PDF Service Manual EP EPT12-EZ Electric Pallet Truck - 845 KB
This service manual contains all the technical information needed to repair and maintain the EP EPT12-EZ Electric Pallet Truck.
It includes troubleshooting guides, wiring diagrams, and detailed repair procedures.
This guide is essential for technicians to keep these efficient pallet trucks operational and minimize warehouse downtime.
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Service Manual
EPT12-EZ
Electric Pallet Truck
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SAFETY WARNING
For your own safety and that of others, please observe the following safety instructions:
Thorough and normative maintenance is one of the most important prerequisites to ensure
stable and reliable operation of truck. Neglecting regular maintenance could easily lead
to the truck malfunction and failure, and potential threats to staff and operational safety.
Therefore, there must be adequate maintenance equipment, professional maintenance
personnel and a comprehensive maintenance plan in place.
Please perform the maintenance and inspections according to the following provisions:
1. To strictly enforce the truck maintenance, lubrication and inspection plans.
2. Truck maintenance, lubrication and inspection personnel must be approved by accredited
certification or evaluation agency.
3. The following operations shall be performed before you leave the truck:
- No parking on slopes.
- Fully lower the forks.
- Cut off the power supply.
- Turn the switch lock to βSTOPβ and remove the key.
4. Prior to truck maintenance:
- Raise the drive wheel off the ground, or cut off the power supply connection.
- Use wooden wedges or other effective fixtures.
- When performing maintenance underneath the vehicle, make sure that the lifting device
or jack leg is secure.
- Park your vehicle in a safe and secure area.
5. Never use an open flame to check level of electrolyte, other oils or fluids for leaks.
6. Keep the parking lot clean, well-ventilated and dry.
7. Regular checks and maintenance should be conducted to braking, steering, control, warning
and safety devices to keep them in good condition.
8. All nameplates and safety signs on the truck should be cleaned regularly to make them
clearly visible.
9. Regular checks and maintenance should be conducted to all the devices of lifting system to
ensure them to be safe for use.
10. The hydraulic system should be checked regularly based on usage. Hydraulic cylinders,
hydraulic valves and other hydraulic components should be ensured to be without leakage.
11. Regular checks and maintenance should be conducted to batteries, motors, controllers,
limit switches, protective devices, wires and connectors, and so on. Please pay particular
attention to the electrical insulation.
12. Park the truck in a clean environment to minimize the risk of fire.
13. Without the permission of the manufacturer, users are not allowed to change or increase
the capacity of the truck. After having been changed under permission, the nameplates and
safety signs on the truck should also be changed accordingly.
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CHASSIS SYSTEM
4.3.3 Removal and Installation - Tap the coiled elastic cylinder (8) out from
the chassis, and tap the long axis (7) out from
Removal the side to separate the lower connecting rod
(10) with the chassis.
- Fully lower the forks and switch off the power
supply; - Tap the coiled elastic cylinder (3) out, tap the
long connecting rod pin shaft (4) out from the
- Tilt the vehicle to the left or right and support side, and remove the wheel frame assembly
it with a block and other supporting stuff; (5).
CAUTION
When replacing the long connecting rod, the
connecting rod must be adjusted so that the fork
surface height can reach the specified value.
4 Installation
- Install according to the reverse order of rem-
oval.
CAUTION
Before going on with the next step, please fix
the wheel bracket first. Be sure to avoid the
falling of wheel bracket during removal, resulting
in personal injury.
- Tap the coiled elastic cylinder (1) into the axle
(2), and tap the axle (2) out from the side
to separate the wheel frame from the front
chassis;
- Remove the cover; (see Section 4.2)
- Tap the coiled elastic cylinder (11) out from
the bearing bridge, and tap the short axis
(12) out from the side to separate the lower
connecting rod (10) with the bearing bridge;
- Tap the coiled elastic cylinder (13) out from
the long connecting rod (6) , and tap the
short axis (9) out from the side to separate
the lower connecting rod (10) with the long
connecting rod (6) ;
REV. 09/2016
30
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DRIVE SYSTEM
Fault Excessive temperature rise Circuit of drive motor
a. Stator winding short circuit;
b. Motor positive and negative
6 electrodes with surface
Cause oxidation, resistance increases
and results in heating;
c. Bearing failure, resulting in
severe heating.
5.4.3 Checking and Testing
Positive
Negative
Checking
- Check if the drive motor and appearance of
cables are in good condition, and if the plug
connection is secure;
- Check if the circuit is connected.
5 Testing
- Remove the cables on the drive motor;
- Carry out ON/OFF test to motor positive and
negative electrodes with a multimeter:
If connected, the motor is normal;
5.5 Gearbox - A
If not connected: 5.5.1 Removal and Installation
1) Broken circuits in rotor coils (replace the
motor); See Section 5.4.1 .
2) Carbon brush wearing, move on to the
next step. CAUTION
- Replace the carbon brush . Please add gear oil to the grease nipple on the
(See Section 5.4.1) gearbox cover (see Section 2.2.3 for specifica-
tion and filling amount)
CAUTION
When replacing the carbon brush, replace the 5.5.2 Faults and Causes
complete set of carbon brushes.
Fault Gearbox Abnormal Noise
1 a. Supporting bearing wear;
Cause b. Gear wear, the gap is too big;
c. Foreign objects in gear oil.
Fault Gearbox Oil Leaks
2
Cause Oil seal wear or aged
Fault Gearbox Stuck
a. Gear fastening screws or nuts
3 loosening;
Cause
b. Support bearing damage
c. Foreign objects in gear oil.
REV. 09/2016
40
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DRIVE SYSTEM
5
REV. 09/2016
50
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HYDRAULIC SYSTEM
7.6 Reach Cylinder - Upon removal, the damage to cylinder
threads, oil port threads, cylinder cap threads,
7.6.1 Cylinder Removal Precautions piston rod surface and inner cylinder wall
should be prevented.
- Before removing the cylinder, be sure to reli-
eve the hydraulic circuit first, which is to lower In order to prevent piston rod from bending or
the lifting mast to the bottom. Otherwise, deformation, support it wooden block when
when removing the tubing connected with the placing.
cylinder, the pressured hydraulic oil within When removing seals, the use of sharp
the circuit may be sprayed out at high speed tools should be avoided, so as not to stab
along with the tubing, and there is risk of the seals. For the seals that are difficult to
causing personal injury. remove, soak them with boiled water, remove
Turn off the power source, so that the entire them when getting softened.
hydraulic system will stop functioning, then - Before removing, try to create conditions
the connecting tubing can be loosened; in
to prevent the cylinder parts from being
order to avoid the residual pressure within the
contaminated by the surrounding dust and
circuit, the tubing joint should be loosened
impurities. For example, try to disassemble
slowly, loosen the joint by half and shake the
the equipment in a clean environment; after
tubing to see if there is overflow of pressured
the disassembly, all parts should be covered
oil, and then go on with the removal;
with plastic, do not cover with cotton cloth or
- Cylinder is the powered actuator in hydraulic other cloth used during operation;
system. Therefore, before removing the - For the cylinder which is found with internal
cylinder from the equipment, the connection or external leakage during use, if the piston
part must be supported with appropriate rod or cylinder tube is not scratched, such
supporting to avoid personal injury or damage case may be due to wear or aged seals.
to the equipment;
- Cylinder is the powered actuator in hydraulic CAUTION
system. Therefore, before removing the
7 cylinder from the equipment, the connection
part must be supported with appropriate
When the seals need to be replaced, replace
with the complete set of seals in the cylinder
supporting to avoid personal injury or damage repair kit.
to the equipment;
- For the cylinder which is found with internal
- Upon disassembly of the cylinder, you should or external leakage during use, if the piston
know the main structure of the cylinder to rod or cylinder tube is not scratched, such
avoid sightless removal. Due to the different case may be due to wear or aged seals (when
size, structure, purpose of use of the replacing seals, replace with the complete set
cylinders, the sequences and methods used of seals in the cylinder repair kit).
for removal are also different;
Pay special attention to the cylinder tube,
- When removing each part, do not hammer piston rod and other moving parts for bumps
forcefully, it such case cannot be avoided, and scratches. If only minor damage, sand
please lay a copper rod to avoid damage the edge point around the damaged part with
to the parts; special tools must be used for fine stone and then polish the part smooth
the parts having such requirements, do not with metallographic sandpaper.
hammer forcefully or pry. Fine pitch threaded
cylinder cap, after being shaken loose,
loosen it with cylinder wrench with even force,
copper rod can be used to hammer the part
that cannot easily deform, do avoid violent
shocks.
REV. 09/2016
70
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ELECTRICAL SYSYTEM
8.3 Emergency Stop Switch 8.3.2 Faults and Causes
Emergency switch is used for emergency cut-off Emergency switch at pulled-out
Fault
of the power supply to all the control circuits. status, the vehicle not energized
1 a. Emergency switch failure;
8.3.1 Removal and Installation Cause b. Emergency switch circuit not
conducted.
Removal
Emergency switch pressed, the
Fault
- Remove the protective cover;(see Section vehicle still energized
4.2)
2 a. Emergency switch failure;
Cause b. Emergency switch shorted
(short circuit)
8.3.3 Checking and Testing
Checking
- Check if the appearance of emergency switch
its wiring harness are in good condition, and
if the connectors are connected securely.
Testing
- Check if the emergency switch circuit is con-
ducted;
- Carry out ON/OFF test to emergency switch
with a multimeter:
- Disconnect the emergency stop switch con- Emergency switch in pulled-out status, circuit
nector from wiring harness; conducted;
- Unscrew the screws on the emergency stop press the emergency switch, the circuit is
switch (1) and remove switch. opened.
Installation 8.3.4 Control Circuit Troubleshooting
8 - Install according to the reverse order of rem-
oval.
Emergency Switch Control Circuit
(Figure 12506)
Check if the circuit is broken by using a multi-
meter:
- Set the multimeter to ON-OFF;
- Check if #0/#1/#3 circuit is conducted.
REV. 09/2016
80
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ELECTRICAL SYSYTEM
8.7.3 Monitor Menu
The parameters in Monitor Menu are real-
time presentation of the running status of the
equipment.
Traction Controller (1212C)
Name Display Range Description
KSI Voltage 0.0 ~ 38.2 V KSI Voltage.
Battery Voltage 0.0 ~ 38.2 V Battery Voltage.
Cap Voltage 0.0 ~ 38.2 V Capacitor Voltage.
Motor Voltage -27.4 ~ +27.4 V Voltage drop between the motor terminals.
Pot Low Voltage 0.0 ~ 5.0 V Pot low voltage.
Temp -55 ~ +120 β Controller's internal temperature.
Current cutback during motor over temperature,
Motor Thermal Cutback 0 ~ 100 % as a percentage of max current.
100% = no cutback.
Armature Current -90 ~ +90 A Measured motor armature current.
Ultimate current limit of the controller, taking into
Current Limit -90 ~ +90 A
account boost mode, thermal protection, etc.
Measured system resistance, when the motor is
Resistance 0 ~ 854 mohm
stalled.
Throttle -100 ~ 100 % A vailable throttle input.
BDI 0 ~ 100 % Status of battery capacity in percentage.
Hours of operation since the hourmeter was last
8 Hourmeter
Mode Switch
0 ~ 99999.9 hours
On / Off
reset.
Status of the mode switch (at J1-4).
Forward Switch On / Off Status of the forward switch .
Reverse Switch On / Off Status of the reverse switch.
Interlock Switch On / Off Status of the interlock input switch (at J1-6).
EMR Switch On / Off Status of the emergency reverse switch .
AUX Switch On / Off Status of the AUX input switch (at J1-9).
REV. 09/2016
90
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ELECTRICAL SYSYTEM
Electrical Lowering
CONTROLLER
MAIN WIRE
HARNESS
SOLENOID
VALVE
HORN
Interlock SW.
HANDHELD
UNIT
PUMP
CONTACTOR
POWER WIRE
HARNESS
8
ELBOW WIRE
HARNESS
BATTERY KEY SW.
INSTRUMENT
E-STOP LIFTING
SW. LIMIT SW.
LOWERING SW. TRAVEL SW.
REV. 09/2016
100