ep ESD122 Operation Manual
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ep ESD122 Operation Manual

Electric pallet stacker
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Operation Manual
ESD122
Electric Pallet Stacker
Part No.508000005410
V2 10/2022

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  • Page 1 Operation Manual ESD122 Electric Pallet Stacker Part No.508000005410 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 Intended use The lift truck is designed for transporting and stacking the loads stated in the load capacity diagram. In particular we refer to: • the safety rules of your trade association. • the special measures required for driving onpublic roads in accordance with the StVZO (Road Traffic Licencing Regulations).
  • Page 5 Driving The electronic control unit ensures comfortable use and lower costs. Precise control of driving speed. Jolt-free starting and smooth acceleration to maximum speed. Simply release or turn the drive direction switch to brake. Booster circuit prevents the truck rolling back when starting on a gradient. Hydraulics Gear pump driven by fully enclosed air-cooled motor.
  • Page 6 Conformity marking The manufacturer uses the conformity mark- ing to document the conformity of the industri- al 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 −...

  • Page 8: Table Of Contents

    Table of contents A Identification points and data plates ..................A1 B Operation ..........................B1 1.1 Utilization safety specification.....................B1 1.1.1 EN standards ........................B3 1.1.2 Conditions for application ....................B4 1.1.3 Stability ...........................B4 1.2 Display and manipulation ....................B5 1.2.1 Control handle .........................B5 1.2.2 Key switch ........................B6 1.2.3 Display instrument ......................B6 1.3 Truck use and operation .....................B8 1.3.1 Preparation for use ......................B8...

  • Page 9: A Identification Points And Data Plates

    Identification points and data plates 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 508000000121 508000000072 508000004075 508000001895 5080000000075 508000003809 508000000094 5080000004076 5080000001580 Item Description Item Description Hoisting Emergency stop switch label Notice “No standing under the load No riding label carriage”label Anti-pinch hand label Operation instructions label Anti-pinch foot label Charging light indicator label Capacity plate Data plate REV.
  • Page 11 The load capability chart The capacity plate gives the capacity (Q) of the truck in kg for a vertical mast. Q (kg) 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).

  • Page 12: B Operation

    Operation 1.1 Utilization safety specification • Average ambient temperature Don’t use the truck in Don’t use the truck in non- for continuous duty: ＋ 25℃ ; rainwater. position. • Maximum ambient temperature, short term (up to 1h): ＋ 40℃ ; •...
  • Page 13 Improper use Avoid the use of the truck by non- Don’t use the truck on slippery Don’t carry goods on working personnel. road surfaces. steep slope to prevent Don’t ride on the truck. (such as road surfaces with oil goods from sliding off. Don’t carry or lift people by the stain or residual snow or those truck.

  • Page 14: 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 15: 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 16: Display And Manipulation

    1.2 Display and manipulation 1.2.1 Control handle Lowering button Lower loading parts Lifting button Lift loading parts Drive switch Controls travel direction and speed Horn button Send out sound warning signals Through touching the button, truck drives Emergency reverse switch away from operator.

  • Page 17: Key Switch

    1.2.2 Key switch 1.Key switch 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. 1.2.3 Display instrument LED (1) displays the remaining electric of the battery;...
  • Page 18 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 19: Truck Use And Operation

    1.3 Truck use and operation 1.3.1 Preparation for use WARNING The following are inspection and preparation operations that must be implemented before the truck is put into daily use. Daily Check Items O.K.(√) Remark Check for Fluid Leakage Check operation switch, display equipment and component functions.

  • Page 20: Commissioning

    1.3.2 Commissioning 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 21: Truck Starting

    1.3.3 Truck starting 1. Release the emergency stop switch(1); 2.Turn the key switch (2) to start the truck; 3.Test the horn button(3); The truck is now operational. Put the tiller in the drive position(M,see 2.3.3)and use the drive switch to control direction and speed. REV.

  • Page 22: Running, Swerving And Braking

    1.3.4 Running, steering and braking 1.Running Running area Tilt the control shaft into the running area (M) and control the running direction and speed of the using the drive switch(1). (the lager the turning angle, the faster corresponding speed) NOTE When using the truck on a ramp or a uneven road, please lift the mast to prevent its bottom from colliding with the road surface.
  • Page 23 2.Steering Turn the control handle (1) left or right according to the desired direction. 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. CAUTION If the control handle moves slowly into the brake position, identify the cause and rectify...
  • Page 24 Emergency stop switch Press the emergency stop switch, and then all the electrically propelled functions will be interrupted. 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.

  • Page 25: Goods Picking

    1.3.5 Goods picking 1.Lifting Keep pressing the lifting button until reaching the required lifting height 2.Lowering Lower the truck to the bottom through pressing the lowering button. REV. 09/2022...
  • Page 26 Keep the 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. 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 stacker mast to the...

  • Page 27: Parking The Truck Securely

    1.3.6 Parking the truck securely Lower the mast to the bottom; Turn off the key switch（1）; REV. 09/2022...

  • Page 28: Drive Direction

    1.3.7 Drive direction The drive directions of the truck are forward (2) and reverse (1). 1.3.8 Loading 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.
  • Page 29 Carrying a load DANGER Personnel must not stand under or near the mast when the load is in the raised position. DANGER Never transport a load with the forks in the raised position as the equipment may become unstable. Always drive forwards for optimum visibility. When carrying a load on a slope, always climb and descend with the load up-hill.
  • Page 30 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 centimeter again. CAUTION Be careful not to touch nearby loads or those behind the equipment.
  • Page 31 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 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. Make sure that the ground is dry with a nonslip surface and that the route is clear.

  • Page 33: Operating The Truck Without Its Own Drive System

    1.3.10 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 34 NOTE The stacker should be loaded and unloaded by specially trained personnel. Effective measures must be taken based on the specific situation to ensure the correctness and safety of measurement and loading/unloading operations. REV. 09/2022...

  • Page 35: Hoisting

    1.3.12 Hoisting Remove the load before hoisting the stacker. 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 stacker is being lifted. Do not sling the truck by the control handle. REV.

  • Page 36: C Battery Use And Maintenance

    Battery use and maintenance 1.1 Handling the battery 1.1.1 Safety regulations for handling maintenance-free batteries These trucks are equipped with maintenance-free batteries. No distilled water can beadded to this battery type.The cell covers are fixed tight and must not be opened. Opening the covers will damage the battery.
  • Page 37 • Dangerous voltage! • No smoke and fire! • Avoid hot plugging! • Avoid the existence of • Notice: the metal part of open fire, fiery metal wire the storage battery cell is or sparks around the electrified, so don’t place any storage battery, otherwise external object or tool on the explosion or fire disaster...

  • Page 38: Battery Charging

    1.2 Battery charging 1.2.1 Precautions • Charging the batteries shall only be carried out in adequately ventilated rooms and e.g. not in the offices or break rooms; • Avoid the existence of any metal object in the surface of the battery; •...
  • Page 39 In case of malfunctions, the customer service or the manufacturer's customer service must be notified. The charger may only be used for the batteries supplied by EP. Swapping with other industrial trucks is not permitted. The battery must not be connected to two chargers at the same time.
  • Page 40 1.2.3 Battery type & dimensions & Charging time All the batteries are maintenance free. Battery types & dimensions are as follows: voltage/ Charging Charger Tuck type rated Dimension time capacity ESD122 2x12/85 260x165x210 REV. 09/2022...

  • Page 41: Battery Removal And Installation

    1.3 Battery removal and installation Removing and installing from the top Park the truck securely as described in paragraph 1.3.6 of chapter B and turn off the power before removal and installation of the battery. Battery removal and installation steps: a: Unscrew the three screws (1) and remove the cover(2).
  • Page 42 c: Remove the three battery cables shown in the image(5). Remove the battery(6). NOTE Pay attention to the operation of the battery to avoid short circuits. NOTE Route the battery cable so that it is not trapped when the battery is inserted. Installing the battery Installation is in the reverse order, pay attention on battery installation position and cable connection.

  • Page 43: 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 44: Maintenance Table

    1.1.4 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 the functions of hydraulic system 250-hour/60-Day maintenance After operating for 250 hours in total, the truck should also be maintained according to the following procedures in addition to the 50-hour maintenance mentioned above...
  • Page 45 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 the running, lifting and lowering speed, braking distance and other operation performances of the truck Inspect and add gearbox lubrication grease Inspect where there is any damage in the oil cylinders and whether...
  • Page 46 Hydraulic oil injection nozzle Gear oil injection nozzle Gear oil discharge nozzle REV. 09/2022...
  • Page 47 Lubricants Code Type Specification Amount Position Hydraulic Anti-wear hydraulic oil L-HM32 See Table 1 System Sliding surface Multi-purpose grease Polylub GA352P Appropriate amount (See Table 2) Grease (MoS 110 grams Gearbox Table 1 Application Amount of Hydraulic Oil Lifting height Amount Mast Series (mm)
  • Page 48 Table 2 Sliding Surface Lubrication Table Code Position Caster Steel channel and rollers Chains Steering Bearing Drive Wheel Contact surface REV. 09/2022...

  • Page 49: Maintenance Instructions

    1.2 Maintenance Instructions 1.2.1 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.

  • Page 50: Checking Fuses

    1.2.3 How to add grease 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. Install following the above steps in reverse order.

  • Page 51: Drive Wheel

    1.2.5 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 52: Load Wheels-Removal And Installation

    1.2.6 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. Place a wooden wedge under the chassis near load wheel, make the load wheel off the ground.

  • Page 53: Caster - Removal And Installation Removal

    Installation and Commissioning Install according to the reverse order of removal; Run the truck to see if the load wheel is functioning properly. If there is blocking or noise, please install again. CAUTION When installing, please apply appropriate amount of grease on the axle first. 1.2.7 Caster - Removal and Installation Removal...
  • Page 54 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 does –Battery cables not plugged –Check the battery cables and not start.

  • Page 55: 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 Model designation ESD122 Drive unit electrics Operator type pedestrian rated capacity 1200 Load center distance...
  • Page 56 Tyre size, driving mm Ø210×70 wheels(diameter×width) Tyre size, loading mm Ø100×50 wheels(diameter×width) Tyre size, caster mm Ø100×50 wheels(diameter×width) Wheels, number driving, caster/ mm 1x +1/4 loading (x=drive wheels) Track width, front,driving side mm 531 Track width,rear,loading side mm 1060 Dimensions Maximum lifting height h1+h13 H 2490...
  • Page 57 4.32 Ground clearance, center of wheelbase 4.34.1 Aisle width for pallets 800 × 2305 1200 lengthways 4.34.2 Turning radius 2233 4.35 Turning radius 1477 Performance data Travel speed, laden/ unladen km/h 4.2 /4.5 Lifting speed, laden/ unladen m/ s 0.10/0.14 Lowering speed, laden/ m/ s 0.10/0.10...
  • Page 58 Dimensions REV. 09/2022...

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