EP Equipment CPD15TV8 Operation Manual
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EP Equipment CPD15TV8 Operation Manual

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Operation Manual
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CPD15/18/20TV(W)8
CPD15/18/20TVL
Original Instruction
Part No.508000003110
V2 09/2021

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Summary of Contents for EP Equipment CPD15TV8

  • Page 1 Operation Manual & CPD15/18/20TV(W)8 CPD15/18/20TVL Original Instruction Part No.508000003110 V2 09/2021...
  • Page 2 Fig0000-00011OM EP EQUIPMENT CO.,LTD. is one of the world’s With business all over the world, EP has leading companies manufacture, which design thousands of employees and hundreds of agents material handling equipment and provide related worldwide to provide our global customers with service.
  • Page 3 Foreword The present operation manual is designed to provide sufficient instructions for the safe operation of the industrial truck. The information is provided clearly and concisely. Our trucks are under ongoing development. EP reserves the right to alter the design, equipment and technical features of the system.
  • Page 4 Legal requirements for marketing Declaration EP EQUIPMENT CO., LTD. Address: No.1 Xiaquan Village, Lingfeng Street, Anji, Huzhou, Zhejiang We declare that the 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 5: Table Of Contents

    Table of contents A Introduction...........................A1 1.1 Intended use ........................A2 1.2 Improper use ........................A3 1.3 Forklift truck handover .......................A3 1.4 Schematic views ........................A3 B Truck description ........................B1 1.1 Application ..........................B1 1.2 Truck Assemblies .......................B2 1.2.1 Display ..........................B4 1.2.2 Controls ........................B10 1.2.3 Components .........................B16 1.2.4 Cover and Seat......................B19 1.3 Standard version specifications ..................B22 1.3.1Performance data for standard truck ................B22...
  • Page 6 Table of contents 1.4.2 Drive wheels removal and installation ................G10 1.4.3 Check the gear oil level ....................G12 1.4.4 Check the hydraulic oil level ..................G12 1.4.5 Check the electrical fuses....................G13 1.4.6 Checking the brake fluid level..................G14 1.4.7 Seat belt maintenance ....................G15 1.4.8 Lift chain tension check ....................G15 Cleaning ........................G16 Decommissioning the trucks..................G17...

  • Page 7: A Introduction

    Introduction The truck described in the present operator manual is an industrial truck designed for lifting and transporting load units. It must be used, operated and maintained according to the information 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

    a) arranges for the modification or alteration to be designed, tested and implemented by an engineer(s) expert in industrial trucks and their safety. b)maintains a permanent record of the design, test(s) and implementation of the modification or alteration. c) approves and makes appropriate changes to the capacity plate(s), decals, tags and instruction handbook.

  • Page 9: Improper Use

    • When driving on public roads, the corresponding regulations must be observed, as well as country-specific restrictions for winter road conditions. • The operating company is responsible for adequate fire protection in the vicinity of the industrial truck. Industrial trucks may only be used to tow trailers if they are intended for this purpose by the •...

  • Page 10: B Truck Description

    B Truck Description Application These are battery-powered trucks. Three-wheel electric forklift truck is a new product with a small turning radius, an attractive design, a small and compact structure, a low centre of gravity, good stability, dual motor front wheel drive, steering and lifting by the same pump as well as superior performance.With maximum economic efficiency, safety and driving comfort.

  • Page 11: Truck Assemblies

    Truck Assemblies TW8,TV8 Fig3218-00001OM Fig3216-00006OM Drive wheel Rear combination light Battery behind panel Overhead guard Chassis Mast Counterweight Headlight Steer wheels Driver's seat Fork arms Caution light REV. 09/2021...
  • Page 12 Fig3218-00002OM Fig3216-00006OM Lift/ Tilt lever Tilting lever Side shifter/Attachment lever Emergency stop switch Attachment lever Key switch Side Combined lamp switch lever Steering column tilting angle Accelerator pedal adjuster Display Brake pedal Caution light switch (if necessary) Paking bake lever Steering wheel Lifting lever REV.

  • Page 13: Display

    1.2.1 Display Fig0000-00116OM BATTERY DISCHARGE INDICATOR RED-ORANGE-GREEN (5) KEY BOARD BUTTON: OUT (4) KEY BOARD BUTTON: SET DOWN (3) KEY BOARD BUTTON: SET UP (2) KEY BOARD BUTTON: ROLL DOWN (1) KEY BOARD BUTTON: ROLL UP (*) KEY BOARD BUTTON: ENTER Fig0000-00144OM REV.
  • Page 14 PERFORMANCE CHOICE#1#2 START The display sends the chosen performance to traction and pump controllers via can; they will manage this information. MAIN PAGE WITH OR WITHOUT ALARMS If there are no alarms, the main page shows battery charge, traction hour meter and truck speed.
  • Page 15 Fig0000-00230OM Battery Indicator【1】 DIS00-UP display doesn’t calculate the remaining capacity of the battery. It just reads the battery information from the controller and shows the percentage with twenty grids. Fig0000-00231OM If the battery is fully charged and the controller verifies the capacity of battery is 100%, the display will show twenty grids as 100%.
  • Page 16 STEER ANGLE ( featuring Steering Angle feedback trcuk) 【2】 Below the battery indicator, there’s the information of steer angle . Fig0000-00234OM If the controller can update the steer angle information by can net, the display could show this onbelow the battery indicator. It’s showed through a moving grid. When the grid is in the middle, it means the steer angle is 0 deg, and the truck is moving straight.
  • Page 17 Information of accelerator【4】 The information of accelerator is consisting of two parts. One is pedal enable signal and another one is speed require signal. The left grid is used for pedal enable signal. When the pedal is released the display will show the information like picture below. When you push the pedal gently, the display will show the information like picture above.
  • Page 18 ICON EXPLANATION If this icon is showed on display, the truck is in normal high speed mode. This mode is the default mode, and can be selected by button 1 If this icon is showed on display, the truck is in low speed mode.

  • Page 19: Controls

    1.2.2 Controls Steering When the steering wheel is turned right, the forklift will turn to the right; when the steering wheel is turned left, the forklift will turn to the left. The rear end of the forklift swings out when turning. WARNING This forklift truck adopts a fully hydraulic steering system.
  • Page 20 Hand brake lever When braking, pulling on the brake lever generates a braking force on the front wheels. To release the brake, Press the button ,move the lever forwards at the same time. WARNING If parking on the slope is unavoidable, block the wheels with solid wedge.
  • Page 21 TV8,TVL Travel Combination Switch for TV8 and TVL For switching travel direction of truck: Forward (F) , Reverse (R) and Neutral (N). The travel combination switch is used to switch between forward and reverse directions of travel. When the combination switch is pushed forward and the accelerator pedal is depressed, the forklift truck will travel forward.
  • Page 22 Emergency stop switch In an emergency, press the red mushroom head button to cut off the vehicle's main power supply. The vehicle will not be able to move, turn or lift. CAUTION Do not use the emergency stop switch to stop the truck under normal circumstances as the key switch.
  • Page 23 Brake pedal Depressing the brake pedal will slow down or stop the forklift. CAUTION Do not depress the accelerator and brake pedals at the same time, as this will damage the drive motor. TV8,TW8 Brake pedal Accelerator pedal Accelerator pedal Brake pedal Accelerator pedal Slowly depress the accelerator pedal, the drive motor will start running and the forklift will move...
  • Page 24 Tilt lever for TV8 and TVL Tilt/Lift lever The tilt lever is used to tilt the mast forward and backward. Push forward to tilt the mast forward, pull backward to tilt the mast back. The tilting speed is determined by the distance that the lever is moved.

  • Page 25: Components

    1.2.3 Components Fork stopper Used when adjusting the spacing of the forks. Pull up the fork stopper and rotate it 90°, then adjust the forks to the desired positions according to the load to be handled. WARNING Fork spacing should be adjusted symmetrically to the truck centreline.
  • Page 26 Overhead guard The overhead guard protects the operator turn signal against injury from falling objects. It must lights have sufficient impact strength. Its gap is Headlights used to lift battery. Do not use the forklift without the overhead guard. Fig3625-00016OM Caution light Caution light Press the caution light button, the caution...
  • Page 27 Safety step and handrail A safety step is provided on one side of the forklift body and a handrail is located on the left pillar of the overhead guard. Use the step and handrail to safely get on /off the forklift. Fig3216-00007OM Rear combination lights Rear combination lights...

  • Page 28: Cover And Seat

    1.2.4 Cover and Seat TV8,TW8 Procedures to open the battery hood • Pull the switch (1), then the cover(2) will be open. • With the help of air spring in the cover, the cover can be fully opened upward with small force. Procedures to close the cover Release the spring, and meanwhile press the cover.
  • Page 29 Seat and adjusting lever（2） Adjust operator’s seat to position which is comfortable for you and provides easy access to all hand and foot controls. The seat is unlocked by turn the adjusting lock (2) anticlockwise.Hold seat back and pulling backwards or pushing the handle can change the lean of seat.
  • Page 30 WARNING In any case, if there is damage or flaw etc. on the safety belt, please repair or replace it immediately. Never do any changes to the safety belt. Replace a new one after each accident. DANGER The seat belt should be fastened when using the forklift truck! The seat belt can only be used by one person.

  • Page 31: Standard Version Specifications

    1.3 Standard Version Specifications Technical specification details in accordance with VDI2198. Technical modifications and additions reserved. 1.3.1 Performance data for standard truck Distinguishing mark Manufacturer Model designation CPD15TV(W)8 CPD18TV(W)8 CPD20TV(W)8 Drive unit Electrics Electrics Electrics Operator type seated seated seated rated capacity Q kg 1500...

  • Page 32: Dimensions

    Tyre size, steering 15X4.5-8 15X4.5-8 15X4.5-8 wheels Wheels, number driving/ 2x/ 2 2x/ 2 2x/ 2 steering (x=drive wheels) Tread, Driving wheels Tread, Steering wheels Dimensions Tilt of mast/fork carriage α/ β (°) forward/backward Height, mast lowered 2060 2060 2060 Free lift (load backrest) Lift height 3000...
  • Page 33 Performance data Travel speed, laden/ unladen km/h 13/ 14 13/ 14 13/ 14 Lifting speed, laden/ unladen m/ s 0.29/ 0.43(TV8) 0.27/ 0.43(TV8) 0.26/ 0.43(TV8) 0.29/ 0.34(TW8) 0.27/ 0.32(TW8) 0.26/ 0.31(TW8) Lowering speed, laden/ m/ s 0.44/ 0.435(TV8) 0.44/ 0.435(TV8) 0.44/ 0.435(TV8) unladen 0.44/ 0.29(TW8)
  • Page 34 Dimensions Fig3218-00032OM REV. 09/2021...
  • Page 35 Distinguishing mark Manufacturer Model designation CPD15TVL CPD18TVL CPD20TVL Drive unit Electrics Electrics Electrics Operator type seated seated seated rated capacity Q kg 1500 1800 2000 Load center distance Load distance centre of drive axle to fork Wheelbase 1230 1330 1330 Weight Service weight (include 2950...
  • Page 36 Tyre size, steering 15X4.5-8 15X4.5-8 15X4.5-8 wheels Wheels, number driving/ 2x/ 2 2x/ 2 2x/ 2 steering (x=drive wheels) Tread, Driving wheels Tread, Steering wheels Dimensions Tilt of mast/fork carriage α/ β (°) forward/backward Height, mast lowered 2075 2075 2075 Free lift (load backrest) Lift height 3000...
  • Page 37 Performance data Travel speed, laden/ unladen km/h 13/ 14 13/ 14 13/ 14 Lifting speed, laden/ unladen m/ s 0.33/ 0.5 0.4/ 0.5 0.38/ 0.48 Lowering speed, laden/ m/ s 0.55/ 0.55 0.55/ 0.55 0.53/ 0.53 unladen Drawbar pull, laden/unladen N Max.
  • Page 38 1.3.2 Dimensions REV. 09/2021...

  • Page 39: Identification Points

    1.4 Identification points Helmet safety label Gas spring Hand brake label indicator label “Fill port”label Notice “No standing under the load carriage”label Safety warning label Anti-pinch label Emergency stop switch label No driving in the rain “Instruction” label Bolt fastening label Sling label Fig3218-00034OM REV.

  • Page 40: Truck Data Plate

    Truck data plate For queries regarding the truck or ordering spare parts please quote the truck serial number. Item Description Item Description PRODUCT NAME RATED CAPACITY MODEL TYPE LOAD CENTER SERIAL NO. MAX BATTERY WEIGHT MANUFACTURE DATE MIN BATTERY WEIGHT UNLADEN MASS UNLADEN MASS WITHOUT BATTERY BATTERY VOLTAGE...

  • Page 41: The Load Capability Chart

    The load capability chart The capacity plate gives the capacity (Q) of the truck in kg for a vertical mast. The maximum capacity is shown as a table with a given load centre of gravity D (in mm) and the required lift height H (in mm). The capacity plate of the truck indicates the truck's capacity with the forks as originally supplied.

  • Page 42: 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 material. Aisles and roadways should be unobstructed and well ma- rked. Operators must know the classification for the truck and use the truck only in permissible areas.
  • Page 43 5. Protect yourself Operator must wear helmet, safety shoes and work(protective) clothes, whenever you operate and maintain the truck, handle the consumables etc. 6. Prevent explosion Because there will be explosive gas in the bosom of the battery, prohibit any flame or sparks nearby it strictly.
  • Page 44 Prohibit sudden stops, starts or sharp turns Operate the controls smoothly. Avoid sudden stops, starts or sharp turns. It is dangerous to make a sudden brake. for it may cause the truck to overturn. Fig0000-00021OM 12.Focus on the travelling route· Pay attention to the route of the truck, be sure to keep a clear view of it and look in the direction of travelling.
  • Page 45 15. Concentrating on your work Keep your mind on your work. Learn to estimate danger before it arises. 16.Mount and dismount properly Never mount or dismount the moving truck. Use the safety steps and safety handgrip and face the truck when mounting or dismounting the truck.
  • Page 46 22. Overhead guard and load backrest Safeguard protect you not to be hurt by the goods fallen. Load backrest can keep the load stable. It is forbidden to use truck without overhead guard or load backrest. Any additional bores or welding to the overhead guard on the overhead guard will compromise its rigidity.
  • Page 47 27. Tilt backwards when loaded Travel with load as low as possible and tilt back. If operating with steel pallet or the like, be sure to tilt back the mast to prevent it from slipping off the forks. 28.Watch for doorways and slow down at corners Watch for branches, cables, doorways, or overhangs.
  • Page 48 In the case of tip-over The stability of your truck is ensured if used properly and as intended. But once it tips over during unapproved applications or incorrect operation, always follow the instructions below: • Stay buckled up; Don’t jump; •...
  • Page 49 37. Check the ground of the work area Inspect the surface over which you will run. Look for holes, drop-offs, obstacles, and protrusions. Look for anything that might cause you the truck to lose control, or jolt. Clear away trash and debris. Pick up anything that might puncture a tire or let the load lose balance.

  • Page 50: Battery Safety

    Battery Safety WARNING Batteries contain dissolved sulfuric acid for equiped lead-acid battery turck, which is poisonous and caustic. Batteries also can produce explosive gases • Remain aware of the following information. • Wear protective equipment (protective apron and gloves) and protective glasses when working with battery.
  • Page 51 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 •...

  • Page 52: D Transport And Commissioning

    D Transport and Commissioning Transport Use a truck or flatbed trailer to carry the forklift truck. • Lower the lift mast. • Apply the parking brake lever. • Secure the front wheels and rear wheels with chocks to prevent slipping. •...
  • Page 53 • Loop the lifting straps around the main traverse (3) on the outer mast of the lift mast as shown; Fasten the sling onto the sling ponit (2) or towing pin (5) of counterweight; • Hang all sling ends on the lifting hook (1) of the hoist. •...
  • Page 54 Towing regulations When the truck needs to be moved, a tow rope or rod can be attached to the towing bar (1). A tow rope can also be attached to the base of the lift mast. CAUTION Braking can only be performed by the brake pedal or hand brake lever during towing.

  • Page 55: The Structure And Stability Of Truck

    DANGER If the towing vehicle brakes, there is a risk that the truck will drive into the towing vehicle! If a rigid connection has not been used for power transmission in two directions during towing, the truck may drive into the towing vehicle when the towing vehicle brakes.
  • Page 56 WARNING combined gravity center Gravity center and stability truck gravity center Load gravity center The combined gravity center that is composed of the forklift center and the load gravity center determine the stability of lift trucks. When unloaded, the barycenter does not change;...

  • Page 57: Using The Truck For The First Time

    Using the Truck for the First Time Only operate the trucks with battery current. Preparing the trucks for operation after delivery or transport. Procedures: Check whether is complete. • Check the hydraulic oil level. • Install the battery if necessary, (see Battery removal and installation" ) do not damage battery •...

  • Page 58: E Operation

    E Operation Checks and operations to be performed before starting daily work Visually inspect the entire truck (in particular wheels) for obvious damage. • • Visually inspect the battery attachment and cable connections. Check the mast , load backrest and forks for visible damage such as cracks. •...

  • Page 59: Switching On The Truck

    Checking the emergency off function • Find a sufficiently large, open area in which nobody will be obstructed. • Accelerate the truck to walking speed. • Push the emergency off switch (2). • Actuate the parking brake. • The truck must decelerate and remain stationary. •...
  • Page 60 WARNING The distance from the driver's head to the overhead guard has been reduced in certain manufacturer forklift trucks (such as the container overhead guard, etc.). Only drivers where the distance from the driver's head to the overhead guard exceeds 30 mm are permitted to operate this kind of forklift truck.

  • Page 61: Loading

    Loading Adjusting the fork spacing • Toggle the fork positioning lock; • Move the forklift truck closer to or further away from the goods to be lifted according to their size. Note that the two forks should be equidistant from the centreline of the forklift truck.
  • Page 62 • Raise the fork carriage until the load rests freely on the forks. Fig0000-00333OM • Set the travel combination direction switch (1) to reverse and release the parking brake. TV8,TVL Fig0000-00045OM Fig3216-00010OM • Reverse carefully and slowly until the load is outside the storage area.
  • Page 63 WARNING Do not get on the goods being loaded due to the danger of falling or being hit. WARNING Lift the goods, and make sure that they are within the load range of the truck to avoid toppling and falling. CAUTION Do not stand below lifted goods.

  • Page 64: Parking The Truck Securely

    Parking the truck securely When you leave the truck it must be securely parked even if you only intend to leave it for a short time. • Lower the fork carriage to the ground; • Pull on the hand brake lever. •...

  • Page 65: Driving On Ascending And Descending Gradients

    Driving on ascending and descending gradients DANGER Danger to life! Driving on ascending and descending gradients carries special dangers! Always follow the instructions below. • Reduce the driving speed on descending gradients. always limit travel speed to 4.8 km/h or less. •...

  • Page 66: Operator Daily Checklist

    Operator daily checklist At the beginning of each shift, inspect your truck by using the EP 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 67 Operator's Daily Checklist Date Operator Truck No. Department Runtime Meter Reading Daily Check Items O.K.(√) Remark Chassis, bodywork and fittings Check the condition and function of the driver's seat and seat belt. Check tire: Using a tire pressure gauge, measure the inflation pressure if necessary Chassis frame Checking the condition of tyres.

  • Page 68: F Battery Maintenance & Charging & Replacement

    Battery Maintenance & Charging & Replacement Battery type & dimension Battery type & dimension as follow: Battery Voltage/ rated Charging Dimension(mm) Tuck type Charger type capacity time(h) lead-acid 200A CPD15TV8(TW8) 48V/400AH 830*620*627 battery lead-acid 200A CPD18TV8(TW8) 48V/500AH 930*620*574 battery lead-acid 200A CPD20TV8(TW8) 48V/600AH...

  • Page 69: Charging The Battery

    Charging the battery Check that the specific gravity of the electrolytes is at least 1.14(refer appendix). Charge and maintain the battery in accordance with instructions from the manufacturer. If there are no instructions, please contact your maintenance agent. CAUTION • No metal objects should be placed on the battery. •...
  • Page 70 Equalizing charge method for TV8 and TW8 Firstly charge the battery normally, then let it rest for 1 hour after charging is complete. Continue charging the battery using the second-stage charge current specified for normal charging until multiple bubbles appear, then stop charging for one hour. Repeat the above steps several times until the voltage and density stop rising and bubbles appear as soon as charging is resumed after the 1-hour interval.
  • Page 71 WARNING Output voltage, current and application range of the charger must match the battery, otherwise it will influence the volume and service life of the battery. Charging cable polarity must match the charger output terminal polarity. WARNING Recharge the battery in time. Do not keep the battery fully discharged or lower than 20%. For TV8，TW8: Checking the battery condition, electrolyte level and specific gravity...

  • Page 72: Battery Removal And Installation

    WARNING Add only distilled water. Before adding distilled water, check if the buoy can move up and down properly to prevent the buoy from failing to float up and resulting in excessive filling. 2) Filler cap without buoy When adding water, stop filling when the electrolyte level is higher than the protective plate for 15~20 mm.

  • Page 73: Lithium-Ion Battery Maintenance(See

    Procedures for TVL: Park the truck on the flat ground, and pull • on the hand brake; Unscrew the four bolts (4), spring (5) and • washers(6); Pull out the seat with the battery hood (8) • to expose the lithium-ion battery; Unscrew the two bolts (1), spring(2) and •...

  • Page 74: G Truck Maintenance

    Truck 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. Used parts, oils and fuels must be disposed of in accordance with the applicable environmental protection regulations.

  • Page 75: 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 76: 1Maintenance Checklist

    1.3.1 Maintenance Checklist ● Maintenance interval ● Clean the fork lift truck if necessary. Before ● Check the time and date settings on the display unit; starting adjust if necessary. maintenance ● Check for error codes on diagnostic software and delete. work: ●...
  • Page 77 ● Maintenance interval ● Chassis, tilt cylinders and steering axle: Check fastening. ● Check the counterweight, motors, chassis, speed reduction gearbox, overhead guard and steering axle Frame and fastenings. installation ● Lubricate the overhead guard pin shaft. ● Check and lubricate the other pins and swivel points. ●...
  • Page 78 ● Maintenance interval ● Check the cylinders for leaks. ● Check the leak resistance of the working and steering hydraulic systems. ● Check the hydraulic oil level. Hydraulics Replace once Clean or replace the hydraulic oil. every 2000 hours. ● Replace the air, pressure and suction filters.

  • Page 79: Lubrication Points

    1.3.2 Lubrication Points Lubricant Improper operations may pose hazards to the operator's health and life, as well as to the surrounding environment. When storing or adding lubricant, use clean containers. It is strictly forbidden to mix different types and specifications of lubricants (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 80 Table 2.1 Application Amount of Table 2.1 Application Amount of Hydraulic Oil - 1 Hydraulic Oil - 3 for Lifting height Amount Mast Series (mm) Lifting height Amount Mast Series (mm) 2000 15.3 3700 2500 16.1 4000 2700 16.4 4350 20.8 3000 16.9...
  • Page 81 Table 2.2 Contact Surface Lubrication Table Code Position Steering axle Tilt cylinder connetor Fork Carriage Steel channel and rollers Contact surface REV. 09/2021...

  • Page 82: Maintenance Instructions

    Maintenance Instructions For TV/TV8/TW8 Prepare the truck for maintenance and repairs All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made: • Park the truck securely ( see chapter E Section1.4).

  • Page 83: Steering Wheels Removal And Installation

    NOTE • Screw the nuts. • Tighten the nuts of steering wheels in order and mark with the torque: 220N·m. • Tighten the nuts of driving wheels in order and mark with the torque: 220N·m . • Turn the wheel to see if it is rotating smoothly, and if there is blocking or not. •...

  • Page 84: Drive Wheels Removal And Installation

    • Remove the five protectors (1) and unscrew the five nuts (2) on the steering wheel assem-bly (3); Remove the steering wheel assembly (3) • from the steering bridge (4). Install according to the reverse order of removal. WARNING Tire is solid tire. When replacing wheels, be sure that the truck won't tilt.

  • Page 85: Check The Gear Oil Level

    1.4.3 Check the gear oil level Pull on the hand brake and switch off the truck. Loosen the oiling port plug (2) and observe the oil level; If oil level is aligning with lower level of oiling port, it indicates that the oil level is normal;...

  • Page 86: Check The Electrical Fuses

    1.4.5 Check the electrical fuses • Prepare the truck for maintenance and repairs. • Open the battery hood. • Check condition and rating of the fuses. The electrical fuses are now checked. Fig3216-00001OM Rating/ Rating/type Item Electric circuit Electric circuit type(TVL) (TV8,TW8) 80V main power...

  • Page 87: Checking The Brake Fluid Level

    1.4.6 Checking the brake fluid level Brake fluid is poisonous and should therefore only be stored in sealed, original containers. • Park the truck securely（see chapter E Section1.4） • Visually inspect the brake fluid level from the brake fluid reservoir (1), if necessary add brake fluid.

  • Page 88: Seat Belt Maintenance

    1.4.7 Seat belt maintenance The driver must check the operation and condition of the seat belt every day before using the industrial truck. Faulty operation can only be detected in good time through regular inspection. Periodically check the safety belt •...
  • Page 89 1.4.6 Fork Inspection Inspect the load forks for bending and wear: • The top surfaces of the forks should be level with each other. • If the height difference between the fork tips is greater than 1.5% of the blade length (A), then the forks must be replaced.
  • Page 90 1.4.7 Lift Chain Inspection and Lubrication During normal operating conditions, inspect and lubricate the lift chains every 450 to 500 hours. If operating in corrosive or extreme working conditions, inspect more frequently. When inspecting, check for: rust and corrosion, cracked plates, raised or turned pins, tight joints, excessive wear, and worn pins and holes.
  • Page 91 1.4.8 Inspect the drive and steer wheels and tires every day before operating the lift truck. Do the following when inspecting the wheels and tires: • Inspect the tires for excessive wear. Replace if needed. • Remove any embedded foreign objects for the tires. •...

  • Page 92: Cleaning

    Cleaning Cleaning the truck WARNING • Risk of fire due to flammable cleaning materials! • Flammable cleaning materials can be ignited by hot components. • Do not use any flammable cleaning materials. CAUTION • If water penetrates the electrical system, there is a risk of short circuit! •...

  • Page 93: Decommissioning The Trucks

    Cleaning load chains WARNING The use of cold/chemical cleaners or fluids that are corrosive or contain acid or chlorine can damage the chains and is forbidden! • Place a collection vessel under the lift mast. • Clean with paraffin derivatives, such as benzine. •...

  • Page 94: Restoring The Truck To Operation After Decommissioning

    1.6.2 Restoring the truck to operation after decommissioning • Thoroughly clean the truck. • Clean the battery. Grease the pole screws using pole grease and reconnect the battery. • Recharge the battery. • Check if the hydraulic oil contains condensed water and change if necessary. •...

  • Page 95: H Troubleshooting

    H Troubleshooting This chapter is designed to help the user identify and rectify basic faults or the results of incorrect operation. When locating a fault, proceed in the order shown in the table. If the fault cannot be rectified after carrying out the remedial procedure, notify the manufacturer ’ s service department ,as any further troubleshooting can only be performed by specially trained and qualified service personnel.The manufacturer has a customer service department specially trained for these tasks.
  • Page 96 Fault Fault Symptom Troubleshooting Order * Troubleshooting Measures Hydraulic 1. The vehicle 1. Pump motor does not work: 1. Pump motor does not work: Failure cannot lift a. Parking brake switch and seat 1) Check if parking brake switch switch or its circuit connection and seat switch or the connec- failure tion of its circuit is normal;...
  • Page 97 Fault Fault Symptom Troubleshooting Order * Troubleshooting Measures Lift Failure 3. Slow Lifting of a. Overload 1) Refer to the rated capacity Vehicle marked on the nameplate; b. Hydraulic pipeline leakage 2) Check the pipe and hydraulic c. Valve failure: components for oil leaks;...
  • Page 98 Fault Fault Symptom Troubleshooting Order * Troubleshooting Measures Other Failures 1. Lights do not light a. Light failure or circuit not 1) Check the light and its circuit conducted connection; 2) Check Lighting combination b. Lighting combination switch or switch and its connection its circuit connection failure circuit;...

  • Page 99: Appendix

    Appendix Lithium-ion battery REV. 09/2021...

  • Page 100: Lithium Battery Use And Maintenance Manual

    Lithium Battery Use and Maintenance Manual Information on the conformity of lithium-ion batteries The manufacturer of the lithium-ion battery and EP group provider declares that: the lithium- ion battery conforms with the provisions of the following EU directive 2014/30/EU in accordance with EN12895. This declaration of conformity with EU directives applies only to battery use that conforms to the recommendations described in the operating instructions.

  • Page 101: Safety And Warning

    DANGER Failure to comply with these safety instructions can result in fire and explosion or the leakage of harmful materials. 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! BMS (Battery Management System)
  • Page 102 •Don’t trample on the battery to prevent it from fierce shaking or shacking! Fig0000-00007OM Do not place the battery on top of conductive objects. Fig0000-00006OM •Explosion or fire disaster is likely to occur; avoid short circuit! Fig0000-00004OM •Don’t knock over the battery! •Using lifting and delivery devices as specified.

  • Page 103: Hazard Of Faulty Or Discarded Battery

    1.3 Hazard of faulty or discarded battery Please monitor the battery status when in use and in storage. If you find any broken batteries, electrolyte leakage, abnormal expansion or pungent odors due to shipping damage or abnormal vibration, please stop use immediately and keep at least a 5 meter perimeter around the effected batteries.

  • Page 104: Battery Indicator

    Battery indicator ？ ？ Fig0000-00056OM Name Description When all 10 cells are on, it indicates that the battery is full; When the first cell and the second flash alternately, it indicates Energy display that the battery is low and must be charged. The battery remaining charge is displayed;...
  • Page 105 ？ ？ Fig0000-00057OM Name Description Maximum cell Maximum value of cell voltage voltage No. of cell Identification No. of the cell with maximum voltage. Minimum cell Minimum value of cell voltage voltage Cell No. of minimum cell Identification No. of the cell with minimum voltage. voltage REV.

  • Page 106: Lithium Battery Nameplate

    Lithium Battery Nameplate Item Description Battery Model Nominal Voltage Li-ion Battery System Nominal Energy Battery Model Cell Type Battery weight Nominal Voltage Nominal Capacity Serial No. Nominal Energy Version No. Cell Type Battery weight Date Nominal Capacity Serial No. Version No. Date Charging •...

  • Page 107: Storage

    WARNING Lithium batteries are strictly prohibited from overcharging and over discharging. CAUTION 1. The normal charging temperature range of the battery is: 5°C~40°C. 2. The voltage difference between the maximum and minimum cell voltages during charging is less than 0.1V. 3.

  • Page 108: Instructions For Disposal

    For UN3480 Lithium-ion Batteries For UN3481 Lithium-ion Batteries packed with Equipment or Lithium batteries built into Equipment Fig0000-00080OM Shipping faulty batteries To transport these faulty lithium-ion batteries, contact the manufacturer's customer service department. Faulty lithium-ion batteries must not be transported independently. NOTE It is recommended that the original packaging is kept for any subsequent dispatch.
  • Page 109 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 110: Common Problems And Solutions

    1.10 Common Problems and Solutions During the use and maintenance of the lithium-ion battery, the battery or battery system may have one or more of the following abnormal conditions, please organize the professional engineers and technicians to perform the necessary processing according to the instructions in this manual;...

  • Page 111: Service

    1.11Service Daily Maintenance No. Maintenance content Method of operation Note Frequency Check if battery capacity Check instrumentation Make sure the battery is Everyday 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 112 No. Maintenance content Method of operation Note Frequency Whether the external Perform a visual Make the wiring harness weekly wiring harness has worn, inspection fixed well imprint, creases and exposed line core Check that the surface of No dust, no water, no Clean surface if you found weekly lithium-ion battery looks...

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