ep EPL151 Operation Manual
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ep EPL151 Operation Manual

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

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Summary of Contents for ep EPL151

  • Page 1 Operation Manual EPL151 HPL152 WPL201 RPL201/RPL201H RPL202 Original Instruction Part No.508000003010 V3 09/2020...
  • Page 2 EP EQUIPMENT CO.,LTD. is one of the world’s With business all over the world, EP has leading companies manufacture, design thousands of employees and hundreds material handling equipment and provide related of agents worldwide to provide our global service. With over 100,000 square metres plant customers with prompt local service.
  • Page 3 QR code, Login after registration, Select “Parts purchase" function and input part number or model name to find the truck. Note: After registration, please send email to info@ ep-care.com to activate your account...
  • Page 4 The rules for the intended and approved use of industrial trucks must be followed under all circumstances by the responsible persons, especially by the operator and service personnel. The user, and not EP, is responsible for any danger arising from applications not authorised by the manufacturer.
  • Page 5 Obligations and responsibilities of equipment user In the manual, “equipment user” refers to any natural person or legal person directly using or appointing or authorizing others to use the carrier. In such special situations as renting or sales, the “equipment user” represents the interested parties supposed to bear operation obligations as specified by the contractual terms concluded between equipment owner and corresponding users.
  • Page 6 Legal requirements for marketing Declaration EP EQUIPMENT CO., LTD. Address: No.1 Xiaquan Village, Lingfeng Street, Anji, Huzhou, Zhejiang We declare that the machine Industrial truck: according to this operation manual Type: according to this operation manual complies with the most recent version of Machinery Directive 2006/42/EC.

  • Page 7: Table Of Contents

    Table of contents A Nameplates and alarming labels ..................A1 B Operation ..........................B1 2.1Utilization safety specification....................B1 2.1.1 EN standards ........................B2 2.1.2 Conditions for application ....................B2 2.1.3 Stability ...........................B2 2.2 Display and manipulation ....................B3 2.2.1 Control handle .........................B3 2.2.2 Key switch ........................B4 2.2.3 Display instrument ......................B5 2.3 Truck use and operation .....................B8 2.3.1 Preparation for use ......................B8...
  • Page 8 7 Nameplate ..........................F3 7.1Safety and warning ......................F3 8 Transportation........................F5 8.1 Shipping faulty batteries .....................F5 Instructions for disposal ......................F6 10 Storage ..........................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...

  • Page 9: A Nameplates And Alarming Labels

    Nameplates and alarming labels Have the nameplates of a truck fixed its main body and alarming labels pasted on its outer cover. Should any nameplate or alarming label lose or be damaged, please conduct replacement immediately or contact with the sales department or corresponding agent of our company when necessary.
  • Page 10 Do not rest on the side arms Hoisting Remove the load before hoisting the pallet truck. Disconnect the power supply. Attach slings in the positions identified by the hook symbol. DANGER Personnel must not stand below or near the truck when the pallet truck is being lifted. HPL152 WPL201 REV.
  • Page 11 RPL201/ RPL201H/RPL202 EPL151 REV. 09/2020...

  • Page 12: B Operation

    Operation 2.1Utilization safety specification Applicable environment Don’t use the truck in Don’t use the truck in non- temperature: -10 °C - 40 °C rainwater. position. NOTE The ruck can by no means be used under the temperature lower than 5 °C for a long time, or in refrigeratory or under the condition that such environmental factor as temperature or humidity changes extremely before special equipment is additionally installed and the permit of the manufacturer is acquired.

  • Page 13: Standards

    Don’t leave the truck before Don’t use the truck when any Don’t place any part it is parked as regulated. non-working personnel is in the of your body in any dangerous area. moving part of the truck Don’t be distracted when using to avoid being clamped.

  • Page 14: Conditions For Application

    2.1.2 Conditions for application Working condition requirements: - Indoor use and outdoor use. - The walking, lifting and lowering devices, harness and components are IP55 dust and water- resistant - The truck's maximum operation altitude is up to 2000m. - 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.

  • Page 15: Display And Manipulation

    2.2Display and manipulation 2.2.1 Control handle 1.Control handle A Lowering button Lower loading parts Lifting button EPL151/RPL201/ Lift loading parts RPL201H Horn button Send out sound warning signals Driving switch Controls travel direction and speed Emergency reverse button Tortoise speed button...
  • Page 16 Connect and interrupt control current. • When the key rotates to gear “OFF”, the control current of the truck will be interrupted; • When the key rotates to gear “ON”, the control current of the truck will be connected. RPL201/RPL201H/RPL202/EPL151 REV. 09/2020...
  • Page 17 • LED (4) displays the total running time normally. If fault, display the fault code. • LED (1) displays the remaining charge.when EPL151 1st block and 2nd block blinks alternatively, it indicates low power needs to be charged • LED (2) displays remaining charge percentage;...
  • Page 18 右视图 Right Error Code 2 = Traction controller Controller number 6 = Steering controller Error code note Note: Consult the service manual • LED (1) displays the remaining charge; • LED (9) indicate the the acceleration status of the accelerator. •...
  • Page 19 The LCD display (3) show battery residual HPL152 capacity. The color of the LCD (3) represent the following conditions: Residual capacity Component LCD color Green 30-100% Continuous 15-30% Yellow Slow Standard flashing red battery 7-15% light(Flashing residual period 2s) capacity Quick flashing red light 0-7%...

  • Page 20: Truck Use And Operation

    2.3 Truck use and operation 2.3.1 Preparation for use The following are inspection and preparation operations that must be implemented before the truck is put into daily use. Table 1. Table of daily inspections by operators Operator's Daily Checklist Date Operator Truck No.
  • Page 21 Table 1: Table of Daily Inspections by Operators is only a sample table for the daily inspections of operators, and it can be adjusted according to specific requirements. WARNING The truck should be regularly maintained by qualified maintenance engineers or technicians that have passed the training of and also been authorized by the manufacturer.

  • Page 22: Truck Starting

    2.3.2 Truck starting 1. Release the emergency stop switch 2.Press the button to start the truck HPL152 REV. 09/2020...

  • Page 23: Running, Swerving And Braking

    2.Open the key switch to start the truck WPL201 RPL201/RPL201H/RPL202/EPL151 2.3.3 Running, swerving and braking 1.Running Rotary button Running area Control the running direction and speed of the truck using the drive switch (1). (the large the rotary angle, the faster corresponding speed)
  • Page 24 WPL201 EPL151/RPL202 NOTE 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. We distinguish between two travel modes for RPL202/RPL201/RPL201H: Pedestrian mode: Push the side arms in, fold up the operator platform.
  • Page 25 3.Braking Braking area 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 Emegency reverse switch Braking can be accomplished by changing the direction of travel. Press the reverse switch in the opposite direction until the truck comes to a stop, then release the drive switch.

  • Page 26: Goods Picking

    2.3.4 Goods picking 1.Lifting WPL201 RPL201/RPL201H/EPL151/RPL202 Keep pressing the lifting button until 2.Lowering reaching the required lifting height Lower the pallet forks to the bottom through pressing the lowering button. REV. 09/2020...

  • Page 27: Parking The Truck Securely

    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. WARNING Goods failing to be arranged and fixed may result in accidents.

  • Page 28: Drive Directions

    Turn off the key switch or pull out the key; Press the emergency stop switch to cut off storage battery connection; WARNING •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;...

  • Page 29: Loading

    2.3.7 Loading •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 with the load immediately ahead.

  • Page 30: Using The Truck On A Slope

    2.3.8 Using the truck on a slope NOTE Incorrect use of the truck on slopes places stress on the traction motor, brakes and battery. Be particularly careful near slopes: Never attempt a slope with a gradient greater than that specified in the truck’s data sheet.

  • Page 31: Truck Transport

    NOTE Incorrect use of the truck on slopes places stress on the traction motor, brakes and battery. 2.3.9 Truck transport •Place the truck on a wooden pallet. •Fix the truck to the pallet to prevent loosening. NOTE Only use haulage equipment with sufficient load capacity.

  • Page 32: Operating The Truck Without Its Own Drive System

    (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 WPL201/HPL152/EPL151 destination, unscrew two screws(1). Braking action is restored. WARNING This operating mode is not permitted when negotiating inclines and gradients.

  • Page 33: 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 WPL201/EPL151/HPL152 the socket on the truck to start charging. NOTE The charging voltage is single-phase, ranging from 100V to 240V, please don’t exceed the voltage range mentioned above.
  • Page 34 Charging indicator(1) LED status Phenomenon Cause Remedy Description Red light is on Trouble free Charging Green light is on Trouble free End of charging Current/ Return to factory voltage Indicator failure Charger failure maintenance changes The power input Charger line is in good indicator light No change in failure,return...

  • Page 35: Charging The Battery With External Charger

    Remove the battery；(see section 3.4) • Plug into charging stand and charge; • The LED light on the charging stand comes on. A fully charging time see described in paragraph 3.2.4. EPL151 WPL201 NOTE Correctly plug the battery into the charging stand. NOTE LED light mode on the charging stand •...

  • Page 36: Battery Type & Dimensions&Charging Time

    Tuck type battery type capacity time Internal External 245×160×380 WPL201 Li-ion 48V/30Ah RPL201/ 550×190×500 50A/100A 3h/1.6h 24V/160Ah Li-ion RPL201H 175×124×407 5.5h/2.5h EPL151 24V/55Ah Li-ion HPL152 Li-ion 24/20AH 193x81x300 Li-ion 50A/100A 3h/1.6h RPL202 24V/160Ah 550 x 190 x 500 (optional) 30A/50A 9.5h/6h RPL202...
  • Page 37 Battery removal and installation steps: • Just hold the handle and pull the battery out. • Install in reverse order. WPL201, EPL151 • Open the battery cover; • Unplug the battery; • Attach the hooks to the battery handle or strap;...

  • Page 38: Truck Maintenance

    Maintenance 4.1 Truck maintenance Only through regularly implementing truck maintenance work can the sustainable and reliable use of the forklift be ensured. Only those receiving professional training and approved as qualified can be competent in various equipment care maintenance operations. If you intend to independently implement maintenance, you are recommended to have your maintenance personnel receive on-site training from the service representative of the equipment supplier.
  • Page 39 Safety tests to be performed at intervals and after unusual incidents The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector. The manufacturer offers a safety inspection service which is performed by personnel specifically trained for this purpose.

  • Page 40: Maintenance Table

    After operating for 500 hours in total, the truck should also be maintained according to the following procedures in addition to the 250-hour maintenance mentioned above Inspect or add the gear grease(for WPL201 and EPL151) Inspect and lubricate using the lithium-based lubrication grease the lubrication mouths in moving parts...
  • Page 41 EPL151/HPL152/WPL201 RPL201/RPL201H/ RPL201/RPL201H/RPL202 RPL202 EPL151 Table 1 Lubricants Code Type Specification Amount Position Anti-wear hydraulic oil L-HM32 0.48 L((WPL201/EPL151/ Hydraulic HPL152)1.25(RPL201/ Low temperature anti-wear System L-HV32 RPL201H/RPL202) hydraulic oil (cold storage) 110 grams(EPL151/ Grease 3#(MoS Gearbox HPL152/WPL201) 1500ml(RPL201/RPL201H/ Heavy duty gear oil...

  • Page 42: E Technical Data

    Technical data Standard Version Specifications Technical specification details in accordance with VDI 2198. Technical modifications and additions reserved. Performance data for standard trucks Distinguishing mark Manufacturer Model designation RPL201H RPL201 RPL202 Drive unit Electrics Electrics Electrics Operator type standing Pedestrian Pedestrian rated capacity 2000...
  • Page 43 Tyre size, driving mm Ф230x75 Ф230x75 Ф230 x 75 wheels(diameter×width) Tyre size, loading Ф85x70 / Ф85x70 / Ф85 x 70 / wheels(diameter×width) Ф83x115 Ф83x115 Ф83 x 115 Tyre size, caster mm Ф130x55 Ф130x55 Ф130 x 55 wheels(diameter×width) Wheels, number driving, mm 1x,2/4(1x,2/2) 1x,2/4(1x,2/2) 1 x +2 / 4 caster/loading (x=drive wheels)
  • Page 44 Lowering speed, laden/ m/ s 0.067 / 0.054 0.067 / 0.054 0.067 / 0.054 unladen Max. gradeability, laden/ 8 / 16 8 / 16 8 / 16 unladen 5.10 Service brake type Electrom Electrom Electrom agnetic agnetic agnetic Electric-engine Drive motor rating S2 60 min hp kW 2.5 Lift motor rating at S3 15% kW 2.2...
  • Page 45 RPL201/RPL201H REV. 09/2020...
  • Page 46 RPL202 REV. 09/2020...
  • Page 47 Distinguishing mark Manufacturer Model designation EPL151 HPL152 WPL201 Drive unit Electrics Electrics Electrics Operator type Pedestrian Pedestrian Pedestrian rated capacity 1500 1500 2000 Load center distance Load distance 883/946 883/946 1000 Wheelbase 1105/1168 1105/1168 1268 Weight Service weight (include battery)
  • Page 48 Tyre size, driving Ф210x70 Ф210x70 Ф250x102 wheels(diameter×width) Tyre size, loading 2x Ф78x60 2x Ф78x60 2×Ф82x85/ wheels(diameter×width) (Ф78x88) (Ф78x88) Ф82×115 Tyre size, caster Ф74x48 Ф74x48 wheels(diameter×width) Wheels, number driving, 1×,2/4(1× 2/2) 1x,4(1x,2) 1×,2/4(1× 2/2) caster/loading (x=drive wheels) Track width, front,driving side b10 mm Track width,rear,loading side b11 mm...
  • Page 49 Lowering speed, laden/ 0.034/0.023 Hand down 0.04 / 0.022 unladen Max. gradeability, laden/ 5/16 5 / 10 8 / 16 unladen 5.10 Service brake type Electroma Electroma Electrom gnetic gnetic agnetic Electric-engine Drive motor rating S2 60 0.65 0.75 0.75 Lift motor rating at S3 15% man-up 0.84...
  • Page 50 EPL151 REV. 09/2020...
  • Page 51 HPL152 REV. 09/2020...
  • Page 52 WPL201 REV. 09/2020...
  • Page 53 Lithium-ion battery REV. 09/2020...

  • Page 54: Information On The Conformity Of Lithium-Ion Batteries

    • Have class D fire extinguishers or inert gas, carbon dioxide, powder or foam fire extinguishers near the zone in which the lithium-ion batteries are used. • Do only use in trucks manufactured by EP and if the battery type is released for that truck.

  • Page 55: Intended Use

    Failure to comply with these safety instructions can result in fire and explosion or the leakage of harmful materials. 5.Accessories Do not use a charger that is not released by EP for lithium-ion battery. WARNING Should such issues as failing to abide by the operation manual, failing to use the original parts...

  • Page 56: Safety And Warning

    7.1Safety and warning •Abide by the operation manual! •All the operations related to the storage battery must be implemented under the instruction of professionals! Always wear protective clothing (e.g. safety goggles and safety gloves) when working on cells and batteries. •No smoke and fire! •Avoid the existence of open fire, fiery metal wire or sparks around the storage battery, otherwise explosion or fire disaster may occur!

  • Page 57: Transportation

    Transportation Before transporting any lithium-ion battery, check the current regulations on the transport of dangerous goods. Comply with these when preparing the packaging and transport. Train authorised staff to dispatch lithium-ion batteries. NOTE It is recommended that the original packaging is kept for any subsequent dispatch. A lithium-ion battery is a special product.

  • Page 58: Instructions For Disposal

    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 mark showing a crossed rubbish bin, these batteries may not be disposed of as domestic waste.

  • Page 59: Common Problems And Solutions

    support.
  • Page 60 Lead-acid battery REV. 09/2020...

  • Page 61: Safety And Warnings

    As for failure to comply with instructions for use, maintenance without using original parts, user corruption, or viola-tion of provisions when adding electrolyte and other circumstances, the quality assurance will automatically void. Accessories •Do not use a charger that is not released by EP for lead-acid battery. REV. 09/2020...

  • Page 62: Use Of Battery

    2 Use of Battery 2.1 Pre-use Checks Check if the battery status is normal and also check for mechanical failures; Connect the battery connectors, make sure the contact is solid, the electrodes are connected properly, otherwise may cause damage to the battery, truck or charger; Check if the electrode bolt of each battery interface is tightened;...

  • Page 63: Temperature

    2.4 Temperature Rated temperature of electrolyte is 30 °C. If the temperature is too high, it will reduce the service life of the battery; too low may reduce the battery capacity. When the temperature reaches the limit temperature of 55 ° C, it is prohibited to run the battery. 3 Maintenance &...

  • Page 64: Monthly Maintenance

    There are two types of battery filler cap used proper electrolyte 合适的电 on battery cell: liquid leveL 解液液位 1) Filler cap with buoy Battery 电瓶 Add distilled water, red buoy will float until while rod appears under the red scale. WARNING Add only distilled water.

  • Page 65: Care

    3.4 Care 1. Keep it clean Battery surface should be clean and dry to prevent the occurrence of leakage currents; Battery cables, terminals and connectors mu-st be tightened and clean, a small amount of special grease should also be applied. WARNING •Do not use a dry cloth or fabric to clean the surface of the battery, so that to prevent the occurrence of static electricity, resulting in explosion;...
  • Page 66 Battery Fault Analysis Fault Negative Phenomena Cause Handling Methods Insufficient 1. Low static voltage 1. Charger voltage and current 1. Adjust and repair the 2. Low density, cannot meet are set too low charger Battery the requirements after being 2. Insufficient initial charge 2.
  • Page 67 Battery Fault Analysis Fault Negative Phenomena Cause Handling Methods Electrode 1. Battery capacity drops 1. Insufficient initial charge 1. Over-discharge method during normal discharge 2. Long time of storage under 2. Repeated charging plate sulfation 2. Density drops to be lower the state of discharge method than normal value...
  • Page 68 Battery Fault Analysis Fault Negative Phenomena Cause Handling Methods Battery 1. Low static voltage below 2V 1. Electrode plate deformed and Battery needs to be replaced 2. Electrolyte density is too low short circuit Short 3. High temperature during 2. Spacer missing or broken Circuit charging during assembly...

This manual is also suitable for:

Hpl152Wpl201Rpl201Rpl201hRpl202

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