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REV. 12/2020

6

C

1.3 Battery removal and installation

Park the truck securely as described in

paragraph 2.3.6 of chapter B and turn off the

power before removal and installation of the

battery.

Removing and installing from the top

Battery removal and installation steps:

a: Unscrew the three screws (1) and remove

the cover(2).

b: Unscrew the 2 screws(3) and remove the

battery cover(4).

c: Remove the three battery cables shown in

the image(5).

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2

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Summary of Contents for EST122

Page 1: ...EST122 Original Instruction Part No 508000004104 V2 12 2020 Operation Manual ...

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: ... specification s or design s of our products at any time without any beforehand notification Indicates an extremely hazardous situation Failure to comply with this instruction will result in severe irreparable injury and even death 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 ...

Page 4: ... 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 op...

Page 5: ...ulic system Brake system The electromagnetic brake with dust protection function can be used as a safety brake and parking brake Braking is controlled by the drive controller the brake s electromagnet acts on the motor shaft and automatic braking is activated when the tiller is in the horizontal or vertical position end stop brake Battery It uses a large capacity lead acid battery or lithium ion b...

Page 6: ...her applicable EC EU directives effective 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 Unauthorized modiﬁcation or addit...

Page 7: ...ting the truck B21 2 3 12 Hoisting B23 C Battery use and maintenance C1 1 1 Safety and warning C1 1 1 1 Safety regulations for handling acid batteries C1 1 2 Handling the battery C3 1 2 1 Battery charging C3 1 2 2 Battery type dimensions Charging time C5 1 2 3 Handling of the battery acid C5 1 3 Battery removal and installation C6 D Maintenance D1 1 1 Truck maintenance D1 1 1 1 Safety announcement...

Page 8: ... 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 Instructions label Anti pinch hand label Do not rest on the stacker label Notice No standing under the load carriage la...

Page 9: ...truck indicates the truck s capacity with the forks as originally supplied Truck nameplate For queries regarding the truck or ordering spare parts please quote the truck serial number Item Description 1 TRUCK NAME 2 MODEL TYPE 3 SERIES NO 4 MANUFACTURE DATE 5 UNLADEN MASS 6 UNLADEN MASS WITHOUT BATTERY 7 BATTERY VOLTAGE 8 RATED DRIVE POWER 9 MAX CAPACITY 10 MAX LIFT HEIGHT 11 RATED CAPACITY 12 LOA...

Page 10: ...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 from sliding off Conditions of operation road surface the truck should run on...

Page 11: ...uous 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 discharge accor...

Page 12: ...pose 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 araised l...

Page 13: ...owering button Lower loading parts 18 Lifting button Lift loading parts 19 Drive switch Controls travel direction and speed 20 Horn button Send out sound warning signals 21 Emergency reverse swith Through touching the button truck drives away from operator Fig0000 00069OM ...

Page 14: ...itch 2 2 3 Display instrument Fig0000 00070OM LED 1 displays the remaining electric 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 functions of LED 1 i Truck failure is in the service manual cont...

Page 15: ...d 0 20 If remaining battery capacity is below 30 A flashing red LCD shows warning If remaining battery capacity is below 20 Two flashing red LCDS show warning And lifting is now prohibited The battery must be charged The battery discharge indicator has a memory function it can remember the battery power after the power is turned off and next time when it is turned on it will show the power in it s...

Page 16: ...cy reverser function Check the battery installation making sure not to damage the battery cables Check the function of the steering funciton Check the battery charging plug Check the drive wheels and rollers for wear and damage Check the hydraulic functions Check brake function of electromagnetic brakes Check whether optional functions are operating normally WARNING Table 1 Table of Daily Inspecti...

Page 17: ...tion Check the lifting and lowering function Check the driving function Check the steering function The truck can now be started see 2 3 3 Truck starting 2 3 2 Commissioning If the truck is delivered in multiple parts setup and commissioning must only be performed by trained authorised personnel i NOTE Wheel flattening If the truck has been parked for a long period the wheel surfaces may tend to f...

Page 18: ...g 1 Release the emergency stop switch 1 2 Turn the key switch 2 to start the truck 3 Test the horn button 3 The truck is now operational Put the tiller in the drive position M and use the drive switch to control direction and speed 1 2 3 ...

Page 19: ... the mast to prevent its bottom from colliding with the road surface i NOTE Tilt the control shaft into the running area M and control the running direction and speed of the using the drive switch 1 the lager the turning angle the faster corresponding speed R V R V B M B i NOTE V is forwards R is reverse B is brake M is running area 1 ...

Page 20: ...s released The mechanical brake engages when the tiller is positioned in Braking area If the control handle moves slowly into the brake position identify the cause and rectify the fault If necessary replace the gas spring CAUTION B B 1 1 2 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 ...

Page 21: ...l the electrically propelled functions will be interrupted Regenerative braking Release the drive switch The drive switch will automatically return to the initial position and the vehicle will begin to enter the regenerative braking state When it decelerates to 1 km h the electromagnetic brake will bring the motor to a stop Open the drive switch if the drive switch cannot quickly return to the ini...

Page 22: ...B 2 3 5 Goods picking 1 Lifting Keep pressing the lifting button until reaching the required lifting height 2 Lowering Lower the truck to the bottom through pressing the lowering button Fig2108 00024OM Fig2108 00025OM ...

Page 23: ...be executed if the hydraulic system develops a fault The solenoid valve with the emergency lowering screw is located on the valve body of the hydraulic pump Do not stand in the vicinity of the forks when the fork arms are being lowered Always keep your hands on the screw during lowering so you can stop the lowering operation at any time Unscrew the two large screws 1 and pull out the cover 2 Fig21...

Page 24: ...REV 12 2020 15 B 2 3 6 Parking the truck securely Lower the mast to the bottom Turn off the key switch 2 Fig2108 00026OM 3 1 The emergency lowering screw is located on the solenoid valve 3 ...

Page 25: ...hicle Lower the forks so that they can easily be inserted into the pallet Insert the forks below the pallet If the goods are shorter than the forks move the goods a few centimetres from the end of the forks so as not to scratch the goods in front Lift the goods a few centimetres Safety footwear must be worn CAUTION CAUTION Do not touch nearby loads or loads positioned at the side or in front of th...

Page 26: ...r deposit ing a load Since visibility in this direction is restricted you should only travel at very low speed Never drive with an unstable load If visibility is poor let someone guide you Be careful of low passageways low door ways scaffolding pipes etc To facilitate movement over obstacles increase the ground clearance Check that the width of the load is compatible with the width of the aisle DA...

Page 27: ...ed behind the equipment Before you remove the load ensure that there are no people in the vicinity CAUTION CAUTION CAUTION Personnel must not stand under or near the truck when the load is in the raised position Carefully drive the machine to the required location Raise the forks clearly above the level where the load is to be placed Drive the truck backward into the racking Lower the load until t...

Page 28: ...the equipment CAUTION Picking up a load at height Carefully drive the machine to the required location Raise the forks to the height of the pallet Carefully move the forks forward under the pallet Lift the forks until the pallet moves away from the racking Reverse the truck to free the pallet Lower the goods again until they are a few centimeters away from the ground Fig2108 00031OM ...

Page 29: ...In all cases travel at avery low speed and brake very gradually In all cases you must 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 park the truck on a slope Never make a U turn or take shortcuts on a slope The driver must drive very slowly on slopes DANGER Starting on a slope If you have to stop and the...

Page 30: ...d when negotiating inclines and gradients WARNING 2 3 11 Transporting the truck When transporting the truck check that it is properly supported on wooden blocks and correctly tied with rope Fold the side protection bars and foldable platform so they do not protrude from the vehicle body CAUTION Tie points and position Lower the fork arms to the lowest position Use wooden chocks 1 to secure the fro...

Page 31: ...ker should be loaded and unloaded by specially trained personnel Effective measures must be taken based on the specific situation to ensure the correctness and safety of measurement and loading unloading operations i NOTE 1 1 2 ...

Page 32: ...before hoisting the stacker Disconnect the power supply Attach slings in the positions identified by the hook symbol Personnel must not stand below or near the truck when the stacker is being lifted Do not sling the truck by the control handle DANGER ...

Page 33: ...ting materials must be present or stored within a distance of 2 meters of the truck parked for battery recharging The location must be well ventilated and fire fighting equipment must be kept ready Only trained and authorized personnel are permitted to charge service and replace the batteries Batteries are recycled in accordance with national regulations please comply with the relevant regulations...

Page 34: ... the event of accidental skin contact with electrolyte the affected parts shall be washed with large quantities of water or with adequate neutralizing solutions If irritation of skin persists medical attention shall be obtaine Accidental contact first aid Acid and alkaline electrolytes create burns in eyes and on the skin A source of clean water from tap or a dedicated sterile reservoir shall be p...

Page 35: ...ck should not be moved Charging the battery with internal charger 1 2 1 2 1 Battery charging The vehicle must be parked in a wellventilated room There must be no metal parts on the surface of the battery Before charging check all cables and plug connections for visible damage Before and after charging make sure power is turned OFF It is essential to follow the safety regulations of the battery cha...

Page 36: ...e The power input line is in good contact with the socket and the charger 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...

Page 37: ... immediately Battery maintenance The battery cell covers must be kept dry and clean The terminals and cable shoes 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 Cleaning the battery Do not use dry cloth or fibre cloth to clean the battery to prevent static charging and explosion Unfix battery...

Page 38: ...ter B and turn off the power before removal and installation of the battery Removing and installing from the top Battery removal and installation steps a Unscrew the three screws 1 and remove the cover 2 b Unscrew the 2 screws 3 and remove the battery cover 4 c Remove the three battery cables shown in the image 5 1 2 ...

Page 39: ...tion is in the reverse order pay attention on battery installation position and cable connection Make sure to protect the cables to avoid damage when you install the battery Well place cables to avoid be damaged when you remove and install battery i NOTE i NOTE Route the battery cable so that it is not trapped when the battery is inserted ...

Page 40: ...pproved spare parts If required to be parked for over one month the truck must be placed in a dry and frost free environment Raise and chock the truck the wheels must not touch the ground in order to prevent irreversible deformation of the tyres Clean the truck carefully Check the hydraulic oil level and replenish if necessary see page D5 Coat any unpainted metal parts with a thin layer of oil or ...

Page 41: ...n to the 250 hour maintenance mentioned above 12L Inspect or add the gear grease 13L Inspect and lubricate using the lithium based lubrication grease 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 t...

Page 42: ...ation performances of the truck Inspect and add gearbox lubrication grease 23L Inspect and replace gearbox gear oil 24 Inspect where there is any damage in the oil cylinders and whether corresponding installations are reliable 25 Check hoses pipes and interfaces for damage and ensure their tightness and sealing 27 Inspect whether the bearing capacity reaches the rated load and implement correspond...

Page 43: ...REV 12 2020 4 D Sliding surface Hydraulic oil injection nozzle Gear oil injection nozzle Gear oil discharge nozzle ...

Page 44: ...lic System Low temperature anti wear hydraulic oil cold storage L HV32 B Multi purpose grease Polylub GA352P Appropriate amount Sliding surface See Table 2 C Grease MoS2 110 grams Gearbox Table 1 Application Amount of Hydraulic Oil Mast Series Lifting height mm Amount L 2 stage mast 2500 4 2 2700 4 2 3000 4 5 3300 4 8 ...

Page 45: ...REV 12 2020 6 D Table 2 Sliding Surface Lubrication Table Code Position L1 Caster L3 Steel channel and rollers L4 Chains L5 Steering Bearing L6 Drive Wheel ...

Page 46: ...rding to Lubrication Points You can lift again after you have finished adding the oil You must continue checking the hydraulic oil level if there is still a banging noise Reinstall the disassembled parts in reverse order i NOTE i NOTE Only use hydraulic oil that meets the specifications Refer to Lubricants Points It is necessary to add hydraulic oil when you heard explosion sound from pipe during ...

Page 47: ...ove steps in reverse order Fully lower the mast Press the emergency stop switch Remove the front hood Check that all fuses are in working order If necessary replace them with fuses that match the parameters specified in the table below No Checking fuses for the following functions or components Value 1 Traction Lift motor fuse 150A 2 Wire harness fuses 5A 1 2 3 How to add grease 1 2 4 Checking fus...

Page 48: ...ing to the reverse order of removal 1 2 5 Drive Wheel Tyre wear can affect the stability of the truck adjust the caster with minor wear on a regular basis or replace the caster with heavy wear Quality of tyres directly affects the stability and driving performance of the device If you need to replace the factory fitted tyres please use original spare parts provided by the equipment manufacturer to...

Page 49: ...heel bridge with an ejector pin of 4mm in diameter Turn the wheel bridge to vertical direction knock out the wheel pin shaft 3 from side and remove the load wheel and bearing assembly Remove the bearing 5 of load wheel 4 with hammer and jacking equipment 1 2 6 CAUTION CAUTION Loosen the set screw 1 in the fork leg with a wrench Knock out the wheel pin shaft 2 from side and remove washers 3 load wh...

Page 50: ...rews 1 then remove the caster 3 and adjustment shim 2 Installation Install according to the reverse order of removal 1 2 7 CAUTION Make sure the lifting equipment is solid and secure and the load capacity should be greater than the total weight of the vehicle Lifting height of not more than 300mm to prevent the hazards to the maintenance personnel working under the vehicle for caster removal and i...

Page 51: ...k if the caster is functioning properly After long time of use the drive wheel will wear and tear to certain level at this time adjust the height of caster 3 through increasing or decreasing the number of adjustment shims 2 to make the two casters and drive wheel to be in close contact with the ground Upon maintenance or replacement for parts of the caster please refer to two figures as below ...

Page 52: ...ry cables and connect if necessary Set key switch to I Check battery charge charge battery if necessary Check fuses Interrupt charging Load cannot be lifted Charging capacity too low Truck not operational Hydraulic oil level too low Charging the battery Carry out all measures listed under Truck does not start Check the hydraulic oil level Troubleshooting Final decommissioning disposal The final sc...

Page 53: ...1 2 Model designation EST122 1 3 Drive unit electrics 1 4 Operator type pedestrian 1 5 rated capacity Q t 1 2 1 6 Load center distance c mm 600 1 8 Load distance x mm 798 1 9 Wheelbase y mm 1212 Weight 2 1 Service weight include battery kg 595 2 2 Axle loading laden driving side loading side kg 670 1125 2 3 Axle loading unladen driving side loading side kg 450 145 Types Chassis 3 1 Tyre type drivi...

Page 54: ...ons 4 2 Height mast lowered h1 mm 1956 4 3 Free lift h2 mm 4 4 Lift height h3 mm 2630 4 5 Height mast extended h4 mm 3271 4 9 Height drawbar in driving position min max h14 mm 750 1340 4 10 Height of wheel arms 4 15 Lowered height h13 mm 85 4 19 Overall length l1 mm 1713 4 20 Length to face of forks l2 mm 563 4 21 Overall width b1 b2 mm 792 4 22 Fork dimensions s e l mm 60 170 1150 4 24 Fork carri...

Page 55: ...10 0 14 5 3 Lowering speed laden unladen m s 0 10 0 10 5 8 Max gradeability laden unladen 4 10 5 10 Service brake type Electromagnetic Electric engine 6 1 Drive motor rating S2 60 min hp kW 0 75 6 2 Lift motor rating at S3 15 hp kW 2 2 6 3 The maximum allowed size battery in mm 260x165x210 6 4 Battery voltage nominal capacity K5 V Ah 2x12 85 6 5 Battery weight lb kg 2x24 Addition data 8 1 Type of ...

Page 56: ...REV 12 2020 4 E Dimensions ...

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