
11
hp
Tyre type driving wheels/loading wheels
Polyurethane
Type of drive unit
AC
Steering type
Electronic
Park brake type
Electromagnetic
Battery voltage/nominal capacity K5
SEE Form 4.1
V/Ah
Sound pressure level at the driver’s ear
75
dB(A)

6
1.3.2 Dimensions
Item
Description
CQD16
CQD20
单位
y
Wheelbase
53.3
in.
b11
Track width, Load end
35.2
in.
α/β
Mast/fork carriage tilt, forward/backward
2 / 4
°
l1
Overall length
See Form1
in.
b1 /b2
Overall width
40/40
in.
h1
Height, mast lowered
See Form3
in.
h2
Free lifting height
See Form3
in.
h3
Lifting height
See Form3
in.
h4
Height, mast raised
See Form3
in.
h6
Height over overhead guard (cab)
77.4
in.
h7
Seat height
36.6
in.
h8
Height of wheel arms
12.2
in.
l2
Length to face of forks
See Form1
in.
l4
Reach distance
See Form1
in.
l7
Length across wheel arms （exclusive fork）
See Form1
in.
b3
Fork carriage width
37.7
in.
b4
Distance between wheel arms/loading
surfaces
27.5
in.
b5
Distance between fork-arms
7.9-25.6
in.
s/ e/ l
Fork dimensions
1.6×4×42
in.
m1
Ground clearance, laden, below mast
2.75
in.
m2
Ground clearance, center of wheelbase
2.36
in.
Wa
最小转弯半径
61.8
in.
Ast
Aisle width for pallets 1000 × 1200 crossways
See Form1
in.
Ast
Aisle width for pallets 800 × 1200 lengthways
See Form1
in.
Tyre size, driving wheels（diameter×width）
Φ10.2×4.1
in.
Tyre size, loading wheels（diameter×width）
Φ11.2×3.7
in.
Tyre size, caster wheels（diameter×width）
Φ4×2
in.
Wheels, number driving，caster/loading
(x=drive wheels)
1，2，2
Note ：Including safety distance a = 7.87 in

7
Form 1
Model designation
CQD12R/RF
CQD12R/RF
Sidesway
Mast Type
2-stage
3-stage
2-stage
3-stage
Overall length （minimum）
l1
89.96
90.94
91.34
92.32
Length to face of forks
l2
47.83
48.82
49.21
50.2
Reach distance
l4
21.06
19.69
Aisle width for pallets 1000
× 1200 crossways
Ast
104.53
105.12
105.51
106.1
Aisle width for pallets 800
× 1200 lengthways
Ast
106.5
107.28
107.87
108.66
Aisle width for pallets 1000
× 1200 lengthways
Ast
108.46
109.25
109.65
110.43
Aisle width for pallets 800
× 1200 crossways
Ast
100.2
100.98
101.38
102.17
Form 2
Mast Type
Lift height(in.)
Service weight （without battery）lb.
CQD12R/RF
2-stage
98.43
4345
106.3
4389
118.11
4433
129.92
4477
141.73
4521
157.48
4576
169.29
4620
3-stage
137.8
4642
157.48
4708
177.17
4774
188.98
4818
196.85
4840
216.54
4906

8
Form 3
Mast Type
Lift height(in.)
Height, mast
lowered(in.)
Free lift (in.)
Height, mast
extended(in.)
h3
h1
h2
h2(*)
h4
h4(*)
2-stage
98.43
71.46
--
--
137.8
121.06
106.3
75.39
--
--
145.67
128.94
118.11
81.3
--
--
157.48
140.75
129.92
87.2
--
--
169.29
152.56
141.73
93.11
--
--
181.1
164.37
157.48
100.98
--
--
196.85
180.12
169.29
106.89
--
--
208.66
191.93
2-stage
Side sway
98.43
71.46
--
--
138.78
121.06
106.3
75.39
--
--
146.65
128.94
118.11
81.3
--
--
158.46
140.75
129.92
87.2
--
--
170.28
152.56
141.73
93.11
--
--
182.09
164.37
157.48
100.98
--
--
197.83
180.12
169.29
106.89
--
--
209.65
191.93
3-stage
137.8
68.31
29.13
45.87
177.17
160.43
157.48
74.8
35.63
52.36
196.85
180.12
177.17
81.3
42.13
58.86
216.54
199.8
188.98
85.24
46.06
62.8
228.35
211.61
196.85
87.8
48.62
65.35
236.22
219.49
216.54
94.29
55.12
71.85
255.91
239.17
3-stage
Side sway
137.8
68.31
28.15
45.87
178.15
160.43
157.48
74.8
34.65
52.36
197.83
180.12
177.17
81.3
41.14
58.86
200.79
199.8
188.98
85.24
45.08
62.8
212.6
211.61
196.85
87.8
47.64
65.35
220.47
219.49
216.54
94.29
54.13
71.85
240.16
239.17
Note：with(*)for without backrest parameters

9

10
1.4 Identification points and data plates

11
Item
Description
1
“Never put your hands in inner and outer mast.“ warning
2
Warning decal
3
“Don't drive in rain.“ warning
4
Operator warning
5
Operator decal
6
Operator warning decal
7
Truck data plate
8
Security mark
9
Hydraulic pressure decal
10
Model decal
11
Capacity chart
12
“Never stand ” warning
13
CE decal
14
Strap points for crane lifting

12
1.4.1 Truck data plate
Item
Description
Item
Description
1
Model
8
Rated Capacity
2
Serial no.
9
Mass without battery
3
Service weight without load
10
Max. Battery Mass
4
Production Date
11
Min. Battery Mass
5
Battery Voltage
12
Lifting Height
6
Capacity
13
Load weight
7
Lifting height(max.)
14
Load center
For queries regarding the truck or ordering spare parts please quote the truck serial
number(2).
1.4.2 Capacity chart
The chart given above shows the relation
between the load center and the weight of
loads.

13
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 "4.5 Battery removal and
installation" ) do not damage battery cable.
•Charge the battery, (see "4.4 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.
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.