Operation Manual

EPL1531

Original Instruction Part No. 508000003738

V1 07/2020
 Foreword

The present operation manual are designed to provide sufficient instruction for the safe operation
of the industrial truck. The information is provided clearly and concisely.
Our trucks are subject to ongoing development. EP reserves the right to alter the design,
equipment and technical features of the system. No guarantee of particular features of the truck
should therefore be assumed from the present operation manual.

Safety notices and text markups

Safety instructions and important explanations are indicated by the following graphics:
Please strictly adhere to these safety instructions to avoid personal injury or major damage to
equipment.

Please pay attention to the important safety instructions.

i Pay attention to Instructions.

EP EQUIPMENT CO., LTD

Address: XIAQUAN, DIPU, ANJI, ZHEJIANG, CHINA
Tel: + 86-571-28023920
Website: www.ep-ep.com
Email: [email protected]

ALL RIGHTS RESERVED

2020.7 15st EDITION
 Legal requirements for marketing

Declaration
EP EQUIPMENT CO., LTD
Address: XIAQUAN, DIPU, ANJI, ZHEJIANG, CHINA

We declare that the

Industrial truck: according to these operation manual

Type: according to these operation manual

complies with the most recent version of Machinery Directive 2006/42/EC.

Personnel authorised to compile the technical documents:

See EC/EU Declaration of Conformity

EP EQUIPMENT CO., LTD

EC/EU Declaration of Conformity

The manufacturer declares that this industrial truck complies with the EC Machinery Directive
and the provisions of other applicable EC/EU directives effective at the time of sale. This can be
verified by means of the EC/EU Declaration of Conformity and the relevant certification label on the
nameplate.

The industrial truck is supplied with the EC/EU Declaration of Conformity document. This
declaration proves that this truck complies with the requirements of the EC Machinery Directive.
Unauthorised modification or additional installation of equipment to the structure of the industrial
truck may affect its safety, and will therefore invalidate the EC/EU Declaration of Conformity.

The EC/EU Declaration of Conformity must be carefully conserved and kept ready to be presented
to the relevant authorities. If this industrial truck is sold, this declaration document must be handed
over to the new owner.
 Table of contents
Pg.
A Application.............................................................................................................................A1
B Truck Description..................................................................................................................B1
1.1 Application...........................................................................................................................B1
1.2 Truck assemblies.................................................................................................................B2
1.2.1 Control handle..................................................................................................................B3
1.2.2 Key switch........................................................................................................................B4
1.2.3 Charging indicator............................................................................................................B4
1.2.4 Emergency reverse button...............................................................................................B5
1.3 Identification points and data plates....................................................................................B6
1.3.1Truck data plate.................................................................................................................B7
1.4 Standard version specifications...........................................................................................B8
1.4.1Performance data for standard trucks...............................................................................B8
1.4.2 Dimensions.......................................................................................................................B9

C Safety....................................................................................................................................C1
1.1 Before operation..................................................................................................................C1
1.2 Operating position...............................................................................................................C1
1.3 Travel...................................................................................................................................C2
1.4 Battery safety......................................................................................................................C3
1.5 EMC-Electromagnetic compatibility . ..................................................................................C4

D Transport And Commissioning..............................................................................................D1

1.1Truck transport.....................................................................................................................D1
1.2 Operating the truck without its own drive system................................................................D1
1.3 Using the truck for the first time...........................................................................................D2
1.4 Break-in period precautions................................................................................................D2

E Operation..............................................................................................................................E1
1.1 Safety regulations for the operation of pallet trucks............................................................E1
1.2 Operate and run the truck...................................................................................................E1
1.2.1 Turning the truck on and off . ...........................................................................................E1
1.2.2 Driving, steering, braking..................................................................................................E2
1.2.3 Loading.............................................................................................................................E3
1.3 Raising and lowering the forks............................................................................................E5
1.4 Parking the truck securely...................................................................................................E5
1.5 Using the truck on a slope...................................................................................................E6
1.5.1 Starting on a slope...........................................................................................................E6
1.6 Hoisting the truck(See 1.3 dentification points and data plates).........................................E7
1.7 Operator daily checklist.......................................................................................................E8

F Battery Maintenance & Charging..........................................................................................F1

1.1 Safety regulations for handling acid batteries.....................................................................F1
1.2 Battery type & dimension....................................................................................................F1
1.3 Charging the battery............................................................................................................F1
1.4 Battery removal and installation..........................................................................................F2
1.5 Daily maintenance...............................................................................................................F3
1.6 Storage................................................................................................................................F3
1.7 Transportation.....................................................................................................................F4
 Pg.
G Pallet Truck Maintenance.....................................................................................................G1
1.1 Operational safety and environmental protection................................................................G1
1.2 Maintenance safety regulations...........................................................................................G1
1.3 Servicing and inspection.....................................................................................................G2
1.3.1Maintenance checklist.......................................................................................................G3
1.3.2 Lubrication points.............................................................................................................G4
1.4 Maintenance Instructions....................................................................................................G6
1.4.1Prepare the truck for maintenance and repairs.................................................................G6
1.4.2 Remove the cover............................................................................................................G6
1.4.3 How to add oil...................................................................................................................G7
1.4.4 How to add grease...........................................................................................................G7
1.4.5 Checking the fuses...........................................................................................................G7
1.4.6 Recommissioning.............................................................................................................G8
1.5 Decommissioning the industrial truck..................................................................................G8
1.5.1 Prior to decommissioning.................................................................................................G8
1.5.2 Restoring the truck to operation after decommissioning..................................................G8
1.6 Safety checks to be performed at regular intervals and following any unusual incidents. G9
1.7 Final decommissioning, disposal.........................................................................................G9
1.8 Tire replacement..................................................................................................................G9

H Troubleshooting....................................................................................................................H1
 A Application
The truck described in these operation manual is designed for transporting loads. It must be used,
operated and maintained according to the information presented in this operation manual. Any
other uses exceed the design scope and can lead to injury to persons or damage to equipment
and property. Above all, overloading caused by excessively heavy or unbalanced loads must be
avoided. The max. permissible load to be picked up is indicated on the nameplate or load curve
label shown on the truck. The truck must not be operated in spaces subject to fire or explosion
hazards, or in spaces where corrosive or very dusty atmospheres prevail.

Duties of the user: A “user” within the meaning of these operation manual is defined as any
natural or legal person who either uses the truck himself, or on whose behalf it is used. In special
cases (e.g. leasing or renting), the user is considered the person, who, in accordance with
existing contractual agreements between the owner and the user of the truck, is charged with the
observance of the operating duties.
The user must ensure that the truck is not abused and only used within its design scope and that
all danger to the operator, or third parties, is avoided. In addition to this, it must be ensured that
the relevant accident prevention regulations and other safety related provisions, as well as the
operating, servicing and maintenance guidelines, are observed. The user must also ensure that
all persons operating the truck have read and understood this operation manual.

If this operation manual is not observed, the warranty becomes void. The same applies if
improper works are carried out on the device by the customers and/or third parties without
permission of our customer service.

Adding attachments: Adding or fitting any attachments which will interfere with, or supplement,
the functions of the truck is permitted only after written approval by the manufacturer has been
obtained. If necessary, the approval of local authorities has to be obtained. Any approval obtained
from local authorities does not, however, make the approval by the manufacturer unnecessary.

Modification: If you want to use the truck for purposes that are not mentioned in the user manual,
please contact dealers accredited by EP. Any modification to your truck, in particular fitting of
equipment or conversion to the truck, is prohibited without the permission of the manufacturer.

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 Intended use
The truck is designed for transporting and stacking the loads indicated in the load capacity
diagram. Especially:
• In accordance with the safety rules of your industry association
• Other local regulations

In all cases, the people in charge, particularly operators and service personnel, must comply with
the specific approved rules for the use of industrial trucks.
The user, and not the manufacturer EP, is liable for any hazards caused by any application not
authorised by the truck manufacturer.
Please contact your authorised dealer if you want to use the truck for an application that is not
specified in this manual.
The truck must not be altered, especially by making modifications or installing attachments,
without the manufacturer's approval.

Improper use
The operating company or driver, and not the manufacturer, is liable if the truck is used in a
manner that is not permitted.One of the main causes of accidents is the driver ignoring or being
unaware of the basic safe operating practices of the truck.

The following basic safe operating practices must be observed to ensure the safety of operators
and others.Never operate the truck in environments with s potentially explosive atmosphere.

• Never carry passengers.

• Do not overload the truck. (by exceeding the rated load indicated on the load designation plate)
• Overloading can affect braking distances, truck stability and the strength of the lift mast.
• Do not pick up an off-centre load.
• Do not stack loads or turn when driving on a ramp.
• Do not operate the truck on loose or greasy surfaces.
• Do not drive on uneven or obstructed surfaces. Never park the truck in a place that may obstruct
fire extinguishers, fire escapes or aisles.
• Do not dismount from the truck while it is moving.
• Do not leave the truck unattended when the load is raised.
• Never leave the vehicle unattended on a ramp. When driving, do not place any part of your body
outside the confines of the truck, lean on the edge of the truck or attempt to jump onto another
truck or object.
• Do not use the forks or any other part of the truck to push, pull or support items, unless the design
permits this.

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 B Truck Description
1.1 Application
The truck is intended for transporting goods on a level floor. It can pick up pallets that are open
to the ground or trolleys.

Permissible application temperature range of truck -10°C to 40°C. Lithium-ion battery operation
application 0°C to 40°C.

i NOTE
The truck may only be operated in cold stores temporarily. If the truck remains too long in a
cold store,we recommend coid store equipment for the truck.

Only use the truck at altitudes not exceeding 2000 meters.

The walking, lifting and lowering devices, harnesses and components are IP55 dust and water-
resistant.
Trucks can only be operated in adequately illuminated working areas to avoid injuries. In case
of insufficient light, an additional lighting equipment is needed to ensure that the driver can see
properly.
If you must travel on an incline, the gradients should be below A% at full load, or below B%
without a load.(For the value of A and B, refer to the Gradability in Performance Data Sheet)

There should be no risks of fire, explosion or corrosion in the working area, or too much dust.

Forks can only be operated in adequately illuminated working areas to avoid injuries or injuries.
In case of insufficient light, an additional equipment is needed to run the fork lift truck.

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1.2 Truck assemblies

1 Control handle 6 Forks

2 Control lever 7 Emergency stop switch
3 Lift cylinder 8 Lowering lever
4 Driving wheel 9 Load wheels
5 Battery Box

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1.2.1 Control handle

Fig1113-00006OM Fig1113-00006OM

Item Control / Display Function

1 "Horn" button Activates the horn.

Press the lift button and hold. The forks will be lifted
2 "Lifting" button
to its maximum height and stop on its own.

Pull the lowering lever and hold. The forks will be

3 Lowering lever
lowered to its minimum height and stop on its own.

Emergency reverse By pressing this switch, the vehicle starts to travel in

4
switch the opposite direction.

5 Drive switch Select the required driving direction and speed.

Keep the handle in the vertical state, and press creep

6 Creep speed switch speed switch and drive switch at the same time, then
the vehicle will move at a low speed.

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1.2.2 Key switch

Connect and interrupt the control

current. Key switch

• When pulling out the key switch, the

control current of the truck will be
interrupted;
• When inserting the key switch, the
control current of the truck will be
connected.

Pulling out the key switch of a truck

before leaving can prevent the truck
from starting accidentally.

1.2.3 Charging indicator

The LED (1) remain green light lit under
normal, flashing show the failure state of truck.
(See section H Controller Error Message)

The LED display (2) show battery residual

capacity.
The color of the LED (2) represent the
following conditions:

Residual
Component LED color capacity
Green 30-100%
Continuous 15-30%
yellow
2
Quick
Standard
flashing red
battery 7-15%
light(Flashing
residual
period 2s)
capacity
Slow flashing
red light
0-7%
(Flashing
period 1s)

If the controller detects a battery failure,

flashes of LED（2）represent battery failure
information until the failure is remedied.
Details of failure information are shown as
below:

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• Under-voltage of single cell battery: The green light repeats in a cycle of flashing once in 1
second, pausing for 2 seconds and then flashing twice, pausing for 3 seconds.
• Over-voltage of single cell battery: The green light repeats in a cycle of flashing once in 1
second, pausing for 2 seconds and then flashing three times, pausing for 3 seconds.
• Short circuit protection: The green light repeats in a cycle of flashing once in 1 second, pausing
for 2 seconds and then flashing four times, pausing for 3 seconds.
• Over-current protection: The green light repeats in a cycle of flashing once in 1 second, pausing
for 2 seconds and then flashing five times, pausing for 3 seconds.
• Battery temperature is too high: The green light repeats in a cycle of flashing twice in 1 second,
pausing for 2 seconds and then flashing three times, pausing for 3 seconds.
• Battery temperature is too low: The green light repeats in a cycle of flashing twice in 1 second,
pausing for 2 seconds and then flashing four times, pausing for 3 seconds.
• Contactor-related failures: The green light repeats in a cycle of flashing three times in 1 second,
pausing for 2 seconds and then flashing four times, pausing for 3 seconds.
• The yellow light flashes rapidly in 1 second when other failures happen.

When powered off, if the green light of power indicator is always on, it means that
the battery is in a balanced state, which is a normal phenomenon.

1.2.4 Emergency reverse switch

To protect the operator from becoming pinned against an obstacle by the control handle,
an emergency reverse switch is provided at the end of the control handle. If this switch is
pressed during operation, the truck will move off in reverse. The mechanical brake will then
engage to stop the truck. The travel control must then be returned to neutral before the truck
can again be operated.

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1.3 Identification points and data plates

Item Description Item Description

1 Hydraulic oil label 8 Anti pinch hand label
2 Charging trouble light label 9 Function label
5 Nameplate 10 Lithium-ion label
6 “Instructions” label 11 Type label
7 No riding label

Right Front

4
2
5

Top 9

Left

10

11

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1.3.1 Truck data plate
For queries regarding the truck or ordering spare parts please quote the truck serial
number.
Item Description Item Description
1 MODEL TYPE 7 RATED DRIVE POWER
2 SERIAL NO. 8 BATTERY VOLTAGE
3 MANUFACTURE DATE 9 MAX BATTERY WEIGHT
4 RATED CAPACITY 10 MIN BATTERY WEIGHT
UNLADEN MASS WITHOUT
5 LOAD CENTER 11
BATTERY
6 LIFT HEIGHT 12 UNLADEN MASS WITH BATTERY

1
2
3
4
5
6
7
8
9
10

11
12

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 1.4 Standard version specifications
Technical specification details in accordance with VDI 2198. Technical modifications and
additions reserved.

1.4.1 Performance data for standard trucks

Distinguishing mark
1.1 Manufacturer EP
1.2 Model EPL1531
designation
1.3 Drive unit Battery
1.4 Operator type Pedestrian

1.5 rated capacity Q lb. kg 1500

1.6 Load center c in. mm 600

distance

1.8 Load distance x in. mm 950(880)

1.9 Wheelbase y in. mm 1190/1120

Weight
2.1 Service weight lb. kg 120
(include battery)
2.2 Axle loading, lb. kg 480/1140
laden driving side/
loading side
2.3 Axle loading, lb. kg 90/30
unladen driving
side/loading side
Types,Chassis
3.1 "Tyre type driving PU/PU
wheels/loading
wheels"

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3.2 Tyre size, driving in. mm Ф210x70
wheels(diameter×width)

3.3 Tyre size, loading in. mm Ф80x60

wheels(diameter×width) (Ф74x88)

3.5 Wheels, number driving, in. mm 1x, 4(1x, 2)

caster/loading (x=drive
wheels)
3.6 Track width, front,driving b10 in. mm /
side

3.7 Track width,rear,loading b11 in. mm 410 (535)

side
Dimensions
4.4 Lift height h3 in. mm 115
4.9 Height drawbar in driving h14 in. mm 750/1190
position min./max.
4.15 Lowered height h13 in. mm 80
4.19 Overall length l1 in. mm 1540
4.20 Length to face of forks l2 in. mm 400
4.21 Overall width b1/ b2 in. mm 685
4.22 Fork dimensions s/ e/ l in. mm 50x150x1150
4.25 Distance between fork- b5 in. mm 560(685)
arms
4.32 Ground clearance, center m2 in. mm 30
of wheelbase
4.34.1 Aisle width for pallets 1000 Ast in. mm 2145
× 1200 crossways
4.34.2 Aisle width for pallets 800 Ast in. mm 2050
× 1200 lengthways
4.35 Turning radius Wa in. mm 1330
Performance data
5.1 Travel speed, laden/ km/ h mph km/h 4.5/5
unladen
5.2 Lifting speed, laden/ fpm m/ s 0.017/0.020
unladen

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5.3 Lowering speed, laden/ fpm m/ s 0.09/0.06
unladen

5.8 Max. gradeability, laden/ % 6\16

unladen
5.10 Service brake type Electromagnetic
Electric-engine
6.1 Drive motor rating S2 60 hp kW 0.75
min
6.2 Lift motor rating at S3 15% hp kW 0.7
6.3 The maximum allowed size in. mm 200x100x300
battery
6.4 Battery voltage/nominal V/ Ah 24V/20
capacity K5

6.5 Battery weight lb. kg 7

Addition data
8.1 Type of drive control DC
10.5 Steering type mechanical
10.7 Sound pressure level at dB (A) <74
the driver’s ear

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1.4.2 Dimensions

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 C Safety
1.1 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. Ensure that there are no loose objects on the truck or in the operator
compartment, especially on the floor plate where they could interfere with pedal operation (if
equipped) or foot room. Fire extinguishers and other emergency equipment should be visible
and easy to reach.
Wear safety equipment when required. Don’t smoke in “No Smoking” areas, or while charging
batteries or refueling combustion engine trucks. Never operate the truck with greasy hands.
This will make the controls slippery and result in loss of truck control. Any questions or
concerns about safety should be brought to the attention of a supervisor. If an accident should
occur, it must be reported immediately.

WARNING
Unauthorized modifications to the truck can result in injury or death.
Do not remove, disable or modify any safeguards or other safety devices. These include
any alarms, lights, mirrors, overhead guards, and load backrest extensions. If present, an
overhead guard is intended to provide protection to the operator from falling objects, but
cannot protect from every possible impact.

1.2 Operating position

The truck may be operated in either direction while walking. When operating in reverse(forks
leading), always keep both hands on the control handle. When operating forwards(forks trail-
ing) keep one hand on the controls and, if possible, walk ahead and to the side of the truck.
During operation, always grasp the handle at the travel control. Keep fingers within the protec
ted area of the handle at all times. Operators must not ride the truck unless it is designed for
riding.

WARNING
Injury to hands can occur if the handle is grasped incorrectly. Keep hands and fingers within
the protected area of the handle. Injury can occur if the truck contacts any part of the body.
Remain clear of the truck frame at all times.

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

WARNING
Loss of control!
Do not travel at excessive speeds; keep your truck under control at all times.
Always watch for pedestrians. When travelling in reverse (load end leading) be careful of
drive end swing. The drive end of the truck will swing out if a turn is made while travelling in
reverse. Always use caution when turning into an aisle. The load wheels can cut the corner
sooner than expected.

Unstable loads are hazardous. Ensure all loads are secure and evenly positioned across
both forks. Never lift a load with only one fork. Never carry anything on any part of the truck
except the forks unless a specific area has been provided by the manufacturer.During travel,
always watch for over head obstructions such as lights, wiring, pipes, sprinkler systems,
doorways, etc. Never overtake another truck at an intersection, blind spot or other dangerous
location. Use the horn at intersections and any location where visibility is limited.
Inclines, Ramps, Docks, Elevators If you must travel on an incline, do so with caution. Do not
operate truck on a wet incline.
Keep the forks upgrade to maintain control when travelling up or down an incline with a
loaded truck.Keep the forks downgrade when travelling up or down an incline with an empty
truck.

R
DANGER
Tip-over will occur if you turn while travelling on a ramp or travel at an angle other than
straight up or straight down a ramp.
Never turn on an incline or ramp either loaded or unloaded. Travel straight up or straight
down.

Be aware that when descending an incline your stopping distance will be greater than when
on a level surface. Reduce your speed, and ensure that there is adequate clear space at the
bottom of the ramp to stop and turn.

To avoid hazards associated with a dock, you should personally check that the trailer brakes
have been applied, wheel chocks are in place, and that any trailer-to-dock locking systems
are being utilized. The impact of moving in and out of a trailer may cause the trailer to creep
or move. Confirm that the driver will not move the trailer until you are done.

Do not drive the truck onto an elevator without specific authorization. Verify that the capacity
of the elevator exceeds the weight of the truck and the weight of the load. Approach elevators
slowly and ensure that the elevator car is level with the floor before entering. Enter elevators
squarely with the load end leading. Ensure that no part of the truck or load contacts any part
of the elevator other than the floor. Once on the elevator, neutralize the truck controls, shut
off the power, and set the brakes. Any other personnel should leave the elevator before the
truck is allowed to enter or leave.

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 Be especially cautious when driving the truck on ramps or bridge plates. Be sure to maintain
a safe distance from each edge. Before driving the truck over a ramp or bridge plate, verify
that its position is secured to prevent movement. Never exceed the rated capacity of a ramp
or bridge plate.

1.4 Battery safety

WARNING
Batteries contain dissolved sulfuric acid, 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 acid. If clothing, skin or eyes come into contact with battery acid,
immediately flush the affected areas with water. If acid contacts the eyes, seek medical
attention at once. Clean spilled battery acid immediately with large amounts of water.
• Remove any metal rings, bracelets, bands, or other jewelry before working with or near
batteries or electrical components.
• Never expose batteries to open flame or sparks.
• Areas in which batteries are stored or charged must be well ventilated to prevent
concentration of explosive gases.
• If a battery is charged while installed in the truck, the battery cover must remain completely
open during the entire charging period.
• Shorting of battery terminals can cause burns, electrical shock, or explosion. Do not allow
metal parts to contact the top surface of the battery. Make sure all terminal caps are in place
and in good condition.
• Batteries may only be charged, serviced, or changed by properly trained personnel.
Always follow all instructions provided by the manufacturers of the battery, charger, and the
truck.

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

CAUTION
The EMC regulations for the truck must be observed.
When replacing truck components the protective EMC components must be installed and
connected again.

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 D Transport and Commissioning
1.1 Truck transport
Place the truck on a wooden pallet.

NOTE
i Only use haulage equipment with sufficient
load capacity.
The load weight is greater than the net
weight of the truck (including battery
•
weight).
The load weight does not just include the
net weight of the truck, it also includes the
•
wooden pallet.
The pallet or wooden box should be large
and strong enough to withstand the weight
•
of the truck.
Pay attention to the fork blades when lifting.

The truck onto the pallet, to prevent injuries

caused by the fork blades trailing on the
ground.
Follow the prescribed steps and park the
vehicle correctly.
Make sure the forks are aligned with
the pallet, move slowly and stop after
insertingthe forks as far into the pallet as
possible.

CAUTION
Operate on open, level ground and pay
attention to ground conditions when lifting
and lowering the palletto prevent the truck
from tipping.
When transporting the truck, make sure
it is fully secured and take precautionary
measures against bad weather.

1.2 Operating the truck without its own

drive system
This operating mode is not permitted when
negotiating
inclines and gradients.
If the truck has to be moved after a failure
has rendered it immobile, proceed as Fig1113-00019OM

follows:
• Set the emergency stop switch “OFF”.
• Set the key switch “OFF” and remove the
key.

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 • Prevent the truck from rolling away.
• Remove the cover(see section 1.4.2 Remove the
cover -G).
• Screw in two screws(2), M4 *35mm)until the truck
can be moved (no braking action).
• After setting down the truck at the destination, unscrew two screws(2).
• Braking action is restored!

1.3 Using the truck for the first time

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.
• Charge the battery.
• Put the truck into operation in the stipulated manner.
When the truck is parked, the surface of the tyres may flatten. The flattening will disappear
after the truck has been operated for a short time.
• Check for fluid leakage.
• Check forks and chassis.
• Check battery connector.
• Check decal condition.
• Check control handle pivot.
• Check operating controls.

1.4 Break-in period precautions

Fasten wheel screws again at 50 hours of operation.
Within the first 100 hours in particular, the following requirements should also be met:
• Excessive discharge of a new battery during initial use must be prevented.It should
generally be charged promptly when at 20%.
• The specified preventive maintenance must be done thoroughly.
• Avoid sudden braking, driving quickly or sharp turns.
• Change oil or lubricant promptly according to the instructions.
• Limit the load weight to 70-80% of the rated load.

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 E Operation

1.1 Safety regulations for the operation of pallet trucks

Driving permission: The fork lift truck must only be operated by persons who have been
trained in the operation of trucks, who have demonstrated to the user or his representative
their capability of moving and handling loads, and who have expressly been charged by the
user or his representative with the operation of the truck.
Rights, duties and conduct of the driver: The driver must be: informed of his rights
and duties; trained in the operation of the fork lift truck; and familiar with the contents of
these operation manual. All necessary rights must be granted to him. If the fork lift truck can
be used in the pedestrian-controlled mode, the driver must wear safety boots when operating
the truck.
Prohibition of unauthorized use: The driver is responsible for the fork lift truck during
working time. He must forbid unauthorized persons to drive or operate the fork lift truck. The
transport or lifting of persons is forbidden.
Repairs: Without specific training and express authorization, the driver is not allowed to
perform any repairs or modifications on the fork lift truck. Under no circumstances must the
driver change the setting of switches or safety installations or render them ineffective.
Danger area: A “danger area” is considered to be the area within which persons are
endangered by the travelling or lifting movements of the fork lift truck or its load lifting devices
(e.g. fork or attachments), or by the loads being transported. This also includes the area
within reach of falling loads or falling / lowering truck attachments.
Unauthorized persons must be asked to leave the danger area. The driver must give a
warning signal whenever a situation presenting danger to persons might develop. The fork lift
truck must immediately be brought to a standstill if persons, although asked, do not leave the
danger area.
Safety devices and warning labels: The safety devices, warning labels and warning
notes described in the present operation manual must always be heeded.

1.2 Operate and run the truck

1.2.1 Turning the truck on and off
Switching the truck on
• Insert the key (3) into the key hole and switch on
the power supply;
• Make sure the emergency stop button (2) is not
pressed;
• Tilt the control handle to the drive positio M;
• Rotate the drive switch (1) to drive the truck forward or
backward.

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 The truck is equipped with a static-return-to-neutral function. If the control handle is held in
its working range (M) when the truck is turned on, the travel function will not operate. The
control handle must then be returned to either end position and then moved back into its
working range to enable travel.

Switching the truck off

To turn the truck off, remove the key from its slot. V
Press the emergency stop switch. R
B
M
1.2.2 Driving, steering, braking
Driving B
Operators must be familiar with all safety procedures R V
that apply to truck operation before driving.
Read and understand all safety information in
Section C before operating the truck.

Tilt the control shaft into the driving range (M) and
set the controller to the desired direction (V or R).

Steering
Steering the truck is done using the control handle. Manually moving it to the left or right will
swivel the drive wheel. The truck then turns in forward or reverse according to the handle
direction.

Emergency stop
Push the emergency stop switch. All of the electrical functions are switched off.

Braking
The braking behaviour of the truck strongly depends on the state of the floor. This must be
taken into account by the driver for his driving behaviour.
The truck can be braked in three ways:
• by using the generator brake (controller)
• by counter-current braking (controller)
• by using the service brake (control shaft)

Braking using the generator brake:

• Release the drive switch.

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 Counter-current braking:
• While driving, switch the controller to the opposite direction.
• The truck is decelerated by counter-current braking until it starts moving in the opposite
direction. In case of emergency, the service brake must be used to brake the truck.

Braking using the service brake:

• Tilt the control shaft upwards or downwards into one of the braking ranges (B).

WARNING
If the control handle moves slowly or not at all to the upper brake zone, the truck must be
taken out of service until the cause of this fault is be rectified.
Replace the gas pressure spring if necessary.

WARNING
In hazardous situations set the control handle to the brake position or set the travel switch to
the opposite direction.

WARNING
If the travel switch moves slowly or not at all to 0, the truck must be taken out of service until
the cause of this fault is be rectified.

WARNING
When driving on a hill or uneven roads, please lift fork to stop the bottom of fork and the
ground being rubbed.

1.2.3Loading

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

Ensure that the load is stable and uniform to prevent

any partial spillage.
Check that the width of the load is compatible with the
width of the forks.

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 Take care not to disturb any adjacent loads, or those which may be to the side or in front of
the load being handled. Loads should be laid out as follows:
Line up loads with a small space between each one and its neighbour to avoid any fouling.

CAUTION
Only transport loads that have been positioned and secured in accordance with regulations.
Take appropriate protective measures if the load is at risk of tipping over or falling during
transport.
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. Raise the load a few centimeters above
its support. Back the truck away from the stack or any neighbouring loads, gently and in a
straight line. Transporting loads Always carry loads in the forward direction of travel (R) in
order to have the best visibility.

When carrying a load on a slope, always ascend or descend with the load uphill. Never drive
sideways across a slope or perform a U-turn. Reverse travel (V) is to be used solely for
unloading. Since visibility is reduced when travelling in this direction, drive only at very slow
speed.

V R

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 Unloading
Carefully drive the truck to the desired
location. Carefully drive the truck to the
unloading area.
Lower the load until the fork arms are free
from the pallet. Back the truck away in a
straight line. Raise the forks to mid-height.

CAUTION
Take care not to disturb any adjacent loads,
or those which may be to the side or in front
of the load being handled.

Fig1113-00012OM
1.3 Raising and lowering the forks
Lifting
Press “Lift” button(2) until the height you
need.

Lowering
Set fork to the lowest position by pulling
lowering lever (1) upward.

WARNING
Before lifting a load unit the driver must
make sure
that it has been correctly stowed and does
not exceed
the truck’s capacity.
Make sure long loads are stable supported
by the forks.

1.4 Parking the truck securely

• Lowering the forks.
• Press emergency stop switch.
• Remove the key.
• It is forbidden to park on the slope for a long
time.

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 1.5 Using the truck on a slope

i 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
non-slip surface and that the route is
clear.

Ascending slopes
Always ascend slopes travelling in the
reverse direction, with the load facing
uphill.
Without a load, it is recommend to
ascend slopes forwards.

Descending slopes
Travel down slopes must always be
forwards, with the load uphill.
Without a load, it is recommended to
descend slopes forwards.
In all cases, travel at a very low speed
and brake very gradually.
DANGER
Risk to life and/or risk of major
equipment damage. Never park the
truck on a slope. Never make a U-turn
or take shortcuts on a slope. On a
slope, the operator must drive very
slowly.
1.5.1 Starting on a slope
If you have to stop and then start on slope, proceed as follows:
• Stop on the slope by pressing the accelerator in the opposite direction until the machine
comes to a standstill.
• Return the accelerator to the neutral position, then release the accelerator control button to
apply the parking brake.
To restart, press the accelerator button for the desired direction.
• The truck will move.

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1.6 Hoisting the truck
This section explains the attachment of lifting equipment to the truck for the purpose of
hoisting. Many methods of rigging to a crane or hoist are possible. Explanation of such
methods as well as operation of lifting equipment is outside the scope of this manual. Both
the attachment of lifting equipment to the truck and the hoisting operation itself must be
performed by personnel experienced in hoisting.

WARNING
Lifting equipment of insufficient capacity can fail and cause severe injury or death.
Ensure that all lifting slings, hardware, or other equipment has sufficient capacity to carry the
weight of the truck. Refer to the truck data plate for truck weight. If a battery is installed, its
weight must be added to the truck weight listed on the data plate. Switch the truck off and
press the emergency stop button. Attach lifting equipment to the holes in each side of the
chassis. Attach lifting equipment to the fork tips to keep the truck approximately horizontal as
it is lifted.

1.7 Handle and handle lever installation

Bend Wire Steel Wire(1)

Control Handle

Hand-operated
valve

Bracket
Controller Wire

Screw

Steel Wire (2)

Fig1113-00021OM

i NOTE
Plug the connector of bend wire into controller wire.

• First, touching hand-operated valve.

• The steel wire(2) rising up Buckle end of the steel wire (1) into end of the steel wire (2)
from manual.
• Release the steel wire (2) and tighten the adjust screw.

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1.7 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. In addition to daily inspection, scheduled maintenance
is vital to safe operation of the truck. Adhere to the inspection, lubrication and maintenance
schedule given in the Maintenance section of this manual.

Check for fluid leakage

Check the entire truck as well as the surface beneath it for signs of fluid leakage.
Check forks and chassis
Inspect the forks, chassis, and if equipped, the load back rest for deformity, cracks, or other
damage.
Check battery connector
Disconnect and reconnect the battery to confirm smooth operation. Inspect the battery
connector and its cables for damage.
Check decal condition
Inspect all decals and the data/capacity plate for condition and legibility. Decal locations are
given in the overview section of this manual. Any damaged or unreadable decals must be
replaced.
Check control handle pivot
Check the pivot point where the control handle attaches to the chassis for smooth operation by
moving the handle through its entire range.
Check operating controls
Returnspring
Pull the control handle down into its operating range and release it. It should return to the
vertical position under spring tension.
Brake interlock - handle
Operate the truck in forward or reverse. Move the control handle all the way up or down out of
the operating range without releasing the travel control. The drive system should switch off and
the brake should engage after a delay.
Brake interlock - travel control
Operate the truck in forward or reverse. Release the travel control without moving the control
handle out of its operating range. The truck should slow to a stop using electric braking.
Emergency reverse button
Operate the truck forwards and press the emergency reverse button. The truck should stop and
then move in the opposite direction until the button is released.

Perform operational check

Before returning the truck to service, perform an operational check of the following items:
• Electro-magnetic brake (audible sound during engage/release)
• Multi-function display/battery discharge indicator
• Horn
• Forward and reverse travel
• Electric braking (plugging)
• Fork lift and lower function (operate through complete range of motion)
• Working lights (if equipped)

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 Operator's Daily Checklist

Date Operator

Truck No. No.

Department

Runtime
Meter Reading

Daily Check Items O.K.(√) Remark

Check for fluid leakage

Check forks and chassis

Check battery capacity

Check decal condition

Check control handle pivot

Check operating controls

Check the load wheels

Check the drive wheels

Check electro-magnetic
brake function

Check horn function

Check Forward and

reverse travel function
Check lift and lower
function

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 F Battery Maintenance & Charging

1.1 Safety regulations for handling acid batteries

The truck must be parked and rendered safe before any operations on batteries are under
taken.Operational application
temperature

Fire protection measures: Smoking and naked flames are not permitted when handling
batteries. No inflammable substances or spark-generating materials must be present or
stored within a distance of 2 meters of the truck parked for battery recharging. The location
must be well ventilated and fire fighting equipment must be kept ready.
DANGER

• Battery has high voltage and energy.

• Do not short circuit.
• Do not place any metal objects on the battery.
• Do not put tools on the battery.

1.2 Battery type & dimension

All the batteries are maintenance free.
Battery type & dimension as follow:

Voltage/ Rated Dimension Charger(A) Charging

Tuck type
capacity(V/AH) (mm) Internal time(h)

EPL1531 24/20 200*100*300 10A 2

1.3 Charging the battery

Safety regulations for charging the battery
• Before charging, check all cables and plug connections for visible signs of damage.
• Before start and finish charging make sure power is turn OFF.
• It is essential to follow the safety regulations of the battery and charging station
manufacturers.

The charging environment temperature should be 5°C to 40°C.

i NOTE
The truck can be operated at -20°C for a short period after it work above 5°C for a while.
WARNING
1.Battery life will be shortened if the battery is used for a long time at low temperature or
stored.
2.No charging below 0°C.
3.Only temporary cold store application permissible as the permissible battery
operating temperature is between 0°C and 40°C

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 i NOTE
A fully charged battery will provide approximately 2 hours of continuous use. Capacity will be
reduced when used in low-temperature environments.

1.4 Battery removal and installation

Park the truck securely(See Parking the truck securely ) and turn off the power before
removal and installation of the battery.

Battery removal and installation steps:

• Turn the battery block;
• Just hold the handle and pull the battery out；
• Install in reverse order.

WARNING
Well place cables to avoid be damaged when you remove and install battery.
Installation is in the reverse order, pay attention on battery install position and cable
connection. Make sure to protect the cables to avoid damage when you install the battery.

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1.5 Daily maintenance

• When it is displayed in the display instrument that the electric quantity is insufficient,
please charge timely without any excessive discharging. Please refer to 2.2.3 display
instrument for details.
• Maintain clean the surface of the battery.

1.6 Storage
If batteries are taken out of service for a lengthy period they should be stored in the fully
charged condition in a dry, frost-free room.
If the battery is not used for an extended period, it must receive a supplementary charge every
two months to prevent permanent damage to the battery.
• We recommend that batteries are stored at a heightbetween 60 and 120 cm.
• Store the battery in a dry place at a temperaturebetween 0 and 40° to preserve its
service life. This area must not be hermetically sealed to allow air renewal.
• In case of long-term storage of the storage battery, the supplementary charging
should be conducted for the battery once every two months, and charging quantity
should be proper but not full, namely maintaining the discharging depth at about 80%.

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1.7 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.

i NOTE
It is recommended that the original
packaging is kept for any subsequent
dispatch.
A lithium-ion battery is a special
product.
Special precautions should be taken
when:
• Transporting a truck equipped with a
lithium-ion battery.
• Transporting only the lithium battery
A class 9 danger label must be affixed
to the packaging for transport.
It is different if the battery is transported
on its own or in a truck. An example
of a label appears in this supplement.
Refer to the latest current regulations
before dispatch as the information might
have changed since this supplement
was written.
Special documents must be sent with
the battery. Refer to the applicable
standards or regulations.

i NOTE
Recharge the lithium-ion battery before
transporting it taking account of the
transport mode (plane, boat, road).
Excessive discharge on arrival could
damage the performance of the battery.

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 G Pallet Truck Maintenance

1.1 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. For oil changes, the oil service of the manufacturer is available to you.
Upon completion of inspection and servicing, carry out the activities listed in the
• “Recommissioning ”section.

1.2 Maintenance safety regulations

Servicing and maintenance personnel:
Only qualified personnel authorized by the owner are permitted to perform maintenance or
repair work. All items listed in the Scheduled Maintenance Charts must be performed by
qualified truck technicians only. They must have knowledge and experience sufficient to assess
the condition of a truck truck and the effectiveness of the protective equipment according to
established principles for testing truck trucks. Any evaluation of safety must be unaffected by
operational and economic conditions and must be conducted solely from a safety standpoint
Daily inspection procedures and simple maintenance checks, e.g. checking the hydraulic oil
level or checking the fluid level in the battery, may be performed by operators. This does not
require training as described above.
Lifting and jacking up:
When a fork truck is to be lifted, the lifting gear must only be secured to the points specially
provided for this purpose. When the truck is to be jacked up, suitable measures must be
taken to prevent the truck from slipping or tipping over (use of wedges, wooden blocks). Work
underneath the raised load lifting device must only be carried out when the fork is immobilised
and supported by a chain of adequate strength.

Cleaning operations:
No inflammable liquids must be used when cleaning the fork truck. Prior to commencing
cleaning operations, all safety measures that are required to prevent sparking (e.g. by short
circuits) have to be taken. For battery operated trucks, the battery plug must be removed. Only
weak pressure, weak compressed air and non-conducting, antistatic brushes must be used for
the cleaning of electric or electronic assemblies.

Work on the electric system:

Work on the electric system of the truck must only be performed by personnel specially trained
for such operations. Before commencing any work on the electric system, all measures required
to prevent electric shocks have to be taken. For battery-operated trucks, the truck must also be
powered down by removing the battery plug.

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 Settings
When repairing or replacing hydraulic, electric or electronic components or assemblies, always
note the truck specific settings.

1.3 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.

The service intervals stated are based on single shift operation under normal operating
conditions. They must be reduced accordingly if the truck is to be used in conditions of
extreme dust, temperature fluctuations or multiple shifts.

The following maintenance checklist states the tasks and intervals after which they should be
carried out. Maintenance intervals are defined as:

W = Every 50 service hours, at least weekly

A = Every 250 operating hours

B = Every 500 operating hours, or at least annually

C = Every 2000 operating hours, or at least annually

W service can be performed by the customer.

In the run-in period - after approx. 100 service hours - or after repair work, the owner must
check the wheel nuts/bolts and re-tighten if necessary.

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1.3.1Maintenance checklist

Maintenance
interval●
W A B C
Brake Check brake plate clearance ●

Electrics Test instruments, displays and control switches. ●

Test warning and safety device. ●
Make sure wire connections are secure and check for ●
damage.
Test micro switch setting. ●
Check relays. ●
Fix the motor and cable ●

Power supply Visually inspect battery ●

Check battery cable connections are secure, grease ●
terminals if necessary.

Travel Check the transmission for noise and leakage. ●

Check travel mechanism, adjust and lubricate if ●
necessary.
Check control handle lifts back to braking position.
Check wheels for wear and damage. ●
Check wheel bearings and attachments. ●

Truck frame Check truck frame for damage. ●

Test hydraulic system. ●

Hydraulic Check that hose and pipe lines and their connections ●
operation are secure, check for leaks and damage.
Check cylinders and piston rods for damage and leaks, ●
and make sure they are secure.
Check hydraulic oil level. ●
Replace hydraulic oil.
●
Check and clean hydraulic oil filter. Replace it if
necessary. ●

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1.3.2 Lubrication Points

Lubricant
Improper operations may constitute hazards to the operator's health and life, as well as to
the surrounding environment.
When storing or adding lubricant, use clean containers. It is strictly forbidden to mix different
types and specifications of lubricants with each other (except for those can be mixed under
clear statement).

CAUTION
The use and disposal of lubricants must be carried out in strict accordance with the
manufacturer's regulations.

Sliding surface

Hydraulic oil injection nozzle

Grease

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Table 1 Lubricants

Code Type Specification Amount Position

Hydraulic
A Anti-wear hydraulic oil L-HM32 180-200mL
System
Sliding surface
B Multi-purpose grease Polylub GA352P Appropriate amount
(See Table 1)
C Grease (MoS2) - 100 grams Gearbox

L1 L2
B

L3

Table 1 Sliding Surface

Lubrication Table
Code Position
L1 Steering shaft
L2 Drive Wheel
L3 Long Shaft

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 1.4 Maintenance Instructions

1.4.1 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 Parking the truck securely).

Remove the key to prevent the truck from accidentally starting.
• When working under a raised lift truck, secure
it to prevent it from tipping or sliding away.

1.4.2 Remove the cover

• Unscrew the screw (1), remove driving cover(2).
• Rotate the handle 90 degrees, unscrew the four screws (4）, remove the hydraulic cover （3）
through the spaces.

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1.4.3 How to add oil
It is necessary to add hydraulic oil when
you heard explosion sound from pipe during
lifting.
• Prepare the truck for maintenance and
repairs (See Maintenance Instructions).
• Remove the hydraulic cover.(See
• Section1.4.2).
• Add hydraulic oil of the correct grade (See
Lubrication point).
• Add hydraulic oil till you can't hear explosion
sound during lifting any more.

Re-installation in the reverse order.

1.4.4 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.

• Re-installation in the reverse order.

WARNING
It is forbidden to add hydraulic oil with
impurity.
1.4.5 Checking the fuses
• Fully lower the forks.
• Press the emergency stop switch.
• Remove the electrical cover(See section
battery removal and installation)
• Fuse 5A installed on main harness. If
necessary, replace it with fuse that match
the parameters specified in the table below

Item To protect: Rating

1 Wire harness 5A

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

1.5 Decommissioning the industrial truck

If the truck is to be decommissioned for a long period, it must be parked in a frost-free and
dry location.
On decommissioning the truck must be jacked up so that all the wheels are clear of the
ground. This is the only way of ensuring that the wheels and wheel bearings are not
damaged.
If the truck is to be out of service for more than 6 months, further measures must be taken in
consultation with the manufacturer’s service department.

1.5.1 Prior to decommissioning

• Clean the truck thoroughly.
• Check the brakes
• Check the hydraulic oil level and top up if required.
• Apply a thin layer of lubricating oil or grease to all nonpainted mechanical components.
• Lubricate the truck in accordance with the lubrication schedule.
• Remove the battery and recharge it at least once per month.
• Clean the battery and apply specialised grease to the terminals.
• Spay all exposed electrical contacts with a suitable contact spray.

WARNING
Charge the battery every two months to avoid depletion of the battery through self-
discharger.

1.5.2 Restoring the truck to operation after decommissioning

• Thoroughly clean the fork 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 required.
• Follow the daily checklist.

If there are switching problems in the electrical system, apply contact spray to the exposed
contacts and remove any oxide layers on the contacts of the operating controls by applying
contact spray repeatedly.
Perform several brake tests immediately after recommissioning the truck.

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1.6 Safety checks to be performed at regular intervals and following any unusual
incidents
Carry out a safety check in accordance with national regulations. EP has a special safety
department with trained personnel to carry out such checks.
The truck must be inspected at least annually (refer to national regulations) or after any
unusual event by a qualified inspector. The inspector shall assess the condition of the truck
from purely a safety viewpoint, without regard to operational or economic circumstances. The
inspector shall be sufficiently instructed and experienced to be able to assess the condition of
the truck and the effectiveness of the safety mechanisms based on the technical regulations
and principles governing the inspection of truck trucks.
A thorough test of the truck must be undertaken with regard to its technical condition from a
safety aspect. The truck must also be examined for damage caused by possible improper
use.
A test report shall be provided. The test results must be kept for at least the next 2
inspections.
The owner is responsible for ensuring that faults are immediately rectified.

A test plate is attached to the truck as proof that it has passed the safety inspection.This
plate indicates the due date for the next inspection.

1.7 Final decommissioning, disposal

Final, proper decommissioning or disposal of the truck must be performed in accordance
with the regulations of the country of application. In particular, regulations governing the
disposal of batteries, fuels, Hydraulic oil, plastic and electronic and electrical systems must
be observed.

i NOTE
Any repairs or maintenance to the truck must be performed only by trained and authorized
technicians.

1.8 Tire replacement

The quality of tyres affects the stability and performance of the truck. When replacing
tyres fitted at the factory, only use the manufacturer’s original spare parts. Otherwise the
data sheet specifications of the truck cannot be guaranteed. When changing wheels and
tyres, ensure that the truck does not slew (e.g. when replacing wheels always left and right
simultaneously).

WARNING
Only original tires have been certified by our quality assurance service. To ensure safe and
reliable operation of the fork truck, only tires of the manufacturer must be used.

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 H Troubleshooting
If the fault cannot be rectified after carrying out the remedial procedure, notify the Manfacture's se-
vice department, as any further troubleshooting can only be performed by specially trained and
qualified service personnel.

Fault Probable Cause Action

Truck does –Battery connector not plugged –Check the battery connector and
not start. in connect if necessary.
–Key switch not insert –Set key switch to “I”
–Incorrect CanCode code –Check code
–Battery charge too low –Check battery charge, charge battery
–Faulty fuse if necessary
–Truck in charge mode –Check fuses.
–Interrupt charging

Load cannot –Charging capacity below 20 / –Charging the battery

be lifted 40% –Carry out all measures listed under
–Truck not operational “Truck does not start”
–Hydraulic oil level too –Check the hydraulic oil level
low –Check fuses.
–Faulty fuse

Controller Error Message to the vehicle, LED will twinkle and indicate the
The error message can be obtained in two ways: fault code; LED won’t restore to the extinguish-
1) By reading the appropriate display on the ing state until the fault is eliminated.
hand held unit ; LED indicates two digit codes: for example, digit
2) By observing the fault codes issued by the code “1, 4” — UNDER VOLTAGE FAULT, the dis-
LED(1) fault indicator. play mode is as follows:

Handheld Unit Diagnostics

The fault information is shown in the Diagnos-
tics menu of the hand held unit.
LED Blinks 1 Second Stop
LED Fault Indicator Diagnostics
When the truck is in normal use, LED fault indi-
cator is always going on; When any fault occurs

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 Error Message
LED LED
BLINKS BLINKS Explanation Possible cause
digit 1 digit 2 Error text

1. Temperature >80°C or <

-10°C.
2. Excessive load on vehicle.
over-/under-temperature
1 1 THERMAL FAULT 3.Operation in extreme
cutback
environments.
4.Electromagnetic brake not
releasing.

1.Throttle input wire open or

shorted.
Pot Low and/or Pot
1 2 THROTTLE FAULT 2.Throttle pot defective.
Wiper out of range
3.Wrong throttle type
selected.

1.Speed limit pot wire(s)

speed limit pot wiper out
1 3 SPEED POT FAULT broken or shorted.
of range
2. Broken speed limit pot.

1. Battery voltage <17 volts.

UNDER VOLTAGE
1 4 battery voltage too low 2. Bad connection at battery
FAULT
or controller.

1. Battery voltage >31 volts.

2. Vehicle operating with
OVER VOLTAGE
1 5 battery voltage too high charger attached.
FAULT
3.Intermittent battery
connection.

main contactor driver Off 1.Main contactor driver failed

2 1 MAIN OFF FAULT
fault open.

1.Main contactor welded or

2 3 MAIN FAULT main contactor fault stuck open.
2. Main contactor driver fault.

main contactor driver On 1.Main contactor driver failed

2 4 MAIN ON FAULT
fault closed.

1.Misadjusted throttle.
HPD fault present >10
3 1 WIRING FAULT 2.Broken throttle pot or
sec.
throttle mechanism.

REV. 07/2020
H2
 Error Message
LED LED
BLINKS BLINKS EXPLANATION Possible cause
digit 1 digit 2 Error text

1.Misadjusted throttle.
HPD fault present >10
3 1 WIRING FAULT 2.Broken throttle pot or
sec.
throttle mechanism.

1.Electromagnetic brake
driver shorted.
3 2 BRAKE ON FAULT brake On fault
2.Electromagnetic brake coil
open.

1. Brake driver shorted.

3 3 PRECHARGE FAULT precharge fault 2. Precharge circuit damaged.
3. MOSFET failure.

1.Electromagnetic brake
driver open.
3 4 BRAKE OFF FAULT brake Off fault
2.Electromagnetic brake coil
shorted.

1. Improper sequence of
HPD (High Pedal throttle and KSI,push, or
3 5 HPD FAULT
Disable) inhibit inputs.
2. Misadjusted throttle pot.

1.Short in motor or in motor

CURRENT SENSE current sense out of
4 1 wiring.
FAULT range
2. Controller failure. ★

1.Motor voltage does not

correspond to throttle request.
HARDWARE motor voltage out of
4 2 2.Short in motor or in motor
FAILSAFE range
wiring.
3. Controller failure. ★

EE CHECKSUM
4 3 EEPROM fault 1. EEPROM failure or fault.
FAULT

1. Battery not connected.

BATTERY
4 5 battery disconnected 2.Poor connection to battery
DISCONNECT FAULT
terminals.

REV. 07/2020
H3