Part No.

508000003127
V1 08/2019
EP EQUIPMENT CO.,LTD. is one of the catalogs.
world’s leading companies manufacture, With business all over the world, EP has
design material handling equipment and thousands of employees and hundreds
provide related service. With over of agents worldwide to provide our
100,000m2 plant it produces over global customers with prompt local
100,000 trucks per year, and provides service.
professional, effective and optimized
material handling solutions worldwide, Based on the concept of sharing
until now it has developed three major economy , EP also offer rental service
kinds of business: for various logistics equipment. Adhering
· Material handling equipment: Focus to the idea “Making the leasing of logistic
on electric forklift and warehouse equipment more simple”, EP is devoted
equipment to providing customized one-stop
·OEM parts: Global parts supply leasing solutions for our customers with
·Imow industry,online: One stop our high quality, reasonable price and
industrial products supply prompt rental service.

Guided by our customer-oriented EP’s mission&vision is “ Let more people

concept, EP has developed service apply the electrical material handling
centers in more than 30 countries equipment to relieve the intensity of
around the world, from which customers labour” and “Let’s grow together”.
are able to receive timely local service.
Moreover, 95% of warranty parts can be EP EQUIPMENT CO., LTD
shipped out within 24 hours after been Address: XIAQUAN, DIPU, ANJI,
ordered. Through our online after-sales ZHEJIANG, CHINA
service system, customers can process Tel: + 86-0571-28023920
their warranty claims, order spare parts Fax: + 86-0571-28035616
and consult the operation manuals, Website: www.ep-ep.com
maintenance materials and spare parts Email: service@ep-ep.com
 Foreword
Thanks for your purchasing our pallet truck.
This manual is about how to use, operation and maintenance. Please operator and
whom in charge of the truck must read the manual carefully before operate the truck.
We have the right to improve the truck, maybe there are some difference between
your product and the description in this manual.
If you have any questions please keep in touch with the sales department or let the
dealer know.
Notes:
1. This manual is used for operation and maintenance , the detail parameters, size
and specifications in context is only for reference , the real parameters will depend on
sale files.
2. Manual pictures for reference only, the real car shall prevail, and shall not affect the
manual use.
3.Manual pictures only sign for one of the models in this series models.

ALL RIGHT RESERVED COPYRIGHT

2019.8 1nd EDITION

 WARNING!
TO PREVENT SETIOUS RISK OF INJURY TO
YOURSELF AND OTHERS OBSERVE THE
FOLLOWING SAFETY INSTRUCTIONS.
These truck may become hazardous if adequate maintenance is neglected. Therefore,
adequate maintenance facilities, trained personnel and procedures should be
provided.

Maintenance and inspection shall be performed in conformance with the following

practices:

1. A scheduled planned maintenance,lubrication and inspection system should be

followed.

2. Only qualified and authorized personnel shall be permitted to maintain, repair,

adjust, and inspect truck.

3. Before leaving the truck:

– Do not park the truck on an incline.
– Fully lower the load forks.
– Set the key switch to the "OFF" position and remove the key.

4. Before starting to operate truck:

– Be in operating position
– Place directional control in neutral
– Before operating truck, check functions of lift systems, directional control,speed
control,steering, warning devices and brakes.

5. Avoid fire hazards and have fire protection equipment present. Do not use open
flame to check lever, or for leakage of electrolyte and fluids or oil. Do not use open
pans of fuel or flammable cleaning fluids for cleaning parts.

6. Brakes,steering mechanisms, control mechanisms,guards and safety devices shall

be inspected regularly and maintained in legible condition.

7. Capacity, operation and maintenance instruction plates or decals shall be

maintained in legible condition.

8. All parts of lift mechanisms shall be inspected to maintain them in safe operating
condition.

9. All hydraulic systems shall be regularly inspected and maintained in conformance

with good practice. Cylinders, valves and other similar parts shall be checked to
assure that "drift" has not developed to the extent that it would create a hazard.

10. Truck shall be kept in a clean condition to minimize fire hazards facilitate
detection of loose or detective parts.

11. Modifications and additions which affect capacity and safe truck operation shall
not be performed by the customer or user without manufacturers prior written
approval. Capacity, operation and maintenance plates or decals shall be changed
accordingly.
 Catalog

Correct use and application................................................................................................1

1. Truck Description.............................................................................................................. 2
1.1Application....................................................................................................................2
1.2 Assemblies..................................................................................................................3
1.2.1Control Handle................................................................................................. 4
1.2.1Key switch......................................................................................................... 4
1.2.3Battery discharge indicator.............................................................................5
1.3 Identification points and data plates....................................................................... 6
1.3.1Truck data plate................................................................................................7
1.4.Standard Version Specifications..............................................................................7
1.4.1Performance data for standard trucks.......................................................... 7
1.4.2Dimensions....................................................................................................... 9

2.Transport and Commissioning..................................................................................... 11

2.1Transport.................................................................................................................... 11
2.2Using the Truck for the First Time.......................................................................... 11
2.3During brake-in..........................................................................................................12

3.Operation............................................................................................................................13
3.1Safety Regulations for the Operation of pallet Trucks........................................ 13
3.2Operate and run the truck....................................................................................... 13
3.2.1 Preparing....................................................................................................... 13
3.2.2 Travel..............................................................................................................14
3.3.3Lifting, transporting and depositing loads.................................................. 16
3.3.4Parking the truck securely............................................................................ 17

4.Battery Maintenance & Charging................................................................................. 18

4.1 Safety regulations for handling acid batteries.....................................................18
4.2 Battery type & dimension....................................................................................... 18
4.3Charging the battery.................................................................................................18
4.4Battery removal and installation............................................................................. 19
4.5Battery maintenance................................................................................................ 20
4.6Battery Disposal........................................................................................................20
5.pallet Truck Maintenance............................................................................................... 21
5.1Operational safety and environmental protection................................................21
5.2Maintenance Safety Regulations........................................................................... 21
5.3Servicing and inspection..........................................................................................23
5.3.1Maintenance Checklist..................................................................................24
5.3.2 Lubrication Schedule................................................................................... 25
5.3.3 Maintenance Instructions............................................................................ 26
5.4Decommissioning the industrial truck....................................................................28
5.4.1Prior to decommissioning............................................................................. 28
5.4.2 Restoring the truck to operation after decommissioning........................29
5.5Safety checks to be performed at regular intervals and following any unusual
incidents...........................................................................................................................29
5.6Final de-commissioning, disposal.......................................................................... 29

6.Troubleshooting............................................................................................................... 30
 Correct use and application

The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
supplied with the truck. The guidelines form part of these operating instructions and
must be observed. National regulations apply in full.
The truck described in the present operator manual is an industrial truck designed for
lifting and transporting load units.
It must be used, operated and serviced in accordance with the present instructions.
Any other type of use is beyond the scope of application and can result in damage to
personnel, the truck or property. In particular, avoid overloading the truck with loads
which are too heavy or placed on one side. The data plate attached to the truck or the
load diagram are binding for the maximum load capacity. The industrial truck must not
be used in fire or explosion endangered areas, or areas threatened by corrosion or
excessive dust.

Proprietor responsibilities
For the purposes of the present operator manual the “proprietor” is defined as any
natural or legal person who either uses the industrial truck himself, or on whose behalf
it is used. In special cases (e.g. leasing or renting) the proprietor is considered the
person who, in accordance with existing contractual agreements between the owner
and user of the industrial truck, is charged with operational duties.
The proprietor must ensure that the truck is used only for the purpose it is intended for
and that danger to life and limb of the user and third parties are excluded.
Furthermore, accident prevention regulations, safety regulations and operating,
servicing and repair guidelines must be followed. The proprietor must ensure that all
truck users have read and understood this operator manual.
Failure to comply with the operator manual shall invalidate the warranty. The same
applies if improper work is carried out on the truck by the customer or third parties
without the permission of the manufacturer’s customer service department.

Attaching accessories
The mounting or installation of additional equipment which affects or supplements the
performance of the industrial truck requires the written permission of the manufacturer.
In some cases, local authority approval shall be required.
Approval of the local authorities however does not constitute the manufacturer’s
Approval.

1
 1. Truck Description

1.1Application
The truck is designed to transport goods on level surfaces. It can lift open bottom or
diagonal board pallets as well as roll cages beyond the area of the load wheels.
Suitable environment temperature is 5°C to 40 °C.
If a long time in less than 5 ° C environment, cold storage or in the extreme conditions
of temperature and humidity changes in the use of pallet, you must install additional
special equipment, and obtain permission from the manufacturer.

2
1.2 Assemblies

Item Component Item Component

1 Control Handle 6 Driving wheel
2 Battery discharge indicator 7 Balance wheel
3 Key switch 8 Lift fork
4 Cover 9 Plug
5 Chassis 10 Battery cover

3
1.2.1Control Handle

Item Description Component

11 “Lower” button Lowers load forks.
12 “Lift” button Raises load forks.
13 Travel switch Controls the driving speed and direction
14 Warning signal Triggers a warning signal.
button
15 Collision safety Safety function which, when activated, forces the truck to
switch reverse for approx. 3 seconds and then cuts out until the
controller is briefly restored to neutral.

1.2.1Key switch
Key switch
Switches control current on and off.
Removing the key prevents the truck from being switched on by unauthorised
personnel.

4
1.2.3Battery discharge indicator
The LEDs (1) represent battery residual capacity,
The LCD (2) displays the operating hours

Battery Discharge Indicator(1)

When the truck has been released via the key
switch, the battery charge status is displayed.
The colours of the LEDs (1) represent the
following conditions:

LED colour value

Green Standard battery residual capacity 70-100%
Orange Standard battery residual capacity 50-60%
Flashing Red Standard battery residual capacity 0-20%

Battery Discharge for 70%, A flashing red show on storage battery charge warning.
Battery Discharge for 80%, Two flashing reds show on battery charge used up
warning, Lifting is now inhibited. The battery must be charged.

Operating hours display

Display range between 0.0 and 99,999.0 hours. Travel and lifting are logged. This is a
backlit display.

Power up test
On power up the display shows:
– the operating hours
– the charge status

Low Voltage Protection

This vehicle has a low-voltage protection function.
When the battery voltage is less than, the vehicle will appear that the driving speed
is slow ,but the fork can be lifted.And now the battery needs to be charged.

5
1.3 Identification points and data plates

Item Description

1 Truck data plate

2 Operator Warning Decal
3 Strap points for crane lifting
4 Warning Decal
5 AC Power Decal

6
1.3.1Truck data plate

Item Description Item Description

1 Manufacturer 6 Fork length(mm)

2 Model name 7 Battery capacity（kg）

3 Type 8 Service weight without battery（kg）

4 Rated capacity（kg） 9 Serial no.

5 Fork width(mm)

For queries regarding the truck or ordering spare parts please quote the truck serial
number(9).

1.4.Standard Version Specifications

Technical specification details in accordance with VDI 2198. Technical modifications
and additions reserved.

1.4.1Performance data for standard trucks

Ite Description Unit
EPT20-20WA EPT25-WA
m
Q Load capacity 2000 2500 kg
C Load center 600 600 mm
laden 5 5 km/h
Travel speed unlade
5.5 5.5 km/h
n
laden 0.051 0.051 m/s
Lifting speed
unlade 0.060 0.060 m/s

7
 n

laden 0.032 0.032 m/s

Lowering
speed unlade
0.039 0.039 m/s
n
Maximum laden 8 6 %
gradeability unlade
S2 5 min. 16 16 %
n
Electromagne Electromag
Service brake
tic netic
Service Incl.
535 565 kg
weight battery
operat
Axle loading,
or/load 955/ 1580 1070/ 1995 kg
laden
side
operat
Axle loading,
or/load 430/ 105 445/ 120 kg
unladen
side
Motor rating Drive 1.1 1.1 Kw
power Lift 0.84 0.84 Kw
Tyre type PU/PU PU/PU
Tyre size, operator
Ф230x75 Ф230x75
side
2x Ф85x70/ 2x Ф85x70/
Tyre size, load side
Ф83x115 Ф83x115
Balance wheels
Ф85x48 Ф85x48
(dimensions)
Industry Industry
Type
battery battery
voltage/
Battery
rated 24/210 24/210
V/Ah
capacity
weight 190 220 kg
Sound level at
74 74 dB(A)
operator's ear

8
1.4.2Dimensions
Ite Description Unit
EPT20-20WA EPT25-WA
m
Load distance (Raised/ 916/98 937/ 916/98 937/1
X mm
Lowered) 2 1003 2 003
148
Y Wheelbase 1418 1418 1488 mm
8
h3 Lift height 120 120 mm
load
b11 370/ 430/515 370/ 430/515 mm
side
Tread
operat
b10 498 498 mm
or side
lowere
h13 Fork height 85 85 mm
d
Height of min 715 715 mm
control
h14 handle arm in
operating max 1200 1200 mm
position
174
l1 Overall length 1818 1748 1818 mm
8
l2 Length to face of forks 598 598 mm
b1 Overall width 710 710 mm
Thickn
s 55 55 55 55 mm
ess
Fork
e Width 170 170 170 170 mm
dimensions
115
l Length 1220 1150 1220 mm
0
b5 Fork spread, min/ max 540/600/685 540/600/685 mm
Ground clearance,
m2 30 30 mm
center of wheelbase
Wa Outer turning radius 1595 1595 mm
Aisle width, 1000 ×
1815 1815 mm
1200 pallet crossways
Ast
Aisle width, 800×1200
2015 2015 mm
pallet lengthways

9
EPT20-20WA
EPT25-25WA

10
 2.Transport and Commissioning

2.1Transport
Lifting the truck by crane
There are two way to pack the truck: one is
use a stock, the other is use a box. The way
to pick up depend on transport.
1.Only use crane handling equipment gear
with sufficient capacity.
2.Loading weight > net weight of truck (+
battery weight for electric trucks).Loading
weight not only net weight of truck but
also the stock or the box.
3.Stock (box) should be big enough and
strong enough to bear hole truck.
– Park the truck securely.(see 3.2.4
Parking the truck securely on page 17).
– Make sure forks are positioned properly
for the pallet. Move forward slowly to
insert forks into the pallet as far as
possible and then stop the truck.

Warning!
– To avoid break the fork be hurt when you move the truck to stock.
– In order to keep the truck out of be scraped,please move the truck void in
void and flat place.
– when you lowering the stock advert status of the place to avoid collapse.

2.2Using the Truck for the First Time

Only operate the truck with battery current. Rectified AC current will damage the
electronic components. Cable connections to the battery (tow leads) must be less
than 6 m .
Preparing the truck for operation after delivery or transport
Procedure
– Check the equipment is complete.
– Check the hydraulic oil level.
– Install the battery if necessary (where required), (see "4.4 Battery removal and
installation" on page 19) do not damage battery cable.
– Charge the battery, (see "4.3 Charging the battery" on page 18).
When the truck is parked the surface of the tyres will flatten. The flattening will

11
disappear after a short period of operation.
2.3During brake-in
We recommended operating the machine under light load conditions for the first stage
of operation to get the most from it. Especially the requirements given below should
be observed while the machine is in a stage of 100 hours of operation.
1. Must prevent the new battery from over discharging when early used. Please
charging when remain power less than 20%.
2. Perform specified preventive maintenance services carefully and c.ompletely.
3. Avoid sudden stop, starts or turns.
4. Oil changes and lubrication are recommended to do earlier than specified.
5. Limited load is 70～80% of the rated load.

12
 3.Operation

3.1Safety Regulations for the Operation of pallet Trucks

Driver authorisation: The pallet truck may only be used by suitably trained personnel,
who have demonstrated to the proprietor or his representative that they can drive
and handle loads and have been authorised to operate the truck by the proprietor or
his representative.

Driver’s rights, obligations and responsibilities: The driver must be informed of

his duties and responsibilities and be instructed in the operation of the truck and
shall be familiar with the operator manual . The driver shall be afforded all due rights .
Safety shoes must be worn with pedestrian operated trucks.

Unauthorised Use of Truck: The driver is responsible for the truck during the time it
is in use. He shall prevent unauthorised persons from driving or operating the truck.
It is forbidden to carry passengers or lift personnel.

Damage and Faults: The supervisor must be immediately informed of any damage
or faults to the pallet truck. Trucks not safe for operation (e.g. wheel or brake
problems) must not be used until they have been rectified.

Repairs: The driver must not carry out any repairs or alterations to the pallet truck
without the necessary training and authorisation to do so. The driver must never
disable or adjust safety mechanisms or switches.

Hazardous area: A hazardous area is defined as the area in which a person is at

risk due to truck movement, lifting operations, the load handler (e.g. forks or
attachments) or the load itself. This also includes areas which can be reached by
falling loads or owering operating equipment.

Unauthorised persons must be kept away from the hazardous area.

Where there is anger to personnel, a warning must be sounded with sufficient notice.
If unauthorised personnel are still within the hazardous area the truck shall be brought
to a halt immediately.

Safety Devices and Warning Signs: Safety devices, warning signs and warning
instructions shall be strictly observed.

3.2 Operate and run the truck

3.2.1 Preparing
Before the truck can be commissioned, operated or a load unit lifted, the driver must
ensure that there is nobody within the hazardous area.

13
Checks and operations to be performed before starting daily work

– Visually inspect the entire truck (in particular wheels and load handler) for obvious
damage.
– Visually inspect the battery attachment and cable connections.

3.2.2 Travel
Do not drive the truck unless the panels are closed and properly locked.

Driving in low speed

Set the control handle to the travel range (s), and press the travel switch in the desired
direction (fwd. or rev.).
The more the control handle rotates，the speed is faster.

Driving in high speed

Set the control handle to the travel range (k)，and press the travel switch in the desired
direction (fwd. or rev.).
The more the control handle rotates，the speed is faster.(Keep travel switch in a
position, the speed will changed follow control handle. The travel speed when control
handle in area K will fast than area S. )

14
Steering
– Apply the control handle to the left or

right.

Braking
Emergency stop:
Pull out the plug(9), all electrical
functions are cut out and the truck
automatically brakes. Warning!
If the control handle moves slowly or
Automatic braking not at all to the upper brake zone, the
When the control handle is released it truck must be taken out of service until
automatically sets itself to the upper the cause of this fault is be rectified.
brake zone (B) and automatic braking Replace the gas pressure spring if
ensues. necessary.

Regenerative braking
If the travel switch is set to "0", the truck Warning!
automatically brakes regeneratively. If the travel switch moves slowly or not
When the speed below 1Km/h, the at all to 0, the truck must be taken out
brake then applies and motor brake of service until the cause of this fault is
stop. be rectified.
Replace the control handle if
necessary.

Inversion braking
You can set the travel switch (13) to Warning!
the opposite direction when travelling. In hazardous situations set the control
The truck brakes regeneratively until it handle to the brake position or set the
starts to move in the opposite direction. travel switch (13) to the opposite
direction.

15
3.3.3Lifting, transporting and depositing loads
Unsecured and incorrectly positioned loads can cause accidents
·Instruct other people to move out of the hazardous area of the truck. Stop working
with the truck if people do not leave the hazardous.
· Only carry loads that have been correctly secured and positioned. Use suitable
precautions to prevent parts of the load from tipping or falling down.
·Damaged loads must not be transported.
·Never stand underneath a raised load handler.
·Do not stand on the load handler.
·Do not lift other people on the load handler.
·Insert the forks as far as possible underneath the load.

Lift Warning!
Press “Lift” button(12) until the height Before lifting a load unit the driver
you need. must make sure that it has been
correctly stowed and does not exceed
Lower the truck’s capacity.
Press “Lower” button （ 11 ） until the Do not lift long loads at an angle.
lowest position.

16
3.3.4Parking the truck securely
• Press “Lower” button（3）, fully lower the
load handler. Warning!
• Turn off the key (1)switch and remove Parking the truck securely.
the key. Forbid parking on an incline.
• Draw plug(2). Always fully lower the forks.
The truck is parked.

17
 4.Battery Maintenance & Charging

4.1 Safety regulations for handling acid batteries

Park the truck securely before carrying out any work on the batteries.

Maintenance personnel : Batteries may only be charged, serviced or replaced by

trained personnel .The present operator manual and the manufacturer ’s instructions
concerning batteries and charging stations must be observed when carrying out the
work.

Fire protection :
– Smoking and naked flames must be avoided when working with batteries.
– Wherever a truck is parked for charging there shall be no inflammable material or
operating fluids capable of creating
sparks within 2 meters around the truck.
– The area must be well ventilated.
– Fire protection equipment must be
provided.

Protection against electric shock:

– Battery has high voltage and energy.
– Do not bring short circuit.
– Do not approach tools to the two poles of the battery，which can cause the sparkle.

4.2 Battery type & dimension

Battery type & dimension as follow :

Tuck type Battery voltage/ rated Battery Battery Battery
type capacity height (mm) length (mm) width (mm)
Industry
EPT20-20WA 24/210 540 650 200
battery
Industry
EPT25-25WA 24/210 540 650 200
battery

When replacing or installing batteries, ensure that the battery is correctly secured in
the battery compartment of the truck.

4.3Charging the battery

Safety regulations for Charging the battery

– To charge the battery, the truck must be parked in a closed and properly ventilated
room. When charging, the tops of the battery cells must be exposed to provide
sufficient ventilation.
– Do not place any metal objects on the battery.

18
– Before charging, check all cables and plug connections for visible signs of damage.
– Forbid add water to battery directly.
– Before start and finish charging to Warning!
make sure power is turn OFF. Before closing the battery cover make
– It is essential to follow the safety sure that the battery lead cannot be
regulations of the battery and charging damaged.
station manufacturers.

Charging step
– Check whether the condition is
according with "Safety regulations for
Charging the battery".
– Park the truck securely(See 3.2.4
Parking the truck securely Page17 ).
– Remove the battery plug (1).
–Connect the battery plug (1) with the
charging lead of the stationary charger
(2) and turn on the charger.

4.4Battery removal and installation

– Park the truck securely(See 3.2.4
Parking the truck securely Page 17 ).
– Expose the battery
– Place the battery plug(2) or the
battery cable in such a way that they
will not get caught on the truck when
the battery is removed.
– The hooks must be attached to
the eyes of the battery in such a way.
– Start the crane, lifting the
battery.

Warning!
The truck must be parked on level ground. To prevent short circuits, batteries with
exposed terminals or connectors must be covered with a rubber mat.
When transporting batteries using a crane, ensure that the crane is of adequate
Capacity. The lifting gear must exert a vertical pull so that the battery container is
not compressed. Forbid falling lift tool on battery surface.

– Installation is in the reverse order of operations.

19
4.5Battery maintenance
Do not overuse battery:
– If you use up the energy of battery till the pallet immovability, you will shorten its
working hours.
– Shower for battery appears need for charge，please charge it quickly.

Inspection for electrolyte:

– Do not using pallet which is absent electrolyte.
– Inspection for electrolyte level every week.
– When electrolyte level is low，you must add distilled water to the level appointed.

Battery maintenance:
The battery cell covers must be kept dry and clean. The terminals and cable shoes
must be clean, secure and have a light coating of dielectric grease.Batteries with non
insulated terminals must be covered with a non slip insulation mat.

Warning!
1. Do not use dry cloth or fibre cloth to clean the battery，avoiding static to bring the
explosion.
2. Unfixing battery plug.
3. Cleaning with wet cloth.
4. Wearing glasses for protecting eyes rubber overshoes and rubber glove.

4.6Battery Disposal
Batteries may only be disposed of in accordance with national environmental
protection regulations or disposal laws.The manufacturer’s disposal instructions must
be followed.

Batteries contain an acid solution which is poisonous and corrosive . Therefore ,

always wear protective clothing and eye protection when carrying out work on
batteries . Above all avoid any contact with battery acid.

Nevertheless, should clothing, skin or eyes come in contact with acid the affected
parts should be rinsed with plenty of clean water-where the skin or eyes are affected
call a doctor immediately. Immediately neutralise any spilled battery acid.

Only batteries with a sealed battery container may be used.

The weight and dimensions of the battery have considerable affect on the operational
safety of the truck. Battery equipment may only be replaced with the agreement of the
manufacturer.

20
 5.pallet Truck Maintenance

5.1Operational safety and environmental protection

– The servicing and inspection operations contained in this chapter must be
performed in accordance with the intervals indicated in the servicing checklists.

– Any modification to the pallet truck assemblies, in particular the safety

mechanisms, is prohibited. The operational speeds of the truck must not be changed
under any circumstances.

– Only original spare parts have been certified by our quality assurance department.
To ensure safe and reliable operation of the pallet truck, use only the manufacturer's
spare parts. Used parts, oils and fuels must be disposed of in accordance with the
relevant environmental protection regulations. For oil changes, contact the
manufacturer’s specialist department.

– Upon completion of inspection and servicing, carry out the activities listed in the
“Recommissioning (on page 28)” section.

5.2Maintenance Safety Regulations

Maintenance personnel
Industrial trucks must only be serviced and maintained by the manufacturer’s trained
personnel.
The manufacturer’s service department has field technicians specially trained for
these tasks. We therefore recommend a maintenance contract with the
manufacturer’s local service center.

Lifting and jacking up

When an industrial truck is to be lifted, the lifting gear must only be secured to the
points specially provided for this purpose.
When jacking up the truck, take appropriate measures to prevent the truck from
slipping or tipping over (e.g. wedges, wooden blocks).
You may only work underneath a raised load handler if it is supported by a sufficiently
strong chain.

Cleaning
Do not use flammable liquids to clean the industrial truck.
Prior to cleaning, all safety measures required to prevent sparking (e.g. through short
circuits) must be taken. For battery-operated trucks, the battery connector must be
removed.
Only weak suction or compressed air and non-conductive antistatic brushes may be
used for cleaning electric or electronic assemblies.
If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical

21
and electronic components must be carefully covered beforehand as moisture can
cause malfunctions.
Do not clean with pressurised water.
After cleaning the truck, carry out the activities detailed in the “Recommissioning
(on page 28)” section.

Electrical System
Only suitably trained personnel may operate on the truck’s electrical system.
Before working on the electrical system, take all precautionary measures to avoid –
electric shocks.
For battery-operated trucks, also de-energise the truck by removing the battery
connector.

Welding
To avoid damaging electric or electronic components, remove these from the truck
before performing welding operations.

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

Tyres
The quality of tyres affects the stability and performance of the truck. When replacing
factory fitted tyres only used original manufacturer’s spare parts, as otherwise the
data plate specifications will not be kept.
When changing wheels and tyres, ensure that the truck does not slew (e.g. when
replacing wheels always left and right simultaneously).

Lift chains
Lift chains wear rapidly if not lubricated.
The intervals stated in the service checklist apply to normal duty use. More
demanding conditions (dust, temperature) require more regular lubrication.
The prescribed chain spray must be used in accordance with the instructions.
Applying grease externally will not provide sufficient lubrication.

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5.3Servicing 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 intervals are to 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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5.3.1Maintenance Checklist
Maintenance
interval ●
W A B C
Brake Check magnetic brake air gap. ●

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 contactors . ●
Check battery plug ●
Fix the motor and cable ●

Power Visually inspect battery ●

supply
Check battery cable connections are secure, grease ●
terminals if necessary.
Check acid density, acid level and battery voltage. ●

Travel Check the transmission for noise and leakage. ●

Check travel mechanism, adjust and lubricate if ●
necessary.
Check control handle recuperating function.
Check wheels for wear and damage. ●
Check wheel bearings and attachments. ●

Truck Check truck frame for damage. ●

frame

Hydraulic Test hydraulic system. ●

operation
Check that hose and pipe lines and their connections 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 clearn hydraulic oil filter ●
. Replace it if necessary.

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5.3.2 Lubrication Schedule

25
Fuels, coolants and lubricants

Handling consumables: Consumables must always be handled correctly. Follow the

manufacturer’s instructions.

Improper handling is hazardous to health, life and the environment. Consumables

must only be stored in appropriate containers. They may be flammable and must
therefore not come into contact with hot components or naked flames.

Only use clean containers when filling up with consumables. Do not mix consumables
of different grades. The only exception to this is when mixing is expressly stipulated in
the Operating Instructions.

Avoid spillage. Spilled liquids must be removed immediately with suitable bonding
agents and the bonding agent/consumable mixture must be disposed of in
accordance with regulations.

Code Description Used for

A HM46# Hydraulic system
B Grease, Polylube GA352P Lubrication
C GL-5 85W-90 Gear case

5.3.3 Maintenance Instructions

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 3.2.4 Parking the truck securely Page 17 ).
– Disconnect the battery to prevent the truck from accidentally starting.
– When working under a raised lift truck, secure it to prevent it from tipping or sliding
away.

Removing the front panel

– Remove the two screws (1).
–Turn the control handle to the right limit
position.
– Remove the screws(2) in left.
– Turn the control handle to the left limit
position.
– Unscrew the other side.
– Carefully lift off the front panel (3).

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Replacing the drive wheel
The drive wheel must only be replaced by authorised service personnel.

Checking the hydraulic oil level

It is going to add hydraulic oil when you
Warning!
heard explosion sound from pipe during
Forbid adding hydraulic oil within
lifting.
impurity.

– Prepare the truck for maintenance and repairs ( See 5.3.3 Maintenance
Instructions Page26).
– Opening the front panel(See 5.3.3 Maintenance Instructions Page26).
– Add hydraulic oil of the correct grade ( See 5.3.2 Lubrication Schedule P25 ) .
Add hydraulic oil till you cant hear explosion sound during lifting.
Installation is the reverse order.

Check transmission oil level

– Prepare the truck for maintenance and repairs (See 5.3.3 Maintenance Instructions
Page26 ).
– Remove the front panel (See 5.3.3 Maintenance Instructions Page26).
– Turn the control handle to the right limited pisition.
– Check the transmission oil level, it should be at the control plug level (See 5.3.2
Lubrication Schedule Page25).
– Add transmission oil every800-1000 Warning!
operating hours, or at least annually (See Forbid adding transmission oil within
5.3.2 Lubrication Schedule Page25). impurity.
Installation is the reverse order.
Checking electrical fuses
– Prepare the truck for maintenance and
repairs (See 5.3.3 Maintenance
Instructions Page26 ).
– Dismantle the front panel (See 5.3.3
Maintenance Instructions Page26).
– Check rating of all fuses in accordance
with table, replace if necessary.

Item To protect: Rating

1 Controller Fuse 10A

2 Traction / Lift motor 200A

Fuse

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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 schedule.

5.4Decommissioning the industrial truck

If the industrial truck is to be decommissioned for more than two months , e.g. For
operational reasons,it must be parked in a frost-free and dry location and all
necessary measures must be taken before, during and after decommissioning as
described.
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.

5.4.1Prior to decommissioning
– Thoroughly clean the truck.
– Check the brakes.
– Check the hydraulic oil level and replenish as necessary (See 5.3.3 Maintenance
Instructions Page26 ).
– Apply a thin layer of oil or grease to any non-painted mechanical components.
–Lubricate the truck in accordance with
the maintenance schedule (See 5.3.2
Lubrication Schedule P25 ). Warning！
– Charge the battery (See 4.3Charging Charge every months:
the battery P17). – Charge the battery.
– Disconnect the battery, clean it and Battery powered trucks:
apply grease to the terminals. The battery must be charged at
In addition, follow the battery regular intervals to avoid depletion of
manufacturer’s instructions. the battery through self-discharge.
– Spay all exposed electrical contacts The sulfatisation would destroy the
with a suitable contact spray. battery.

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5.4.2 Restoring the truck to operation after decommissioning
– Thoroughly clean the truck.
– Lubricate the truck in accordance with the maintenance schedule (See 5.3.2
Lubrication Schedule P25 ).
– Clean the battery, grease the terminals and connect the battery.
– Charge the battery (See 4.3Charging the battery P17).
– Check transmission oil for condensed water and replace if necessary.
– Check hydraulic oil for condensed water and replace if necessary.
– Start up the truck (see 3.2.2Operate and run the truck P14).

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 them repeatedly.
Perform several brake tests immediately after re-commissioning the truck.

5.5Safety 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 pallet 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.

5.6Final de-commissioning, 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 and electronic and electrical systems must
be observed.

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 6.Troubleshooting
This chapter is designed to help the user identify and rectify basic faults or the results
of incorrect operation. When locating a fault, proceed in the order shown in the table.
Fault Possible cause Action
Truck does – Battery connector not – Check the battery connector and
not start. connected connect if necessary.
－ Key switch in “0” position – Set key switch to “I”
－Battery charge too low – Check battery charge, charge
battery if Necessary
－Faulty fuse – Test fuses
－Truck in charge mode – Interrupt charging
Load can – Charge capacity below 20% – Charging the battery
not be / 40%
lifted – Hydraulic oil level too low – Check the hydraulic oil level
– Excessive load – Note maximum capacity (see
data plate)

If the fault cannot be rectified after carrying out the remedial procedure, notify the
manufacturer ’ s service department ,as any further troubleshooting can only be
performed by specially trained and qualified service personnel.

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