Baoli EP16-N01 Service Maintenance Manual
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Baoli EP16-N01 Service Maintenance Manual

Pallet truck
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Pallet truck EP16-N01 EP20-N04
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  • Page 1         Service & Maintenance Manual Service & Maintenance Manual     Pallet truck EP16-N01 EP20-N04 Pallet truck EP16-N01 EP20-N04     Warning Warning You must read the instructions in this manual You must read the instructions in this manual before using the manual.

  • Page 2: Table Of Contents

        CONTENT CONTENT     FOREWORD FOREWORD ………… ………… ....……………………………………………………………………… ………………………………………………………………………     1 1 GENERA GENERAL ............. L ..............................................4 4     1.1 INTRODUCTIO INTRODUCTION N  –  – MAINTENANCE MAINTENANCE SAFETY SAFETY PRECAUTIO PRECAUTIO ......

  • Page 3: Foreword

        FOREWORD FOREWORD The handling car operation, please read the manual carefully and fully understand the use of the car, The handling car operation, please read the manual carefully and fully understand the use of the car, improper operation easily lead to danger. improper operation easily lead to danger.

  • Page 4: 1 Genera General

        1. GENERAL 1. GENERAL  –  – 1.1 INTRODUCTION 1.1 INTRODUCTION  MAINTENANCE SAFETY PRECAUTIO  MAINTENANCE SAFETY PRECAUTIO Maintenan Maintenance work may cause injuries. Always take care ce work may cause injuries. Always take care to perform work safe, at to perform work safe, at least observing the least observing the following.
  • Page 5         Maintenance vehicles when remove rings, watches and jewelry. Maintenance vehicles when remove rings, watches and jewelry.           Drill grinding or hammer to wear a Drill grinding or hammer to wear a helmet, safety shoes and work helmet, safety shoes and work ...
  • Page 6     work. Park machine company, the ground. work. Park machine company, the ground.     In the sulfuric acid toxic battery electrolyte, it can burn skin and cl In the sulfuric acid toxic battery electrolyte, it can burn skin and clothes of othes of ...

  • Page 7: Measure Measurement Ment Conver Conversions

        1.2 MEASUREMENT CONVERSIONS 1.2 MEASUREMENT CONVERSIONS    Length Length unit unit in in ft ft mile mile 0.01 0.01 0.00001 0.00001 0.3937 0.3937 0.03281 0.03281 0.01094 0.01094 0.000006 0.000006 0.001 0.001 39.37 39.37 3.2808 3.2808 1.0936 1.0936 0.00062 0.00062 100000 100000...
  • Page 8     Pressure Pressure unit unit kgf/cm kgf/cm Pa=N/m Pa=N/m lbf/in lbf/in lbf/ft lbf/ft kgf/cm kgf/cm 0.98067 0.98067 98066.5 98066.5 98.0665 98.0665 14.2233 14.2233 2048.16 2048.16 1.01972 1.01972 100000 100000 14.5037 14.5037 2088.6 2088.6 Pa=N/m Pa=N/m 0.00001 0.00001 0.001 0.001 0.001 0.001 0.00015...
  • Page 9     INCH TABLE INCH TABLE    4T, 5T Classification Bolt type Classification Bolt type Bolt Bolt size size Torque Torque kgf kgf · · m m (lbf (lbf · · ft) ft) Torque Torque kgf kgf · · m m (lbf (lbf ·...
  • Page 10     PF THREAD THREAD O O  –  –    ring ring Plug Plug Thread Thread Torque Torque (kgf·m) (kgf·m) 1.1 ± ± 0.1 2.6 ± ± 0.2 4.6 ± ± 0.3 8.5 ± ± 0.4 19 ± ± 1.0 33 ±...
  • Page 11         APPROXIMATE CONVERSIONS APPROXIMATE CONVERSIONS SI SI Conv Conv Non  –  –SI SI Conv Conv SI SI Unit Unit Factor Factor Unit Unit Factor Factor Unit Unit Torque Torque Newton meter (N·m) Newton meter (N·m) × × = ln·in = ln·in ×...

  • Page 12: Overview Of Main Components

        2. 2. SPECIFICA SPECIFICATION TION 2.1 OVERVIEW OF MAIN COMPONENTS 2.1 OVERVIEW OF MAIN COMPONENTS 1. 1. Electrical Electrical box box cover cover Driving Driving wheel wheel 2. 2. Discharge Discharge indicator, indicator, LED LED charging charging Steering Steering wheel wheel parts parts...
  • Page 13     CONTROL HANDLE CONTROL HANDLE        Safety Safety switch switch Lifting Lifting switch switch Drive Drive control control switch switch horn horn button button     https://www.besttruckmanuals.com/...

  • Page 14: Table

        2.2 TECHNICAL PARAMETER TABLE 2.2 TECHNICAL PARAMETER TABLE Depending on the type of industrial Depending on the type of industrial vehicles VDI 2198 standard table vehicles VDI 2198 standard table EP16-N01 EP16-N01 type type Fixed Fixed the the pedal...
  • Page 15     Drive Drive control control Ac speed speed control control t t h h  According to the EN12053  According to the EN12053 driver's ear noise lev driver's ear noise level el dB(A) dB(A)     https://www.besttruckmanuals.com/...

  • Page 16: Lubricatio Lubrication N

        2.3 LUBRICATION 2.3 LUBRICATION HYDRAULIC OIL HYDRAULIC OIL The hydraulic oil must have the The hydraulic oil must have the anti-wear propertie anti-wear properties, and it s, and it is forbidden to different brands is forbidden to different brands or types of oil or types of oil are mixed together, because their additives or comparable viscosity values...

  • Page 17: 3 Electrica Electrical L System System

        3 ELECTRICAL SYSTEM 3 ELECTRICAL SYSTEM 3.1 ELECTRIC DIAGRAM 3.1 ELECTRIC DIAGRAM Electric diagram Electric diagram FUSE01 : 150A FUSE01 : 150A FUSE02 : 80 A FUSE02 : 80 A FUSE1 : 10 A FUSE1 : 10 A  ...

  • Page 18: Electric Electric Installatio Installation

        3.2 ELECTRIC INSTALLATION 3.2 ELECTRIC INSTALLATION     Electrical assembly Electrical assembly     https://www.besttruckmanuals.com/...
  • Page 19     ELECTRICAL ASSEMBLY ELECTRICAL ASSEMBLY Name Name Quantity Quantity Remarks Remarks Dc power power supply supply switch switch ZDK32-350 ZDK32-350 Dc power supply switch Dc power supply switch ZDK32-350 micro ZDK32-350 micro switch switch cross recessed pan head screw cross recessed pan head screw M4×25 M4×25...

  • Page 20: Wheel

            3.3 DRIVING WHEEL 3.3 DRIVING WHEEL FIGURE 14 ROTARY-DRIVEN ASSEMBLY FIGURE 14 ROTARY-DRIVEN ASSEMBLY Name Name Quantity Quantity Remarks Remarks Electromagn Electromagnetic etic brake brake M8x40 M8x40 hexagon socket cap screws hexagon socket cap screws    ...

  • Page 21: Hydraulic Hydraulic Power Power Unit Unit

        3.4 HYDRAULIC POWER UNIT 3.4 HYDRAULIC POWER UNIT HYDRAULIC ASSEMBLY HYDRAULIC ASSEMBLY Name Name Quantity Quantity Remarks Remarks Oil cylinder cylinder pin Composite Composite set × × × × Shaft Shaft with with elastic elastic ring ring - - type type A A M8x16 M8x16...
  • Page 22     Straight Straight pipe pipe joint joint hexagon hexagon socket socket cap cap screws screws M10x20 M10x20 Oil cylinder cylinder Support Support ring ring 50X55X15 50X55X15 Y Y type type sealing sealing ring ring 50X60X6/7 50X60X6/7 Dust Dust ring ring 50X58X5/6.5 50X58X5/6.5...

  • Page 23: Battery Battery Compon Components

        3.5 BATTERY COMPONENTS 3.5 BATTERY COMPONENTS BATTERY COMPONENTS BATTERY COMPONENTS Name Name Quan Quantity tity Remarks Remarks Charger(Asian Charger(Asian Chinese) Chinese) 24V/25A 24V/25A Charger Charger (Asian (Asian English) English) 24V/25A 24V/25A 24V/25A 24V/25A Charger Charger (European style (European style  ...

  • Page 24: Controll Controller Er

        3.6 CONTROLLER CONTROLLER ELECTRICAL CONTROL GROUP ELECTRICAL CONTROL GROUP Name Name Quantity Quantity Remarks Remarks Aluminium Aluminium sheet sheet controlle controller r AC-0-24V/200A AC-0-24V/200A Hang Hang line line board board Traction Traction motor motor contactor contactor C100/120 C100/120 DC24V DC24V electric electric relay...
  • Page 25     M8 terminal terminal BD-M8 BD-M8 Copper Copper platoon platoon Programmer plugin fixed Programmer plugin fixed frame frame Flat Flat washer washer class class C C Standard Standard spring spring washer washer M8x16 M8x16 hexagon socket cap screws hexagon socket cap screws  ...

  • Page 26: Battery Charging Battery Charging And And Replaceme Replacement Nt

    Please consider the highest working temperature of the battery the battery a. a. REPLACEMENT REPLACEMENT EP16-N01 EP16-N01 Safe parking vehicles, shut off the key switch (8), and press the abrupt Safe parking vehicles, shut off the key switch (8), and press the abrupt stop switch (7) to stop switch (7) to shut down the vehicle.
  • Page 27     Only when the battery charging right, the right Only when the battery charging right, the right of the LED of the LED lights up.As the battery charged condition, leds lights up.As the battery charged condition, leds     light up in turn, but only on one at a light up in turn, but only on one at a time.
  • Page 28         MAINTENANCE LIST MAINTENANCE LIST Table 3 maintenance list Table 3 maintenance list Time interval(month)) Time interval(month)) Hydraulic system Hydraulic system Check Check the the hydraulic hydraulic oil oil cylinder, cylinder, piston piston for for damage damage and and leakage leakage ...
  • Page 29     Check Check electromagnetic electromagnetic braking braking air air gap       Detection Detection of of emergency emergency braking braking function function       Detect Detect reverse reverse braking braking and and regenerative regenerative braking braking function function ...
  • Page 30     CHECK THE FUSE CHECK THE FUSE Remove the main cover, the fuse is Remove the main cover, the fuse is located in the position shown in figure 17. located in the position shown in figure 17. Fuse position     Fuse position location  ...

  • Page 31: Electrica Electrical L Compone Components Nts Replaceme Replacement Nt

        3.8 ELECTRUCAL COMPONENTS REPLACEMENT 3.8 ELECTRUCAL COMPONENTS REPLACEMENT The bolt with Allen wrench unscrew can The bolt with Allen wrench unscrew can remove the cover. remove the cover. REPLACEMENT OF ELECTRIC SCALE, THE KEY SWITCH AND URGENT STOP SWITCH REPLACEMENT OF ELECTRIC SCALE, THE KEY SWITCH AND URGENT STOP SWITCH 1.
  • Page 32     3 The proximity switch connector to disconnect 3 The proximity switch connector to disconnect 4. With four bolts on 4. With four bolts on Allen instrument fixed plate. Allen instrument fixed plate. 5. With cross up remove the two screws on the abrupt stop switch. 5.
  • Page 33     6. To remove the mushroom head. 6. To remove the mushroom head. 7. With the 7. With the 2.5 mm wrench to integrate the 2.5 mm wrench to integrate the instrument fixed plate and the leaf shape panel connection of instrument fixed plate and the leaf shape panel connection of four screws four screws unscrewed.
  • Page 34     9. Can replace the urgent stop switch. 9. Can replace the urgent stop switch. 10. Unscrew the fixed nut, can 10. Unscrew the fixed nut, can replace the voltameter. replace the voltameter. 11. Counterclockwise to dismantle the key switch on the nut, 11.
  • Page 35     REPLACING THE FUSE REPLACING THE FUSE 1. Using a 1. Using a wrench unscrew the nut correspondin wrench unscrew the nut corresponding to replacing the fuse g to replacing the fuse Open the fuse seat cover, remove the fuse and replace Open the fuse seat cover, remove the fuse and replace  ...
  • Page 36     ． ． To get off To get off four bolts fixed controller (one on each corner), can change the four bolts fixed controller (one on each corner), can change the electric control. electric control.     https://www.besttruckmanuals.com/...

  • Page 37: Of Electric Plug

        3.9 TOOL FOR REPAIRING THE PIN OF ELECTRIC PLUG 3.9 TOOL FOR REPAIRING THE PIN OF ELECTRIC PLUG  Application  Application Pictures Pictures     Tool Tool for for removal removal of of pins pins / / sleeves sleeves Tool Tool for for applicatio...

  • Page 38: System

        4 HYDRAULIC SYSTEM 4 HYDRAULIC SYSTEM HYDRAULIC CIRCUIT HYDRAULIC CIRCUIT lift cylinder lift cylinder lowering valve lowering valve pressure control pressure control Throttle valve Throttle valve Hydraulic power unit Hydraulic power unit (motor and oil pump) (motor and oil pump) oil box oil box CHECK THE HYDRAULIC OIL...

  • Page 39: Cleaning Tank And Filter

        4.1 CLEANING TANK AND FILTER 4.1 CLEANING TANK AND FILTER Reduce the pallet fork, release the h Reduce the pallet fork, release the hydraulic oil ydraulic oil     Remove Remove the the pump pump station station  ...

  • Page 40: Change Of Pump 2 Change Of Pump Station

        Filler plug is used ventilation, down by the Filler plug is used ventilation, down by the screw, the air goes out from the tank, it is likely screw, the air goes out from the tank, it is likely to to take out a small amount of hydraulic oil and gas b take out a small amount of hydraulic oil and gas bubble, so there will be oily be ubble, so there will be oily be soiled screw plug.

  • Page 41: Replace The Hydraulic Oil

        3. Remove the connectors by hand 3. Remove the connectors by hand 4. With 5 mm twist under two fixed screw, can remove the oil pump. 4. With 5 mm twist under two fixed screw, can remove the oil pump. 4.3 REPLACE THE HYDRAULIC OIL 4.3 REPLACE THE HYDRAULIC OIL  ...

  • Page 42: Replace The Filter

        1. Remove the oil pump, unscrewed the cap, 1. Remove the oil pump, unscrewed the cap, then pour out the waste oil, then pour out the waste oil, and then tank can be and then tank can be installed installed into the car, the into the car, the installation process is the inverse process of disassembly.

  • Page 43: Replace Carbon Brush

        1.In 5 mm Allen wrench unscrew the bolts, remove the oil pump 1.In 5 mm Allen wrench unscrew the bolts, remove the oil pump 2. After the oil 2. After the oil pump down, can replace filter pump down, can replace filter 4.5 REPLACE CARBON BRUSH 4.5 REPLACE CARBON BRUSH 1.
  • Page 44     2. Open the hood shield 2. Open the hood shield 3. With a 3. With a phillips screwdriv phillips screwdriver unscrewed the screw, can take er unscrewed the screw, can take out the carbon brush, for out the carbon brush, for replacemen replacement.The installation process is t.The installation process is the process of...

  • Page 45: Adjust The Pump Press 4.6 Adjust The Pump Pressure

        4.6 ADJUST THE PUMP PRESSURE 4.6 ADJUST THE PUMP PRESSURE 1. With 24 mm socket wrench unscrew the bolt 1. With 24 mm socket wrench unscrew the bolt 2. Adjust the pressure oil pump with 6 mm, 2. Adjust the pressure oil pump with 6 mm, adjust the reoccupy after the completion of 24 mm socket adjust the reoccupy after the completion of 24 mm socket wrench and tighten the bolt wrench and tighten the bolt...

  • Page 46: Driving Wheel

        5 DRIVING WHEEL 5 DRIVING WHEEL DRIVING WHEEL ASSEMBLY DRIVING WHEEL ASSEMBLY Name Name Quantity Quantity Remarks Remarks Electromagne Electromagnetic tic brake brake Hexagon Hexagon socket socket cap cap screws screws M8x40 M8x40 Standard Standard spring spring washer washer Driving Driving wheel...

  • Page 47: Replace The Drive Wheels

        5.1 REPLACE THE DRIVE WHEELS 5.1 REPLACE THE DRIVE WHEELS （ （ Note - : when the demolition of driving wheel need Note - : when the demolition of driving wheel need professiona professional lifting equipment, ascends, please l lifting equipment, ascends, please pay attention to safety pay attention to safety...
  • Page 48     Unscrew five screws, take out the Unscrew five screws, take out the wheels can be replaced wheels can be replaced https://www.besttruckmanuals.com/    ...

  • Page 49: Adjust The Brake Of The Air Gap

        5.2 ADJUST THE BRAKE OF THE AIR GAP 5.2 ADJUST THE BRAKE OF THE AIR GAP Due to wear and tear, the rated air gap Due to wear and tear, the rated air gap would be a big Z. In order to ensure brake torque, enough in the a would be a big Z.

  • Page 50: Hand Shank

        6 HAND SHANK 6 HAND SHANK HANDLE ASSEMBLY HANDLE ASSEMBLY Name Name Quantity Quantity Remarks Remarks Hexagon Hexagon socket socket cap cap screws screws M8x25 M8x25 Canbus Canbus control control handle handle C C 94300-90 94300-90 Handle Handle bar bar assembly assembly Spiale...

  • Page 51: Remove The Handle

        Envelope Envelope Composite cover with Composite cover with 20X22X12 20X22X12 shoulder shoulder Handle Handle control control wiring wiring harness harness 6.1 REMOVE THE HANDLE 6.1 REMOVE THE HANDLE         1.In the punch on the hole, the elastic pin with a hammer to knock out. 1.In the punch on the hole, the elastic pin with a hammer to knock out.
  • Page 52     6.2 REPLACE THE GAS SPRING 6.2 REPLACE THE GAS SPRING 1. Pull out the 1. Pull out the rubber plug rubber plug 2. With 6 mm 2. With 6 mm Allen wrench screw down the bolt Allen wrench screw down the bolt 3.

  • Page 53: Change The Interloc 6.3 Change The Interlock Switch

        4. Remove the gas spring 4. Remove the gas spring 6.3 CHANGE THE INTERLOCK SWITCH 6.3 CHANGE THE INTERLOCK SWITCH 1. With 6 mm 1. With 6 mm Allen wrench screw down the bolt Allen wrench screw down the bolt 2.
  • Page 54     3. Remove the joint (pay attention to 3. Remove the joint (pay attention to the wiring harness) the wiring harness) 4. Remove the switch 4. Remove the switch 5. With a 5. With a phillips screwdriv phillips screwdriver unscrewed the screw er unscrewed the screw https://www.besttruckmanuals.com/  ...
  • Page 55     6. Can replace the interlock switch 6. Can replace the interlock switch 6.4THE HANDLE OF THE HEAD REPLACEMENT 6.4THE HANDLE OF THE HEAD REPLACEMENT 1. Remove the 3 1. Remove the 3 screws can remove the handle back cover. screws can remove the handle back cover.
  • Page 56     5. Remove the screws on the fixed plate, pull out the connector, then you can replace the circuit 5. Remove the screws on the fixed plate, pull out the connector, then you can replace the circuit     board.

  • Page 57: Caster

        7 CASTER 7 CASTER 7.1 CASTER OPERATION 7.1 CASTER OPERATION 1 First remove the four 1 First remove the four bolts be desirable in caster components bolts be desirable in caster components 2 Unscrew the nut can 2 Unscrew the nut can replace the wheels replace the wheels https://www.besttruckmanuals.com/  ...
  • Page 58     3. Remove the bolts 3. Remove the bolts 4. Remove the wheels 4. Remove the wheels https://www.besttruckmanuals.com/    ...
  • Page 59     5.Remove the shaft with punch, can replace the 5.Remove the shaft with punch, can replace the roller roller https://www.besttruckmanuals.com/    ...

  • Page 60: 8 Labels Labels

        8. LABELS 8. LABELS     Label for EU Label for EU ASSEMBLY (EU) ASSEMBLY (EU) Name Name Quantity Quantity Remarks Remarks  A  A     Prompt labeling Prompt labeling     Travelling on labeling Travelling on labeling Load labeling (1600kg) Load labeling (1600kg) Load labeling (2000kg)
  • Page 61     Label for US Label for US ASSEMBLY (US) ASSEMBLY (US) Name Name Quantity Quantity Remarks Remarks  A  A Prompt Prompt labeling labeling Load Load labeling labeling (5500 (5500 LBS) LBS) Hook Hook labeling labeling Refuel Refuel labeling labeling Warning Warning label label...

  • Page 62: 9 Maintenance Maintenance List

        9 MAINTENANCE LIST 9 MAINTENANCE LIST Name Name Quantity Quantity Remarks Remarks Rubber Rubber ring ring Rubber Rubber ring ring  Appearance  Appearance Rubber Rubber ring ring Rubber Rubber ring ring Composite Composite set set 25×28×20 25×28×20 Composite Composite set set 20×23×20 20×23×20 Composite...
  • Page 63     Composite Composite set set 20×22×12 20×22×12 双 双 Deep Deep groove groove ball ball bearing bearing 6204 6204 8( 8( Load wheel Load wheel 双 双 Wheel Wheel bearing bearing 84X84 84X84 4( 4( assembly assembly Composite cover with Composite cover with （...

  • Page 64: Fault Fault Analysi Analysis S

        10 FAULT ANALYSIS 10 FAULT ANALYSIS PROGRAMMI PROGRAMMI NG NG UNIT UNIT SHOWS SHOWS CODE CODE FAULT FAULT PHENOMENON PHENOMENON FAULT FAULT DIAGNOSIS DIAGNOSIS BATTERY BATTERY DISCONNECT DISCONNECT FAULT FAULT BATTERY BATTERY NOT NOT CONNECTED CONNECTED 1. 1. BATTERY BATTERY NOT NOT CONNECTED CONNECTED...
  • Page 65     MAIN MAIN OFF OFF FAULT FAULT MAIN MAIN CONTACTOR CONTACTOR COIL COIL 1. THE OPENING OF MAIN 1. THE OPENING OF MAIN DRIVER "OFF"FAULT DRIVER "OFF"FAULT CONTACTOR COIL ERROR CONTACTOR COIL ERROR MAIN MAIN ON ON FAULT FAULT MAIN MAIN CONTACTOR CONTACTOR COIL...
  • Page 66     THE ACCELERATOR PORT OR THE ACCELERATOR PORT OR ACCELERATOR BREAK DOWN. ACCELERATOR BREAK DOWN. https://www.besttruckmanuals.com/    ...
  • Page 67     https://www.besttruckmanuals.com/    ...

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Ep20-n04

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