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ED EPT20-15EHJ Service Manual

Semi-electric pallet truck
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MANUAL NO. SM1121 01.16

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Summary of Contents for ED EPT20-15EHJ

  • Page 1 MANUAL NO. SM1121 01.16...

  • Page 2: Table Of Contents

    CONTENTS Table of contents 1.LOAD WHEELS................1 1.1 Disassembly and Assembly ............1 2.DRIVE UNIT ..................2 2.1 Disassembly and Assembly ............2 3. TILLERHEAD .................4 4. HYDRAULIC SYSTEM ..............7 4.1Disassembly and Assembly ............7 4.2 Commissioning ................8 4.3 General Failures and Troubleshooting ........9 4.4 Oil Seal Replacement ..............12 4.5 Other Issues ................15 5.

  • Page 4: Load Wheels

    LOAD WHEELS 1.LOAD WHEELS 1.1 Disassembly and Assembly Place hardwood block under the Frame as shown in Figure 01101.Remove the riser pivot shaft (index 2) after extracting roll pin (index 1). CAUTION In order to avoid scratching the surface of vehicle,put a piece of rubber mat on the hardwood block.

  • Page 5: Drive Unit

    DRIVE UNIT 2.DRIVE UNIT 2.1 Disassembly and Assembly Place hardwood blocks under the Frame as shown in Figure 01201.Make the drive wheel hang in the air CAUTION Put the hardwood block as neer the drive wheel as possible. Unfasten the four screws (index 1, Figure 01202) by using a wrench and remove the upper cover (index 3) and the lower cover (index 2) .
  • Page 6 DRIVE UNIT Refer to Figure 01204. Knock out the motor (index 13)and pick out the oil seal (index 14).After the six screws (index 15) have been removed, knock out the gear ring (index 16) and the bearings (index 17) .Then the drive wheel can be changed. Change the brushes If the brushes (index 7) must be repalced,the motor will have to be dismantled.

  • Page 7: Tillerhead

    TILLERHEAD 3. TILLERHEAD 3.1 Disassembly and Assembly IMPORTANT-SAFETY Verify that spring safety pin is in place. The pin should be well rested in the holes situated on each side of the pump housing. If the safety pin is not rested properly in one of the holes, put pressure on the spring using a “C”...
  • Page 8 TILLERHEAD Make sure that handle pin is completely through the handle and resting on the other side. Feed the chain and nut first back inside the handle through the handle pin's center hole. IMPORTANT-TIP Release the up/down lever to its lowest position to make the process easier.
  • Page 9 TILLERHEAD Connect the both electrical plugs. IMPORTANT-FINAL CHECK Test all the features of the semi-electric pallet truck before this step. The handle should be pumped with full strokes to prime and eliminate air in the system. The up/down lever should be checked at the handle’s lowest position for this puts the most tension on the chain.

  • Page 10: Hydraulic System

    HYDRAULIC SYSTEM 4. HYDRAULIC SYSTEM 4.1Disassembly and Assembly Remove the handle (index 1) and the controller (index 2).Remove the hydraulic assembly by unscrewing the screw (index 3) and the four screws (index 4).Place hardwood blocks under the Frame as shown in Figure 01401. CAUTION Put the hardwood block as neer the drive wheel as possible.

  • Page 11: Commissioning

    HYDRAULIC SYSTEM 4.2 Commissioning After the handle is installed to the new vehicle, or the vehicle has been used for more than 6 months, further commissioning should be conducted to the hydraulic pump, make sure that the hydraulic pump is always working in the best condition. Gear lever on the handle is associated with the screws on the lever plate.

  • Page 12: General Failures And Troubleshooting

    HYDRAULIC SYSTEM 5. Relieve Valve Commissioning If the vehicle can lift light load, but cannot lift rated load, such case may be caused by the relief valve being opened in advance, follow the steps below for commissioning: Firstly, remove the external screw plug of the relief valve, and then adjust it with screwdriver;...
  • Page 13 HYDRAULIC SYSTEM Check if the unloading valve stem is Cause 3 blocked. Troubleshooting: Push the unloading valve stem in the direction of the arrow as shown in the fi gure, if the stem can automatically reset, then it indicates that the fault is due to insufficient commissioning, the fault can be fi...
  • Page 14 HYDRAULIC SYSTEM 3. The vehicle can lift but cannot retain, by turn- ing the handle, the vehicle can lift, or although the vehicle can lift, but then automatically lower? Cause 1 Valve blocked by debris. Troubleshooting: Remove all the parts within the valve, clean them up and re-install, the fault can then be fi...

  • Page 15: Oil Seal Replacement

    HYDRAULIC SYSTEM 5. The vehicle cannot lower to bottom? Cause 2 Parts deformation of parts. Troubleshooting: Check other parts of the vehicle, remove foreign objects and replace the parts with deformation. 6. Oil leakage? Cause 1 Damaged seals. Troubleshooting: Replace the damaged seals. Cause 2 Loose parts.
  • Page 16 HYDRAULIC SYSTEM Removal of pump seals can roughly be divided into four steps, as shown below: 1.Use tool A, apply a force in the direction of the arrow, squeeze the tool between the oil seal and the engaging surface of the groove; 2.
  • Page 17 HYDRAULIC SYSTEM 4. Adjust the oil seal in the groove to rectify it in place. The tools shall be with no sharp edges and corners, otherwise may easily damage the oil seal! DO NOT attempt this repair operation without proper training! 2.

  • Page 18: Other Issues

    HYDRAULIC SYSTEM 4. Install the big piston seal and other parts in rever- se order of the removal procedure. The removal of big piston seal can be carried out with tool A, B and C, and the method is the same as that for pump seal, if so, the guide bushing does not need to be loosened.
  • Page 19 HYDRAULIC SYSTEM 7. If the seals within the pump need to be replaced, smooth tools must be used, any sharp tool can cause damages to the seals, resulting in failure of hydraulic functions. 8. Upon removal or demolition, pay attention to the order and direction of the removal, the parts re- moved must be kept properly to avoid the occurr- ence of loss, scratches and deformation, all parts...

  • Page 20: Electrical

    ELECTRICAL 5. ELECTRICAL 5.1 Disassembly and Assembly Change the batteries Lift the forks by moving the handle (index 1) up and down to the highest.Rotate the handle a few degrees to the left or right as shown in Figure 01501. Remove the two screws (index 2) and take out the battery cover (index 4).
  • Page 21 (index 1). How to use the handheld programmer? Please see the manual of handheld programmer. The parameters of EPT20-15EHJ are in the document which is the "Parametric sheet for EPT20-15EHJ". REV. 03/2015...

  • Page 22: Electrical Schematic Diagram

    ELECTRICAL 5.2 Electrical Schematic Diagram REV. 03/2015...

  • Page 23: Power Cables

    ELECTRICAL 5.3 Power Cables ITEM PART NAME Battery connector cable B- cable M1 cable M2 cable Connector assembly Fuse-Battery cable REV. 03/2015...

  • Page 24: Controller Troubleshooting

    ELECTRICAL 5.4. Controller Troubleshooting 1. Disconnect the battery charger and connect the programmer to the 4-pin connector (Figure01508) 5.4.1. Fault Detection on the controller. The controller provides diagnostics information to assist technicians in troubleshooting drive system problems. When a fault is detected, the appropriate fault code is signaled via the panel mounted LED.
  • Page 25 ELECTRICAL 3. Put the controller into the diagnostic mode by 5. Put the controller into the test mode by using the pressing the "Arrow Keys" (Figure 01508). Arrow Keys to select the "Monitor" menu. Using the Navigation key, select the Faults Select the Monitor mode by pressing the "Right"...

  • Page 26: Diagnostic History

    ELECTRICAL 4. Reconnect the batteries and turn on the key 5.4.5. Diagnostic History switch . The handheld programmer can be used to access 5. Leave the key switch on and remove the in-line the controller's diagnostic history fi le. When the prog- fuse wire.

  • Page 27: Diagnostics And Troubleshooting

    ELECTRICAL 5.4.8. Diagnostics and Troubleshooting For suggestions about possible causes of the various faults, refer to Table 2 Troubleshooting Chart. The motor controller provides diagnostics information to assist in troubleshooting drive system problems. 5.4.9. Programmer Diagnostics The diagnostics information can be obtained in two ways: With a programmer, diagnostics and troubleshooting is more direct than with the LED alone.
  • Page 28 ELECTRICAL Table 2 Troubleshooting Chart PROGRAMMER POSSIBLE CAUSE FAULT CLEARANCE CODE LCD DISPLAY 1. Battery not connected. Battery Disconnect Battery disconnected Fault 2. Poor connection to battery terminals. 1. Electromagnetic brake driver open. Battery OFF Fault Brake OFF Fault 2. Electromagnetic brake coil shorted. 1.
  • Page 29 ELECTRICAL Table 2 Troubleshooting Chart- Continued PROGRAMMER POSSIBLE CAUSE FAULT CLEARANCE CODE LCD DISPLAY 1. Throttle input wire open or shorted. PotLow and /or PotWiper out of Throttle Fault 2. Throttle pot defective. range 3. Wrong throttle type selected. 1. Battery voltage <17 volts. Undervoltage Fault Battery voltage too low 2.

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