This document is a service manual for the ED中力 EPT20-15EHJ Semi-electric Pallet Truck. It provides detailed instructions for the disassembly, assembly, maintenance, and troubleshooting of various components of the pallet truck.
Function Description
The ED中力 EPT20-15EHJ is a semi-electric pallet truck designed for lifting and transporting pallets. It features an electric drive unit for propulsion and a hydraulic system for lifting, making it suitable for material handling tasks that require both powered movement and manual lifting control. The "semi-electric" designation implies that while the drive is electric, some functions, such as the initial lifting action or steering, might involve manual input or a combination of electric and manual operation.
Important Technical Specifications
Hydraulic System:
- Hydraulic Oil Type: Anti-wear hydraulic oil ISO-32 is recommended for general regions. For extremely cold areas or cold storage, ISO VG 15 hydraulic oil is recommended.
- Allowed Oil Volume: The pump should contain 250-280mL of hydraulic oil.
- Oil Type Mixing: Different brands or vendors of hydraulic oils should not be mixed, as this can accelerate premature deterioration and failure of the hydraulic oil.
- Lift Capacity Adjustment: The lift capacity can be adjusted by screwing the relief valve screw inward (for bigger capacity) or outward (for smaller capacity).
Electrical System:
- Battery: The system uses two 12V batteries, connected to a 1212P controller.
- Fuse: A power fuse is integrated into the power circuit.
- Controller: The 1212P controller manages the electrical functions, including motor control and diagnostics.
- Diagnostic LED Codes: The controller uses a Status LED to indicate faults with specific flashing patterns (e.g., 00 for Undervoltage Fault, 000 for Overvoltage Fault, 00000 for Brake ON Fault, etc.).
- Programmer: An optional handheld programmer is available for detailed diagnostics, parameter programming, and fault history readout.
Drive Unit:
- Motor: The drive unit includes an electric motor with replaceable brushes.
- Gearbox: A gearbox is part of the drive unit, transmitting power to the drive wheel.
- Brake: An electromagnetic brake is integrated into the drive unit.
Usage Features
- Handle Control: The tiller head features a handle with a gear lever for controlling lifting (Gear 1), traveling (Gear 2), and lowering (Gear 3).
- Safety Pin: A spring safety pin is crucial for proper operation of the pump housing and must be correctly seated.
- Emergency Reverse (Belly Button): The truck is equipped with an emergency reverse feature for operator safety.
- Programmable Parameters: The controller allows for customization of performance characteristics (e.g., speed limits, operating modes) to suit different applications and operator preferences, accessible via a handheld programmer.
- MultiMode™ Feature: The controller supports two distinct operating modes (Mode 1 and Mode 2), which can be programmed for different operating characteristics, such as slow speed for indoor maneuvering and higher speed for long-distance travel.
Maintenance Features
General Maintenance:
- Daily Inspection: Daily inspection and maintenance are essential, including cleaning the pump's appearance to prevent foreign objects from scratching piston rods.
- Commissioning: The hydraulic pump should be commissioned every 6 months to ensure the control stem is in the correct position.
- Oil Replacement: Hydraulic oil should be refilled or replaced upon inspection, ensuring the new oil is filtered and meets viscosity requirements.
- Part Cleaning: All parts must be thoroughly cleaned after repair and before reinstallation to prevent contamination.
Load Wheels:
- Disassembly: Load wheels can be replaced by removing the riser pivot shaft and extracting the roll pin, then removing bearings.
Drive Unit:
- Motor Brush Replacement: Motor brushes are replaceable after dismantling the motor.
- Drive Wheel Replacement: The drive wheel can be changed after removing the motor, oil seal, gear ring, and bearings.
Tillerhead:
- Chain Management: Proper feeding of the chain on the outside of the piston stem roller is critical during assembly to prevent breakage.
- Electrical Plug Connection: Ensure both electrical plugs are connected.
Hydraulic System:
- Air Discharge: If the vehicle cannot lift, air may be trapped in the hydraulic system. This can be resolved by flipping the gear lever to the lowering position and fully turning the handle several times.
- Oil Seal Replacement: Detailed procedures are provided for replacing the main oil seal of the piston pump and the oil seals of the big cylinder using specialized tools.
- Relief Valve Commissioning: The relief valve can be adjusted to correct issues with lifting light or rated loads.
- Troubleshooting Guide: Comprehensive troubleshooting charts are provided for various issues, including inability to lift, inability to lift to maximum height, inability to retain lift, inability to lower, and oil leakage, along with possible causes and fault clearance steps.
Electrical System:
- Battery Replacement: Instructions for safely removing and replacing batteries are provided.
- Charger Replacement: Instructions for replacing the charger, including disconnecting wiring and removing mounting hardware.
- Controller Replacement: Instructions for replacing the controller, including disconnecting wiring and mounting screws.
- Controller Settings: The controller settings can be adjusted using a handheld programmer, with parameters detailed in a separate "Parametric sheet for EPT20-15EHJ."
- Diagnostics: The controller offers fault detection via an LED and detailed diagnostics through an optional handheld programmer, including fault recording and history.
- Fault Detection Circuitry Test: A procedure is outlined to test the fault detection circuitry using an inline fuse.
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