ep EPL151 Operation Manual Download

Page: 67 / 68

REV. 09/2020

Battery Fault Analysis

Fault

Negative Phenomena

Cause

Handling Methods

Electrode
plate sulfation

1. Battery capacity drops

during normal discharge

2. Density drops to be lower

than normal value

3. Voltage drops quickly when

discharging

4. Start charging under high

voltage

5. Bubbles generated during

charging

6. Coarse crystallization of

PbSO4

1. Insufficient initial charge

2. Long time of storage under

the state of discharge

3. Long-term insufficient

charged

4. Electrolyte density is too high

5. Electrolyte level is too low,

the upper part of electrode

plate is exposed outside of

the electrolyte

6. Impure electrolyte

7. Internal short circuit

1. Over-discharge method

2. Repeated charging

method

3. Water treatment method

Excessive

shedding

of active

substances

1. There is gray-brown

substance rising from the

bottom when charging

2. Battery capacity reduced

1. Brown precipitation is due to

excessive large charging

current

2. White sediment is due to

over-discharge

3. Battery electrolyte is impure

1. Clean up the precipitation

2. Adjust the density

3. Battery needs to be

replaced if necessary

Battery

overcharged

1. Color of battery filling cap

becomes yellow, and then

red

2. Battery casing deformation

3. Battery spacers

carbonization, deformation

4. Positive electrode corrosion,

broken

5. Electrode pole rubber

bushing raised, aged and

cracked

6. Frequent water-adding,

electrolytic turbidity during

charging

7. Evenly shedding of active

substances from electrode

plate

8. Positive electrode plate

detonation

1. Charger voltage and current

are set too high

2. Charging time is too long

3. Frequent charging

4. Less discharging, but much

charging

5. Charger failure

1. Adjust and repair the

charger

2. Adjust the charging

system

3. Battery needs to be

replaced in severe

situations

Battery Over-

discharge

1. Low static voltage

2. Electrolyte density is still

low after charging

3. Positive and negative

electrode plates curved or

fractured

1. Go on using the battery

despite of insufficient charge

2. Battery pack short circuit

3. Small current long time

discharge

1. Supplementary charging

2. Repair the vehicle

3. Battery needs to be

replaced in severe

situations

Summary of Contents for EPL151

Page 1: ...EPL151 Original Instruction Part No 508000003010 V3 09 2020 Operation Manual WPL201 RPL201 RPL201H RPL202 HPL152 ...

Page 2: ...een 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 al...

Page 3: ...y maintains the right to modify the specification s or design s of our products at any time without any beforehand notification Means that failure to comply can cause risk to life and or major damage to property 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 Instruc...

Page 4: ...nerative service brake and hold by an automatic electromagnetic parking brake in it s parking position The load is lifted by a hydraulic cylinder that activates a lifting shaft that transmits the lifting movement by a push rod to the load wheels The control handle is used for smooth steering and control of drive speed lifting and lowering braking and the horn without changing the position of the h...

Page 5: ...vention 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 responsi...

Page 6: ...tive at 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 th...

Page 7: ...age 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 bat...

Page 8: ...ge F6 11 Common Problems and Solutions F7 G Lead acid batteries G1 1 Safety and Warnings G2 2 Use of Battery G3 2 1 Pre use Checks G3 2 2 Discharging G3 2 3 Charging G3 2 4 Temperature G4 3 Maintenance Care G4 3 1 Daily Maintenance G4 3 2 Weekly Maintenance G4 3 3 Monthly Maintenance G5 3 4 Care G6 4 Storage G6 5 Troubleshooting G6 ...

Page 9: ...act 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 Nameplates and alarming labels A Nameplate Instructions label Anti pinch label Do not rest on the pallet label Lithium label...

Page 10: ...oisting the pallet truck Disconnect the power supply Attach slings in the positions identified by the hook symbol WPL201 Personnel must not stand below or near the truck when the pallet truck is being lifted DANGER HPL152 Do not rest on the side arms ...

Page 11: ...REV 09 2020 3 A RPL201 RPL201H RPL202 EPL151 ...

Page 12: ...Applicable environment temperature 10 C 40 C Don t use the truck in rainwater Don t use the truck in non position 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 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...

Page 13: ...e 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 confirms compliance with the limit values for electromagnetic emission and interference immunity as well as testing of static electricity dischar...

Page 14: ... 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 point...

Page 15: ...201H Display instrument Not for RPL201 RPL201H RPL202 Display the electric quantity of the truck Key switch Connect and interrupt control current Tortoise speed button Key switch Connect and interrupt control current Emergency reverse button Through touching the button truck drives away from operator Driving switch Controls travel direction and speed Horn button Send out sound warning signals Disp...

Page 16: ... 2 Key switch RPL201 RPL201H RPL202 EPL151 HPL152 Lowering lever Power switch button Horn button Emergency reverse switch Drive switch Pull and hold the manual lower switch 2 The forks will lower to the minimum height until they stop by themselves Start the truck Activates the horn Press the emergency reverse switch The vehicle will begin to travel in the opposite direction Select the required dri...

Page 17: ...running time normally If fault display the fault code 1 2 3 4 70 EPL151 WPL201 i NOTE 2 2 3 Display instrument RPL201 RPL201H RPL202 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 flashing it indicates travel forward properly LED 4 flashing it indicates travel backward...

Page 18: ... 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 i NOTE LED 1 displays the remaining charge LED 9 indicate the the acceleration status of the accelerator LED 2 indicate fault warning LED 3 indi...

Page 19: ... flashing three times pausing for 3 seconds Battery temperature is too low The green light repeats in a cycle of flashing twice in 1 second pausing for 2 seconds and then flashing four times pausing for 3 seconds Contactor related failures The green light repeats in a cycle of flashing three times in 1 second pausing for 2 seconds and then flashing four times pausing for 3 seconds The yellow light...

Page 20: ...atches 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 firmly Check the vertical creep of the truck if equipped Check the lithium...

Page 21: ...00h Prevent the new storage battery from discharging excessively during its initial use Implement complete preventive maintenance as specified Avoid emergency braking starting or swerving during the use of the truck Implement oil fluid replacement and lubrication before the time specified Limit the loading weight at 70 80 of the rated loading Should it be necessary to repair the truck for any faul...

Page 22: ...REV 09 2020 11 B 2 3 2 Truck starting 1 Release the emergency stop switch 2 Press the button to start the truck HPL152 ...

Page 23: ...on Control the running direction and speed of the truck using the drive switch 1 the large the rotary angle the faster corresponding speed 2 3 3 Running swerving and braking 1 Forward Backward 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 i NOTE ...

Page 24: ...etween two travel modes for RPL202 RPL201 RPL201H Pedestrian mode Push the side arms in fold up the operator platform Operate the drive switch and press creep speed button for RPL202 at the same time The truck can travel at the low speed CAUTION In pedestrian mode make sure you have sufficient distance from the truck Rider mode Push the side arms out fold down the operator platform The truck can b...

Page 25: ...uck comes to a stop then release the drive switch Emergency stop switch Press the emergency stop switch and then all the electrically propelled functions will be interrupted Braking area 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 Braking area ...

Page 26: ...fting 2 3 4 Goods picking Keep pressing the lifting button until reaching the required lifting height WPL201 RPL201 RPL201H EPL151 RPL202 2 Lowering Lower the pallet forks to the bottom through pressing the lowering button ...

Page 27: ...ife of the oil cylinder try not to lift the pallet forks to the highest state for every lifting operation WARNING NOTE i 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 HPL152 ...

Page 28: ...attery connection Should it be necessary for operators to leave the truck even for just a moment the truck should also be well parked as specified Never park the truck on a slope The forks must be lowered to the bottom WARNING 2 3 6 Drive directions The drive directions of the truck are forward 1 and reverse 2 1 2 ...

Page 29: ... straight line Transporting loads Always carry loads in the forward direction of travel R in order to have the best visibility R F 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 If the field of vision is poo...

Page 30: ...very low speed and brake very gradua lly 2 3 8 Using the truck on a slope Incorrect use of the truck on slopes places stress on the traction motor brakes and battery 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 ...

Page 31: ... forks are aligned with the pallet move slowly and stop after inserting the forks as far into the pallet as possible 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 Place the truck on a wooden pallet...

Page 32: ...revent the truck from rolling away Remove the cover Screw in two screws 1 M4 35mm until the truck can be moved no braking action Tighten two screws 1 the truck can be moved no braking action for RPL201 RPL201H RPL202 After setting down the truck at the destination unscrew two screws 1 Braking action is restored This operating mode is not permitted when negotiating inclines and gradients WARNING RP...

Page 33: ... by Charging environment 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 satisfied 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 ch...

Page 34: ...ger Charger failure return to factory maintenance Charger failure 5 Red light flashes The power input cable is not in good contact with the socket Check if the input power line is in good contact 6 Yellow light is on Storage battery fails battery reverse connection Eliminate battery failure 7 Storage battery fails battery is not connected Eliminate battery failure 8 Yellow light flashes Ambient te...

Page 35: ... the storage battery through an external charger Inspect whether relevant charging requirements are satisfied 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 LED light mode on the charging stand Charging red LED light Fully char...

Page 36: ...ity Dimensions Charger Charging time Internal External WPL201 Li ion 48V 30Ah 245 160 380 15A 15A 2h RPL201 RPL201H Li ion 24V 160Ah 550 190 500 50A 100A 3h 1 6h EPL151 Li ion 24V 55Ah 175 124 407 10A 20A 5 5h 2 5h HPL152 Li ion 24 20AH 193x81x300 10A 10A 2h RPL202 Li ion optional 24V 160Ah 550 x 190 x 500 50A 100A 3h 1 6h RPL202 lead acid 24V 280Ah 621 x 281 x 625 30A 50A 9 5h 6h ...

Page 37: ...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 RPL201 RPL201H RPL202 Before removing the battery make sure the vehicle is completely powered off WARNING HPL152 Just hold the handle and pull the battery...

Page 38: ...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...

Page 39: ... parts have been certified by our quality assurance department To ensure safe and reliable operation of the Pallet truck use only the manufacturer s spare parts Used parts oils and fuels must be disposed of in accordance with the relevant environmental protection regulations For oil changes contact the manufacturer s specialist department Safety tests to be performed at intervals and after unusual...

Page 40: ...ease the lubrication mouths in moving parts 14 Inspect and lubricate using the lithium based lubrication grease the bearing between the driving engine and the gear box 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 ...

Page 41: ... are reliable 25L Clean the oil tank and replace the hydraulic oil 26 Inspect and replace the hydraulic filter 27 Inspect whether the bearing capacity reaches the rated load and implement corresponding adjustment through the flood valve adopted in the hydraulic station 28 Inspect whether all the labels are clear and intact Table 1 Lubricants Code Type Specification Amount Position A Anti wear hydr...

Page 42: ...erator type standing Pedestrian Pedestrian 1 5 rated capacity Q kg 2000 2000 2000 1 6 Load center distance c mm 600 600 600 1 8 Load distance x mm 916 982 937 1003 916 982 937 1003 980 1 9 Wheelbase y mm 1418 1418 1438 Weight 2 1 Service weight include battery kg 630 630 755 2 2 Axle loading laden driving side loading side kg 1020 1610 1020 1610 1090 1665 2 3 Axle loading unladen driving side load...

Page 43: ...1150 1470 1150 1470 1170 4 15 Lowered height h13 mm 85 85 85 4 19 Overall length l1 mm 1860 1860 1930 4 20 Length to face of forks l2 mm 710 710 804 4 21 Overall width b 1 b2 mm 730 730 730 4 22 Fork dimensions s e l mm 55 170 1170 55x170x1150 55x170x1220 4 25 Distance between fork arms b5 mm 540 600 685 540 600 685 540 685 4 32 Ground clearance center of wheelbase m2 mm 30 30 30 4 34 1 Aisle widt...

Page 44: ...Drive motor rating S2 60 min hp kW 2 5 1 6 1 6 6 2 Lift motor rating at S3 15 hp kW 2 2 2 2 2 2 6 3 The maximum allowed size battery in mm 550 190 500 550 190 500 621 x 281 x 625 6 4 Battery voltage nominal capacity K5 V Ah 24 210 24 160 24 280 6 5 Battery weight lb kg 70 70 255 Addition data 8 1 Type of drive control AC AC AC 10 5 Steering type electronic electronic electronic 10 7 Sound pressure...

Page 45: ...REV 09 2020 4 E RPL201 RPL201H ...

Page 46: ...REV 09 2020 5 E RPL202 ...

Page 47: ...1500 2000 1 6 Load center distance c mm 600 600 600 1 8 Load distance x mm 883 946 883 946 1000 1 9 Wheelbase y mm 1105 1168 1105 1168 1268 Weight 2 1 Service weight include battery kg 165 130 250 2 2 Axle loading laden driving side loading side kg 574 1091 558 1172 685 1565 2 3 Axle loading unladen driving side loading side kg 130 35 84 46 185 65 Types Chassis 3 1 Tyre type driving wheels loading...

Page 48: ...on min max h14 mm 700 1170 638 1275 716 1240 4 15 Lowered height h13 mm 80 80 82 5 4 19 Overall length l1 mm 1523 1518 1592 4 20 Length to face of forks l2 mm 375 381 423 4 21 Overall width b 1 b2 mm 600 548 645 625 4 22 Fork dimensions s e l mm 50 150 1150 50 150 1150 55 170 1170 4 25 Distance between fork arms b5 mm 540 540 540 685 4 32 Ground clearance center of wheelbase m2 mm 30 30 27 4 34 1 ...

Page 49: ...r rating S2 60 min hp kW 0 65 0 75 0 75 6 2 Lift motor rating at S3 15 hp kW 0 8 man up 0 84 6 3 The maximum allowed size battery in mm 175 124 407 193 81 300 245 160 380 6 4 Battery voltage nominal capacity K5 V Ah 24V 1 40Ah 24 20AH 48 30 Li ion 6 5 Battery weight lb kg 13 1 5 1 14 Addition data 8 1 Type of drive control DC DC DC 10 5 Steering type mechanical mechanical mechanical 10 7 Sound pre...

Page 50: ...REV 09 2020 9 E EPL151 ...

Page 51: ...REV 09 2020 10 E HPL152 ...

Page 52: ...REV 09 2020 11 E WPL201 ...

Page 53: ...REV 09 2020 1 F Lithium ion battery ...

Page 54: ... state state It is forbidden to use and store the battery at low power the use and storage of power loss will cause the early loss of battery system capacity and accelerate the service life of the battery pack During the charging process liquid and metal substances are not allowed on the charger and it is forbidden to use the charger in a high temperature and high humidity environment It is forbid...

Page 55: ... overcharge 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 WARNING 5 Accessories 6 BMS Battery Management System The battery is permanently monitored by the BMS Battery Management System This provides the communication with the truck The...

Page 56: ...nt it from fierce shaking or shacking Explosion or fire disaster is likely to occur avoid short circuit Keep the battery away from all fire sources heat sources and flammable or explosive materials Don t knock over the storage battery Using lifting and delivery devices as specified Prevent the storage battery cell interface and connection cable from being damaged by the lifting hook If the materia...

Page 57: ...port It is different if the battery is transported on its own or in a truck An example of a label appears in this supplement see figure below 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 bat...

Page 58: ...nsure that the battery system is in the semi electric state The positive and negative terminals of the battery system are prohibited from contacting with metal objects during storage 10 Instructions for disposal Lithium ion batteries must be disposed of in accordance with the relevant environmental protection regulations Used cells and batteries are recyclable economic goods In accordance with the...

Page 59: ...alities 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 fix If the polarity of the positive and negative terminals of the battery is found not match the polarity id...

Page 60: ...REV 09 2020 1 G Lead acid battery ...

Page 61: ...he battery at a cool well ventilated place Dumping of battery is prohibited Only use proper lifting equipment to lift or transport the battery It is necessary to add water regularly other wise may cause damage to the battery due to water loss The water must be added after the battery is fully charged adding water before charging can cause electrolyte overflow The amount of water to be added must b...

Page 62: ...ife the battery should avoid excessive discharge during runtime capacity less than 20 of the rated capacity Re charge the battery immediately after discharging without delay 2 3 Charging When charging only DC can be used Connect the battery with proper charger for specification and size to avoid overload of circuit and interface and to avoid electrolyte foaming or overflow from the cell The charge...

Page 63: ...uid level may reduce the battery capacity and thus reduce the service life of battery Higher liquid level may lead to electrolyte overflow when charging which may cause corrosion to the battery compartment or even the vehicle Checking the battery condition electrolyte level and specific gravity Inspect battery for cracks raised plates and electrolyte leaks Unscrew the battery cover and check the e...

Page 64: ...ging is completed measure and record the electrolyte concentration and temperature of the battery cell How to tell if the battery is normal As for a normal set of fully charged batteries the voltage of each of the battery cell should be around 2 08V specific gravity of electrolyte should be around 1 28 After being fully charged if the voltage of battery cell is lower than 1 85V or the specific gra...

Page 65: ...e salt Slight sulfation clean top of the element with a damp cloth Severe sulfation the battery must be remov ed for powerful cleaning the battery base should also be cleaned Very severe sulfation or a large amount of electrolyte overflow please contact the after sales service department as soon as possible DO NOT arbitrarily discharge acidic wast ewater after cleaning dispose such water in accord...

Page 66: ...ctrolyte density is not less than 1 300g cm3 after charging 2 Battery static voltage is higher 3 Initial capacity is good but reduced after a period of use 4 Electrolyte is turbid Low density 1 Electrolyte density is still lower than the specified value after charging 2 Battery capacity is low Adding impure liquid 1 Battery capacity is low 2 Electrolyte is turbid and of abnormal color 3 Battery wi...

Page 67: ...e 3 Battery electrolyte is impure 1 Clean up the precipitation 2 Adjust the density 3 Battery needs to be replaced if necessary Battery overcharged 1 Color of battery filling cap becomes yellow and then red 2 Battery casing deformation 3 Battery spacers carbonization deformation 4 Positive electrode corrosion broken 5 Electrode pole rubber bushing raised aged and cracked 6 Frequent water adding el...

Page 68: ... current discharge 4 Poor wiring connection or disconnected 5 Electrode plate corrosion 1 Battery needs to be repaired 2 Battery needs to be replaced if necessary Battery Reverse Electrodes 1 Negative voltage values 2 Electrolyte density is lower than 1 20g cm3 after charging 3 Positive and negative electrode lugs colors of electrode plates are reversed Wrong connections of positive and negative e...

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ep EPL151, Operation Manual

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