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EP Equipment EST124 Operation Manual

Electric pallet stacker
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Operation Manual
EST124
Electric pallet stacker
508000005668
Part No.
V1 02/2023

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Summary of Contents for EP Equipment EST124

  • Page 1 Operation Manual EST124 Electric pallet stacker 508000005668 Part No. V1 02/2023...
  • 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 Preface Thank you for buying our products. The manual will show you the way of correctly using the truck as well as relevant preventive maintenance and safety operation. The truck should be operated only by well-trained professionals and by no means by non-working personnel. Operators are supposed to read through the manual before actually operating the truck.

  • Page 4: Intended Use

    Series EST124 is operating handle-type electric pallet stackers with pedestrian.They are suitable for lifting and handling goods on level surfaces. In addition to picking up roller trolleys, this type of stacker can pick up pallets that are outside the range of the load wheels.
  • Page 5 (end stop brake). Battery EST124 comes with an 24V/10A integrated charger and a 24V/80Ah AGM battery, providing charging convenience and flexibility for daily usage. Mounting of attachments Any installation or retrofitting of any additional device that may influence or enhance the functions of the carrier must be approved by our company in writing before hand.

  • Page 6: Conformity Marking

    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 operation manual.
  • 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 ........................B2 1.1.2 Conditions for application ....................B3 1.1.3 Stability ...........................B3 1.2 Display and manipulation ....................B4 1.2.1 Tiller ..........................B4 1.2.2 Key switch ........................B5 1.2.3 Display instrument ......................B6 1.3 Truck use and operation .....................B8 1.3.1 Preparation for use ......................B8...
  • Page 9 Table of contents 1.3.7 Load Wheels-Removal and Installation ................. D8 1.3.8 Caster - Removal and Installation ................. D9 1.4 Troubleshooting ........................ D9 1.5 Final decommissioning, disposal ..................D9 E Technical data ........................E1 F Lithium-ion batteries ......................F1 1 Information on the conformity of lithium-ion batteries ............F2 2 It is necessary to respect the following guidelines..............F2 3 Intended use .........................F2 4 Reasonably foreseeable misuse ..................F2...
  • Page 10 Nameplates and alarming labels Plates and labels, such as nameplate, load curve plate, warning labels must be legible, if identification is unclear, and must be replaced. The figure below shows the approximate location of the various identity resides. Before operating the truck, please understand the meaning of the various identities REV.

  • Page 11: Item Description

    Item Description Read the“Instruction handbook”before operation label • Never permit anyone to walk or stand under upraised forks or attachments. • Do not allow anyone to stand on the forks. Emergency stop switch label Risk of serious injury or death due to entrapment. Never place your hands in between the inner and outer masts.

  • Page 12: B Operation

    Operation 1.1 Utilization safety specification Fig0000-00016OM • 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

    Improper use Fig0000-00181OM • Avoid the use of the truck by Don’t use the truck on slippery Don’t carry goods on non-working personnel. road surfaces. steep slope to prevent • Don’t ride on the truck. (such as road surfaces with oil goods from sliding off.

  • 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: • Operation only on secure, level surfaces with sufficient capacity. • Indoor use and outdoor use • The truck's maximum operation altitude is up to 2000m. • Used in specified area as factory, tourist attraction and recreation place. •...

  • Page 16: Display And Manipulation

    1.2 Display and manipulation 1.2.1 Truck overview Fig2103-00005OM Control handle Load wheels Cover Forks Driving wheel Controller Hydraulic unit Charger plug Caster Emergency stop switch Charger Mast Fork carriage Cylinder REV. 09/2022...

  • Page 17: Key Switch

    1.2.2 Control handle Fig0000-00069OM 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. 1.2.3 Key switch Connect and interrupt control current.

  • Page 18: Display Instrument

    1.2.4 Display instrument LED (1) displays the remaining electric of the battery; LCD (2) displays the total operation time of the truck; LCD (3) is a fault indicating light. DISPLAY DESCRIPTION Continuous red Normal Flashing Truck failure. Fig2108-00018OM Refer to relevant descriptions in “discharge indicator and hour meter”...

  • 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. •...
  • Page 21 1.3.4 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) and use the drive switch to control direction and speed.

  • Page 22: Running,Steering And Braking

    1.3.4 Running,Steering and braking Running 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 Forward travel/reverse travel Forward travel Use your thumb to press the drive switch, gently and gradually increasing the force in the (V) direction. The vehicle will accelerate and move forwards according to the pressure applied to the drive switch. Reverse drive Use your thumb to press the drive switch, gently and gradually increasing the force in the (R) direction.

  • Page 24: Emergency Stop Switch

    Emergency stop switch Press the emergency stop switch(1), 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 Fig2108-00024OM Keep pressing the lifting button until reaching the required lifting height 2.Lowering Fig2108-00025OM 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; CAUTION Park the truck on a level surface. In special cases the truck may need to be secured with wedges. WARNING Parking the truck on an incline, without the brakes applied or with a raised load Fig0000-00096-1OM or mast is dangerous and is strictly...

  • Page 28: Loading

    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. Fig0000-00127-1OM •...
  • Page 30 Stacking a load Carefully drive the machine to the required location. Raise the forks clearly above the level where the load is to be placed. Drive the truck backward into the racking. Lower the load until the fork arms are free. Move the forks straight back.

  • Page 31: 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 32: 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 33 Fig2103-00016OM 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 34: Hoisting

    1.3.12 Hoisting • Park the truck securely. • Secure the lifting slings to the strap point, and prevent them from slipping. Crane slings should be fastened in such a way that they do not come into contact with any attachments •...

  • Page 35: C Battery Use And Maintenance

    Battery use and maintenance 1.1 Safety and warning 1.1.1 Safety regulations for handling maintenance-free batteries The truck must be parked and rendered safe before any operations on batteries are under taken. 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.
  • Page 36 •Don’t trample on the storage Keep the battery away from battery to prevent it from fierce all fire sources, heat sources shaking or shacking! and flammable or explosive materials. Avoid the battery becoming Do not place the battery on top corroded by water or corrosive of conductive objects.

  • Page 37: Handling The Battery

    1.2 Handling the battery 1.2.1 Battery charging Precautions • The vehicle must be parked in a well ventilated place. • There must be no metal parts on the surface of the battery. • Before charging, check all cables and plug connections for visible damage.

  • Page 38: Charging Indicator

    Recharge the battery observing the instructions provided by the battery supplier and by the battery charger supplier. 1.2.2 Battery type & dimensions & Charging time Battery types & dimensions are as follows: Charging voltage/ rated Charger Tuck type Dimension capacity time 215*260*169 EST124 24/80 REV. 09/2022...

  • Page 39: Battery Removal And Installation

    1.3 Battery removal and installation Removing and installing from the top Park the truck securely as described in section1.3.6 of chapter B and turn off the power before removal and installation of the battery. Battery removal and installation steps: •Undo six screws(1) on the front cover with a wrench;...

  • 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: Restoring The Truck To Operation

    1.1.4 Restoring the truck to operation 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. Follow the daily checklist, see Chapter B section 1.3.2. 1.1.5 Tyres The quality of the tyres greatly affects the stability and the driving behaviour of the fork-lift truck.

  • Page 42: Maintenance Table

    1.1.9 Maintenance table 50-hour/7-Day maintenance Check the functions of the operation switches and display Check alarm system functions Check the brake system functions Check steering system functions Check the drive wheel and load wheel for worn or damage 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 following procedures in addition to the 50-hour maintenance mentioned above...
  • Page 43 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 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 44: Lubrication Points

    Lubrication Points Hydraulic oil injection nozzle Gear oil injection nozzle Contact surface Mast chain REV. 09/2022...
  • Page 45 Lubricants Code Type Specification Amount Position Anti-wear hydraulic oil L-HM32 See Table 1 (See Table 1) Low temperature anti-wear L-HV32 hydraulic oil (cold storage) Contact surface Multi-purpose grease Polylub GA352P Appropriate amount (See Table 2) Grease (MoS 100 grams Gearbox Chain spray or Engine oil / Chains Appropriate amount...

  • Page 46: Maintenance Instructions

    1.3 Maintenance Instructions 1.3.1 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 B Section 1.3.6). •...

  • Page 47: Checking The Hydraulic Oil Level

    1.3.3 Checking the grease oil • Prepare the truck for maintenance and repairs (See Maintenance Instructions ). • Park the truck securely • 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 48: Checking Fuses

    1.3.5 Checking fuses • Prepare the truck for maintenance and repairs (see section 1.3.1 ). • Remove the cover (see Chapter D section1.3.2). • Check that all fuses are in working order. • If necessary, replace them with fuses that match the parameters specified in the table below.
  • Page 49 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...
  • Page 50 Remove the coiled elastic cylindrical pin(1) within the wheel bridge with an ejector pin of 4mm in diameter; Turn the wheel bridge to vertical direction, knock out the wheel pin shaft(3) from side, and remove the load wheel and bearing assembly; Remove the bearing(5) of load wheel(4) with hammer and jacking equipment.

  • Page 51: Installation

    1.3.8 Caster - Removal and Installation Removal Remove the cover (see Chapter D section1.3.2). Lift the truck carefully with lifting equipment through the lifting holes at front and back. Unscrew four screws(1), then remove the caster(3) and dust shim(if necessary). Installation Install according to the reverse order of removal.
  • Page 52 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 53: 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 EST124 Drive unit Electrics Operator type Pedestrian rated capacity 1200 Load center distance...
  • Page 54 3.2.1 Tyre size, driving mm Ø210×70 wheels(diameter×width) 3.3.1 Tyre size, loading mm Ø74×72 wheels(diameter×width) Tyre size, caster mm Ø130×55 wheels(diameter×width) Wheels, number driving, mm 1x ,1/2 caster/loading (x=drive wheels) 3.6.1 Track width, front,driving mm 645 side 3.7.1 Track width,rear,loading mm 418 side Dimensions MAX.Lift Height...
  • Page 55 Performance data Travel speed, laden/ unladen km/ h km/h 4.0/4.5 Lifting speed, laden/ unladen m/ s 0.10/0.15 Lowering speed, laden/ m/ s 0.12/0.10 unladen Max. gradeability, laden/ 3/10 unladen 5.10 Service brake type Electromagnetic Electric-engine Drive motor rating S2 60 min hp 0.75 Lift motor rating at S3 15% Battery voltage/nominal...
  • Page 56 Dimensions REV. 09/2022...

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