ep EPL151 Operation Manual
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ep EPL151 Operation Manual

Electric pallet truck
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Operation Manual
Electric pallet trcuk
EPL151
HPL152
EPL154
EPL185
WPL201
Part No.508000003010
V3 09/2020

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Summary of Contents for ep EPL151

  • Page 1 Operation Manual EPL151 HPL152 EPL154 EPL185 WPL201 Electric pallet trcuk 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 Introduction........................A1 1.1Nameplates and alarming labels ..................A1 1.2 Utilization safety specification..................A4 1.3 Related Safety Instruction and Standard(For CE) ............A6 1.3.1 EN standards .......................A6 1.3.2 Conditions for application ....................A7 1.3.3 Vibration ........................A7 1.4 Transport and commissiong ...................A8 1.4.1 Truck transport......................A7 1.4.2 Comissioning .......................A7 B Operation ......................B1 1.1 Overview, Display, Manipulation .................B1...
  • Page 8 Table of contents 1 Information on the conformity of lithium-ion batteries ..........F2 2 It is necessary to respect the following guidelines:..........F2 3 Intended use ......................F3 4 Reasonably foreseeable misuse ................F3 5.Accessories ......................F3 6.BMS (Battery Management System) ..............F3 7 Safety and warning ....................F4 .................F5 Hazard of faulty or discarded battery 9 Transportation......................F5...

  • Page 9: A Introduction

    Introduction 1.1 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 Load the truck and park it securely at its destination. DANGER Personnel must not stand below or near the truck when the pallet truck is being lifted. Only use lifting gear with sufficient capacity (for truck weight see truck nameplate ). When hoisting or laying down, it should be stable and slow to avoid collision or accident. EPL151 REV. 09/2020...
  • Page 11 EPL154、EPL185 HPL152 WPL201 REV. 09/2020...

  • Page 12: Utilization Safety Specification

    1.2 Utilization safety specification • Average ambient temperature Don’t use the truck in Don’t use the truck in non- rainwater. for continuous duty: ＋ 25℃ ; position. • Maximum ambient temperature, short term (up to 1h): ＋ 40℃ ; • Lowest ambient temperature for trucks intended for use in normal indoor conditions: ＋...
  • Page 13 Improper use Avoid the use of the truck by non- Don’t use the truck on slippery Don’t carry goods on steep working personnel. road surfaces. slope to prevent goods Don’t ride on the truck. (such as road surfaces with oil from sliding off.
  • Page 14 Safety Instructions • Only trained and authorized operator shall be permitted to operate the truck. • Operator must wear helmet, working shoes and uniform • Do wash the inner of the truck, do not place the truck outdoors and exposed to the rain. •...

  • Page 15: Related Safety Instruction And Standard(For Ce)

    1.3 Related Safety Instruction and Standard(For CE) 1.3.1 EN standards Continuous sound level: ＜ 74 dB(A) according to EN 12053 as stipulated in ISO 4871 The 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.

  • Page 16: Vibration

    1.3.3 Vibrations Vibrations to which the hands and arms are exposed The following value is valid for all truck models: Specified characteristics for upper limb vibrationspecified characteristics for upper limb vibrations vibration characteristics < 2.5 m/s2 NOTE It is mandatory to specify the hand-arm vibrations, even where the values do not indicate any danger, as in this case. CAUTION The value expressed above can be used to compare forklift trucks of the same category. It ...

  • Page 17: Transport And Commissiong

    1.4 Transport and commissiong 1.4.1 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. •The load weight includes the net weight of the truck(including battery  weight) and the wooden pallet. •The pallet or wooden box should be large and strong enough to withstand the weightof the truck.

  • Page 18: Comissioning

    1.4.2 Comissioning The truck must only be operated on battery current! To prepare the truck for operation after delivery or transportation, the following operations must be performed: Check the equipment for completeness. If necessary, install the battery. Make sure that the battery cable is not damaged. Fully charge the battery.

  • Page 19: B Operation

    Operation 1.1 Overview , Display, Manipulation 1.1.1 Truck overview EPL151 Control Handle Key switch hydraulic unit Drive wheel Caster Charger(optional) Batttery Load wheels Forks Emergency stop switch REV. 09/2020...
  • Page 20 HPL152 Control Handle hydraulic unit Drive wheel Load wheels Forks Batttery Emergency stop switch REV. 09/2020...
  • Page 21 WPL201 Control Handle Key switch hydraulic unit Drive wheel Caster Batttery Load wheels Forks Emergency stop switch REV. 09/2020...
  • Page 22 EPL154/EPL185 Control Handle Key switch hydraulic unit Drive wheel Emergency stop switch Load wheels Forks Batttery Battery cover REV. 09/2020...

  • Page 23: Control Handle

    1.1.2 Control handle 1.Control handle A Lowering button Lower loading parts Lifting button EPL151/EPL154/ Lift loading parts EPL185 Horn button Send out sound warning signals Driving switch Controls travel direction and speed Emergency reverse button Creep speed button Through touching the button, truck drives away from operator.
  • Page 24 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. EPL151/ EPL154/EPL185 REV. 09/2020...
  • Page 25 • LED (4) displays the total running time normally. If fault, display the fault code. EPL151/EPL185 • LED (1) displays the remaining charge; • LED (2) only display full working hours normally. If fault, display the fault code for display instrument and lithium-ion battery;...
  • Page 26 • LED (7) indicate rise and fall indication. • LED (8) indicate the operating hours. WARNING when the LED (1) sign show red. please  charge the battery in time. WPL201 NOTE Low Voltage Protection for EPL151/ EPL154/EPL185/WPL201 The car has low voltage protection function. When the battery power of forklift truck is 7%- 15%. the display screen shows L1(only for  WPL201) . At this time, the forklift truck can  not lift goods, but it can run normally. When ...
  • Page 27 The LCD display (3) show battery residual 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% (Flashing...
  • Page 28 • 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.

  • Page 29: Truck Use And Operation

    1.2 Truck use and operation 1.2.1 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 30: Truck Starting

    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. 1.2.3 Truck starting 1. Release the emergency stop switch EPL151 HPL152 EPL154/EPL185 WPL201 REV. 09/2020...
  • Page 31 2.Press the button(1) to start the truck. HPL152 2.Open or connect the key switch to start the truck EPL151/EPL154/EPL185 WPL201 REV. 09/2020...

  • Page 32: Running, Swerving And Braking

    1.2.4 Running, swerving and braking 1.Running Running area Example Running area Rotary button Example Control the running direction and speed of the truck using the drive switch (1). (the large the rotary angle, Backward the faster corresponding speed) Forward NOTE When using the truck on a ramp or a uneven road, please lift the leg of the forklift to prevent its bottom from colliding...
  • Page 33 Creep speed Keep the control handle in the vertical state, and press creep speed button (1) and drive switch (2) at the same time, then the vehicle will move at a low speed. WPL201 EPL151/EPL154/EPL185 HPL152 REV. 09/2020...
  • Page 34 2.Steering Rotate the operation hand shank leftward or rightward as required. Rightward Leftward Example 3.Braking Mechanical operating brake Braking The truck is braked when the operating area handle is released. The mechanical brake engages when the tiller is positioned in Braking area. Braking CAUTION area...
  • Page 35 To protect the driver from any risk of being trapped between an obstacle and the machine,the end of the tiller is fitted with a emergency emergency reverse switch. Once the safety reverser is triggered, the equipment will stop immediately, then slowly move back in the direction of the fork. EPL151/EPL154/EPL185 WPL201 HPL152 Reverse braking Braking can be accomplished by changing the direction of travel.
  • Page 36 Emergency stop switch Press the emergency stop switch, and then all the electrically propelled functions will be interrupted. EPL151 HPL152 WPL201 EPL154/EPL185 REV. 09/2020...

  • Page 37: Goods Picking

    1.2.5 Goods picking 1.Lifting WPL201 EPL154/EPL185/EPL151 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 38: 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 39 Press the button (1) to turn off the truck. HPL152 Turn off the key switch or pull out the key; Press the emergency stop switch to cut off storage battery connection; EPL151 HPL152 REV. 09/2020...

  • Page 40: Drive Directions

    WPL201 EPL154/EPL185 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; •The forks must be lowered to the bottom. 1.2.7 Drive directions The drive directions of the truck are forward (1) and reverse (2).

  • Page 41: Loading

    1.2.8 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 42: Using The Truck On A Slope

    1.2.9 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. Make sure that the ground is dry with a non-slip surface and that the route is clear.

  • Page 43: Operating The Truck Without Its Own Drive System

    NOTE Incorrect use of the truck on slopes places stress on the traction motor, brakes and battery. 1.3 Operating the truck without its own drive system If the truck has to be moved after a failure has rendered it immobile, proceed as follows: Set the emergency stop switch “OFF”. • Set the key switch “OFF” and remove the key. •...

  • Page 44: C Battery Use And Maintenance

    “1.1.1 precautions”; •Park the truck securely as described chapter B Section1.2.6; •Open the upper cover if necessary; •Connect the power plug (1) and have it inserted into a proper power supply. WPL201/EPL151 REV. 09/2020...
  • Page 45 HPL152 EPL154/EPL185 WARNING Charger maximum input power: 1KW for WPL201,666W for EPL151,667W for EPL185,333W for EPL154 and HPL152. Please strictly implement the above data to prevent equipment damage and accidental risks such as fire. Battery Charging Light indicator EPL185 WPL201 REV. 09/2020...
  • Page 46 EPL151 EPL154 NOTE Charging indicator for HPL152 see chapter B section 2.2.3. The LED (1) remain red light lit under normal, flashing show the failure state of truck. LED Fault Indicator Diagnostics for EPL154 When the truck is in normal use, LED fault indi- cator is always going on; When any fault occurs to the vehicle, LED will twinkle and indicate the fault code;...
  • Page 47 Error Message BLINKS BLINKS Explanation Possible cause Error text digit 1 digit 2 1. Temperature >80°C or < -10°C. 2. Excessive load on over-/under- vehicle. THERMAL FAULT temperature cutback 3.Operation in extreme environments. 4.Electromagnetic brake not releasing. 1.Throttle input wire open or shorted.
  • Page 48 Error Message BLINKS BLINKS EXPLANATION Possible cause Error text digit 1 digit 2 1.Misadjusted throttle. HPD fault present >10 WIRING FAULT 2.Broken throttle pot or sec. throttle mechanism. 1.Electromagnetic brake driver shorted. BRAKE ON FAULT brake On fault 2.Electromagnetic brake coil open.
  • Page 49 Charging indicator(2) LED status Phenomenon Cause Remedy Description Red light is on Trouble free Charging End of Green light is on Trouble free 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 50: Charging The Battery With External Charger

    Remove the battery；(see section 1.2) • Plug into charging stand and charge; • The LED light on the charging stand comes on. A fully charging time see described in paragraph 1.2.4. EPL151 WPL201 NOTE Correctly plug the battery into the charging stand. NOTE LED light mode on the charging stand •...

  • Page 51: Battery Type & Dimensions&Charging Time

    Battery types & dimensions are as follows: Voltage/ Charger Battery Charging Dimensions Tuck type Rated type time Internal External capacity 245×160×380 WPL201 Li-ion 48V/30Ah 270×110×400 EPL154 Li-ion 24V/30Ah 175×124×407 5.5h/2.5h EPL151 Li-ion 24V/55Ah HPL152 Li-ion 24/20AH 193x81x300 270×110×400 EPL185 Li-ion 48V/20Ah REV. 09/2020...

  • Page 52: Battery Connector Pins Maintenance

    1.2 Battery connector pins maintenance Check the battery bottom connector pins prior to initial start-up（See chapter B section 1.2.1) Perform a visual inspection of connector pins at the bottom of the battery for integrity, deformation,ablation. deformation NOTE If any ablation or deformation occurs in  daily inspection, the battery connector pins should be replaced in time.
  • Page 53 2 Allen wrench PILLIPS Screwdrivers Electric screwdriver Connector pins removal and installation steps: • Unscrew the two screws from the battery bottom module using electric screwdriver and PILLIPS Screwdrivers; charging and discharging module • Pull out of the charging and discharging module;...
  • Page 54 • Pull out of the positive and negative connector pins from the battery cable; positive connector pins negative connector pins • Remove the damage connector pins and install the normal connector pins according to the sign of the positive and negative on the charging and discharging module.

  • Page 55: Battery Removal And Installation

    Battery removal and installation steps: • Just hold the handle and pull the battery out. • Install in reverse order. WPL201, EPL151 • Just hold the handle and pull the battery out. • Install in reverse order. HPL152 •...

  • Page 56: D Maintenance

    Maintenance 1.1 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 57 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 58: Maintenance Table

    1.2 Maintenance table 50-hour/7-Day maintenance Check the functions of the operation switches and display. Check display equipment, alarm system and safety devices. Check the emergency reverse switch, reverse braking, emergency disconnect switch and regenerative braking. Check tiller steering functions. Check the drive wheel and load wheel for worn or damage. Check for brake condition when the control handle on horizontal position and vertical position.
  • Page 59 HPL152 WPL201 Hydraulic oil injection nozzle Geat oil injection nozzle EPL154/EPL185 EPL151 Table 1 Lubricants Code Type Specification Amount Position 0.48 L((WPL201/EPL151/ Hydraulic Anti-wear hydraulic oil L-HM32 HPL152) System 0.18-0.2L(EPL154,EPL185) Grease 3#(MoS 110 grams Gearbox CAUTION Into the fuel tank of hydraulic oil must be filtered, and the injection volume of the hydraulic oil  tank does not exceed the maximum scale. REV. 09/2020...

  • Page 60: Check The Electrical Fuses

    1.2.1 Check the electrical fuses • Prepare the truck for maintenance and repairs. • Check condition and rating of the fuses in accordance with your parts manual or service manual. 1.2.2 Recomissioning The truck may only be recommissioned after cleaning or repair work, once the following operations have been performed.

  • Page 61: 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 EPL154 EPL185 Drive unit Battery Battery Operator type Pedestrian Pedestrian rated capacity 1500 1800 Load center...
  • Page 62 Tyre size, driving Ф210x70 Ф210x70 wheels(diameter×width) Tyre size, loading Ф80x60( Ф80x60( wheels(diameter×width) Ф74x88) Ф74x88) Tyre size, caster Ф74x30 Ф74x30 wheels(diameter×width) Wheels, number driving, caster/ 1x,2/4(1x,2/2) 1x,2/4(1x,2/2) loading (x=drive wheels) Track width, front,driving side Track width,rear,loading side 390/(535) 390/(535) Dimensions Lift height Height drawbar in driving position 700/1260 700/1260...
  • Page 63 Lowering speed, laden/ m/ s 0.068/0.043 0.065/0.030 unladen Max. gradeability, laden/ 6\16 6\16 unladen 5.10 Service brake type electric electric Electric-engine Drive motor rating S2 60 min kW 0.75 Lift motor rating at S3 15% kW 0.8 The maximum allowed size mm 270*110*440 270x110x440 battery...
  • Page 64 EPL154 REV. 09/2020...
  • Page 65 EPL185 REV. 09/2020...
  • Page 66 Distinguishing mark Manufacturer Model designation EPL151 HPL152 WPL201 Drive unit Electrics mechanical Electrics and electric Operator type Pedestrian Pedestrian Pedestrian rated capacity 1500 1500 2000 Load center mm 600 distance Load distance mm 883/946 1000 Wheelbase mm 1105/1168 1170 1268...
  • Page 67 3.2.1 Tyre size, driving Ф210x70 Ф210x70 Ф250x102 wheels(diameter×width) 3.3.1 Tyre size, loading 2x Ф78x60 Ф80x61 2×Ф82x85/ wheels(diameter×width) (Ф78x88) Ф82×115 Tyre size, caster Ф74x48 Ф74x48 wheels(diameter×width) Wheels, number driving, 1×,2/4(1× 2/2) 1x,-/4 1×,2/4(1× 2/2) caster/loading (x=drive wheels) 3.6.1 Track width, front,driving side b10 mm 3.7.1 Track width,rear,loading side b11 mm 370/(515)
  • Page 68 Lowering speed, laden/ m/ s 0.037/0.021 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 min hp kW 0.65 0.75 0.75...
  • Page 69 EPL151 REV. 09/2020...
  • Page 70 HPL152 REV. 09/2020...
  • Page 71 WPL201 REV. 09/2020...

  • Page 72: F Lithium-Ion Battery

    Lithium-ion battery REV. 09/2020...

  • Page 73: 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. REV. 09/2020...

  • Page 74: Intended Use

    •Do not overcharge. DANGER 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 for maintenance or damaging caused by users themselves occur, the quality guarantee will be invalid automatically! 6.BMS (Battery Management System)

  • Page 75: Safety And Warning

    7 Safety 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 76: Hazard Of Faulty Or Discarded Battery

    Please dispose of the damaged batteries properly and contact a recycling company to recycle the batteries. For batteries that are under EP warranty policy, EP will access the warranty claim according to your submission of the battery nameplate photo .

  • Page 77: Transportation

    9 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. Special precautions should be taken when: •...

  • Page 78: Instructions For Disposal

    1、Only authorized EP dealers who have attended the after sales training, are authorized to do repairs on EP batteries. 2、All Li-ion battery should be placed in safe place according to the EP Li-ion battery Manual; 3、The transport of Li-ion battery must meet local regulation, EP will supply UN38.3 and MSDS files according with UN and ADR regulation;...

  • Page 79: Charging

    WARNING Don't bump, handle gently. 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. Return and / or recycling must be ensured as required by the Batteries Act (Act regarding the commissioning, return and environmentally responsible disposal of batteries and accumulators).

  • Page 80: Storage

    support.

This manual is also suitable for:

Hpl152Epl185Epl154Wpl201

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