Learn how to operate the DP2 3-wheel counterbalanced battery forklift truck by reading this operating manual, providing step-by-step instructions and guidelines for efficient usage.
Thanks for your purchasing our forklift truck. 3 wheel counterbalanced battery forklift truck is our company's new product. It has the character of small turning radius, beautiful shape, small dimensions, low gravity. This series forklift truck use 2-motor drive, rear wheel turning, lifting and turning share one pump ext. new technology. This manual has two parts. First one is how to use, operation and maintenance 3 wheel battery forklift truck. The second part simply introduces the structure and principle of the 3 wheel forklift truck and some of the trouble shooting. Please operator and whom in charge of the 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 sales department of E-P Equipment or let the agents know. 1.3-2.0t V series three wheel battery forklift has already passed CE certificate.
Meaning of model
Model
Traction controller
Pump controller
Rated capacities (t)/ Load centers(mm)
V13
DUAL SEM2 (ZAPI)
HP48/350(ZAPI)
1.3/500
V15
DUAL SEM2 (ZAPI)
HP48/350(ZAPI)
1.5/500
V16
DUAL SEM2 (ZAPI)
HP48/350(ZAPI)
1.6/500
V18
DUAL SEM2 (ZAPI)
HP48/350(ZAPI)
1.8/500
V20
DUAL SEM2 (ZAPI)
HP48/350(ZAPI)
2.0/500
ALL RIGHT RESERVED COPYRIGHT @2004.5 2ND EDITION E-P Equipment
CONTENT
Description of main parts
1
Instrument
3
Controls
7
Pedals
9
Body and others
9
Safety instructions
11
Relationship between load and stability of truck
18
During break in
20
Daily maintenance
21
Driving and operation
23
Deposit
25
Storage battery
27
Maintenance
33
Table for oil used in the truck
45
Truck’s convey, lifting, Towing
46
3-wheel battery forklift specification
57
Part two
Drive system
49
Steering system
52
Brake system
55
Hydraulic system
57
Lifting system
60
Electrical system
67
V18 Error Code
86
PART ONE
Description of main parts
1. Fork 2. Load back rest 3. Mast 4. Lifting cylinder 5. Safe guard 6. Steering wheel 7. Seat 8. Counter weight 9. Rear wheel 10. Chassis 11. Left & right battery cover hood 12. Front wheel
1
Instrument
1.Steering wheel 2. Direction switch 3. Parking brake lever 4. Emergency disconnect switch 5. Adjusting lever 6. Accelerator pedal 7. Brake pedal 8. Key switch 9. Combined lamp Switch (turning light & big lamp) 10.Lifting lever 11. Tilting lever 12. Side lever 13. Meter panel
2
3
The meaning of six indicators:
Power indicator (A) Only lights on when power supply is OK.
Error indicator (B) When operation is wrong , error code will display on the dashboard. The error indicator lights on.
Low battery warning (C) When battery quantity is lower than 20% of the maximum capacity. The indicator lights on, at the same time, buzzer beep. When LED shows no power, please charge battery as quick as possible.
Parking brake warning (D)
Parking brake indicator (E)
When pulling on the parking brake lever, this lamp lights on.
Safety belt indicator (F) When the safety bel is off, this lamp lights on.
ENTER Button: Save all changing
ROLL DOWN Button: Change the digit marked by cursor
ROLL DOWN Button: Change the digit marked by cursor
SET DOWN Button: Shift cursor on previous digit
SET DOWN Button: Shift cursor on the following digit
OUT Button: Cancel all charging
Dash Display LED (M) When turn on the key switch, the system will self-diagnose, the lamp will lights on one by one. After self-diagnose, LED will display truck speed and battery capacity. You can know your truck's working condition through the LED dashboard.
4
Key switch [3] The key switch has two “on/off” position, you should push the forward-reverse lever to neutral and loose the accelerator pedal, then turning the key switch to “on” position clockwise.
Warning!
1.Turning the key switch “on” does not make the forklift truck to move, if the Forward-Reverse lever is not in the neutral position or the accelerator pedal is being pushed. 2.Error code maybe appear, don't worry about it.
3.When the forklift can be operated then the error code should be disappeared.
Horn button [5] Press down the horn button on the center of the steering wheel. The beeper will beep. The horn sounds even when thew key switch is off.
Combined light switch [7] This combined light switch is composed of turning light switch and big/small lamp switch. Turning light indicates the travelling direction. When turn on the switch, the lamp flashes.
Forward
Left turning lamp flashes
Neutral
Lamp goes off
Backward
Right turning lamp flashes
Warning! The turn signal lever does not automatically return to the neutral position unlike general passenger cars. Reset it by hand
Big/small Lamp Switch has two shifts. First shift small lamp lights on; second shift big and small lamp all light Emergency disconnect switch [9] When happen emergency,, presses down the emergency cut off power switch, the main power of the reach truck will be cut off.
Warning!
Please don't use the emergency disconnect switch to substitute the function of key switch
Rear big lamp switch [10] optional Rear big lamp switch has only one shift. X means connected
Connector/Position
Battery
Far light
0
X
1
X
X
Warning!
This light does not relate to key switch possition so please don't forget to turn off the rear big lamp when you leave the truck.
Fuse box
1st is control circuit fuse 15 A..
2nd, 3rd and 4th are light and beeper circuit fuse. All of them are 15 A. 5th and 6th is a spare fuse 15 A.
Warning! When replace a new fuse. please choose the same capacity fuse of the old one.
5
CONTROLS Steering wheel [1] The steering hand-wheel is operated in the conventional manner, that is, when the wheel is turn right, the truck will turn to the right. When the wheel is turn left, the truck will turn to the left. The steer wheels are located at the rear of the truck. These cause the rear of the truck to swing out when a turn is made.
Warning! This truck is provided with the power steering, so heavy hand-wheel operation is caused when the steering motor comes to stall. To put the power ste the steering motor without delay. entering in operation again restart.
Parking brake lever [4]
Use this parking brake lever to park the lift truck. And the parking brakes are applied on the front two wheels by pulling up on this lever. To release the parking brakes, move the lever forwards. There is a micro switch at the left side of the parking brake lever, it can make running invalid to tense the lever.
Warning! If parking on a grade is unavailable, be sure to block the wheel.
Foward-reverse lever [6] The forward-reverse lever is for switching between forward and backward moves. When the lever is pushed forward and accelerator pedal pressed, the forklift trucks moved forward. When the lever is pushed backward, the forklift trucks moved backward.
Warning! While travelling, if change the Foward-Reverse lever, electric braking will operate, speed will lower until stop, then travel to the opposite direction.
Warning! Turning the key switch “on” does not make the forklift truck move, if the Forward-Reverse lever is not in the neutral position or the accelerator pedal is being pressed. In this case, the Forward-Reverse lever should be returned to neutral and move your foot from the accelerator pedal. Then the truck can be operated.
6
Lift lever [11]
The forks can be raised or lowered by pulling backwards or pushing the lever. Lifting speed can be controlled by tilt backwards angle of lever and accelerator pedal effort while the lowering speed can be controlled by tilt forwards angle of the lever. The motor speed or accelerator pedal does not have to do with the lowering speed of the forks. Tilt lever [12]
The mast can be tilted by operation of this tilt lever. Pulling on this lever backwards will tilt the mast backwards, and pushing it forwards will tilt the mast forwards. The tilt speed can be controlled by tilt angle of the lever.
Warning! The tilt lock mechanism built in the hydraulic control valve does not allow the mast to tilt forwards while the engine is being shut down even if the tilt lever is pushed forwards.
Control valve lever lock rod [13] Use this rod you can push the control valve lever forward to open the battery hood. Pull up the rod and push forward, the lift lever and tilt lever will moved forward, at this time you can open the hood. On the contrary, when close the hood, you should pull backward the rod to make the tilt and lift lever on its original position.
7
Pedals
Brake pedal [14] Press this pedal to slow or stop the truck. At the same time, the brake light comes on.
Warning! no permitted to press the brake pedal and accelerator pedal at one time, otherwise, it should harm the travelling motor.
Accelerator pedal [14] As the accelerator pedal is slowly pressed, the drive motor star turning and the forklift truck will start to move. According to the force applied to the pedal, the speed is adjusted with not steps.
Warning! Before open the key switch to press the accelerator pedal, the more function digital indicator shall show alarm information. Then you must release the accelerator pedal.
Warning! When loosen the accelerator pedal, truck can make soft brake because of electric control's regenerate brake.
Body and others
Seat and adjusting lever Adjust operator's seat to position which is comfortable for you and provides easy access to all hand and foot controls. The seat is unlocked by moving the adjusting lever to the light. Before proceeding with work, adjust operator's seat and make sure that it is securely locked.
Overhead safe guard The overhead guard used is strong enough to meet safety standard, and protects the operator from falling materials. The top gap is used to the lift batteries. It is forbidden for use a truck that does not with safeguard. Hood[15] The hood can be swung up fully to provide easy examining and maintenance of the storage batteries. You can lift up the hood with little effort with an aid of hood damper. To lock the hood, push the button of the air spring, and push down on the front of the hood until it covered.
Warning! 1. Be careful do not to catch your fingers in the hood when closing it. 2. When you want to open the hood, you should pull up the control valve lock rod and push forward the rod. 3. On the contrary, you should push the rod backward to make the rod into its original position when close the rod.
Left & Right side battery cover hood It is cover hood of battery one left and one right. When you want to take off the hood, you should take off the knob at first and pull to upside. Fork stopper Fork stoppers are locked the forks in position. To adjust fork spacing, pull up fork stoppers, turn and shift the forks to the desired position. The fork spacing should be adjusting according to loads to be handled.
8
Warning!
Before open the key switch to press the accelerator pedal, the move function digital indicator shall show alarm information. Then you must release the accelerator pedal.
Safety step and safety grip The safety steps are provided on both side of the truck body. The safety grip is provided on the front left pillar of the overhead guard. Use the safety step and safely grip facing the truck when mounting and dismounting the truck. Brake fluid reservoir cup The brake booster is located at the under of the front floor.
Warning!
The brake fluid is poisonous, be careful do not drop down. When add brake fluid, be careful do not let dirt and other thing drop into reservoir cup.
Head lights and combination Two headlights and combination lights (turn signal, parking and backup) are installed at the front side of the truck. Take care of the lights, and wipe dirt, if any, and replace any damage lights immediately. Rear combination lights
The combination lights at the rear side serve as turn signal, show with lamp, brake lamp, parking lamp, back-up lamp and rear reflector. Pay attention to keep them from being damaged or covered with dust, if any, clean or replace immediately. Steering column tilting angle adjuster
The tilting angle of the steering column is adjustable with a range of 12.5 degrees to suit individual operators. The steering column is unlocked by turning the right handle counterclockwise and locked by turning the right handle clockwise. Hydraulic oil reservoir cap The hydraulic oil reservoir cap is located at the left side below the battery hood; open the left side battery hood when adding oil. The cap is provided with the dipstick. After fill in clean hydraulic fluid, tighten lock the cap. Air leakage plug There is an air leakage plug on the oil tank to let air in the tank goes out. You'd Better often check the plug and see whether been jammed. Dead man switch (optional) When the operator leaves seat, this switch cut off, and the power of truck is cut off. Safety seat belt (optional) There is a safety belt on the seat, before you operate the forklift truck, please fasten the seat belt to protect yourself. Rear big lamp (optional) The rear big lamp is set on the safeguard. If is broken, please replace a new one at once.
9
Safety instructions Safety is your business and your responsibility. The “Safety Instructions” covers basic safety procedures and warnings of general application to the typical forklift truck. However, safety precautions given on the following pages are also applicable to lift trucks that have special specifications or attachments. Read this manual thoroughly and become completely familiar with your truck to get the most out of it. 1. Know your truck For the purpose of doing material handling job, the forklift truck is different from general passenger cars is structure as follows: Poor front view due to the hoist system. Rear wheel steering lets the rear of the truck swing outwards when going around corners. Compactly designed, the forklift truck is heavy. Most of the weight of the truck is heavy. Most of the weight of the truck and loads is on the front wheels when loaded so the truck stability. Read the operator's manual and name plates on the truck, and become familiar with your truck and operating procedures. If there is something in the manual you do not understand, ask your supervisor to explain it to you.
2. Get permission from supervisor.
Only trained and authorized operator shall be permitted to operate the truck.
3. Make periodic checks Inspect the truck at periodic intervals for oil or water leak, deformation, lousiness, ect. if neglected, short life of components will be caused and in the worst case a fatal accident would occur. make sure having replaced good parts during periodic check. Wipe oil, grease or water from the floor board and foot and hand controls, if any. Strictly prohibit smoking and spark nearby the storage battery when checking it. If maintenance on high position, such as mast, front and rear lamp, please be careful to prevent fall down clamped. Be careful do not be scalded when inspect the motor, controller and ect. 4. Stop using the forklift when it is in trouble
Whatsoever in trouble, you must stop the forklift, hang a mark of “danger” or “trouble” and take off the key, at the same time inform the manager. Only after the trouble is removed, you may use the forklift.
5. Protect yourself Operation must wear helmet, safety shoes and work clothes. 6. Prevent exploding Because there will bring exploding gas in the bosom of the battery, prohibit any flame nearby it absolutely.
Don't let any tools close the two terminal of the battery to avoid spark or short circuit. Make sure to operate the truck on concrete firmly enough or bituminous macadam.
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The weather of working condition is: Air temperature -20C~50C Wind speed: Less than 5m/s. Air specific humidity: Less than 90%. (Temp at 20C). Truck cannot be operated in explosive gas environments. 7. Mount properly Never mount or dismount the moving truck. Use the safety step(s) and safety grip facing the truck when mounting or dismounting the truck.
8. Never move controls unless properly seated Never attempt to work the controls unless properly seated. Before staring, adjusting the seat so you can get easy access to all hand and foot controls.
9. Start safely Before starting up, make sure that: The parking brake lever is applied securely. The foward-reverse lever is in neutral. Before starting, make sure no one is under, on and close to the truck. Don't step the accelerate pedal or control the lifting lever or tilting lever before turning on the power. 10. Prohibit sudden stop or turning Operate the controls smoothly. Avoid
Sudden stops or turns. It is dangerous to make a sharp brake. otherwise the truck has the possibility of overturn.
11. Pay attention to the route of the truck -Pay attention to the route of the truck. be sure to make a wide sight.
12. Don't offer rides to others Never allow other person(s) to ride on the forks, pallets or on truck.
13. Know the load to be handled Taking account of the shape and material of the load to be handled, use a proper attachments and tools. Avoid hoisting the load, with wire rope hung
11
on the fork or attachment, since the wire rope may slide off. If needed, a qualified personnel for slinging operation should performed, making use of a hook or crane arm attachment. Take care not to protrude the forks out of the load. The protruded fork tips may damage or turn over the adjacent load. 14. Know capacity of truck Know the rated capacity of your lift truck and its attachment, if any, and never exceed it.
Do not use a man as an additional counterweight. It's quite dangerous. 15. Don't daydream Keep your mind on your work. Learn to anticipate danger before it arises.
16. Remain seated Keep your head , hands, arms, feet and legs within the confines of the operator's compartment. Never reach into upright for any reason.
17. Use proper pallet The pallet and skid used should be strong enough to endure the load. Never use damaged or deformed ones. 18.Use proper attachment We afford all type of attachment, such as rotating roll clamp, bale clamp, side shifter, and crane iib. You should refit the truck under ours license if you want . It is forbidden to refit it by yourself. 19 Attach safeguard and load bracket Safeguard protect you do not be hurt by the goods fallen. Load bracket protect you load goods smoothly. It is forbidden to use truck without safeguard or load bracket 20. Forbidden walk down or up the fork It is forbidden to walk down the fork or attachment. It is forbidden to walk up the fork or stand on the fork
21. Avoid be clamped by the mast It is forbidden to put your hands, arms or head stretch between the mast and safeguard. It is forbidden to put your hands in inner and outer mast.