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REV. 07/2020

1

F

                                 

 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.Operational application

temperature

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 recharging. 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(V/AH)

Dimension

(mm)

Charger(A) Charging 

time(h)

Internal

EPL1531

24/20

200*100*300

10A

2

• 

• 

•

• 

1.1

1.2

         

DANGER

 Charging the battery
Safety regulations for charging the battery

Before charging, check all cables and plug connections for visible signs of damage.

Before start and finish charging  make sure power is  turn OFF.

It is essential to follow the safety regulations of the battery and charging station 

manufacturers

.

1.3

• 

• 

• 

The charging environment temperature should be 5°C to 40°C.

i

NOTE

The truck can be operated at -20°C for a short period after it work above 5°C for a while.

WARNING

1.Battery life will be shortened if the battery is used for a long time at low temperature or 

stored.

2.No charging below 0°C.

3.Only temporary cold store application permissible as the permissible battery

   operating temperature is between 0°C and 40°C

Содержание EPL1531

Страница 1: ...Original Instruction Part No 508000003738 V1 07 2020 Operation Manual EPL1531 ...

Страница 2: ...s of the truck should therefore be assumed from the present operation manual Safety notices and text markups Safety instructions and important explanations are indicated 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 EQUIPME...

Страница 3: ...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...

Страница 4: ... drive system D1 1 3 Using the truck for the first time D2 1 4 Break in period precautions D2 E Operation E1 1 1 Safety regulations for the operation of pallet trucks E1 1 2 Operate and run the truck E1 1 2 1 Turning the truck on and off E1 1 2 2 Driving steering braking E2 1 2 3 Loading E3 1 3 Raising and lowering the forks E5 1 4 Parking the truck securely E5 1 5 Using the truck on a slope E6 1 ...

Страница 5: ...intenance and repairs G6 1 4 2 Remove the cover G6 1 4 3 How to add oil G7 1 4 4 How to add grease G7 1 4 5 Checking the fuses G7 1 4 6 Recommissioning G8 1 5 Decommissioning the industrial truck G8 1 5 1 Prior to decommissioning G8 1 5 2 Restoring the truck to operation after decommissioning G8 1 6 Safety checks to be performed at regular intervals and following any unusual incidents G9 1 7 Final...

Страница 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...

Страница 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...

Страница 8: ...vices 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 gradients should be below A at full load or below B without a load For the value of A and B refe...

Страница 9: ...REV 05 2020 2 B 1 Control handle 6 Forks 2 Control lever 7 Emergency stop switch 3 Lift cylinder 8 Lowering lever 4 Driving wheel 9 Load wheels 5 Battery Box 1 2 Truck assemblies ...

Страница 10: ...g lever and hold The forks will be lowered to its minimum height and stop on its own 4 Emergency reverse switch By pressing this switch the vehicle starts to travel in the opposite direction 5 Drive switch Select the required driving direction and speed 6 Creep speed switch Keep the handle in the vertical state and press creep speed switch and drive switch at the same time then the vehicle will mo...

Страница 11: ...re state of truck See section H Controller Error Message Charging indicator 1 2 3 If the controller detects a battery failure flashes of LED 2 represent battery failure information until the failure is remedied Details of failure information are shown as below 1 2 2 Key switch Connect and interrupt the control current When pulling out the key switch the control current of the truck will be interru...

Страница 12: ...ght repeats in a cycle of flashing once in 1 second pausing for 2 seconds and then flashing four times pausing for 3 seconds Over current protection The green light repeats in a cycle of flashing once in 1 second pausing for 2 seconds and then flashing five times pausing for 3 seconds Battery temperature is too high The green light repeats in a cycle of flashing twice in 1 second pausing for 2 sec...

Страница 13: ...s Item Description Item Description 1 Hydraulic oil label 8 Anti pinch hand label 2 Charging trouble light label 9 Function label 5 Nameplate 10 Lithium ion label 6 Instructions label 11 Type label 7 No riding label Front Right Top Left 1 2 6 7 8 9 10 11 4 5 ...

Страница 14: ... serial number Item Description Item Description 1 MODEL TYPE 7 RATED DRIVE POWER 2 SERIAL NO 8 BATTERY VOLTAGE 3 MANUFACTURE DATE 9 MAX BATTERY WEIGHT 4 RATED CAPACITY 10 MIN BATTERY WEIGHT 5 LOAD CENTER 11 UNLADEN MASS WITHOUT BATTERY 6 LIFT HEIGHT 12 UNLADEN MASS WITH BATTERY 1 3 1 1 2 3 4 5 6 7 8 9 10 11 12 ...

Страница 15: ...l designation EPL1531 1 3 Drive unit Battery 1 4 Operator type Pedestrian 1 5 rated capacity Q lb kg 1500 1 6 Load center distance c in mm 600 1 8 Load distance x in mm 950 880 1 9 Wheelbase y in mm 1190 1120 Weight 2 1 Service weight include battery lb kg 120 2 2 Axle loading laden driving side loading side lb kg 480 1140 2 3 Axle loading unladen driving side loading side lb kg 90 30 Types Chassi...

Страница 16: ...h14 in mm 750 1190 4 15 Lowered height h13 in mm 80 4 19 Overall length l1 in mm 1540 4 20 Length to face of forks l2 in mm 400 4 21 Overall width b1 b2 in mm 685 4 22 Fork dimensions s e l in mm 50x150x1150 4 25 Distance between fork arms b5 in mm 560 685 4 32 Ground clearance center of wheelbase m2 in mm 30 4 34 1 Aisle width for pallets 1000 1200 crossways Ast in mm 2145 4 34 2 Aisle width for ...

Страница 17: ...ic engine 6 1 Drive motor rating S2 60 min hp kW 0 75 6 2 Lift motor rating at S3 15 hp kW 0 7 6 3 The maximum allowed size battery in mm 200x100x300 6 4 Battery voltage nominal capacity K5 V Ah 24V 20 6 5 Battery weight lb kg 7 Addition data 8 1 Type of drive control DC 10 5 Steering type mechanical 10 7 Sound pressure level at the driver s ear dB A 74 ...

Страница 18: ...REV 07 2020 11 B 1 4 2 Dimensions ...

Страница 19: ...ould 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...

Страница 20: ...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...

Страница 21: ...d contacts the eyes seek medical attention at once Clean spilled battery acid immediately with large amounts of water Remove any metal rings bracelets bands or other jewelry before working with or near batteries or electrical components Never expose batteries to open flame or sparks Areas in which batteries are stored or charged must be well ventilated to prevent concentration of explosive gases If...

Страница 22: ...peration at the planned usage location under the electromagnetic interference conditions to be expected there An EMC test thus firstly measures the electro magnetic interference emitted by the truck and secondly checks it for sufficient resistance to electromagnetic interference with reference to the planned usage location A number of electrical measures are taken to ensure the electromagnetic compa...

Страница 23: ...ed steps and park the vehicle correctly Make sure the forks are aligned with the pallet move 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 palletto prevent the truck from tipping When transporting the truck make sure it is fully secured and take precautionary meas...

Страница 24: ...on 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 initial use must be prevented It should generally be charged promptly when at 20 The specified preventive maintenance must be done thorou...

Страница 25: ...t allowed to 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 o...

Страница 26: ...ore operating the 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 All of the electrical...

Страница 27: ...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...

Страница 28: ...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 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 Reverse travel V is to be u...

Страница 29: ...ke sure that it has been correctly stowed and does not exceed the truck s capacity Make sure long loads are stable supported by the forks WARNING 1 3 Parking the truck securely Lowering the forks Press emergency stop switch Remove the key It is forbidden to park on the slope for a long time 1 4 Unloading Carefully drive the truck to the desired location Carefully drive the truck to the unloading a...

Страница 30: ...ys 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 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 i 1 5 DANGER Starting on a slope If you have to stop and the...

Страница 31: ...rry the weight of the truck Refer to the truck data plate 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 lifted WARNI...

Страница 32: ...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 Returnspring 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 con...

Страница 33: ...Remark Check for fluid leakage Check forks and chassis Check battery capacity Check decal condition Check control handle pivot Check operating controls Check the load wheels Check the drive wheels Check electro magnetic brake function Check horn function Check Forward and reverse travel function Check lift and lower function ...

Страница 34: ... batteries are maintenance free Battery type dimension as follow Tuck type Voltage Rated capacity V AH Dimension mm Charger A Charging time h Internal EPL1531 24 20 200 100 300 10A 2 1 1 1 2 DANGER Charging the battery Safety regulations for charging the battery Before charging check all cables and plug connections for visible signs of damage Before start and finish charging make sure power is tur...

Страница 35: ...e and pull the battery out Install in reverse order 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 A fully charged battery will provide approximately 2 hours of continuous use Capacity wil...

Страница 36: ...he battery is not used for an extended period it must receive a supplementary charge every two months to prevent permanent damage to the battery We recommend that batteries are stored at a heightbetween 60 and 120 cm Store the battery in a dry place at a temperaturebetween 0 and 40 to preserve its service life This area must not be hermetically sealed to allow air renewal In case of long term stor...

Страница 37: ...tery Transporting only the lithium battery A class 9 danger label must be affixed to the packaging for transport It is different 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...

Страница 38: ...ily 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 suita...

Страница 39: ...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...

Страница 40: ...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 ...

Страница 41: ... 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 statement Lubricant CAUTION The use and disposal of lubricants must be carried out in strict accordance with the manufacturer s regulations Hydraulic oil injection nozzle Sliding surface Grease ...

Страница 42: ...wear hydraulic oil L HM32 180 200mL Hydraulic System B Multi purpose grease Polylub GA352P Appropriate amount Sliding surface See Table 1 C Grease MoS2 100 grams Gearbox Table 1 Sliding Surface Lubrication Table Code Position L1 Steering shaft L2 Drive Wheel L3 Long Shaft B L1 L2 L3 ...

Страница 43: ...parations must be made Park the truck securely See Parking the truck securely Remove the key to prevent the truck from accidentally starting When working under a raised lift truck secure it to prevent it from tipping or sliding away Remove the cover Unscrew the screw 1 remove driving cover 2 Rotate the handle 90 degrees unscrew the four screws 4 remove the hydraulic cover 3 through the spaces 1 4 ...

Страница 44: ...se 5A installed on main harness If necessary replace it with fuse that match the parameters specified in the table below Item To protect Rating 1 Wire harness 5A WARNING 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 Remove the hydraulic cover See Section1 4 2 Add...

Страница 45: ...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 fork truck Clean the battery Grease the pole screws using pole grease and reconnect the battery Recharge the battery Check if the hydraulic...

Страница 46: ...t 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 applic...

Страница 47: ...operational Hydraulic oil level too low Faulty fuse Charging the battery Carry out all measures listed under Truck does not start Check the hydraulic oil level Check fuses Controller Error Message The error message can be obtained in two ways 1 By reading the appropriate display on the hand held unit 2 By observing the fault codes issued by the LED 1 fault indicator Handheld Unit Diagnostics The f...

Страница 48: ...ot wire s broken or shorted 2 Broken speed limit pot 1 4 UNDER VOLTAGE FAULT battery voltage too low 1 Battery voltage 17 volts 2 Bad connection at battery or controller 1 5 OVER VOLTAGE FAULT battery voltage too high 1 Battery voltage 31 volts 2 Vehicle operating with charger attached 3 Intermittent battery connection 2 1 MAIN OFF FAULT main contactor driver Off fault 1 Main contactor driver fail...

Страница 49: ...Off fault 1 Electromagnetic brake driver open 2 Electromagnetic brake coil shorted 3 5 HPD FAULT HPD High Pedal Disable 1 Improper sequence of throttle and KSI push or inhibit inputs 2 Misadjusted throttle pot 4 1 CURRENT SENSE FAULT current sense out of range 1 Short in motor or in motor wiring 2 Controller failure 4 2 HARDWARE FAILSAFE motor voltage out of range 1 Motor voltage does not correspo...

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