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Summary of Contents for ep RPL201
- Page 1 Operation Manual RPL201 RPL201H RPL251 RPL301 Electric pallet trcuk Part No.508000004501 V2 10/2022...
- Page 2 With business all over the world, EP has EP EQUIPMENT CO.,LTD. is one of the world’s thousands of employees and hundreds of agents leading companies manufacture, which design worldwide to provide our global customers with material handling equipment and provide related 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 Conformity marking The manufacturer uses the conformity marking to document the conformity of the industrial truck with the relevant directives at the time of placing on the market: ● CE: in the European Union (EU) ● UKCA: in the United Kingdom (UK) The conformity marking is applied to the nameplate.
- Page 7 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 type: corresponding to these this operation manual Model: corresponding to these this operation manual Serial No.: corresponding to these this operation manual Fulfills all the relevant provisions of Directives −...
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Page 8: Table Of Contents
Table of contents A Nameplates and alarming labels ..................A1 B Operation ..........................B1 1.1Utilization safety specification....................B1 1.1.1 EN standards ........................B2 1.1.2 Conditions for application ....................B2 1.1.3 Stability ...........................B2 1.2 Overview, Display, manipulation ..................B3 1.2.1 Truck overview.........................B3 1.2.2 Control handle .........................B5 1.2.3 Key switch ........................B5 1.2.4 Display instrument ......................B6 1.3 Truck use and operation .....................B8 1.3.1 Preparation for use ......................B8... - Page 9 Table of contents A Nameplates and alarming labels ..................A1 B Operation ..........................B1 1.1Utilization safety specification....................B1 1.1.1 EN standards ........................B2 1.1.2 Conditions for application ....................B2 1.1.3 Stability ...........................B2 1.2 Overview, Display, manipulation ..................B3 1.2.1 Truck overview.........................B3 1.2.2 Control handle .........................B5 1.2.3 Key switch ........................B5 1.2.4 Display instrument ......................B6 1.3 Truck use and operation .....................B7 1.3.1 Preparation for use ......................B7...
- Page 10 Table of contents 11 Charging ..........................F8 12 Storage ..........................F8 13 Common Problems and Solutions ..................F9 14 Service..........................F10 Lead-acid battery operating instructions ................G2 1.1 Safety and warning ......................G2 1.2 Use of Battery ........................G3 1.2.1 Pre-use Checks ......................G3 1.2.2 Discharging........................G3 1.2.3 Charging ........................G3 1.2.4 Temperature ........................
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Page 11: 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 12 Truck Nameplate Item Description PRODUCT NAME MODEL TYPE SERIAL NO. MANUFACTURE DATE LIFT HEIGHT UNLADEN MASS UNLADEN MASS WITHOUT BATTERY BATTERY VOLTAGE RATED DRIVE POWER MAX BATTERY WEIGHT Fig0000-00015OM MIN BATTERY WEIGHT RATED CAPACITY LOAD CENTER Lithium-ion battery nameplate Item Description Battery Model Nominal Voltage...
- Page 13 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. REV.
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Page 14: B Operation
Operation 1.1 Utilization safety specification Don’t use the truck in Don’t use the truck in non- • Average ambient temperature rainwater. for continuous duty: ＋ 25℃ ; position. • Maximum ambient temperature, short term (up to 1h): ＋ 40℃ ; •... - Page 15 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.
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Page 16: Standards
1.1.1 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 17: Conditions For Application
1.1.2 Conditions for application Working condition requirements: – Use in specified rated load. – Used in specified area as factory, tourist attraction and recreation place. – Used on the flat ground, that is fixed and owns enough carrying capacity. – It is prohibited to pass the bulge or cavity as the small wheel diameter may cause truck tipping over. -
Page 18: Overview, Display, Manipulation
1.2 Overview , Display,Manipulation 1.2.1 Truck overview Control Handle Forks Key switch Load wheels Side arms Emergency stop switch Hydraulic unit Operator platform Drive wheel Caster Display instrument REV. 09/2022... - Page 19 1.2.2 Control handle Lowering button Lower loading parts Lifting button Lift loading parts Horn button Send out sound warning signals Driving switch Controls travel direction and speed Emergency reverse button Through touching the button, truck drives away from operator. 1.2.3 Key switch Connect and interrupt control current.
- Page 20 1.2.4 Display instrument When the truck start up, it will show a startup display interface; • The LED (1) show the No Serialnumber. It indicates the circular meter has no bluetooth SN:EC2815372079 DIS2 function. • The LED (2) show the DIS3. It indicates the 011H version of the product.
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Page 21: Truck Use And Operation
1.3 Truck use and operation 1.3.1 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 22: Comissioning
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 23: Truck Starting
1.3.3 Truck starting 1.Check and Plug into the battery plug if necessary. 2. Release the emergency stop switch. 3.Turn on the key switch. 4.If you need to stand on the pedal to operate for the Stand-on operating mode, you need open the pedal and side arm. -
Page 24: Running, Steering And Braking
1.3.4 Running, steering and braking 1.Running Running area 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) NOTE When using the truck on a ramp or a Push the side uneven road, please lift the forks of the arms out state... - Page 25 NOTE It's forbidden to operate the truck which you don't push the side arm out at the rider mode. There are two positions for the folding platform: • Position A: fold up the operator platform • Position B: fold down the operator platform REV.
- Page 26 2.Steering Rotate the operation hand shank leftward or rightward as required. Leftward Rightward 3.Braking 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 CAUTION Braking area If the control handle moves slowly into...
- Page 27 Regenerative braking Release the drive switch. The drive switch will automatically return to the initial position and the vehicle will begin to enter the regenerative braking state. When it decelerates to <1 km/h, the electromagnetic brake will bring the motor to a stop.
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Page 28: Goods Picking
1.3.5 Goods picking 1.Lifting Keep pressing the lifting button until reaching the required lifting height 2.Lowering Lower the pallet forks to the bottom through pressing the lowering button. REV. 09/2022... -
Page 29: Parking The Truck Securely
WARNING Goods failing to be arranged and fixed may result in accidents. NOTE To avoid shortening the service life of the oil cylinder, try not to lift the pallet forks to the highest state for every lifting operation. 1.3.6 Parking the truck securely Lower the forks to the bottom;... -
Page 30: Drive Directions
Press the emergency stop switch to cut off storage battery connection; Fold pedal and side arm . If park for long time, remove the battery plug. 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. -
Page 31: Loading
1.3.8 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 32: Using The Truck On A Slope
1.3.9 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. -
Page 33: Truck Transport
NOTE Incorrect use of the truck on slopes places stress on the traction motor, brakes and battery. 1.3.10 Truck transport CAUTION When transporting the truck, check that it is properly supported on wooden blocks and correctly tied with rope. Fold the side protection bars and foldable platform so they do not protrude from the vehicle body. -
Page 34: Operating The Truck Without Its Own Drive System
1.3.11 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: • Press emergency stop switch . • Set the key switch “OFF” and remove the key. •... -
Page 35: C Battery Use And Maintenance
Battery use and maintenance 1.1 Battery charging 1.1.1 Precautions • Charging the batteries shall only be carried out in adequately ventilated rooms and e.g. not in the offices or break rooms for equipped with lead-acid battery truck. • Avoid the existence of any metal object in the surface of the lithium-ion battery; •... -
Page 36: Charging The Battery With External Charger
1.1.2 Charging the battery with external charger lithium-ion For equiped with battery truck Charge lithium-ion battery through a external charger. •Inspect whether relevant charging requirements are satisfied according to “1.1.1 precautions”; • Park the truck securely as described Chapter B section1.3.6 •Open the battery cover;... -
Page 37: Battery Type & Dimensions&Charging Time
1.1.3 Battery type & dimensions&Charging time Battery types & dimensions are as follows: Voltage/ Rated Charging Dimensions Charger Tuck type battery type capacity time More than 550×190×500 50A/100A RPL201 24V/205Ah Li-ion 4.1h/2.05h More than 550×190×500 50A/100A RPL201H 24V/205Ah Li-ion 4.1h/2.05h RPL201/ 650×200×540... -
Page 38: Battery Removal And Installation
1.2 Battery removal and installation Park the truck securely see chapter B section 1.3.6 and turn off the power before removal and installation of the battery. Battery removal and installation steps: For equipped with lithium-ion battery truck • Open the battery cover; •... - Page 39 WARNING The lifting gear must exert a vertical pull so that the battery container is not compressed. The hooks must be attached to the eyes WARNING Before removing the battery, make sure the vehicle is completely powered off. WARNING After installing the battery again, check all cables and plug connector for visible signs of damage.
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Page 40: 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 41 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.
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Page 42: Maintenance Table
1.2 Maintenance table 50-hour/7-Day maintenance Check the functions of the operation switches and display Check alarm system functions Check the emergency switch functions Check steering system functions Check the drive wheel and load wheel for worn or damage Check if there is crack or fracture on front fork or rear fork. Check the functions of hydraulic system 250-hour/2-month maintenance After operating for 250 hours in total, the truck should also be maintained according to the... - Page 43 1000-hour/6-month maintenance After operating for 1000 hours in total, the truck should also be maintained according to the following procedures in addition to the 50-hour maintenance, 250-hour maintenance and 500- hour maintenance mentioned above Inspect whether the bearing capacity reaches the rated load and implement corresponding adjustment through the flood valve adopted in the hydraulic station Inspect whether all the labels are clear and intact...
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Page 44: Recommissioning
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. 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. -
Page 45: E Technical Data
Technical date 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 Drive unit Electrics Electrics Operator type standing Pedestrian rated capacity 2000... - Page 46 3.3.1 Tyre size, loading Ф85x70 / Ф83x115 Ф85x70 / Ф83x115 wheels(diameter×width) Tyre size, caster mm Ф130x55 Ф130x55 wheels(diameter×width) Wheels, number driving, mm 1x,2/4(1x,2/2) 1x,2/4(1x,2/2) caster/loading (x=drive wheels) Track width, front,driving b10 mm 510 side Track width,rear,loading mm 370/515 370/515 side Dimensions Lift height mm 120...
- Page 47 Performance data Travel speed, laden/ unladen k m / 9.0 / 12.0 7.5 / 8 Lifting speed, laden/ unladen m/ s 0.050/0.054 0.050 / 0.054 Lowering speed, laden/ m/ s 0.067 / 0.054 0.067 / 0.054 unladen Max. gradeability, laden/ 8 / 16 8 / 16 unladen...
- Page 48 RPL201/RPL201H REV.12/2020...
- Page 49 Distinguishing mark Manufacturer Model designation RPL251 RPL301 Drive unit Electrics Electrics Operator type standing standing rated capacity 2500 3000 Load center mm 600 distance Load distance mm 916 Wheelbase mm 1531 1531 Weight Service weight 802(lithium-ion 802(lithium-ion (include battery) battery) battery) 875(lead-acid 875(lead-acid...
- Page 50 3.2.1 Tyre size, driving mm Ф230x75 Ф230x75 wheels(diameter×width) 3.3.1 Tyre size, loading Ф85x70 / Ф83x115 Ф85x70 / wheels(diameter×width) Ф83x115 Tyre size, caster mm Ф130x55 Ф130x55 wheels(diameter×width) Wheels, number driving, mm 1x,2/4(1x,2/2) 1x,2/4(1x,2/2) caster/loading (x=drive wheels) Track width, front,driving side b10 mm 510 Track width,rear,loading side b11 mm 370/495...
- Page 51 Lowering speed, laden/ m/ s 0.067 / 0.054 0.067 / 0.054 unladen Max. gradeability, laden/ 6 / 16 6 / 16 unladen 5.10 Service brake type Electrom Electrom agnetic agnetic Electric-engine Drive motor rating S2 60 min hp kW 1.6 Lift motor rating at S3 15% kW 2.2 Battery voltage/nominal...
- Page 52 Dimensions RPL251/RPL301 REV.12/2020...
- Page 53 Lithium-ion battery REV. 09/2022...
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Page 54: Information On The Conformity Of Lithium-Ion Batteries
40° C to ensure the smoothness of charging); • Use water-based extinguishers,CO2, dry chemical fire extinguishers. • Do only use in trucks manufactured by EP and if the battery type is released for that truck. REV. 09/2022... -
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: 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 58: 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 59: 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 60: 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 61: Common Problems And Solutions
support. -
Page 62: Service
14.Service Daily Maintenance No. Maintenance content Method of operation Note Frequency Check if battery Check instrumentation Make sure the battery is Everyday capacity is too low SOC display not stored without charge for a long time. If the battery system needs to be put on hold for a long time, it is best to keep the battery in half power state... - Page 63 No. Maintenance content Method of operation Note Frequency Clean the lithium battery Perform a visual Make sure it tight weekly and charger with a dry inspection, Wear cloth or compressed air. insulated gloves and shake it gently Whether the external Perform a visual Make the wiring harness weekly...
- Page 64 0ºC to 40ºC (32ºF to 104ºF) or in an environment with greater than 85% humidity. EP recommends to opportunity charge lithium-ion batteries. This is when the battery is recharged for short intervals during a shift period. It reduces or eliminates the need for long charging periods, changing batteries during a shift, and extending shift periods.
- Page 65 Lead-acid battery REV. 09/2022...
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Page 66: Safety And Warning
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. 09/2022... -
Page 67: Use Of Battery
1.2 Use of Battery 1.2.1 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 68: Temperature
1.2.4 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. 1.3 Maintenance &... -
Page 69: 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 70: Care
1.3.4 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 71 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 72 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 73 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...
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