EP EPL151, HPL152, WPL201, RPL201, RPL201H Operation Manual

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Page 1

Operation Manual

EPL151

HPL152

WPL201

RPL201/RPL201H

Original Instruction Part No.508000003010

V2 12/2019

Page 2

EP EQUIPMENT CO.,LTD. is one of the world’s leading companies manufacture, 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.

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”.

EP EQUIPMENT CO., LTD Address: XIAQUAN, DIPU, ANJI, ZHEJIANG, CHINA Tel: + 86-0571-28023920 Website: www.ep-ep.com Email: [email protected]

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Preface

Thank you for buying our products.

The manual will show you the way of correctly using the truck as well as relevant preventive maintenance and safety operation. The truck should be operated only by well-trained professionals and by no means by non-working personnel. Operators are supposed to read through the manual before actually operating the truck.

Explanations on the manual

With the continuous upgradation and improvement of our company’s products, you may find a

slight di󰀨erence existing between your carrier and some introductions in the manual.

All the information, specications and illustrations in the manual are e󰀨ective in times of printing and our company maintains the right to modify the specication (s) or design (s) of our products at any time without any beforehand notication.

Safety signs and corresponding esplations

DANGER

Means that failure to comply can cause risk to life and/or major damage to property.

WARNING

Please strictly adhere to these safety instructions to avoid personal injury or major damage to equipment.

CAUTION

Please pay attention to the important safety instructions.

NOTE

Pay attention to Instruction.

Internet address and QR code of Parts manual

By entering the address http://www.epcare.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

Page 4

Use provisions

The kind of carrier introduced in the manual belongs to ground delivery equipment applicable to goods uplifting and delivery, and it must be used, operated and maintained in strict accordance with the provisions in the operation instruction. All the other uses of the equipment beyond the operation instruction shall be regarded as operation behaviors violating the provisions of the operation instruction that may result in personnel injury or losses on the carrier or other properties. The most

important thing (for operators) is to keep the carrier away from excessive or unbalanced loading while strictly abiding by the maximum loading capacity specied in corresponding nameplate or loading diagram. The carrier should not be used in the areas with such dangers as re disaster and explosion or likely to result in corrosion, rusting or large dusts.

Obligations and responsibilities of equipment user

In the manual, “equipment user” refers to any natural person or legal person directly using or

appointing or authorizing others to use the carrier. In such special situations as renting or sales,

the “equipment user” represents the interested parties supposed to bear operation obligations

as specied by the contractual terms concluded between equipment owner and corresponding users. Equipment users must ensure the use of the carrier only for purposes specied and timely

eliminate all the dangers that may threaten the life and health of the users themselves or any other third party, in addition to which they must also strictly abide by accident prevention provisions, other safety technology provisions and equipment operation, maintenance and repair guidelines, and ensure that all the operators seriously read and completely understand the contents of the operation instruction.

Should any violation of the operation instruction occur, the quality guarantee of our company will be invalid automatically, and our company will assume none of the responsibilities for losses resulting from any nonstandard operation of the equipment implemented by any client, equipment user or

any third party without the authorization of the client service department of our company.

Equipment ret

Any installation or retrotting of any additional device that may inuence or enhance the functions

of the carrier must be approved by our company in writing beforehand.

Company name: Zhejiang EP Equipment Co., Ltd

Address: Zhongli Industrial Park, Xiquan Village, Dipu Town,

Anjij County, Huzhou City, Zhejiang Province

Website: www.ep-ep.com

Telephone: 86-571-28035656/28878695

E-mail:[email protected]

Page 5

Legal requirements for marketing

Declaration

EP EQUIPMENT CO., LTD.

Address: XIAQUAN, DIPU, ANJI, ZHEJIANG, CHINA

We declare that the machine

Industrial truck: according to this operation manual

Type: according to this operation manual

complies with the most recent version of Machinery Directive 2006/42/EC.

Personnel authorised to compile the technical documents:

See EC/EU Declaration of Conformity

EP EQUIPMENT CO., LTD.

EC/EU Declaration of Conformity

The manufacturer declares that this industrial truck complies with the EC Machinery Directive

and the provisions of other applicable EC/EU directives e󰀨ective at the time of sale. This can be veried by means of the EC/EU Declaration of Conformity and the relevant certication label on the

nameplate.

The industrial truck is supplied with the EC/EU Declaration of Conformity document. This declaration proves that this truck complies with the requirements of the EC Machinery Directive.

Unauthorised modication or additional installation of equipment to the structure of the industrial truck may a󰀨ect its safety, and will therefore invalidate the EC/EU Declaration of Conformity.

The EC/EU Declaration of Conformity must be carefully stored and made available to be presented to the relevant authorities when necessary. If this industrial truck is sold, this declaration document must be handed over to the new owner.

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Table of contents

A Nameplates and alarming labels ..........................................................................................A1

B Operation .............................................................................................................................B1

2.1Utilization safety specication..............................................................................................B1

2.1.1 EN standards ...................................................................................................................B2

2.1.2 Conditions for application ...............................................................................................B2

2.1.3 Stability ...........................................................................................................................B2

2.2 Display and manipulation ...................................................................................................B3

2.2.1 Control handle .................................................................................................................B3

2.2.2 Key switch ......................................................................................................................B4

2.2.3 Display instrument ...........................................................................................................B5

2.3 Truck use and operation .....................................................................................................B8

2.3.1 Preparation for use ..........................................................................................................B8

2.3.2 Truck starting .................................................................................................................B10

2.3.3 Running, swerving and braking .....................................................................................B11

2.3.4 Goods picking ................................................................................................................B14

2.3.5 Parking the truck securely .............................................................................................B15

2.3.6 Drive directions ..............................................................................................................B16

2.3.7 Loading ..........................................................................................................................B17

2.3.8 Using the truck on a slope .............................................................................................B18

2.3.9 Truck transport...............................................................................................................B19

2.3.10 Operating the truck without its own drive system ........................................................B20

C Storage battery use and maintenance .................................................................................C1

3.1 Safety and warning .............................................................................................................C1

3.2 Storage battery charging ....................................................................................................C2

3.2.1 Precautions......................................................................................................................C2

3.2.2 Charging the battery with internal charger.......................................................................C2

3.2.3 Charging the battery with external charger......................................................................C3

3.2.4 Battery type & dimensions&Charging time ......................................................................C4

3.3 Handling of the lithium-ion battery .....................................................................................C5

3.3.1 Information on the conformity of lithium-ion batteries .....................................................C5

3.3.2 Special lithium-ion safety rules .......................................................................................C5

3.3.3 Transportation .................................................................................................................C6

3.3.4 Scrapping lithium-ion batteries .......................................................................................C6

3.3.5 Storage ...........................................................................................................................C7

3.3.6 Scrapping lithium-ion batteries .......................................................................................C7

3.3.7 Disposal of Used Battery Packs .....................................................................................C7

3.4 Battery removal and installation .........................................................................................C6

D Maintenance ........................................................................................................................D1

4.1 Truck maintenance .............................................................................................................D1

4.2 Maintenance table ..............................................................................................................D2

E Technical data .......................................................................................................................E1

Pg.

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Nameplates and alarming labels

Have the nameplates of a truck xed its main body and alarming labels pasted on its

outer cover.

Should any nameplate or alarming label lose or be damaged, please conduct replacement immediately or contact with the sales department or corresponding agent of our company when necessary.

Such truck-related information as product model, serial number, manufacturing date, rated load lifting capacity, lifting height, load centre distance and dead weight are all shown in the nameplates.

Nameplate

Anti-pinch label

Battery nameplate

Do not rest on the pallet label

Lithium label

Instructions label

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Hoisting

Remove the load before hoisting the pallet

truck.

Disconnect the power supply.

Attach slings in the positions identied by

the hook symbol.

DANGER

Personnel must not stand below or near the truck when the pallet truck is being lifted.

WPL201

REV. 12/2019

HPL152

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RPL201/ RPL201H

EPL151

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Operation

Applicable environment temperature: -10 °C - 40 °C

NOTE

The carrier can by no means be used under the temperature lower than 5 °C for a long time, or in refrigeratory or under the condition that such environmental factor as temperature or humidity changes extremely before special equipment is additionally installed and the permit of the manufacturer is acquired.

2.1Utilization safety specication

Don’t use the truck in rainwater.

Don’t use the truck in nonposition.

Avoid the use of the truck by non-working personnel. Don’t ride on the truck. Don’t carry or lift people by the truck.

NOTE

Conditions of operation road surface: the truck should run on solid, at, level and paved road

surfaces (including both running and lifting)

Don’t use the truck on slippery road surfaces.

(such as road surfaces with

oil stain or residual snow or

those frozen ones )

Don’t carry goods on steep slope to prevent

goods from sliding o󰀨.

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Don’t leave the truck before it is parked as regulated.

2.1.1 EN standards

Don’t use the truck when any non-working personnel is in the dangerous area. Don’t be distracted when using the truck. Don’t be distracted when using the truck.

Don’t place any part of your body in any moving part of the truck to avoid being clamped.

Continuous sound level:

＜

74 dB(A)

according to EN 12053 as stipulated in ISO 4871

The continuous sound level is a value averaged according to standard regulations, taking the sound pressure level into account when driving, lifting and idling. The sound pressure level is measured at the ear.

Electromagnetic compatibility (EMC)

The manufacturer conrms compliance with the limit values for electromagnetic emission

and interference immunity as well as testing of static electricity discharge according to EN 12895 and the references to other standards contained therein.

Electrical or electronic components and their arrangement may only be modied after

written approval by the manufacturer has been obtained.

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2.1.2 Conditions for application

Working condition requirements:

- Indoor use and outdoor use.

- The walking, lifting and lowering devices, harness and components are IP55 dust and waterresistant

- The truck's maximum operation altitude is up to 2000m.

- Trucks can only be operated in adequately illuminated working areas to avoid injuries. In case

of insu󰀩cient light, an additional lighting equipment is needed to ensure that the driver can see

properly. 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 Gradability in technical data)

2.1.3 Stability

Stability is guaranteed if your truck is used properly in accordance with its intended purpose. Common reasons for a loss of truck stability include:

• Emergency stops or sharp turns

• Driving with a raised load or a load handling device

• Turning the vehicle around on or driving across a slope

• Driving up or down a slope with the load pointing downhill

• Driving with a wide load

• Carrying a swinging load

• Driving near the edge of a ramp or up steps

• Tilting the mast forward while carrying a raised load

• Driving on uneven surfaces

• Overloading the truck

• Carrying bulky loads in strong winds

• When carrying liquid, its centre of mass inside the container may shift due to

inertial force (such as when pulling away, braking or turning)

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2.2.1 Control handle

1.Control handle A

EPL151/RPL201/ RPL201H

2.2Display and manipulation

Lowering button

Lower loading parts

Lifting button

Lift loading parts

Horn button

Send out sound warning signals

Driving switch

Controls travel direction and speed

Tortoise speed button

(Not for RPL201/RPL201H)

Display instrument

Display the electric quantity of the truck

(Not for

RPL201/RPL201H

Key switch

Connect and interrupt control current

Lowering button

Lower loading parts

Lifting button

Lift loading parts

Horn button

Send out sound warning signals

Display instrument

Display the electric quantity of the truck

Driving switch

Controls travel direction and speed

Emergency reverse button

Through touching the button, truck drives away from operator.

)

WPL201

Emergency reverse button

Through touching the button, truck drives away from operator.

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Tortoise speed button

Key switch

Connect and interrupt control current

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HPL152

Lowering lever

Pull and hold the manual lower switch (2).The

forks will lower to the minimum height until they stop by themselves.

Power switch button

Start the truck

"Horn" button

Activates the horn.

Emergency reverse switch

Press the emergency reverse switch. The vehicle will begin to travel in the opposite direction.

Drive switch

Select the required driving direction and speed.

2.2.2 Key switch

1.Key switch A

Connect and interrupt control current.

• When the key rotates to gear “OFF”, the control current of the truck will be interrupted;

• When the key rotates to gear “ON”, the control current of the truck will be connected.

RPL201/RPL201H/EPL151

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2.Key switch B

70％

Connect and interrupt the control current.

When pulling out the induction key, the

•

control current of the truck will be interrupted;

• When inserting the induction key, the control current of the truck will be connected.

NOTE

Pulling out the key switch of a forklift before leaving can prevent the forklift from starting accidentally.

2.2.3 Display instrument

WPL201

• LED (1) displays the remaining charge;

• LED (2) displays remaining charge

percentage;

• LED (3) displays Interlock switch status indication;

• LED (4) displays the total running time normally. If fault, display the fault code.

• LED (1) displays the remaining charge.when

1st block and 2nd block blinks alternatively, it indicates low power needs to be charged

• LED (2) displays remaining charge

percentage;

• LED (3) ashing, it indicates travel forward

properly;

• LED (4) ashing, it indicates travel backward

properly;

• LED (5) ashing, it indicates lifting properly;

• LED (6) ashing, it indicates lowering

properly;

• LED (7) always on, it indicates interlock switch opened, LED(7) ashing, it indicates

interlock switch closed, the display start timing.

• LED (8) displays the total running time normally. If fault, display the fault code.

EPL151

RPL201/RPL201H

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Error Code

2 = Traction

Controller

number

controller

6 = Steering

controller

• LED (1) displays the remaining charge;

• LED (2) indicate the speed of truck.

• LED (3) indicate fault warning;

• LED (4) indicate charging status,when

charging, it turns into a battery;

• LED (5) indicate emergency reverse switch

status;

• LED (6) indicate truck stop or walk, if the

truck stop display"P", if the truck travel display"N";

• LED (7) indicate turtle speed status;

• LED (8) indicate rise and fall indication.

• LED (9) indicate the operating hours.

Error code note

Note: Consult the service manual

NOTE

Low Voltage Protection

The car has low voltage protection function. When the battery power of forklift truck is 7%-15%, the display screen shows L1. At this time, the forklift truck can not lift goods, but it can run normally. When the battery power is less than 7%, the display screen shows L2. At this time, the forklift can not be lifted and the driving speed becomes slower.

9 2

6 8 7

WPL201

LCD (1) displays the state of charge;

DISPLAY DESCRIPTION Continuous red Charge is charging Continuous green Battery charging is

complete

The LCD (2) remain green light lit under normal, ashing show the failure state of truck.

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The LCD display (3) show battery residual

capacity. The color of the LCD (3) represent the following conditions:

Residual

Component LCD color

Green 30-100%

Continuous

Yellow

Standard

battery

residual

capacity

After the red light starts flashing, the battery will enter the low-voltage protection state.

According to the battery state, The truck will appear accidental power-o󰀨 protection. Please

charge the battery after restarting to avoid damage to the battery.

Slow

ashing red light(Flashing period 2s)

Quick ashing

red light

(Flashing period 1s)

capacity

15-30%

7-15%

0-7%

HPL152

If the controller detects a battery failure, ashes of LCD（3） 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 ashing twice, pausing for 3 seconds.

Over-voltage of single cell battery: The green light repeats in a cycle of flashing once in 1

•

second, pausing for 2 seconds and then ashing three times, pausing for 3 seconds. Short circuit protection: The green light repeats in a cycle of ashing once in 1 second, pausing

•

for 2 seconds and then ashing four times, pausing for 3 seconds.

Over-current protection: The green light repeats in a cycle of ashing once in 1 second, pausing

•

for 2 seconds and then ashing ve times, pausing for 3 seconds. Battery temperature is too high: The green light repeats in a cycle of ashing twice in 1 second,

•

pausing for 2 seconds and then ashing three times, pausing for 3 seconds.

Battery temperature is too low: The green light repeats in a cycle of ashing twice in 1 second,

•

pausing for 2 seconds and then ashing four times, pausing for 3 seconds. Contactor-related failures: The green light repeats in a cycle of ashing three times in 1 second,

•

pausing for 2 seconds and then ashing four times, pausing for 3 seconds.

•

The yellow light ashes rapidly in 1 second when other failures happen.

When powered o, 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.

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2.3 Truck use and operation

2.3.1 Preparation for use

WARNING

The following are inspection and preparation operations that must be implemented before the truck is put into daily use.

Table 1. Table of daily inspections by operators

Operator's Daily Checklist

Date

Truck No.

Department

Runtime Meter Reading

Daily Check Items O.K.(√) Remark

Check for Fluid Leakage

Check for scratches, deformation or cracks.

Check Decal Condition

Check the smooth movement of the wheels.

Check the function of the emergency brake by activating the emergency stop switch.

Check, the tiller arm- switch braking function

Check the lifting and lowering functions by operating the buttons.

Check if all bolts and nuts are tightened

rmly. Check the vertical creep of the truck.(if

equipped)

Operator

No.

Check the

sure not to damage the battery cables.

Recharge the lithium-ion battery

lithium-ion

installation,

making

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Table 1:

operators, and it can be adjusted according to specic requirements.

Table of Daily Inspections by Operators is only a sample table for the daily inspections of

WARNING

The truck should be regularly maintained by qualied maintenance engineers or technicians

that have passed the training of and also been authorized by the manufacturer.

NOTE

Precautions in the run-in period

After being put into use, the truck should operate under a low load at the initial stage and satisfy the following requirements, especially before its operation time reaches 100h:

•Prevent the new storage battery from discharging excessively during its initial use.

•Implement complete preventive maintenance as specied.

•Avoid emergency braking, starting or swerving during the use of the truck.

•Implement oil uid replacement and lubrication before the time specied.

•Limit the loading weight at 70%-80% of the rated loading.

WARNING

Should it be necessary to repair the truck for any fault or the truck be found with any unsafe condition, please immediately report to designated competent department, and please don’t use the truck before potential faults or hazards are eliminated. All the repairs or adjustments should be implemented under authorization, and all the services must be executed by

qualied maintenance technicians.

REV. 12/2019

10B

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2.3.2 Truck starting

1. Release the emergency stop switch

2.Press the button to start the truck

HPL152

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Page 21

2.Open the key switch to start the truck

WPL201

2.3.3 Running, swerving and braking

1.Running

Running area

RPL201/RPL201H/EPL151

Rotary button

Control the running direction and speed of the truck using the drive

switch (1). (the large the rotary angle, the faster corresponding speed)

Backward

Forward

NOTE

When using the truck on a ramp or a uneven road, please lift the leg of the forklift to prevent its bottom from colliding with the road surface.

REV. 12/2019

12B

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WPL201 EPL151

NOTE

Keep the handle in the vertical state, and press tortoise speed button (1) and drive switch(2) at the same time, then the vehicle will move at a low speed.

2.Swerving

Rotate the operation hand shank leftward or rightward as required.

Rightward swerving

Leftward swerving

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Page 23

3.Braking

Mechanical operating brake

The truck is braked when the operating handle is released. The mechanical brake engages when the tiller is positioned in Braking area.

Emegency reverse switch

Braking can be accomplished by changing the direction of travel. Press the reverse switch in the opposite direction until the truck comes to a stop, then release the drive switch.

Braking area

Emergency stop switch

Press the emergency stop switch, and then all the electrically propelled functions will be interrupted.

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14B

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2.3.4 Goods picking

1.Lifting

2.Lowering

WPL201

RPL201/

RPL201H/

Keep pressing the lifting button until reaching the required lifting height

EPL151

Lower the pallet forks to the bottom through pressing the lowering button.

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Lifting

Press lowering lever(2) to the bottom. Lift the forks by moving the control shaft (1) up

and down until the desired lifting height is

achieved.Reset the lowering lever(2).

Lowering

Set forks to the lowest position by pulling

lowering lever(2) upward.

WARNING

Goods failing to be arranged and fixed may result in accidents.

NOTE

To avoid shortening the service life of the oil cylinder, try not to lift the pallet forks to the highest state for every lifting operation.

2.3.5

Parking the truck securely

Lower the forks to the bottom;

HPL152

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16B

Page 26

Turn o󰀨 the key switch or pull out the

key;

Press the emergency stop switch to

cut o󰀨 storage battery connection;

WARNING

•Should it be necessary for operators to leave the truck, even for just a moment, the truck should also be well parked as

specied.

•Never park the truck on a slope

•The forks must be lowered to the bott om.

；

2.3.6

The drive directions of the truck are forward (1) and reverse (2).

Drive directions

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2.3.7 Loading

•

Approach the load carefully.

•

Adjust the height of the forks until they

can be easily inserted into the pallet.

•

Insert the forks under the load.

•

If the load is shorter than the forks, position the forks so that the front of the load overhangs them by a few centimeters, to avoid interference with the load immediately ahead.

•

Raise the load a few centimeters above its support.

•

Back the truck away from the stack or any neighbouring loads, gently and in a straight line.

Transporting loads

Always carry loads in the forward

direction of travel (R) in order to have

the best visibility.

WARNING

When carrying a load on a slope, always ascend or descend with the load uphill. Never drive sideways across a slope or perform a U-turn.

NOTE

Since visibility is reduced when travelling in this direction, drive only at very slow speed.

Unloading

Carefully drive the truck to the desired location. Carefully drive the truck to the unloading area. Lower the load until the fork arms are free from the pallet. Back the truck away in a straight line. Raise the forks to proper height.

CAUTION

•If the eld of vision is poor, ask a guide

for assistance.

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18B

Page 28

2.3.8 Using the truck on a slope

NOTE

Incorrect use of the truck on slopes

places stress on the traction motor,

brakes and battery.

Be particularly careful near slopes:

Never attempt a slope with a gradient

greater than that specied in the truck’s

data sheet. Make sure that the ground

is dry with a non-slip surface and that

the route is clear.

Ascending slopes

Always ascend slopes travelling in the

reverse direction, with the load facing

uphill. Without a load, it is recommend

to ascend slopes forwards.

Descending slopes

Travel down slopes must always be

forwards, with the load uphill. Without

a load, it is recommended to descend

slopes forwards. In all cases, travel at a

very low speed and brake very gradua-

lly.

DANGER

Risk to life and/or risk of major equipment damage. Never park the truck on a slope. Never make a U-turn or take shortcuts on a slope. On a slope, the operator must drive very slowly.

Starting on a slope

If you have to stop and then start on

slope, proceed as follows:

•

Stop on the slope by pressing the accelerator in the opposite direction until the machine comes to a standstill.

•

Return the accelerator to the neutral position, then release the accelerator control button to apply the parking brake.

•

To restart, press the accelerator button for the desired direction.

•

The truck will move.

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Page 29

NOTE

Incorrect use of the truck on slopes places stress on the traction motor, brakes and battery.

2.3.9 Truck transport

Place the truck on a wooden pallet.

NOTE

Only use haulage equipment with sufcient load capacity.

•The load weight includes the net weight of the truck(including battery weight) and the wooden pallet.

•The pallet or wooden box should be large and strong enough to withstand the weightof the truck.

• Pay attention to the fork blades when lifting the truck onto the pallet, to prevent injuries caused by the forks.

Follow the prescribed steps and park the vehicle correctly.

Make sure the forks are aligned with the pallet, move slowly and stop after inserting the forks as far into the pallet as possible.

CAUTION

Operate on open, level ground and pay attention to ground conditions when lifting and lowering the pallet to prevent the truck from tipping.

When transporting the truck, make sure it is fully secured and take precautionary measures against bad weather.

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20B

Page 30

2.3.10 Operating the truck without its own drive system

If the truck has to be moved after a failure has rendered it immobile, proceed as follows: Set the emergency stop switch “OFF”. Set the key switch “OFF” and remove the key.

•

Prevent the truck from rolling away.

•

Remove the cover.

•

Screw in two screws(1), M4*35mm)until the truck can be moved (no braking action).

After setting down the truck at the destination, unscrew two screws(1)

Braking action is restored.

WARNING

This operating mode is not permitted when negotiating inclines and gradients.

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Page 31

Battery use and maintenance

3.1 Safety and warning

•Abide by the operation manual!

•All the operations related to the storage battery must be implemented under the instruction of professionals!

•Protective gloves must be worn for storage battery operation!

•No smoke and re!

•Avoid the existence of open re, ery metal wire or sparks

around the storage battery,

otherwise explosion or re

disaster may occur!

•Don’t trample on the storage battery to prevent

it from erce shaking or

shacking!

•Explosion or re disaster is

likely to occur; avoid short circuit!

•Don’t knock over the storage battery!

•Using lifting and delivery

devices as specied. Prevent

the storage battery cell, interface and connection cable from being damaged by the lifting hook!

•Dangerous voltage!

•Avoid hot plugging!

•Notice: the metal part of the storage battery cell is

electried, so don’t place any external object or tool on the

battery cell!

Keep the battery away from all

re sources, heat sources and ammable or explosive

materials.

Do not place the battery on top of conductive objects.

WARNING

Should such issues as failing to abide by the operation manual, failing to use the original parts for maintenance or damaging caused by users themselves occur, the quality guarantee will be invalid automatically!

Avoid the battery becoming corroded by water or corrosive liquid.

The charging environment

°C °C

5 - 40

temperature should be 5°C to 40°C.

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3.2 Battery charging

3.2.1 Precautions

•The truck must be parked within a shady and ventilated room;

•Avoid the existence of any metal object in the surface of the storage battery;

•All the cable and plug connection parts should be inspected in terms of obvious damages before charging;

•The charger to be connected or disconnected must be under the state of not connecting to the circuit;

•The safety provisions related to the storage battery and the manufacturer of charging station must be strictly abode by.

Charging environment:

WARNING

Lithium battery must be charged above 0°C, as excessively low charging temperature is likely to result in the short circuit of battery cell.

3.2.2 Charging the battery with internal charger

Charge maintenance-free or lithium battery through a built-in charger

•Inspect whether relevant charging

requirements are satised according to

“3.2.1 precautions”;

Park the truck securely as described 2.3.5

•

Connect the specialized connector(1) to a

•

proper power supply outlet, then plug it into the socket on the truck to start charging.

;

NOTE

The charging voltage is single-phase, ranging from 100V to 240V, please don’t exceed the voltage range mentioned above.

power plug

WPL201/EPL151/HPL152

WPL201

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Charging indicator(1)

DISPLAY DESCRIPTION TROUBLESHOOTING

Continuous red

Continuous green

Continuous yellow

Flashing yellow

Flashing red

NO Lighting Charger failure

Battery is charging Normal status

Battery charging is complete Normal status

Battery failure

Charger failure

Charger without output current

The battery voltage is less than 13V(26V) or greater than 32.5V(65V). (for WPL201)

a. Output overcurrent or overvoltage b. The temperature of charger is too high.

a. Charger failure. b. The battery is not connected ; c. battery failure.

a. Charger failure. b. The input of charger is not connected.

3.2.3 Charging the battery with external charger

•Inspect whether relevant charging requirements are satised according to “3.2.1

precautions”;

Park the truck securely as described 2.3.5;

•

Remove the battery；(see section 3.4)

•

Plug into charging stand and charge;

•

The LED light on the charging stand comes on.

•

A fully charging time see described in paragraph 3.2.4.

EPL151 WPL201

REV. 12/2019

Page 34

NOTE

Correctly plug the battery into the charging stand.

NOTE

LED light mode on the charging stand

• Charging:red LED light

• Fully charged:green LED light

• Charging fault:ashing yellow LED light

• Battery fault:steady yellow LED light

Charge the storage battery through an

external charger

•Inspect whether relevant charging

requirements are satised according to

“3.2.1 precautions”;

Park the truck securely as described 2.3.5

•

;

•Pull out the storage battery plug (1) and

have it connected with the charger joint

(2), so as to facilitate charging through

connecting to the charger.

HPL201

3.2.4 Battery type & dimensions&

All the batteries are maintenance free. Battery types & dimensions are as follows:

Tuck type

WPL201

RPL201/

RPL201H

EPL151

HPL152 Li-ion 24/20AH 193x81x300

battery

type

Li-ion

Voltage/ Rated

capacity

48V/30Ah

24V/160Ah

24V/55Ah

Charging time

Dimensions

245×160×380 15A 15A 2h

550×190×500 / 50A/100A 3h/1.6h

175×124×407 10A 20A 5.5h/2.5h

RPL201/RPL201H

Charger

Charging time

Internal External

10A 10A 2h

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3.3 Handling of the lithium-ion battery

3.3.1 Information on the conformity of lithium-ion batteries

The manufacturer of the lithium-ion battery declares that: the lithium-ion battery conforms with the provisions of the following EU directive 2014/30/EU

in accordance with EN12895. This declaration of conformity with EU directives applies only to battery use that conforms to the recommendations described in the operating instructions.

3.3.2 Special lithium-ion safety rules

DANGER

Have class D re extinguishers or inert gas, carbon dioxide, powder or foam re extinguishers near the zone in which the lithium-ion batteries are used.

DANGER

Do not open the battery. Electrical risk. Only the After-Sales Service Centre technicians can open the battery.

It is necessary to respect the following guidelines:

Read the documents provided with the battery carefully. Only persons who have been trained to work with lithium-ion technology are permitted to work on

the batteries (for example After-Sales Service Centre technicians). Do not place lithium-ion batteries on or near ames or hot heat sources (> 65°C). This may cause the batteries to overheat or burst into ames. This type of use also impairs the performance of the

batteries and reduces their service life. Improper use may cause overheating or serious injury. Respect the following safety rules:

• Never short circuit the battery terminals

• Do not reverse the battery polarity

• Do not open the battery

• Do not submit the battery to excessive mechanical constraints

• Do not expose the battery unit to humidity or water (> 80%)

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3.3.3

Transportation

Before transporting any lithium-ion battery, check the current regulations on the transport of dangerous goods. Comply with these when preparing the packaging and transport. Train

authorised sta󰀨 to dispatch lithium-ion batteries.

NOTE

It is recommended that the original packaging is kept for any subsequent dispatch. A lithium-ion battery is a special product. Special precautions should be taken when:

•

Transporting a truck equipped with a lithium-ion battery

•

Transporting only the lithium battery

A class 9 danger label must be axed to the packaging for

transport.

It is dierent if the battery is transported on its own or in a

truck. An example of a label appears in this supplement. Refer to the latest current regulations before dispatch as the information might have changed since this supplement was written. Special documents must be sent with the battery. Refer to the applicable standards or regulations.

NOTE

Recharge the lithium-ion battery before transporting it taking account of the transport mode (plane, boat, road). Excessive discharge on arrival could damage the performance of the battery.

3.3.4

Scrapping lithium-ion batteries

ENVIRONMENT NOTE

Comply with current regulations for scrapping batteries. Take care to minimise, as far as possible, any impact on the environment. Lithium-ion batteries must be sent to the collection centre to be recycled. Contact the After-Sales Service Centre to agree how to send them. Apply the following main rules for transport Make sure that the battery is discharged

•

A󰀩x the Class

• Use packaging that complies with international regulations

•

Use the original packaging, if possible. Use sturdy packaging capable of bearing the weight of the batteries. Store it in a dry place. Wedge the battery well in the packaging to prevent it moving during transport

• Pack batteries individually in plastic bags. Package them to prevent any risk of shortcircuit

• between terminals. Identify the type and number of batteries on the outside of the packaging

• Do not store near to a heat source.

•

：

REV. 12/2019

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3.3.5

Storage

We recommend that batteries are stored at a height between 60 and 120 cm.

•Store the battery in a dry place at a temperature between 0 and 40° to preserve its service life. This area must not be hermetically sealed to allow air renewal;

•Check the battery charge level regularly. Do this at least every three months to maintainthe charge level above 30%. Recharge the battery if necessary.

3.3.6

Common Problems and Solutions

During the use and maintenance of the lithium-ion battery, the battery or battery system may

have one or more of the following abnormal conditions, please organize the professional

engineers and technicians to perform the necessary processing according to the instructions in this manual; if you have any questions about the status or solutions, please contact ep dealer or after-sales service department of the company to obtain professional technical support.

•

If the battery is found to have abnormal mechanical characteristics such as swelling, cracked casing, melted casing, and distortion of the casing before and during installation, stop using the battery immediately, place it in open and well-ventilated space, and contact the aftersales service.

•

If abnormalities such as looseness, cracks, cracks in the insulation layer, burn marks, etc. of the battery's pole pressing bolts, conductive strips, main circuit wires and connectors are found before and during the installation, stop using the battery immediately, check the reason

for analysis and give it a x;

•

If the polarity of the positive and negative terminals of the battery is found not match the polarity identification before installation, please stop using the battery immediately and contact the after-sales service department to replace the battery or obtain other solutions;

•

If there is re or smoke happens to the battery, move it to the open air immediately, evacuate

people in time, and pour a large amount of cold water onto the battery to cool it down and put

out the re.

•

If the battery is found to emit smoke before and during installation, immediately stop using the battery and bury it with sand, and notify the after-sales service department of the company for record and obtain technical support;

Disposal of Used Battery Packs

3.3.7

To prevent environmental pollution, the battery should be sent to a local recycling center or

special organization.

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3.4 Battery removal and installation

Park the truck securely as descirbed in

paragraph 2.3.5 and turn o󰀨 the power before

removal and installation of the battery.

Battery removal and installation steps:

Just hold the handle and pull the battery out.

•

Install in reverse order.

•

Open the battery cover;

•

Unplug the battery;

•

Attach the hooks to the battery handle or

•

strap;

Carefully lift the battery out of the truck;

•

Install the battery in reverse order.

•

WPL201, EPL151

Just hold the handle and pull the battery out.

•

Install in reverse order.

•

WARNING

Before removing the battery, make sure

the vehicle is completely powered o.

RPL201/RPL201H

HPL152

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Page 39

Maintenance

Only through regularly implementing truck maintenance work can the sustainable and reliable use of the forklift be ensured.

Only those receiving professional training and approved as qualied can be competent in various

equipment care maintenance operations. If you intend to independently implement maintenance, you are recommended to have your maintenance personnel receive on-site training from the service representative of the equipment supplier.

Safety announcement:

• Tyre replacement: please implement tire replacement using the tires designated by the

manufacturer, as unqualied tires may inuence the properties and stability of the products.

• It is improper to clean the truck using inammable liquid.

• Ensure that the power supply has been completely disconnected before actual maintenance operation.

Long-term parking:

• If required to be parked for over one month, the truck must be placed in a dry and frost-free environment.

• Clean the truck carefully.

• Coat any unpainted metal parts with a thin layer of oil or grease.

• In case that the truck is out of use for a long time, the storage battery should better be taken out.

• Recharge the lithium-ion battery every 2 months. Please observe the above instructions.

• Raise and chock the truck: the wheels must not touch the ground in order to prevent irreversible deformation of the tyres.

4.1 Truck maintenance

Scrap treatment:

The nal scrap treatment of the forklift must be implemented according to the current laws and

•

regulations of China, especially the provisions related to such aspects as storage battery, fuels, fuel oil and electric equipment

be recycled. Contact the After-Sales Service Centre to agree how to send them.

. Lithium-ion batteries must be sent to the collection centre to

REV. 12/2019

Page 40

4.2 Maintenance table

Daily maintenance 1 Inspect and manipulate the functions of the Control handle’s manipulation

switches and the display instruments

2 Inspect the emergency outage function of the emergency stop switch or

the storage battery puller.

3 Inspect the swerving function.

4 Inspect the braking function 5 Inspect whether there is any abrasion or damage in the driving wheel/

load wheel/caster 6 Inspect whether there is any damage or abnormality in the truck. 7 Inspect whether the optional functions are under normal operation.

250-hour/2-month maintenance 8 Inspect where there is any damage in the cables and whether the

terminals are reliable 9 Inspect whether there is any screw losing or slipping out 10 Inspect whether there is any abrasion or damage in the oil pipes 11 Inspect where is any leakage in the hydraulic oil 500-hour/3-month maintenance

After operating for 500 hours in total, the truck should also be maintained according to the following procedures in addition to the 250-hour maintenance mentioned above

12L 13L Inspect and lubricate using the lithium-based lubrication grease the

14 Inspect and lubricate using the lithium-based lubrication grease the

After operating for 1000 hours in total, the truck should also be maintained according to the following procedures in addition to the 250-hour maintenance and 500-hour maintenance mentioned above

15 Inspect and fasten the controller and other electrical apparatus elements 16 Inspect whether there is any abnormal sound or disclosure of the gear

17 Inspect the abrasion situations of the driving wheel/bearing wheel/

18 Inspect whether all the oil pipes, pipelines and joints are reliably

19L Inspect the level of the oil liquid, and if the level fails to reach the

20 Inspect the air gap of the electromagnetic brake, and if the air gap is

21 Inspect where is any abrasion or damage in the link mechanism

Inspect

lubrication mouths in moving parts

bearing between the driving engine and the gear box

box

universal wheel and please timely replace seriously abraded ones

connected and whether all the sealing elements are reliable

minimum one as required, please timely add hydraulic oil with the same

specications

larger than 0.4mm, please replace the friction plates.

or add the gear grease(for WPL201 and EPL151)

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Page 41

After operating for 1000 hours in total, the truck should also be maintained according to the following procedures in addition to the 250-hour maintenance, 500-hour maintenance and 1000hour maintenance mentioned above

23L 24

25L 26 27

28 Inspect whether all the labels are clear and intact

Inspect the running, lifting and lowering speed, braking distance and other

operation performances of the truck Inspect and add gearbox lubrication grease

Inspect and replace gearbox gear oil (for RPL201/

Inspect where there is any damage in the oil cylinders and whether corresponding installations are reliable

Clean the oil tank and replace the hydraulic oil

Inspect and replace the hydraulic lter

Inspect whether the bearing capacity reaches the rated load and implement

corresponding adjustment through the ood valve adopted in the hydraulic

station

HPL152

RPL201H、WPL201

)

WPL201

RPL201/RPL201H EPL151

EPL151/HPL152/WPL201

RPL201/RPL201H

Table 1 Lubricants

Code Type Specication Amount Position

Anti-wear hydraulic oil L-HM32

Low temperature anti-wear

hydraulic oil (cold storage)

Multi-purpose grease

L-HV32

Polylub GA352P

0.48 L((WPL201/EPL151 HPL152)1.25(RPL201 RPL201H)

Appropriate amount

Hydraulic System

Sliding surface

(See Table 2)

Grease 3#(MoS2) -

Heavy duty gear oil 85W-90 GL-5 1500ml(RPL201/RPL201H) Gearbox

110 grams(EPL151/ HPL152/WPL201)

Gearbox

REV. 12/2019

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Table 2 Sliding Surface Lubrication Table

Code Position Model

L1 Steering Bearing

L2 Drive Wheel

L3 Load Wheel

L4 Long Shaft

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Page 43

Technical data

Standard Version Specications

Technical specication details in accordance with VDI 2198. Technical modications and

additions reserved.

Performance data for standard trucks

Distinguishing mark

1.1 Manufacturer EP EP

1.2 Model designation

1.3 Drive unit Electrics Electrics

1.4 Operator type Pedestrian Pedestrian

1.5 rated capacity Q kg 2000 2000

1.6 Load center distance

1.8 Load distance x mm 1000 916/982 937/1003

1.9 Wheelbase y mm 1268 1418 1438

Weight

2.1 Service weight

(include battery)

2.2 Axle loading, laden driving side/ loading side

2.3 Axle loading, unladen driving side/loading side

Types,Chassis

c mm 600 600

kg 250 630

kg 685/1565 1020/1610

kg 185/65 500/130

WPL201 RPL201

3.1 "Tyre type driving wheels/loading wheels"

Polyurethane Polyurethane

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3.2 Tyre size, driving

wheels(diameter×width)

mm Ф250x102 Ф230x75

3.3 Tyre size, loading

wheels(diameter×width)

3.4 Tyre size, caster

mm 2×Ф82x85/

Ф82×115

Ф85x70 / Ф83x115

mm Ф74x48 Ф130x60

wheels(diameter×width)

3.5 Wheels, number driving,

caster/loading (x=drive

mm 1×,2/4(1×

2/2)

1x,2/4(1x,2/2)

wheels)

3.6 Track width, front,driving

b10 mm 441 510

side

3.7 Track width,rear,loading

b11 mm 370/(515) 370/430/515

side

Dimensions

4.4 Lift height h3 mm 140 120

4.9 Height drawbar in driving

h14 mm 716 / 1240 1150 / 1470

position min./max.

4.15 Lowered height h13 mm 82.5 85

4.19 Overall length l1 mm 1592 1860 1930

4.20 Length to face of forks l2 mm 423 710

4.21 Overall width b1/ b2 mm 645 / 625 730

4.22 Fork dimensions s/ e/ l mm 55×170×1170 55x170x1150

55x170x1220

4.25 Distance between fork-

b5 mm 540(685) 540/600/685

arms

4.32 Ground clearance, center

m2 mm 27 30

of wheelbase

4.34.1 Aisle width for pallets 1000

Ast mm 1850 1984

× 1200 crossways

4.34.2 Aisle width for pallets 800

Ast mm 2050 2184

× 1200 lengthways

4.35 Turning radius Wa mm 1428 1700

Performance data

5.1 Travel speed, laden/

km/ h km/h 5 / 5.5 5.5 / 6

unladen

5.2 Lifting speed, laden/

m/ s 0.028/0.04 0.050 / 0.054

unladen

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Page 45

5.3 Lowering speed, laden/

unladen

fpm m / s0.04 / 0.022 0.067 / 0.054

5.8 Max. gradeability, laden/

% 8 / 16 8 / 16

unladen

5.10 Service brake type Electromagnetic Electromagnetic

Electric-engine

6.1 Drive motor rating S2 60

hp kW 0.75 1.5

min

6.2 Lift motor rating at S3 15% hp kW 0.84 2.2

6.3 The maximum allowed size

in. mm 245×160×380 550*190*500

battery

6.4 Battery voltage/nominal

V/ Ah 48/30(Li-ion) 24 / 160

capacity K5

6.5 Battery weight lb. kg 14 70

Addition data

8.1 Type of drive control DC AC

10.5 Steering type mechanical electronic

10.7 Sound pressure level at

the driver’s ear

dB (A) <74 <74

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WPL201

REV. 12/2019

Page 47

RPL201/RPL201H

REV. 12/2019

Page 48

Distinguishing mark

1.1 Manufacturer EP EP

1.2 Model

EPL151 HPL152

designation

1.3 Drive unit Electrics Electrics

1.4 Operator type Pedestrian Pedestrian

1.5 rated capacity Q kg 1500 1500

1.6 Load center

c mm 600 600

distance

1.8 Load distance x mm 883/946 883/946

1.9 Wheelbase y mm 1105/1168 1105/1168

Weight

2.1 Service weight

kg 165 130

(include battery)

2.2 Axle loading,

kg 574/1091 558/1172 laden driving side/ loading side

2.3 Axle loading,

kg 130/35 84/46 unladen driving side/loading side

Types,Chassis

3.1 "Tyre type driving wheels/loading wheels"

REV. 12/2019

PU/ PU PU/ PU

Page 49

3.2 Tyre size, driving

wheels(diameter×width)

mm Ф210x70 Ф210x70

3.3 Tyre size, loading

wheels(diameter×width)

3.4 Tyre size, caster

mm 2x Ф78x60

(Ф78x88)

mm Ф74x48 /

2x Ф78x60 (Ф78x88)

wheels(diameter×width)

3.5 Wheels, number driving,

mm 1×,2/4(1× 2/2) 1x,4(1x,2)

caster/loading (x=drive wheels)

3.6 Track width, front,driving

b10 mm 438 /

side

3.7 Track width,rear,loading

b11 mm 390 390

side

Dimensions

4.4 Lift height h3 mm 115 115

4.9 Height drawbar in driving

h14 mm 700 / 1170 638/ 1275

position min./max.

4.15 Lowered height h13 mm 80 80

4.19 Overall length l1 mm 1523 1518

4.20 Length to face of forks l2 mm 375 381

4.21 Overall width b1/ b2 mm 600 548

4.22 Fork dimensions s/ e/ l mm 50/150/1150 50/150/1150

4.25 Distance between fork-

b5 mm 540 540

arms

4.32 Ground clearance, center

m2 mm 30 30

of wheelbase

4.34.1 Aisle width for pallets 1000

Ast mm 1584 1612

× 1200 crossways

4.34.2 Aisle width for pallets 800

Ast mm 1784 1812

× 1200 lengthways

4.35 Turning radius Wa mm 1330 1358

Performance data

5.1 Travel speed, laden/

km/ h km/h 4/4.5 3.5/4

unladen

5.2 Lifting speed, laden/ unladen

m/ s 0.022/0.025 100mm/per

time

REV. 12/2019

Page 50

5.3 Lowering speed, laden/ unladen

fpm m / s0.034/0.023 Hand down

5.8 Max. gradeability, laden/

% 5/16 5 / 10

unladen

5.10 Service brake type Electromagnetic Electromagnetic

Electric-engine

6.1 Drive motor rating S2 60

hp kW 0.65 0.75

min

6.2 Lift motor rating at S3 15% hp kW 0.8 man-up

6.3 The maximum allowed size

in. mm 175*124*407 193*81*300

battery

6.4 Battery voltage/nominal

V/ Ah 24V*1/40Ah 24 / 20AH

capacity K5

6.5 Battery weight lb. kg 13*1 5*1

Addition data

8.1 Type of drive control DC DC

10.5 Steering type mechanical mechanical

10.7 Sound pressure level at

dB (A) <74 <74

the driver’s ear

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EPL151

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HPL152

REV. 12/2019