Baoli EP16-N01 Service Maintenance Manual Download

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Service & Maintenance Manual

Pallet truck EP16-N01 EP20-N04

Warning

You must read the instructions in this manual
before using the manual.

Notice:



The last page, please check the file and
all of the current product type on the
nameplate.



Pay attention to keep for future use.

Summary of Contents for EP16-N01

Page 1: ... truck EP16 N01 EP20 N04 Warning You must read the instructions in this manual before using the manual Notice The last page please check the file and all of the current product type on the nameplate Pay attention to keep for future use ...

Page 2: ... 3 7 BATTERY CHARGING AND REPLACEMENT 26 3 8 ELECTRICAL COMPONENTS REPLACEMENT 31 3 9 TOOL FOR REPAIRING THE PIN OF ELECTRIC PLUG 37 4 HYDRAULIC SYSTEM 38 4 1 CLEANING TANK AND FILTER 39 4 2 CHANGE OF PUMP STATION 40 4 3 REPLACE THE HYDRAULIC OIL 41 4 4 REPLACE THE FILTER 42 4 5 REPLACE CARBON BRUSH 43 4 6 ADJUST THE PUMP PRESSURE 45 5 DRIVING WHEEL 46 5 1 REPLACE THE DRIVE WHEELS 47 5 2 ADJUST TH...

Page 3: ... EN 12053 driver s ear noise level is less than 70dB A NOTICE Waste packaging should be according to the material classification in solid waste box collection processing and specially by the local environmental protection bureau To avoid pollution optional littering is prohibited To avoid the spill situation when use the product the user should prepare some materials can be absorbed waste wood chi...

Page 4: ...ANCE SAFETY IN THIS AREA RESPONSIBIUTY OF THE OWNER OR OPERATOR FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LlSTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION Only specially trained personnel to the local operation Please read it carefully before operation or maintenance vehicle operation and maintenance manual Read all the vehicles with preventiv...

Page 5: ... dangerous substances there is fire don t appear grease or oil To do a good job of using fire extinguishers and other firefighting equipment Keep battery away from fire hazards the generated gas explodes Flammable things far away from the vehicle and smoking is prohibited to work Disconnect the battery when you replace the electrical components Using force recommended oil level according to the en...

Page 6: ... maintenance work Unless you have special instructions must the ability after the motor stopped for maintenance work If the motor run time for maintenance you must have two technicians present a piling car operation and another for maintenance work In this case do not touch any contact with any moving parts Before adjustment lubrication and maintenance work close all the power switch Remove contai...

Page 7: ...76400 1195800 a 0 01 100 0 0001 1 1076 4 119 58 ft2 0 092903 0 000929 1 0 1111 144 000 yd2 0 83613 0 008361 9 1 1296 00 in2 6 4516 0 000645 0 006943 0 000771 1 1ha 100a 1mile2 259ha 2 59km2 Volume unit cm3 cc m3 l in3 ft3 yd3 cm3 m l 1 0 000001 0 001 0 061024 0 000035 0 000001 m3 1000000 1 1000 61024 35 315 1 30796 l 1000 0 001 1 61 024 0 035315 0 001308 in3 16 387 0 000016 0 01638 1 0 000578 0 00...

Page 8: ...m STANDARD TIGHTENING TORQUE The following charts give the standard tightening torques of bolts and nuts METER TABLE Classification 4T 5T 10T Bolt type Bolt size Torque kgf m lbf ft Torque kgf m lbf ft M4 0 2 0 02 0 4 0 04 M5 0 3 0 03 0 8 0 08 M6 0 5 0 05 1 4 0 14 M8 1 2 0 12 3 3 0 3 M10 2 3 0 23 6 5 0 7 M12 4 0 0 4 11 3 1 1 M14 6 4 0 6 17 9 1 8 M16 9 5 0 9 26 7 2 7 M18 13 5 1 4 38 0 3 8 M20 18 6 ...

Page 9: ...7 2 1 38 0 3 80 106 9 10 7 1 1 8 54 1 5 41 152 2 15 2 1 1 4 74 2 7 42 208 9 20 9 1 3 4 98 8 9 88 277 8 27 8 1 1 2 128 2 12 82 360 7 36 1 The torque in above table shall not be applied to nylon or nonferrous bolts or washer The same is valid for not standardized ones H Newton meter 1 Nm 0 1kgfm Split flange bolt tightening torque The following table torque applied to split flange bolts Diameter mm ...

Page 10: ...m 1 8 1 1 0 1 1 4 2 6 0 2 3 8 4 6 0 3 1 2 8 5 0 4 3 4 19 1 0 1 33 2 0 With rotate the nut torque o rings Connector O ring Swivel nut hose Tube O D inch Thread in Torque kgf m 1 2 UN 13 16 16 9 5 0 95 3 4 UN 1 3 16 12 18 1 8 1 UN 1 7 16 12 21 2 1 ...

Page 11: ... 0 069 bar MegaPascal MPa 145 psi 0 00689 MPa Pa N m2 Power r W J s kiloWatt kW 1 36 PS cv 0 736 kW kiloWatt kW 1 34 HP 0 746 kW kiloWatt kW 0 948 Btu s 1 055 kW Watt W 0 74 ft lb s 1 36 W W J s Energy J N m kiloJoule kJ 0 948 Btu 1 055 kJ Joule J 0 239 calorie 4 19 J J N m Velocity and Acceleration meter per sec2 m s2 3 28 ft s2 0 305 m s2 meter per sec m s 3 28 ft s 0 305 m s kilometer per hour ...

Page 12: ...ischarge indicator LED charging indicator 12 Steering wheel parts 3 handle shank 13 hydraulic oil cylinder 4 Drive control switch switch butterfly 14 5 Safety switch button belly 15 6 Instrument panel cover 16 7 Joint emergency button 17 8 Key switch 18 9 Pallet fork chassis 19 10 Load wheel 20 ...

Page 13: ...13 CONTROL HANDLE 5 Safety switch 15 Lifting switch 4 Drive control switch 14 horn button 5 4 14 15 ...

Page 14: ... 530 3 7 Wheel base behind Bearing side b11 mm 367 512 size 4 4 Hoisting height h3 mm 120 4 9 The height of the operating lever in the neutral position h14 mm 1235 1005 1445 4 15 Goods fork minimum height h13 mm 85 4 19 Overall length l1 mm 2667 2122 4 20 Body length l2 mm 1516 971 4 21 overall width b1 mm 790 4 22 Pallet fork size s e l mm 60 173 1150 4 25 Pallet fork out wide b5 mm 540 685 4 32 ...

Page 15: ...15 other 8 1 Drive control Ac speed control 8 4 According to the EN12053 driver s ear noise level dB A 69 ...

Page 16: ...ty index 150 150 Cleveland open cup O C 160 160 Pour point Maximum O C 35 35 Density 15 O C kg m3 861 5 Copper corrosion 100O C 3h Level 1 1 Foaming 93 5 O C ml ml 30 0 30 0 D type vane pump test Biggest loss mg 100 15 3 Wear points of diameter 1200 r min 294N 30min 75 O C mm 0 5 0 5 GEAR BOX OIL Extreme pressure lithium grease 1 Features Unit Penetration 0 1mm 310 340 Drop point O C 170 Extreme p...

Page 17: ...17 3 ELECTRICAL SYSTEM 3 1 ELECTRIC DIAGRAM Electric diagram FUSE01 150A FUSE02 80 A FUSE1 10 A ...

Page 18: ...18 3 2 ELECTRIC INSTALLATION Electrical assembly ...

Page 19: ...ssed pan head screw 2 M3 25 11 Type I hexagonal nut 2 M3 12 General key switch 1 LKS 101A key 13 General key switch 1 LKS 101A 14 voltameter 1 CURTIS 803 15 hexagon socket cap screws 2 M5 16 16 Standard spring washer 2 5 17 Flat washer class C 2 4 18 Standard spring washer 9 4 19 cross recessed pan head screw 5 M4 12 20 AMP core 2 connectors 4 21 Plug in bending plate 1 22 hexagon socket cap screw...

Page 20: ...agon socket cap screws 8 M8x40 3 Standard spring washer 9 8 4 Driving wheel seat 1 5 hexagon socket cap screws 1 M8x16 6 Small washer A class 1 8 7 handle seat 1 8 hexagon socket cap screws 4 M10x20 9 Standard spring washer 4 10 10 Elastic cylindrical pin heavy 2 8x26 11 Vertical communication drive assembly 1 ...

Page 21: ...ntity Remarks 1 Oil cylinder pin 1 2 Composite set 2 20 23 20 3 Shaft with elastic ring type A 2 20 4 hexagon socket cap screws 2 M8x16 5 Standard spring washer 2 8 6 Dc hydraulic power unit cell 1 7 Hydraulic hose assembly 1 8 Seal copper pad 1 9 Joint bolt 1 ...

Page 22: ...pe joint 1 11 hexagon socket cap screws 1 M10x20 12 Oil cylinder 1 13 Support ring 1 50X55X15 14 Y type sealing ring 1 50X60X6 7 15 Dust ring 1 50X58X5 6 5 16 piston rod 1 17 Oil cylinder components 1 18 Sealing parts 1 ...

Page 23: ...rger Asian English 1 24V 25A Charger European style 1 24V 25A Charger Australian 1 24V 25A Charger English style 1 24V 25A Charger American 1 24V 25A 2 Power supply assembly 1 Bolt type 3 Power supply assembly 1 welded 4 Connector components 1 Bolt type battery only 5 Plastic screws 24 Bolt type battery only ...

Page 24: ...ontroller 1 AC 0 24V 200A 3 Hang line board 3 4 Traction motor contactor 1 C100 120 DC24V 5 electric relay 1 ACR01F F 1AD DC24V 6 Bolt the fuse 2 SYY 7 Bolt fuse 1 80A 8 Copper platoon 1 9 Bolt fuse 1 150A 10 Fuse holder for a vehicle 1 BD 1X10A 11 Auto Fuses 2 10A 12 Main contactor mounts 1 ...

Page 25: ...ng washer 2 8 18 hexagon socket cap screws 1 M8x16 19 cross recessed pan head screw 1 M5x10 20 Standard spring washer 5 5 21 Flat washer class C 5 5 22 cross recessed pan head screw 4 M4x16 23 Standard spring washer 10 4 24 Flat washer class C 10 4 25 hexagon socket cap screws 2 M3x25 26 cross recessed pan head screw 6 M4x10 ...

Page 26: ... that all of the cable connected correctly and not interfere with other parts to a vehicle For the standard battery this car is equipped with the following valve control type sealed lead acid battery model One 2VBS 24 V 160 Ah EP16 Only allowed to use the liquid acid sealed batteries The weight of the battery had certain influence on vehicle operation behavior Please consider the highest working t...

Page 27: ...ect the connector from the socket and put it in the designated bags REGULAR MAINTENANCE Only qualified personnel are allowed to repair or to rechange the battery please be sure to follow the manual instructions and battery manufacturers Before maintenance please fork removed the goods from the goods and the goods fork fell to the lowest position For vehicles please according to the fourth chapter ...

Page 28: ...on and damage replace if necessary 12 Lubrication to bearing 13 Check and lubrication pivot point 14 Lubricating grease nipple Electrical system 15 Check whether the wire is damaged 16 Check the electrical connections and terminal 17 Detect abrupt stop switch function 18 Check whether there is electric drive motor noise and damage 19 Test the monitor 20 Check whether or not to use the correct fuse...

Page 29: ...d point Grease required specifications for DIN 51825 standard grease CHECK AND REFILL THE HYDRAULIC OIL AGAIN The hydraulic oil type required H LP 46 DIN 51524 Viscosity is 41 4 47 According to the type of the oil are respectively 0 7 L 16 20 Waste materials such as waste oil waste batteries or other materials must be according to the national laws and regulations for processing and recycling if n...

Page 30: ... CHECK THE FUSE Remove the main cover the fuse is located in the position shown in figure 17 Table 4 Fuse specification Specification FUSE01 150A FUSE02 80A FUSE1 10A Figure 17 Fuse location Fuse position ...

Page 31: ...TS REPLACEMENT The bolt with Allen wrench unscrew can remove the cover REPLACEMENT OF ELECTRIC SCALE THE KEY SWITCH AND URGENT STOP SWITCH 1 The key switch connector to disconnect 2 The electricity meter connector to disconnect ...

Page 32: ...32 3 The proximity switch connector to disconnect 4 With four bolts on Allen instrument fixed plate 5 With cross up remove the two screws on the abrupt stop switch ...

Page 33: ...e the mushroom head 7 With the 2 5 mm wrench to integrate the instrument fixed plate and the leaf shape panel connection of four screws unscrewed 8 With the 3 mm to dismantle the fixed stop switch and the two screws ...

Page 34: ...34 9 Can replace the urgent stop switch 10 Unscrew the fixed nut can replace the voltameter 11 Counterclockwise to dismantle the key switch on the nut remove the key switch ...

Page 35: ...nch unscrew the nut corresponding to replacing the fuse Open the fuse seat cover remove the fuse and replace ELECTRONIC CONTROL OF REPLACEMENT 1 The electric connector pulled up 2 Using a wrench to electric control B B U V W on the bolt ...

Page 36: ...36 3 To get off four bolts fixed controller one on each corner can change the electric control ...

Page 37: ...ictures Application 1 Tool for removal of pins sleeves 2 Tool for application of pins sleeves 3 Tool for release of lock 4 Tool for application of secondary locking 2 pole 5 Tool for application of secondary locking 4 pole 6 Tool for removal of pins sleeves ...

Page 38: ...scosity qualified can continue to use Change color as milk good Mixed with air and water Separation of water or replace the hydraulic oil Become a dark brown color bad oxidation Replace the hydraulic oil Color clear but have small black spots good Mixed and other particles The filtered using lift cylinder lowering valve pressure control valve Hydraulic power unit motor and oil pump oil box Throttl...

Page 39: ...If the failure or damage to the filter to replace Clean the tank on dust and foreign bodies assembly FAULT ANALYSIS Phenomenon Cause Result The hydraulic oil has a bubble There are air into the hydraulic oil Check air from which place into the fuel tank reinforce the loose parts Discoloration Air water and hydraulic oil mixed together Replace the hydraulic oil By oxidation or mixed with other part...

Page 40: ...whether this situation occurred Solenoid valve is wearing parts If after lifting goods fork down automatically the electromagnetic valve can block or damage clean or replace solenoid valve Impact hydraulic pipe joints and hydraulic pipe may be loose and the oil so you need to check if loose to tight 4 2 CHANGE OF PUMP STATION 1 In 13 mm wrench unscrew the screw remove the connection 2 With 22 m an...

Page 41: ...41 3 Remove the connectors by hand 4 With 5 mm twist under two fixed screw can remove the oil pump 4 3 REPLACE THE HYDRAULIC OIL ...

Page 42: ...crewed the cap then pour out the waste oil and then tank can be installed into the car the installation process is the inverse process of disassembly 2 Through the tubing into the hydraulic oil twist the lid 4 4 REPLACE THE FILTER ...

Page 43: ...43 1 In 5 mm Allen wrench unscrew the bolts remove the oil pump 2 After the oil pump down can replace filter 4 5 REPLACE CARBON BRUSH 1 With 10 mm open end wrench screw down bolt ...

Page 44: ...44 2 Open the hood shield 3 With a phillips screwdriver unscrewed the screw can take out the carbon brush for replacement The installation process is the process of inverse process ...

Page 45: ...45 4 6 ADJUST THE PUMP PRESSURE 1 With 24 mm socket wrench unscrew the bolt 2 Adjust the pressure oil pump with 6 mm adjust the reoccupy after the completion of 24 mm socket wrench and tighten the bolt ...

Page 46: ...ocket cap screws 8 M8x40 3 Standard spring washer 9 8 4 Driving wheel seat 1 5 Hexagon socket cap screws 1 M8x16 6 Small washer A class 1 8 7 handle seat 1 8 Hexagon socket cap screws 4 M10x20 9 Standard spring washer 4 10 10 Elastic cylindrical pin heavy 2 8x26 11 Vertical communication drive assembly 1 ...

Page 47: ...e demolition of driving wheel need professional lifting equipment ascends please pay attention to safety Unscrew the eight screws remove the outer cover Pull the plug and socket Using a wrench unscrew the screw pull wiring remove the drive wheels ...

Page 48: ...48 Unscrew five screws take out the wheels can be replaced ...

Page 49: ...an the maximum it may cause brake can t release the brake friction brake is on fire and even cause serious accident Must regularly check and adjust the air gap attention must disconnect the main power supply Operation of a variety of data consistent with the following table please Standard torque Nm Power W Standard torque air gap mm Mounting screw strengthen Nm 5 20 0 3 0 35 2 8 If the air gap is...

Page 50: ...5 2 Canbus control handle C 1 94300 90 3 Handle bar assembly 1 4 Spiale 1 5 Elastic cylindrical pin straight flute heavy 1 4X16 6 Hexagon socket cap screws 2 M3x20 7 Interlock switch 1 8 Hexagon socket cap screws 2 M4x12 9 Switching floor 1 10 Gas spring 1 11 Hexagon socket cap screws 1 M8x20 ...

Page 51: ...r 2 20X22X12 14 Handle control wiring harness 1 6 1 REMOVE THE HANDLE 1 In the punch on the hole the elastic pin with a hammer to knock out 2 With the punch will handle shaft to knock out Note the handle shaft on the attention to handle drop on hands ...

Page 52: ...52 6 2 REPLACE THE GAS SPRING 1 Pull out the rubber plug 2 With 6 mm Allen wrench screw down the bolt 3 The fixed gas spring with 13 mm open end wrench unscrew bottom screw ...

Page 53: ...53 4 Remove the gas spring 6 3 CHANGE THE INTERLOCK SWITCH 1 With 6 mm Allen wrench screw down the bolt 2 Open the handle cover ...

Page 54: ...54 3 Remove the joint pay attention to the wiring harness 4 Remove the switch 5 With a phillips screwdriver unscrewed the screw ...

Page 55: ...ock switch 6 4THE HANDLE OF THE HEAD REPLACEMENT 1 Remove the 3 screws can remove the handle back cover 2 Pull the handle of the connector 3 Remove the two fixed screw can remove the driver switch 4 Remove the drive shaft switch ...

Page 56: ...56 5 Remove the screws on the fixed plate pull out the connector then you can replace the circuit board ...

Page 57: ...57 7 CASTER 7 1 CASTER OPERATION 1 First remove the four bolts be desirable in caster components 2 Unscrew the nut can replace the wheels ...

Page 58: ...58 3 Remove the bolts 4 Remove the wheels ...

Page 59: ...59 5 Remove the shaft with punch can replace the roller ...

Page 60: ...8 LABELS Label for EU ASSEMBLY EU NO Name Quantity Remarks A Prompt labeling 1 B Travelling on labeling 1 C Load labeling 1600kg 1 Load labeling 2000kg D Hook labeling 2 E CE labeling 1 F Refuel labeling 1 ...

Page 61: ... Quantity Remarks A Prompt labeling 1 C Load labeling 5500 LBS 1 D Hook labeling 2 F Refuel labeling 1 G Warning label 1 H Warning label 1 I Warning label 1 J Warning label 1 K Warning label 1 L CE labeling 1 folding CE labeling 1 fixed ...

Page 62: ...23 20 2 12 Composite set 25 29 25 2 13 Composite set 20 22 12 4 14 Pressure distribution type oil cup 6 2 15 Composite set 25 28 20 2 16 Composite set 20 23 20 2 17 Composite set 25 29 25 2 18 Composite set 20 22 12 4 19 Pressure distribution type oil cup 6 2 20 Deep groove ball bearing 6202 12 21 Composite set 25 28 20 2 22 Composite set 20 23 20 2 23 Composite set 25 29 25 2 24 Composite set 20 ...

Page 63: ...ve ball bearing 6204 4 36 Balance wheel 100X40 2 37 9 Interlock switch 1 Handle assembly 38 Gas spring 1 39 envelope 1 40 Composite cover with shoulder 20X22X12 2 41 Support ring 50X55X15 1 Hydraulic assembly 42 Y type sealing ring 50X60X6 7 1 43 Scraper seal 50X58X5 6 5 1 44 Support ring 56X61X15 1 45 Y type sealing ring 56X66X10 11 1 46 Scraper seal 56X64X5 6 5 1 47 Micro switch 1 Electrical ass...

Page 64: ...E SHORT CIRCUIT 4 CURRENTSENSE FAULT 4 1 CURRENT DETECTION FAULT 1 MOTOR OR MOTOR WIRING SHORT CIRCUIT 2 THE CONTROLLER FAILURE 5 EEPROM CHECKSUM FAULT 4 3 EEPROM FAULT 1 EEPROM FAULT OR LOSE EFFICACY 6 HARDWARE FAILSAFE 4 2 THE MOTOR VOLTAGE OVERSPRAY 1 MOTOR VOLTAGE CAN T MATCH THE ACCELERATOR INPUT 2 MOTOR OR COIL SHORT CIRCUIT 3 THE CONTROLLER FAILURE 7 HPD FAULT 3 5 HPD FAULT 1 ACCELERATOR KE...

Page 65: ...E 1 SPEED POTENTIOMETER WIRED OPEN CIRCUIT OR SHORT CIRCUIT 2 THE SPEED LIMIT POTENTIOMETER OPEN CIRCUIT 14 THERMAL FAULT 1 1 OVER LOW TEMPERATURE CUT OFF 1 TEMPERATURE 80 OR 10 2 THE VEHICLE OVERLOAD 3 RUN UNDER THE HARSH ENVIRONMENT 4 ELECTROMAGNETIC BRAKE IS NOT NORMAL RELEASE 15 THROTTLE FAULT 1 2 POTENTIOMETER SLIDE SIDE OR BEYOND THE RANGE OF LOW VOLTAGE 1 ACCELERATOR INPUT OPEN CIRCUIT OR S...

Page 66: ...66 THE ACCELERATOR PORT OR ACCELERATOR BREAK DOWN ...

Page 67: ...67 ...

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