EP Equipment EST121 Operation Manual
  1. Manuals
  2. Brands
  3. EP Equipment Manuals
  4. Forklifts
  5. EST121
  6. Operation manual

EP Equipment EST121 Operation Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Operation Manual
EST121
Original Instruction
Part No.508000002066
V2 08/2019

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the EST121 and is the answer not in the manual?

Questions and answers

Related Manuals for EP Equipment EST121

Summary of Contents for EP Equipment EST121

  • Page 1 Operation Manual EST121 Original Instruction Part No.508000002066 V2 08/2019...
  • Page 2 We are one of the world’s leading companies With business all over the world, We have manufacture, design material handling thousands of employees and hundreds of equipment and provide related service. With agents worldwide to provide our global over 100,000 square metres plant it produces customers with prompt local service.
  • Page 3 Foreword The present operation manual are designed to provide su���������������������� of the industrial truck. The information is provided clearly and concisely. Our trucks are under continuous development. We reserve the right to alter the design, equipment and technical features of the system. No guarantee of particular features of the truck should therefore be assumed from the present operation manual.
  • Page 4 Legal requirements for marketing EC/EU Declaration of Conformity The manufacturer declares that this industrial truck complies with the EC Machinery Directive ������������������������������������������� This can be verified by means of the EC/EU Declaration of Conformity and the relevant certification label on the nameplate.

  • Page 5: Table Of Contents

    Table of contents A Introduction...........................A1 B Truck description ........................B1 1.1 Application ..........................B1 1.2 Truck assemblies ........................B2 1.2.1 Control handle .........................B3 1.2.2 Key ..........................B4 1.2.3 Battery discharge indicator ....................B4 1.2.4 Emergency reverse button ....................B5 1.3 Identification points and data plates ...................B6 1.3.1Truck data plate ........................B7 1.3.2 Load label ........................B7 1.4 Standard version specifications ..................B8...
  • Page 6 Table of contents G Stackers Maintenance ......................G1 1.1 Operational safety and environmental protection ...............G1 1.2 Maintenance safety regulations ..................G1 1.3 Servicing and inspection.....................G2 1.3.1Maintenance checklist ......................G3 1.3.2 Lubrication points ......................G5 1.3.3 Maintenance Instructions....................G8 1.4 Recommissioning ......................G10 1.4.1Decommissioning the industrial truck ................G10 1.4.

  • Page 7: A Introduction

    A Introduction The truck described in these operation manual is suitable for lifting and transporting loads. It must be used, operated and maintained according to the instructions in this operation manual. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property.
  • Page 8 Intended use The truck is designed for transporting and stacking the loads indicated in the load capacity diagram. Especially: • In accordance with the safety rules of your industry association • Other local regulations In all cases, the people in charge, particularly operators and service personnel, must comply with the specific approved rules for the use of industrial trucks.

  • Page 9: B Truck Description

    B Truck Description Application The truck is intended for transporting goods on a level �� . It is designed for use on level ����������������� Ambient temperature: during operation: +5°C to +40°C. Industrial trucks must be specially equipped and approved for continuous use in environments with temperatures below 5°C or in cold stores respectively with extreme temperatures or humidity changes.

  • Page 10: 1.2 Truck Assemblies

    1.2 Truck assemblies Forks Control handle Key switch Battery LED lamp Chassis Hydraulic pump Caster Lift cylinder Cover Battery discharge indicator Driving wheel Battery charge connector Load wheels Emergency stop switch Tank REV. 08/2019...

  • Page 11: Emergency Reverse Button

    1.2.1 Control handle Lowering button Horn button Lifting button Emergency reverse button Travel switch REV. 08/2019...
  • Page 12 1.2.2 ������������������ Removing the key prevents the truck from being switched on by unauthorized personnel. 1.2.3 Battery discharge indicator LCD (1) displays the total operation time of the truck; LCD (2) displays the remaining electric of the battery; LCD (3) is a fault indicating light. DISPLAY DESCRIPTION Continuous red Normal...
  • Page 13 The LCD display (2) show battery remaining charge. When the truck has been released via the key switch, the battery charge status is displayed. The color of the LCD (2) represent the following conditions: LCD color Remaining charge capacity (reference value) Green 70-100% Orange...

  • Page 14: Identification Points And Data Plates

    Identification points and data plates Item Description Item Description LOGO Anti pinch hand label LOGO Nameplate Sling label Safety label Load label Browse manual label No riding label Mast safety label Charging light indicator 前视图 右视图 Front Right 左视图 俯视图 Left Q (kg) Q (kg)
  • Page 15 1.3.1 Truck data plate For queries regarding the truck or ordering spare parts please quote the truck serial number Item Description PRODUCT NAME MODEL TYPE SERIAL NO. MANUFACTURE DATE UNLADEN MASS UNLADEN MASS WITHOUT BATTERY BATTERY VOLTAGE RATED DRIVE POWER MAX CAPACITY MAX LIFT HEIGHT RATED CAPACITY...

  • Page 16: Standard Version Specifications

    Standard version specifications Technical specification details in accordance with VDI 2198. Technical modifications and additions reserved. 1.4.1 Performance data for standard trucks Distinguishing mark Manufacturer Model designation EST121 Drive unit Electric Operator type pedestrian rated capacity 1200 Load center distance Load distance，centre of drive axle to fork...

  • Page 17: 1.4.2 Dimensions

    1.4.2 Dimensions REV. 08/2019...

  • Page 18: C Safety

    C Safety Before operation Before using the truck, inspect the work area. It should be neat, well lit, adequately ventilated, and free from hazardous materials. Aisles and roadways should be unobstructed and well marked. Operators must know the classification for the truck and use the truck only in permissible areas.

  • Page 19: Travel

    Travel The truck is designed for operation on smooth, dry surfaces such as warehouse and factory � oors, loading docks or paved areas. Under all travel conditions operate the truck at a speed that will permit it to be brought to a stop in a safe manner. Avoid running over loose objects on the roadway surface.

  • Page 20: Battery Safety

    Do not drive the truck onto an elevator without specific authorization. Verify that the capacity of the elevator exceeds the weight of the truck and the weight of the load. Approach elevators slowly and ensure that the elevator car is level with the � oor before entering. Enter elevators squarely with the load end leading.

  • Page 21: Emc-Electromagnetic Compatibility

    EMC-Electromagnetic compatibility Electromagnetic compatibility (EMC) is a key quality feature of the truck. EMC involves • Limiting the emission of electromagnetic interference to a level that ensures the troublefree operation of other equipment in the environment. • Ensuring sufficient resistance to external electromagnetic interference so as to guarantee proper operation at the planned usage location under the electromagnetic interference conditions to be expected there An EMC test thus firstly measures the electromagnetic interference emitted by the truck and secondly checks it for sufficient resistance to...

  • Page 22: D Transport And Commissioning

    D Transport And Commissioning Slinging CAUTION Only use slings and a hoist of sufficient capacity.Protect all parts in contact with the lifting device.Correctly install the hook according to the lifting label shown in the figure. Truck weight (with battery):See Performance data for standard trucks. DANGER Personnel must not stand under or next to the truck when it is being lifted.

  • Page 23: Using The Truck For The First Time

    Operating the truck without its own drive system This operating mode is not permitted when negotiating inclines and gradients. If the truck has to be moved after a failure has rendered it immobile, proceed as follows: Set the emergency stop switch “OFF”. •...

  • Page 24: E Operation

    E Operation Safety Regulations for the Operation of Stacker Driving permission: The fork lift truck must only be operated by persons who have been trained in the operation of trucks, who have demonstrated to the user or his representa- tive their capability of moving and handling loads, and who have expressly been charged by the user or his representative with the operation of the truck.

  • Page 25: Operate And Run The Truck

    Operate and run the truck Turning the T�������� 1.2.1 Switching the truck on To turn the truck on, make sure the emergency stop switch(1) is not pushed in and the control handle is released to its vertical position. Insert the key into its keyhole, and turn it to the right. –...

  • Page 26: Driving

    1.2.2 Driving Operators must be familiar with all safety procedures that apply to forklift operation before driving. Read and understand all safety information in Section 2 before operating the truck. WARNING Tilt the control shaft into the driving range (M) and set the controller to the desired direction (V or R).

  • Page 27: Braking

    1.2.3 Braking NOTE The braking performance of the equipment depends very much on the condition of the floor surface.This should be taken into consideration when driving. NOTE The driver must drive carefully and cautiously. When there is no danger, the driver must use moderate braking to avoid the load moving or the trailer becoming detached.

  • Page 28: Steering

    CAUTION Open the drive switch; if the drive switch cannot quickly return to the initial position or resets very slowly, identify the cause and rectify the fault. Reverse braking Switching the drive switch to the opposite direction while travelling brakes the vehicle by reverse current until it starts moving in the opposite direction.

  • Page 29: Loading

    Loading CAUTION Before lifting a load, ensure that its weight does not exceed the truck’s maximum load capacity. Refer to the rated load capacity specified on the 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.

  • Page 30: Carrying A Load

    1.3.2 Carrying a load DANGER Personnel must not stand under or near the truck when the load is in the raised position. DANGER DANGER Never transport a load with the forks in the raised position as the equipment may become unstable.

  • Page 31: Setting A Load Down On The Ground

    1.3.3 Setting a load down on the ground Carefully move the load into the deposit area. Lower the load until the fork arms are free. Move the forks straight back. Lift the forks a few centimetre again. CAUTION Be careful not to touch nearby loads or those behind the equipment.

  • Page 32: 1.3.5 Picking Up A Load At Height

    1.3.5 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.

  • Page 33: Mast Lifting And Lowering

    Mast lifting and lowering Lifting Press the lift button(18) until the goods reach the required height, then release the button. Lowering Press the lower button(17) until the goods are lowered to the required height, then release the button. CAUTION Before picking up the goods, the driver must ensure that the goods have been coded correctly and stacked up well.

  • Page 34: Using The Truck On A Slope

    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 35: Operator Daily Checklist

    Operator daily checklist At the beginning of each shift, inspect your truck by using the our Operator’s Daily Checklist. If necessary, refer to the Maintenance section of this manual for details on how to carry out this inspection. Check for damage and maintenance problems. Any necessary repairs must be completed before the truck is operated.
  • Page 36 Operator's Daily Checklist Date Operator Truck No. Department Runtime Meter Reading Daily Check Items O.K.(√) Remark Check for Fluid Leakage Check that the battery cable connections are tight and grease the battery poles if necessary Check battery charging connector Check travel switch setting function Check the function of the steering system Check Operating Controls Check emergency stop switch...

  • Page 37: F Battery Maintenance & Charging

    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 types & dimensions: Voltage/ Rated Dimension Charging Tuck type Charger(A) capacity(V/AH) (mm) time(h) EST121 2x12/85 260x170x210 REV. 08/2019...

  • Page 38: Charging The Battery

    Charging the battery Safety regulations for charging 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 charging provided by their •...

  • Page 39: Battery Removal And Installation

    NOTE A fully charged battery will provide approximately 3 hours of continuous use. Capacity will be reduced when used in low-temperature environments. Storage If batteries are taken out of service for a lengthy period they should be stored in the fully charged condition in a dry, frost-free room.
  • Page 40 c: Remove the three battery cables shown in the image(5). d: Remove the battery(6). NOTE Pay attention to the operation of the battery to avoid short circuits. Installing the battery Install the batteries in reverse order, paying attention to the location where the batteries are installed and whether the wiring is correct.

  • Page 41: Battery Maintenance

    WARNING Well place cables to avoid be damaged when you remove and install battery. Installation 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. Battery maintenance Do not deep charge battery: If you discharge the battery completely till the trucks do not move any more, you will...

  • Page 42: G Stackers Maintenance

    Stacker Maintenance 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 service checklists. Only use original spare parts that have been certified by our quality assurance. •...

  • Page 43: Servicing And Inspection

    Settings When repairing or replacing hydraulic, electric or electronic components or assemblies, always note the truck specific settings. Servicing and inspection Thorough and expert servicing is one of the most important requirements for the safe operation of the industrial truck. Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment.

  • Page 44: 1Maintenance Checklist

    1.3.1 Maintenance checklist ● Maintenance interval ● Brake Check that electromagnetic brakes are installed and connected. ● Check braking distance of electromagnetic brakes. Check the electromagnetic brake air gap. ● ● Electrics Test instruments, displays and control switches. Test warning and safety device. ●...
  • Page 45 ● Maintenance interval ● Hydraulic system Check cylinders for damage or leakage and ensure that they are properly secured. Check that the oil tank is fixed and check it for leaks. ● Check the hydraulic oil level. ● ● Check hoses, pipes and interfaces for damage and ensure their tightness and sealing.

  • Page 46: 1.3.2 Lubrication Points

    1.3.2 Lubrication Points Lubricant Improper operations may constitute hazards to the operator's health and life, as well as to the surrounding environment. ����������������������������������������������� types and specifications of lubricants with each other (except for those can be mixed under clear statement). CAUTION The use and disposal of lubricants must be carried out in strict accordance with the manufacturer's regulations.
  • Page 47 Hydraulic oil injection nozzle Sliding surface Grease REV. 08/2019...
  • Page 48 Table 2 Sliding Surface Lubrication Table Code Position Caster Load Wheel Steel channel and rollers Chains Steering Bearing Drive Wheel REV. 08/2019...

  • Page 49: Maintenance Instructions

    1.3.3 Check the hydraulic oil level NOTE If there are popping noises coming from the tubing when lifting, this indicates that the hydraulic oil is insufficient and should be promptly replenished. CAUTION Do not add hydraulic oil that contains impurities. Fully lower the mast.
  • Page 50 How to add grease or grease oil Prepare the truck for maintenance and • repairs (See Maintenance Instructions ). Remove the front panel. • Add grease of the correct grade • (See Lubrication point ). • Add transmission oil every 500 operating hours, or at least annually.

  • Page 51: Recommissioning

    Recommissioning • The truck may only be recommissioned after cleaning or repair work, once the following operations have been performed. • Test horn. • Test Emergency stop switch. • Test brake. • Lubricate the truck in accordance with the maintenance point. •...

  • Page 52: Safety Checks To Be Performed At Regular Intervals And Following Any Unusual Incident

    Safety checks to be performed at regular intervals and following any unusual incident Carry out a safety check in accordance with national regulations. We have a special safety department with trained personnel to carry out such checks. The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector.

  • Page 53: Drive Wheel

    1.7.1 Drive Wheel Removal Remove the drive assembly. Dismantle the motor cable mounting base(1), and remove the motor cables(2); Loosen the eight screws(3) with a wrench, and remove the gearbox cover(4) and gear set(5); Unscrew the five screws(6) and knock out the assembly from the gearbox(7);...
  • Page 54 CAUTION 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. ������������������������������ performance of the device. If you need to replace the factory-fitted tyres, please use original spare parts provided by the equipment manufacturer to reach the original design performance of the truck.

  • Page 55: Load Wheels-Removal And Installation

    1.7.2 Load Wheels - removal and installation Removal Lift the vehicle carefully with lifting equipment through the lifting holes at back; CAUTION Make sure the lifting equipment is solid and secure, and the load capacity should be greater than the total weight of the vehicle.

  • Page 56: Caster-Removal And Installationt

    CAUTION 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 reach the original design performance of the truck. 1.7.3 Caster - removal and installation Removal...
  • Page 57 CAUTION 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 reach the original design performance of the...

  • Page 58: Removal And Installation Of Spring

    1.7.4 Removal and installation of spring NOTE The spring may need to be replaced due to frequent operation of the handle rod. Tool 1.Hammer 2.Circlip pliers 3.Shaft 3 (φ6~7.8) 4.Shaft 4 (φ6~7.8) Removal 1.Remove the left or right circlp (5) with circlip pliers, knock out shaft (6) with hammer.
  • Page 59 2.Remove the spring cover (8),now the spring released, remove the spring (the spring is inside the spring cover.). Installation 1.Replace the new spring and insert the shaft(3). 2.Press the handle(7) and insert the shaft (4) to lock the spring.now the spring is locked and remove the shaft(3).
  • Page 60 3.Install the shaft(6) and circlip(5). 4.Press the handle again and remove the shaft(4). Now,the new spring has been installed. REV. 08/2019...

  • Page 61: H Troubleshooting

    H Troubleshooting If the fault cannot be rectified after carrying out the remedial procedure, notify the Manfacture's se- vice department, as any further troubleshooting can only be performed by specially trained and qualified service personnel. Fault Probable Cause Action Truck can not Battery connector not plugged Check the battery connector and be started.
  • Page 62 Fault Probable Cause Action The vehicle a. Solenoid valve or its circuit 1) Check the lowering button and cannot be connection failure. its connection circuit. lowered. b. Lowering switch or its circuit 2) Check the solenoid valve and connection failure. its connection circuit.

Table of Contents