ep F4 Operation Manual
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ep F4 Operation Manual

Electric pallet truck
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Operation Manual
F4
Electric pallet truck
Part No.508000005071
V1 10/2021

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  • Page 1 Operation Manual Electric pallet truck Part No.508000005071 V1 10/2021...
  • Page 2 EP EQUIPMENT CO.,LTD. is one of the world’s With business all over the world, EP has leading companies manufacture, design thousands of employees and hundreds material handling equipment and provide related of agents worldwide to provide our global service. With over 100,000 square metres plant customers with prompt local service.
  • Page 3 Please pay attention to the important safety instructions. NOTE Pay attention to Instruction. Internet address and QR code of Parts manual By entering the address http://www.ep-care.com in a web browser or by scanning the QR code, Login after registration, Select “Parts purchase"...
  • Page 4 A spring returns the control handle always into a vertical position that activates the brake automatically. • The F4 can be equipped with two lithium-ion battery , when the one is low power, it can be removed from side effortlessly, the rest battery can still support the truck to work.
  • Page 5 Obligations and responsibilities of equipment user In the manual, “equipment user” refers to any natural person or legal person directly using or appointing or authorizing others to use the carrier. In such special situations as renting or sales, the “equipment user” represents the interested parties supposed to bear operation obligations as specified by the contractual terms concluded between equipment owner and corresponding users.
  • Page 6 Frame installation • Install the front and rear frame before operating the truck for the first time. • Put the front frame (1) under the rear frame (2) and insert the cylinder (3) into the cylinder block (4); • Connect the harness and wires; •...
  • 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: according to this operation manual Type: according to this operation manual complies with the most recent version of Machinery Directive 2006/42/EC.

  • Page 8: Table Of Contents

    Table of contents A Nameplates and alarming labels ..................A1 B Operation ..........................B1 1.1Utilization safety specification....................B1 1.1.1 EN standards ........................B2 1.1.2 Conditions for application ....................B3 1.1.3 Stability ...........................B3 1.2 Display and Manipulation ....................B4 1.2.1 Truck overview.........................B4 1.2.2 Control handle .........................B5 1.2.3 Key switch ........................B6 1.2.4 Display instrument ......................B6 1.3 Truck use and operation .....................B7 1.3.1 Preparation for use ......................B7...
  • Page 9 Table of contents 8 Transportation........................F5 8.1 Shipping faulty batteries .....................F5 Instructions for disposal ......................F6 10 Charging ..........................F6 11 Storage ..........................F7 12 Common Problems and Solutions ..................F7...

  • Page 10: A Nameplates And Alarming Labels

    1.1 Nameplates and alarming labels Have the nameplates of a truck fixed its main body and alarming labels pasted on its outer cover. Should any nameplate or alarming label lose or be damaged, please conduct replacement immediately or contact with the sales department or corresponding agent of our company when necessary.
  • Page 11 Nameplate Item Description PRODUCT NAME MODEL TYPE SERIAL NO. MANUFACTURE DATE LIFT HEIGHT UNLADEN MASS UNLADEN MASS WITHOUT BATTERY BATTERY VOLTAGE RATED DRIVE POWER MAX BATTERY WEIGHT MIN BATTERY WEIGHT RATED CAPACITY Fig0000-00015OM LOAD CENTER Hoisting Remove the load before hoisting the pallet truck. Disconnect the power supply.

  • Page 12: B Operation

    Operation 1.1 Utilization safety specification Fig0000-00120OM Don’t use the truck in Don’t use the truck in non- • Average ambient temperature for rainwater. position. continuous duty: ＋ 25℃ ; • Maximum ambient temperature, short term (up to 1h): ＋ 40℃ ; •...
  • Page 13 Fig0000-00121OM • Avoid the use of the truck by Don’t use the truck on slippery Don’t carry goods on steep non-working personnel. road surfaces. slope to prevent goods • Don’t ride on the truck. (such as road surfaces with oil from sliding off.

  • Page 14: Standards

    WARNING • Fire extinguisher shall be equipped at the work site. Users can choose truck equipped with fire extinguisher. Driver and manger should be familiar with the fire extinguisher position and application method. • Use tray when carrying small items, do not place on the fork directly. •...

  • Page 15: Stability

    1.1.3 Stability Stability is guaranteed if your truck is used properly in accordance with its intended purpose. Common reasons for a loss of truck stability include: • Emergency stops or sharp turns • Driving with a raised load or a load handling device •...

  • Page 16: Display And Manipulation

    1.2 Display and Manipulation 1.2.1 Truck overview Fig1154-00021OM Control handle Fork arms Control handle cover Supply plug and display instrument Lithium-ion battery Driving hood Controller Driving wheel Load wheels REV. 09/2021...

  • Page 17: Control Handle

    1.2.2 Control handle Key switch Connect and interrupt control current. Fault indicating lamp Shows the error state of the truck( see the chapter error code) Horn button Send out sound warning signals. Raises the load device. When the battery is Lift button consumed about 85%, lifting function will be locked.

  • Page 18: Display Instrument

    1.2.3 Key switch 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. NOTE Pulling out the key switch of a forklift before leaving can prevent the forklift from...

  • 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. Table 1. Table of daily inspections by operators Operator's Daily Checklist Date Operator Truck No.

  • Page 20: Comissioning

    WARNING The truck should be regularly maintained by qualified maintenance engineers or technicians that have passed the training of and also been authorized by the manufacturer. 1.3.2 Comissioning 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.

  • Page 21: Truck Starting

    1.3.3 Truck starting Carry out check before operation and make sure each function and state is normal(see section 1.3.1 Preparation for use). Before start, press the horn button (3) and make sure no people around. 1.Engaged the supply plug (1); 2.Open the key switch (2) to start the truck.

  • Page 22: Running, Steering And Braking

    1.3.4 Running, steering and braking Running Set the control lever to the running area (M) ,Set the drive switch (1) to the required direction (Forward or Backward). Control the travel speed with the drive switch(1) (the lager the turning angle, the faster corresponding speed) Backward Forward Fig1154-00016OM...
  • Page 23 Driver should walk in front of the truck and keep at the side front of the truck when travelling. One hand holds the handle, and operates travel switch with thumb. Always watch moving direction and guide the truck. Or hold the handle with both hands and push the truck go forward. CAUTION •...
  • Page 24 Steering Move the control hand to the left or right. Right Left Fig1154-00020OM 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 (B）area. CAUTION If the control handle moves slowly into the brake position, identify the cause and rectify the fault.
  • Page 25 Reverse braking Braking can be accomplished by changing the direction of travel. Press the reverse switch in the opposite direction until the truck comes to a stop, then release the drive switch. CAUTION Open the drive switch; if the drive switch cannot quickly return to the initial position or resets very slowly, identify the cause and rectify the fault.

  • Page 26: Goods Picking

    1.3.5 Goods picking Keep pressing the lifting button until reaching the required lifting height Lower the pallet forks to the bottom through pressing the lowering button. Fig1154-00012OM 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 forks to the highest state for lifting.

  • Page 27: Parking The Truck Securely

    1.3.6 Parking the truck securely Drive the truck to safe area or appointed area. Lower the forks to the bottom; Fig0000-00071OM Turn off the key switch(1) ; Pull out the supply plug (2）; Fig1154-00003OM WARNING • Should it be necessary for operators to leave the truck, even for just a moment, the truck should also be well parked as specified.

  • Page 28: Drive Directions

    1.3.7 Drive directions The drive directions of the truck are forward (1) and reverse (2). Fig0000-00072OM 1.3.8 Loading •Approach the load carefully. •Adjust the height of the forks until they can be easily inserted into the pallet. •Insert the forks under the load. •If the load is shorter than the forks, position the forks so that the front of the load overhangs them by a few...

  • Page 29: Using The Truck On A Slope

    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 proper height. CAUTION If the field of vision is poor, ask a guide for assistance.
  • Page 30 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. Starting on a slope If you have to stop and then start on slope, proceed as follows: •...

  • Page 31: Truck Transport

    1.3.10 Truck transport Correctly fix the truck to avoid move when using truck or trailer. Procedure: • Park the truck securely. • Sling the tensioning belt (1) around the truck and attach it to the fastening rings of the transporting vehicle. •...

  • Page 32: How To Remove A Broken Truck

    1.3.11 How to remove a broken truck It’s not allowed to tow the forklift truck on the ground directly when the truck is broken down or damaged since the brake of the truck is closed under normal circumstances. Appropriate vehicles should be used to remove the broken trucks.

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

    1.3.12 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: • Pull ou the supply plug. • Set the key switch “OFF” and remove the key. Prevent the truck from rolling away.

  • Page 34: C Battery Use And Maintenance

    Battery use and maintenance 1.1 Battery charging 1.1.1 Precautions • The truck must be parked within a shady and ventilated room; • Do not place metal objects on the battery; • All the cable and plug connection parts should be inspected in terms of obvious damages before charging;...
  • Page 35 The battery is fully charged after 5.0 hours of charging at 100 ~ 240V AC; Fig1154-00010OM Insert the battery into the battery compartment of the truck. Fig1154-00008OM The battery can be operated continuously for 2.0 hours in a fully charged state. Fig1154-00019OM REV.

  • Page 36: Battery Type & Dimensions&Charging Time

    1.1.3 Battery type & dimensions&Charging time Battery types & dimensions are as follows: Voltage/ Rated Dimensions Tuck type Charger Charging time capacity 290*238*76 24V/20Ah 1.2 Battery removal and installation Park the truck securely as described chapter B section 1.3.6 and turn off the power before removal and installation of the battery.

  • Page 37: 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 38 Safety tests to be performed at intervals and after unusual incidents The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector. The manufacturer offers a safety inspection service which is performed by personnel specifically trained for this purpose.
  • Page 39 Error Message Error code LED BLINKS Explanation Possible cause （1,1）□ □ Over Current The controller detects excessive current, Check whether there is a short circuit in the motor phase line. power off and restart. （1,2）□ □□ Over Temperature The controller temperature exceeds 95 °...
  • Page 40 Error code LED BLINKS Explanation Possible cause 4，13 （4,3）□□□□ □□□ EEPROM fault EEPROM failure or fault. （4,4）□□□□ □□□□ Motor Open The motor did not connect （4,5）□□□□ □□□□□ TEMP Sensor The temperature sensor is disconnected or short-circuited. （5,1）□□□□□ □ EMCY STOP The emergency stop button being pressed was detected.

  • Page 41: Maintenance Table

    1.2 Maintenance table 50-hour/7-Day maintenance Check the functions of the operation switches and display. Check display equipment, alarm system and safety devices. Check the emergency reverse switch, reverse braking, emergency disconnect switch and regenerative braking. Check tiller steering functions. Check the drive wheel and load wheel for worn or damage. 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 42 Hydraulic oil injection nozzle Contact surface Grease Fig1154-00023OM Table 1 Lubricants Code Type Specification Amount Position Hydraulic Anti-wear hydraulic oil L-HM32 210-250ml System Polylub Contact Surface Multi-purpose grease Appropriate amount GA352P Grease 3#(MoS 110 grams Gearbox NOTE Add hydraulic oil till you can't hear explosion sound during lifting any more. REV.

  • Page 43: Maintenance Instructions

    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 44: How To Add Hydraulic Oil

    How to add hydraulic oil 1.3.3 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 chapter D Section1.3.2). •...

  • Page 45: 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 Manufacturer Model designation Drive unit Battery Operator type Pedestrian rated capacity 1500 Load center distance Load distance Wheelbase 1180...
  • Page 46 3.2.1 Tyre size, driving Ф210x70 wheels(diameter×width) 3.3.1 Tyre size, loading Ф80x60(Ф74x88) wheels(diameter×width) Tyre size, caster wheels(diameter×width) Wheels, number driving, 1x,2/4(1x,2/2) caster/loading (x=drive wheels) Track width, front,driving side Track width,rear,loading side 410/(535) Dimensions Lift height Height drawbar in driving 750/1190 position min./max. 4.15 Lowered height 4.19...
  • Page 47 Lowering speed, laden/ 0.046/0.058 unladen Max. gradeability, laden/ 5\16 unladen 5.10 Service brake type Electroma gnetic Electric-engine Drive motor rating S2 60 min 0.65 Lift motor rating at S3 15% V/ Ah Battery voltage/nominal 24/20 capacity K5 Battery weight Addition data Type of drive control 10.5 Steering type...
  • Page 48 Fig1154-00015OM REV. 10/2021...
  • Page 49 Lithium-ion battery REV. 10/2021...

  • Page 50: Information On The Conformity Of Lithium-Ion Batteries

    • Have class D fire extinguishers or inert gas, carbon dioxide, powder or foam fire extinguishers near the zone in which the lithium-ion batteries are used. • Do only use in trucks manufactured by EP and if the battery type is released for that truck.

  • Page 51: Intended Use

    Failure to comply with these safety instructions can result in fire and explosion or the leakage of harmful materials. 5.Accessories Do not use a charger that is not released by EP for lithium-ion battery. WARNING Should such issues as failing to abide by the operation manual, failing to use the original parts...

  • Page 52: Safety And Warning

    7.1Safety and warning •Abide by the operation manual! •All the operations related to the storage battery must be implemented under the instruction of professionals! Always wear protective clothing (e.g. safety goggles and safety gloves) when working on cells and batteries. •No smoke and fire! •Avoid the existence of open fire, fiery metal wire or sparks around the storage battery, otherwise explosion or fire disaster may occur!

  • Page 53: Transportation

    Transportation Before transporting any lithium-ion battery, check the current regulations on the transport of dangerous goods. Comply with these when preparing the packaging and transport. Train authorised staff to dispatch lithium-ion batteries. NOTE It is recommended that the original packaging is kept for any subsequent dispatch. A lithium-ion battery is a special product.

  • Page 54: Instructions For Disposal

    9 Instructions for disposal • Lithium ion batteries must be disposed of in accordance with the relevant environmental protection regulations. • Used cells and batteries are recyclable economic goods. In accordance with the mark showing a crossed rubbish bin, these batteries may not be disposed of as domestic waste.

  • Page 55: Storage

    support.

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