EP Equipment EPT18-EHJ Operation Manual Download Page 42

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REV. 08/2019

F Battery Maintenance & Charging

Safety regulations for handling acid batteries

The truck must be parked and rendered safe before any operations on batteries are under

taken.

Fire protection measures:

Smoking and naked flames are not permitted when handling

batteries. No inflammable substances or spark-generating materials must be present or stored

within a distance of 2 meters of the truck parked for battery re-charging. The location must be

well ventilated and fire fighting equipment must be kept ready.

Battery has high voltage and energy.

Do not short circuit.

Do not place any metal objects on the battery.

Do not put tools on the battery.

Battery type & dimension

All the batteries are maintenance free.
Battery type & dimension as follow:

Tuck type

voltage/ rated

capacity

Dimension

Charger

Charging

time

Internal External

EPT20-15ET

24/ 85

215

260

169

10A

EPT20-15ET2

2*12/65

260*169*215

10A

EPT20-ET

4*12

/ 30

255*170*200

20A

1.5

EPT20-15EHJ

2*12

/ 30

175*165*125

EPT18-EHJ

2*12

/ 30

175*165*125

EPT20-18EA

12/ 85

215*265*169

20A

•

1.1

1.2

DANGER

Summary of Contents for EPT18-EHJ

Page 1: ...EPT18 EHJ EPT20 18EA EPT20 ET Original Instruction Part No 508000003007 V3 08 2019 Operation Manual EPT20 15ET EPT20 15ET2 EPT20 15EHJ EPT20 15ETL ...

Page 2: ...ours 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 e...

Page 3: ...ated by the following graphics Please strictly adhere to these safety instructions to avoid personal injury or major damage to equipment Please pay attention to the important safety instructions Pay attention to Instructions EP EQUIPMENT CO LTD Address XIAQUAN DIPU ANJI ZHEJIANG CHINA Tel 86 571 28023920 Website www ep ep com Email info ep care com ALL RIGHTS RESERVED 2019 8 3st EDITION Internet a...

Page 4: ...the time of sale This can be veriﬁed by means of the EC EU Declaration of Conformity and the relevant certiﬁcation 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 modiﬁcation or additional installation of equipment to the struct...

Page 5: ...ng and Lowering the Forks E5 1 3 4 Parking the truck securely E6 1 4 Using the truck on a slope E6 1 5 Hoisting the Truck See 1 3 dentification points and data plates E7 1 6 Operator daily checklist E10 F Battery Maintenance Charging F1 1 1 Safety regulations for handling acid batteries F1 1 2 Battery type dimension F1 1 3 Charging the battery F2 1 4 Battery removal and installation F3 1 5 Battery...

Page 6: ... is not abused and only used within its design scope and that all danger to the operator or third parties is avoided In addition to this it must be ensured that the relevant accident prevention regulations and other safety related provisions as well as the operating servicing and maintenance guidelines are observed The user must also ensure that all persons operating the truck have read and unders...

Page 7: ...or being unaware of the basic safe operating practices of the truck The following basic safe operating practices must be observed to ensure the safety of operators and others Never operate the truck in environments with s potentially explosive atmosphere Never carry passengers Do not overload the truck by exceeding the rated load indicated on the load designation plate Overloading can affect braki...

Page 8: ...y use the truck at altitudes not exceeding 2000 meters The walking lifting and lowering devices harnesses and components are IP55 dust and water resistant Trucks can only be operated in adequately illuminated working areas to avoid injuries In case of insufficient light an additional lighting equipment is needed to ensure that the driver can see properly If you must travel on an incline the gradie...

Page 9: ...oad section 2 Emergency stop switch 9 Stability bracket 3 Battery discharge indicator 10 Driving wheel 4 Key 11 Motor Cover Foot Protection 5 Cover upper 12 LED lamp 6 Power Plug for Internal Charger 13 Forks 7 Lift Cylinder 14 Load wheels EPT20 15ET ...

Page 10: ...trol Handle 8 Load section 2 Emergency stop switch 9 Caster 3 Battery discharge indicator 10 Driving wheel 4 Key 11 Motor Cover Foot Protection 5 Cover upper 12 LED lamp 6 Power Plug for Internal Charger 13 Forks 7 Lift Cylinder 14 Load wheels ...

Page 11: ...cover 2 Emergency stop switch key 9 Pump 3 Battery discharge indicator 10 Driving wheel 4 Key 11 Motor Cover Foot Protection 5 Cover upper 12 LED lamp 6 Power Plug for Internal Charger 13 Forks 7 lowering lever 14 Load wheels EPT18 EHJ EPT20 15EHJ ...

Page 12: ...l Handle EPT20 15ET EPT20 18EA EPT20 15EHJ EPT18 EHJ 15 Drive forward button 19 Drive switch 16 Drive backward button 20 Horn button 17 Lowering button 21 Emergency reverse button 18 Lifing button EPT20 15ET2 EPT20 ET 1 2 1 ...

Page 13: ...urs 1 with hour meter Without hour meter EPT20 15ET2 EPT20 ET EPT20 15ET EPT20 18EA 1 2 2 1 2 3 LCD 1 displays the residual electric charge of the battery LCD 2 displays the total operation time of the truck LCD 3 is a fault indicating light DISPLAY DESCRIPTION Continuous red Normal Flashing Truck failure Refer to relevant descriptions in discharge indicator and hour meter for the display function...

Page 14: ...The battery discharge indicator has a memory function it can remember the battery power after the power turn off and next time the power has be turned on it will show the power in it s memory If you want reset battery discharge indicator please turn on the key after properly charging EPT20 15EHJ EPT18 EHJ When the truck starts up the battery discharge status is shown via the the battery discharge ...

Page 15: ...ted Identification points and data plates Item Description Item Description 1 Direction Decal On Control Handle 7 Caution only US 2 Warning only US 8 Nameplate 3 Charge LCD Mode 10 Emergency stop switch 4 Key 11 Anti pinch hand 5 No riding decal 6 Hook 10 XIAQUAN DIPU ANJI ZHEJIANG CHINA www ep ep com mm mm mm mm kg kg LIFT HEIGHT LOAD CENTER CAPACITY ALT CAPACITY MAX CAPACITY kg TRUCK NAME MODEL ...

Page 16: ...E kg kW MAX BATTERY WEIGHT DRIVE OUTPUT DATE OF BUILD TRUCK WEIGHT WITH BATTERY MIN BATTERY WEIGHT XIAQUAN DIPU ANJI ZHEJIANG CHINA www ep ep com mm mm mm mm kg kg LIFT HEIGHT LOAD CENTER CAPACITY ALT CAPACITY MAX CAPACITY kg TRUCK NAME MODEL NO Y T I C A P A C D A O L O N S E I R E S mm LOAD CENTER TRUCK WEIGHT WITHOUT BATTERY kg kg kg V VOLTAGE kg kW MAX BATTERY WEIGHT DRIVE OUTPUT DATE OF BUILD...

Page 17: ...MAX BATTERY WEIGHT DRIVE OUTPUT DATE OF BUILD TRUCK WEIGHT WITH BATTERY MIN BATTERY WEIGHT 6 8 11 XIAQUAN DIPU ANJI ZHEJIANG CHINA www ep ep com mm mm mm mm kg kg LIFT HEIGHT LOAD CENTER CAPACITY ALT CAPACITY MAX CAPACITY kg TRUCK NAME MODEL NO Y T I C A P A C D A O L O N S E I R E S mm LOAD CENTER TRUCK WEIGHT WITHOUT BATTERY kg kg kg V VOLTAGE kg kW MAX BATTERY WEIGHT DRIVE OUTPUT DATE OF BUILD ...

Page 18: ...erial number Item Description Item Description 1 PRODUCT NAME 8 BATTERY VOLTAGE 2 MODEL TYPE 9 RATED DRIVE POWER 3 SERIAL NO 10 MAX BATTERY WEIGHT 4 MANUFACTURE DATE 11 MIN BATTERY WEIGHT 5 LIFT HEIGHT 12 RATED CAPACITY 6 UNLADEN MASS 13 LOAD CENTER 7 UNLADEN MASS WITHOUT BATTERY 1 3 1 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 19: ...0 685 560 685 4 32 Ground clearance center of wheelbase m2 mm 35 25 35 25 4 34 1 Aisle width for pallets 1000 1200 crossways Ast mm 1739 1629 4 34 2 Aisle width for pallets 800 1200 lengthways Ast mm 1939 1829 4 35 Turning radius Wa mm 1485 1375 Performance data 5 1 Travel speed laden unladen km h km h 4 4 5 3 5 4 5 2 Lifting speed laden unladen m s 0 022 0 025 10mm time 5 3 Lowering speed laden u...

Page 20: ... 4 21 Overall width b1 b2 mm 560 685 645 4 22 Fork dimensions s e l mm 50 150 1150 50x150x1150 4 25 Distance between fork arms b5 mm 560 685 540 645 685 4 32 Ground clearance center of wheelbase m2 mm 30 35 4 34 1Aisle width for pallets 1000 1200 crossways Ast mm 1739 1720 4 34 2Aisle width for pallets 800 1200 lengthways Ast mm 1939 1920 4 35 Turning radius Wa mm 1485 1465 Performance data 5 1 Tr...

Page 21: ...REV 08 2019 14 B 1 4 2 Dimensions EPT20 15ET ...

Page 22: ...REV 08 2019 15 B EPT20 15ET2 ...

Page 23: ...REV 08 2019 16 B EPT20 ET ...

Page 24: ...REV 08 2019 17 B EPT20 18EA ...

Page 25: ...REV 08 2019 18 B EPT20 15EHJ EPT18 EHJ ...

Page 26: ...hould occur it must be reported immediately WARNING Unauthorized modiﬁcations to the truck can result in injury or death Do not remove disable or modify any safeguards or other safety devices These include any alarms lights mirrors overhead guards and load backrest extensions If present an overhead guard is intended to provide protection to the operator from falling objects but cannot protect from...

Page 27: ...he forks upgrade to maintain control when travelling up or down an incline with a loaded truck Keep the forks downgrade when travelling up or down an incline with an empty truck R Tip over will occur if you turn while travelling on a ramp or travel at an angle other than straight up or straight down a ramp Never turn on an incline or ramp either loaded or unloaded Travel straight up or straight do...

Page 28: ...n completely open during the entire charging period Shorting of battery terminals can cause burns electrical shock or explosion Do not allow metal parts to contact the top surface of the battery Make sure all terminal caps are in place and in good condition Batteries may only be charged serviced or changed by properly trained personnel Always follow all instructions provided by the manufacturers o...

Page 29: ... slowly and stop after insertingthe 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 Operating the truck without its own drive system This operating mo...

Page 30: ...truck has been operated for a short time Check for Fluid Leakage Check Forks and Chassis Check Battery Connector Check Decal Condition Check Control Handle Pivot Check Operating Controls Break in period precautions Fasten wheel screws again at 50 hours of operation Within the ﬁrst 100 hours in particular the following requirements should also be met Excessive discharge of a new battery during init...

Page 31: ...perform any repairs or modifications on the fork lift truck Under no circumstances must the driver change the setting of switches or safety installations or render them ineffective Danger area A danger area is considered to be the area within which persons are endangered by the travelling or lifting movements of the fork lift truck or its load lifting devices e g fork or attachments or by the load...

Page 32: ...he truck Tilt the control shaft into the driving range M and set the controller to the desired direction V or R Steering Steering the truck is done using the control handle Manually moving it to the left or right will swivel the drive wheel The truck then turns in forward or reverse according to the handle direction Emergency stop Push the emergency stop switch For EPT20 15EHJ EPT18 EHJ Pull out e...

Page 33: ...e truck s nameplate Ensure that the load is stable and uniform to prevent any partial spillage Check that the width of the load is compatible with the width of the forks If the control handle moves slowly or not at all to the upper brake zone the truck must be taken out of service until the cause of this fault is be rectified Replace the gas pressure spring if necessary WARNING WARNING 1 2 3 Count...

Page 34: ...he forks to mid height R V 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 withthe load immediately ahead Raise the load a few centimeters above its support Back ...

Page 35: ...rol shaft 1 up and down until the desired lifting height is achieved Reset the lowering lever 2 Lowering Set fork to the lowest position by pulling lowering lever 2 upward Don t lift completely to top to avoid shorted life of oil cylinde for EPT20 15EHJ EPT18 EHJ Before lifting a load unit the driver must make sure that it has been correctly stowed and does not exceed the truck s capacity Make sur...

Page 36: ...sforwards In all cases travel at a very low speed and brake very gradually 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 d...

Page 37: ...e for truck weight If a battery is installed its weight must be added to the truck weight listed on the data plate Switch the truck off and press the emergency stop button Attach lifting equipment to the holes in each side of the chassis Attach lifting equipment to the fork tips to keep the truck approximately horizontal as it is lif ted Handle and handle lever installation Individual trucks are a...

Page 38: ...rt the handle pin and chain breakage may occur Align handle holes with pump housing holes and push through handle pin Figure 01302 1 2 Feed the chain and nut first back inside the handle through the handle pin s center hole Release the up down lever to its lowest position to make the process easier Once the chain is in the proper position check to see that it moves freely and that it is not obstru...

Page 39: ...ck before this step The handle should be pumped with full strokes to prime and eliminate air in the system The up down lever should be checked at the handle s lowest position for this puts the most tension on the chain Once the pallet truck is adjusted properly and is performing well drive in the second cotter pin Tie the wire harness with a tie wrap see arrow 1 together Figure 01308 Figure 01309 ...

Page 40: ...rol Handle Pivot Check the pivot point where the control handle attaches to the chassis for smooth operation by moving the handle through its entire range Check Operating Controls Return Spring Pull the control handle down into its operating range and release it It should return to the vertical position under spring tension Brake Interlock Handle Operate the truck in forward or reverse Move the co...

Page 41: ...uck No Department Runtime Meter Reading Operator No Daily Check Items O K Remark Check for Fluid Leakage Check Forks and Chassis Check Battery Connector Check Decal Condition Check Control Handle Pivot Check Operating Controls Perform Operational Check ...

Page 42: ...g The location must be well ventilated and fire fighting equipment must be kept ready Battery has high voltage and energy Do not short circuit Do not place any metal objects on the battery Do not put tools on the battery Battery type dimension All the batteries are maintenance free Battery type dimension as follow Tuck type voltage rated capacity Dimension Charger Charging time Internal External E...

Page 43: ...rnal charger Park the truck securely Open the battery panel To do this hold the panel by the handle mould and lift it up Disconnect the battery connector from the truck connector Expose the battery Connect the battery connector 1 with the charging lead of the stationary charger and turn on the charger Table for internal and external charger DISPLAY DESCRIPTION TROUBLESHOOTING Continuous red Batter...

Page 44: ...ed condition in a dry frost free room If the battery is not used for an extended period it must receive a supplementary charge every two months to prevent permanent damage to the battery Battery removal and installation Park the truck securely See Parking the truck securely and turn off the power before removal and installation of the battery Battery removal and installation steps b Remove four sc...

Page 45: ...Remove battery 6 c Remove battery cable 3 as shown in figure d Rotate control handle 4 to the extreme position e Pull electrical panel 5 a little out f Turn the electrical panel 5 to the direction as shown in picture until it does not cover battery at all ...

Page 46: ...our screws 1 take out the cover 2 b Remove wire harness battery cable Take out the battery 3 EPT20 15ET2 a To toggle lock switch 1 open the cover 2 b Remove sleeves and cables c Remove battery bracket 3 and batteries 4 EPT20 ET ...

Page 47: ...V 08 2019 6 F EPT20 18EA a Remove two screws 1 take out the cover 2 b Remove hose and wire harness 3 battery cable 2 Remove four screws 3 take out the controller board 4 c Put battery in or remove battery ...

Page 48: ...ight b Remove two screws 2 take out the cover 3 c Remove wire harness battery cable Take out the battery 4 Well place cables to avoid be damaged when you remove and install battery Installation is in the reverse order pay attention on battery install position and cable connection Make sure to protect the cables to avoid damage when you install the battery WARNING EPT18 EHJ ...

Page 49: ...hoes must be clean secure this with a light coating of dielectric grease Batteries with non insulated terminals must be covered with a non slip insulation mat Battery Disposal Batteries must only be disposed of as stipulated in the national environmental protection regulations or waste disposal provisions The battery manufacture s specifications for the disposal must be followed Cleaning the batte...

Page 50: ...t Daily inspection procedures and simple maintenance checks e g checking the hydraulic oil level or checking the ﬂuid level in the battery may be performed by operators This does not require training as described above Lifting and jacking up When a fork truck is to be lifted the lifting gear must only be secured to the points specially provided for this purpose When the truck is to be jacked up su...

Page 51: ...ation under normal operating conditions They must be reduced accordingly if the truck is to be used in conditions of extreme dust temperature fluctuations or multiple shifts The following maintenance checklist states the tasks and intervals after which they should be carried out Maintenance intervals are defined as W Every 50 service hours at least weekly A Every 250 operating hours B Every 500 op...

Page 52: ...k the transmission for noise and leakage Check travel mechanism adjust and lubricate if necessary Check control handle lifts back to braking position Check wheels for wear and damage Check wheel bearings and attachments Truck frame Check truck frame for damage Hydraulic operation Test hydraulic system Check that hose and pipe lines and their connections are secure check for leaks and damage Check ...

Page 53: ...box Heavy Duty Gear Oil GL 85W 90 50mL for EPT20 ET Gearbox 1 3 2 Lubrication Points Improper operations may constitute hazards to the operator s health and life as well as to the surrounding environment When storing or adding lubricant use clean containers It is strictly forbidden to mix different types and specifications of lubricants with each other except for those can be mixed under clear sta...

Page 54: ...Surface Lubrication Table Code Position Model L1 Steering Bearing For EPT20 15ET L2 Drive Wheel L3 Load Wheel L4 Mounting Shaft L5 Long Shaft L6 Steering Bearing For EPT20 15ET2 L7 1 Pin Roll For EPT20 ET 2 Long Shaft For EPT20 ET B 7 ...

Page 55: ... front panel Remove the two screws 1 remove cover 2 Remove other six screws 2 Carefully lift off the front panel 3 Replacing the drive wheel The drive wheel must only be replaced by authorised service personnel How to add oil It is necessary to add hydraulic oil when you heard explosion sound from pipe during lifting Prepare the truck for maintenance and repairs See Maintenance Instructions Open t...

Page 56: ...tenance and repairs See Maintenance Instructions Dismantle the front panel Check rating of all fuses in accordance with table replace if necessary Fuse 10A installed on main harness Item To protect Rating 1 Traction Lift motor 100A 2 Wire harness 10A Recommissioning The truck may only be recommissioned after cleaning or repair work once the following operations have been performed Test horn Test E...

Page 57: ...ccordance with the lubrication schedule Remove the battery and recharge it at least once per month Clean the battery and apply specialised grease to the terminals Spay all exposed electrical contacts with a suitable contact spray Charge the battery every two months to avoid depletion of the battery through self discharger Restoring the truck to operation after decommissioning Thoroughly clean the ...

Page 58: ...ext 2 inspections The owner is responsible for ensuring that faults are immediately rectified A test plate is attached to the truck as proof that it has passed the safety inspection This plate indicates the due date for the next inspection Final decommissioning disposal Final proper decommissioning or disposal of the truck must be performed in accordance with the regulations of the country of appl...

Page 59: ...ctor not plugged in Key switch in 0 position Incorrect CanCode code Battery charge too low Faulty fuse Truck in charge mode Check the battery connector and connect if necessary Set key switch to I Check code Check battery charge charge battery if necessary Check fuses Interrupt charging Load cannot be lifted Charging capacity below 20 40 Truck not operational Hydraulic oil level too low Faulty fus...

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