EP Equipment HPL152 Operation Manual
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EP Equipment HPL152 Operation Manual

Electric pallet truck
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Summary of Contents for EP Equipment HPL152

  • Page 2 EP EQUIPMENT CO.,LTD. is one of the With business all over the world, EP has world’s leading companies manufacture, thousands of employees and hundreds design material handling equipment and of agents worldwide to provide our provide related service. With over...
  • Page 3 , the real parameters will depend on sale files. 2. Manual pictures for reference only, the real car shall prevail, and shall not affect the manual use. EP EQUIPMENT CO.,LTD Address: XIAQUAN,DIPU,ANJI,ZHEJIANG,CHINA Tel: 86-571-28031990 Fax: 86-571-28035616 Net: www.ep-ep.com...
  • Page 4 WARNING! TO PREVENT SETIOUS RISK OF INJURY TO YOUORSELF AND OTHERS OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS. These truck may become hazardous if adequate maintenance is neglected. Therefore, adequate maintenance facilities, trained personnel and procedures should be provided. Maintenance and inspection shall be performed in conformance with the following practices: 1.
  • Page 5 9. All hydraulic systems shall be regularly inspected and maintained in conformance with good practice. Cylinders, valves and other similar parts shall be checked to assure that "drift" has not developed to the extent that it would create a hazard. 10.

  • Page 6: Table Of Contents

    Catalog Correct use and application....................1 1. Truck Description......................... 2 1.1 Application........................2 1.2 Assemblies........................3 1.2.1 Control Handle......................4 1.2.3 Discharge indicator....................4 1.3 Identification points and data plates............... 6 1.3.1 Truck data plate...................... 8 1.4 Standard Version Specifications................9 1.4.1 Performance data for standard trucks..............9 2.
  • Page 7 6.Troubleshooting........................31 Error Message........................ 31 Lithium battery operating instructions.................35 Chapter 1 Safety Precautions..................36 Chapter 2 Battery Introduction and Instructions............37 Chapter 3 Charging......................38 Chapter 4 Storage......................39 Chapter 5 Transportation....................40 Chapter 6 Common Problems and Solutions............41 Chapter 7 Maintenance....................42...

  • Page 8: Correct Use And Application

    Correct use and application The guidelines form part of these operating instructions and must be observed. National regulations apply in full. The truck described in the present operator manual is an industrial truck designed for lifting and transporting load units. It must be used, operated and serviced in accordance with the present instructions.

  • Page 9: Truck Description

    1. Truck Description 1.1 Application The truck is designed to transport goods on level surfaces. It can lift open bottom or diagonal board pallets as well as roll cages beyond the area of the load wheels. Suitable environment temperature is 5°C to 40 °C. If a long time in less than 5 °...

  • Page 10: Assemblies

    1.2 Assemblies Item Component Item Component Control handle Battery Control shaft Lowering lever Pump Fork Driving wheel Emergency stop switch Load wheels...

  • Page 11: Control Handle

    1.2.1 Control Handle Item Control / Display Function "Horn" button Activates the horn. Power switch button Starting truck Pull the lowering lever and hold. The forks will be Lowering lever lowered to its minimum height and stop on its own. By pressing this switch, the vehicle starts to travel Emergency stop switch in the opposite direction...
  • Page 12 in 1 second, pausing for 2 seconds and then flashing three times, pausing for 3 seconds. Short circuit protection: The green light 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.

  • Page 13: Identification Points And Data Plates

    1.3 Identification points and data plates Item Description Nameplate “Instructions” label Emergency stop switch label Anti pinch hand label Charging indicator label No Riding Fault Indicator Label LIION Logo Sling Label...

  • Page 15: Truck Data Plate

    1.3.1 Truck data plate Item Description Item Description Product name Battery voltage(v) Model type. Rated drive power(kw) Series no. Max battery weight(kg) Manufacture date Min battery weight(kg) Lift height(mm) Rated capacity(kg) Unladen mass with battery(kg) Load center(mm) Unladen mass without battery(kg) For queries regarding the truck or ordering spare parts please quote the truck serial number(3).

  • Page 16: Standard Version Specifications

    1.4 Standard Version Specifications 1.4.1 Performance data for standard trucks Technical specification details in accordance with VDI2198. Technical modifications and additions reserved. Distinguishing mark Model designation HPL152 Drive unit Battery Operator type Walkie rated capacity lb. kg 1500 Load center distance in.
  • Page 17 4.21 Overall width in. mm 548 4.22 Fork dimensions s/ e/ l in. mm 50/150/1150 4.25 Distance between fork-arms in. mm 540 4.32 Ground clearance, center of wheelbase m in. mm 30 4.34. Aisle width for pallets 1000 × 1200 in.
  • Page 18 HPL152...

  • Page 19: Transport And Commissioning

    2. Transport and Commissioning 2.1 Lifting the truck by crane 1.Only use crane handling equipment gear with sufficient capacity. 2.Loading weight > net weight of truck (battery weight for electric trucks).Loading weight not only net weight of truck but also the stock or the box. 3.Stock (box) should be big enough and strong enough to bear hole truck.

  • Page 20: During Brake-In

    2.3 During brake-in We recommended operating the machine under light load conditions for the first stage of operation to get the most from it. Especially the requirements given below should be observed while the machine is in a stage of 100 hours of operation. •...

  • Page 21: Operation

    3.Operation 3.1Safety Regulations for the Operation of Pallet Trucks Driver authorisation: The Pallet truck may only be used by suitably trained personnel, who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to operate the truck by the proprietor or his representative.

  • Page 22: Operate And Run The Truck

    3.2 Operate and run the truck 3.2.1 Preparing Before the truck can be commissioned, operated or a load unit lifted, the driver must ensure that there is nobody within the hazardous area. Checks and operations to be performed before starting daily work •...

  • Page 23: 3Lifting, Transporting And Depositing Loads

    2.Steering • Apply the control shaft (1) to the left or right. 3.Braking Emergency stop Press the emergency stop switch (2)， all electrical functions are cut out and the truck automatically brakes. Automatic braking When the control handle is released it automatically sets itself to the upper brake zone (B) and automatic braking ensues.

  • Page 24: 4Parking The Truck Securely

    Lift 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). Lower Set fork to the lowest position by pulling lowering lever (2) upward.

  • Page 25: Battery Maintenance & Charging

    4.Battery Maintenance & Charging 4.1 Lithium Battery Precautions ·Please prevent the battery from water or infiltration of any corrosive liquid. Do not let the battery close to any open flame, heat, · flammable and explosive objects. ·Do not place the battery vertically on a conductive object to prevent the electrode from being touched by protruding objects.

  • Page 26: Battery & Charger

    ·Charge the battery at an ambient temperature of 0 to 40°C. Attention: In case of battery fault, please contact the dealer to make appointment for repair. Never attempt to disassemble the battery. 4.2 Battery & Charger...

  • Page 27: Charging The Battery

    4.3 Charging the battery 4.3.1 Vehicle charging Safety regulations for Charging the battery • To charge the battery, the truck must be parked in a closed and properly ventilated room. When charging, the tops of the battery cells must be exposed to provide sufficient ventilation.

  • Page 28: External Charging

    4.3.2 External charging 1. Lift the battery out of the vehicle. 2. Insert the battery into the charging base 3.The LED light lights up. LED MODE Charging mode : LED Red on Full charged : LED Green on Charger fault : LED Yellow flash Battery fault : LED Yellow on Before removing the battery, make sure that the vehicle is completely powered down.

  • Page 29: Charge Completed

    4.4 Charge Completed 1.The battery is fully charged after 2.5 hours of charging at 100 ~240V AC. 2. Insert the battery into the battery compartment of the vehicle. 3.The battery can be operated continuously for 3 hours in a fully charged state. Before plugging the battery back, please make sure that the vehicle is still in the power-off state.

  • Page 30: Charger Installation

    4.5 Charger Installation Charger is recommended to be installed to the wall with expansion screws . 4.6 Maintenance & Care Please replace the wheels with the tires specified by our manufacturer. Non-conforming tires can affect the performance and stability of the product. Do not clean the truck with flammable liquids.

  • Page 31: Pallet Truck Maintenance

    5.Pallet Truck Maintenance 5.1 Operational safety and environmental protection • The servicing and inspection operations contained in this chapter must be performed in accordance with the intervals indicated in the servicing checklists. • Any modification to the Pallet truck assemblies, in particular the safety mechanisms, is prohibited.

  • Page 32: Servicing And Inspection

    and electronic components must be carefully covered beforehand as moisture can cause malfunctions. Do not clean with pressurised water. After cleaning the truck, carry out the activities detailed in the “Recommissioning” section. Electrical System Only suitably trained personnel may operate on the truck’s electrical system. –...

  • Page 33: 1Maintenance Checklist

    5.3.1Maintenance Checklist Maintenance ● interval W A B ● Brake Check magnetic brake air gap. ● Electrics Test instruments, displays and control switches. ● Test warning and safety device. Make sure wire connections are secure and check for ● damage. ●...

  • Page 34: Lubrication Schedule

    5.3.2 Lubrication Schedule Fuels, coolants and lubricants Handling consumables: Consumables must always be handled correctly. Follow the manufacturer’s instructions. Improper handling is hazardous to health, life and the environment. Consumables must only be stored in appropriate containers. They may be flammable and must therefore not come into contact with hot components or naked flames.

  • Page 35: Maintenance Instructions

    Code Description Used for L-HM32 Hydraulic system L-HV32 Polylub GA352P Rotation gear Gear case Grease(contain 5.3.3 Maintenance Instructions Prepare the truck for maintenance and repairs All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made: •...

  • Page 36: Decommissioning The Industrial Truck

    Recommissioning The truck may only be recommissioned after cleaning or repair work, once the following operations have been performed. • Test horn. • Test brake. • Lubricate the truck in accordance with the maintenance schedule. 5.4 Decommissioning the industrial truck If the industrial truck is to be decommissioned for more than two months , e.g.

  • Page 37: Safety Checks To Be Performed At Regular Intervals And Following Any Unusual Incidents

    • Clean the battery, grease the terminals and connect the battery. • Charge the battery (See 4.3Charging the battery ). • Check hydraulic oil for condensed water and replace if necessary. • Start up the truck (see 3.2 Operate and run the truck ). If there are switching problems in the electrical system, apply contact spray to the exposed contacts and remove any oxide layers on the contacts of the operating controls by applying them repeatedly.

  • Page 38: Troubleshooting

    6.Troubleshooting This chapter is designed to help the user identify and rectify basic faults or the results of incorrect operation. When locating a fault, proceed in the order shown in the table. Fault Possible cause Action • • Truck does Key switch in “OFF”...
  • Page 39 1212 MOTOR CONTROLLER LED BLINKS LED BLINKS Error Message digit 1 digit 2 THERMAL FAULT THROTTLE FAULT SPEED POT FAULT UNDERVOLTAGE FAULT OVERVOLTAGE FAULT MAIN OFF FAULT (not used) MAIN FAULT MAIN ON FAULT (not used) WIRING FAULT BRAKE ON FAULT PRECHARGE FAULT BRAKE OFF FAULT HPD FAULT...
  • Page 40 – Temperature >80°C < -10°C. 2. Excessive load on vehicle. over-/under-temperature THERMAL FAULT 3.Operation extreme cutback environments. 4.Electromagnetic brake releasing. 1.Throttle input wire open or PotLow and/or PotWiper shorted. THROTTLE FAULT out of range 2.Throttle pot defective. 3.Wrong throttle type selected. 1.Speed limit pot wire(s) broken speed limit pot wiper out of SPEED POT FAULT...
  • Page 41 1. Brake driver shorted. PRECHARGE FAULT precharge fault 2. Precharge circuit damaged. 3. MOSFET failure. 1.Electromagnetic brake driver open. BRAKE OFF FAULT brake Off fault 2.Electromagnetic brake coil shorted. 1. Improper sequence of throttle HPD FAULT HPD (High Pedal Disable) and KSI,push, or inhibit inputs.

  • Page 42: Lithium Battery Operating Instructions

    Lithium battery operating instructions Table of Content Chapter 1 Safety Precautions....................1 Chapter 2 Battery Introduction and Instructions..............2 2.1 Battery Introduction....................2 2.2 Instructions........................2 2.3 Display Instrument.....................3 2.4 Battery Nameplate.....................4 Chapter 3 Charging......................... 5 Chapter 4 Storage........................6 Chapter 5 Transportation......................6 Chapter 7 Maintenance......................8 7.1 Daily Maintenance.....................

  • Page 43: Chapter 1 Safety Precautions

    Chapter 1 Safety Precautions CAUTION • DO NOT short-circuit the positive and negative terminals of the battery. • Do not collide, handle gently, and avoid the battery being subjected to excessive vibration, external impact, high drop, etc. • DO NOT place the battery or battery pack in a corrosive chemical environment.

  • Page 44: Chapter 2 Battery Introduction And Instructions

    Chapter 2 Battery Introduction and Instructions 2.1 Battery Introduction Battery model EL20A Battery weight Rated voltage Cell material Rated capacity 20Ah Battery size 193x81x300mm Charger voltage Charger current 2.2 Instructions 1. Due to the product in transit or inventory, the lithium battery must be fully charged with the vehicle-specific charger before the first use (do not mix with other models of chargers or use other modified equipment), and then it can be used;...

  • Page 45: Chapter 3 Charging

    lifting rings during the lifting process, and gently lift it to keep it stable and not inclined; 9. The operator must read the instructions carefully before use and receive relevant safety training to be able to handle emergencies; Chapter 3 Charging 1.

  • Page 46: Chapter 4 Storage

    Chapter 4 Storage 1. Try to ensure that the battery or battery pack's power is 60% before long-term storage as the battery has the function of self-discharge, be sure to charge the battery once every 3 months to ensure the battery power is 60%;...

  • Page 47: Chapter 5 Transportation

    Chapter 5 Transportation 1. During the loading, unloading and transportation process, severe vibration and large external impact should be avoided, and throwing, rolling, inverting, squeezing and excessive stacking are prohibited; 2. Prevent rain during transportation; 3. Ensure that the battery or battery pack has been disconnected from the load or charging device before transportation, without any form of charging and discharging.

  • Page 48: Chapter 6 Common Problems And Solutions

    Chapter 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;...

  • Page 49: Chapter 7 Maintenance

    Chapter 7 Maintenance 7.1 Daily Maintenance 1. It is necessary to arrange professionals for care during the charging operation, especially when the battery is almost fully charged; make sure that the plug and the socket are in good contact during the charging process to ensure that the charging device works normally and ensure that the connection points of the battery pack are in good contact.

  • Page 50: Disposal Of Used Battery Packs

    5. Check the insulation resistance between the battery pack and the vehicle body to ensure that the resistance value meets the Chinese national standard ( 500Ω/V) and to ensure that there is no electric leakage with the battery (once a month); 7.3 Disposal of Used Battery Packs To prevent environmental pollution, the battery should be sent to a local recycling center or a dedicated lithium battery processing facility.

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