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EP Equipment JX0 User Manual

EP Equipment JX0
206 pages
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Service Manual
JX0
Task Support Vehicle

Table of Contents

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EP Equipment JX0 Specifications

General IconGeneral
BrandEP Equipment
ModelJX0
CategoryTrucks
LanguageEnglish

Summary

Foreword

Safety Signs and Instructions

Guidelines for safe operation and maintenance.

1. Information & Specifications

1.1 After-sales Service Platform

Procedures and contact for after-sales support.

1.2 Introduction

Overview of the vehicle and its components.

1.3 Common Tools

List of necessary tools for maintenance.

1.4 General Tightening Torques

Specifications for screw and bolt tightening.

4. Chassis System

Load Wheel Service

Procedures for load wheel removal, installation, and troubleshooting.

Caster Service and Adjustment

Steps for caster removal, installation, and adjustment for proper ground contact.

Cover Removal and Installation

Procedures for removing and installing various covers on the vehicle.

5. Drive System

Drive Assembly Service

Steps for removing, installing, and troubleshooting the drive assembly.

Electromagnetic Brakes Service

Procedures for removing, installing, and checking electromagnetic brakes.

Electromagnetic Brakes Checking and Troubleshooting

Details air gap, foreign body, spring checks, and control circuit troubleshooting.

Drive Wheel Service and Faults

Steps for drive wheel removal, installation, and identifying common faults.

Drive Motor Service and Faults

Procedures for drive motor removal, installation, carbon brush replacement, adjustment, and fault diagnosis.

Speed Encoder Service and Faults

Steps for speed encoder removal, installation, and identifying common faults.

Gearbox Service and Faults

Procedures for gearbox removal, installation, and fault analysis.

Proximity Switch Service and Faults

Steps for proximity switch removal, installation, fault diagnosis, and checking.

Steering Motor and Chain Service and Faults

Procedures for steering motor and chain removal, installation, and fault diagnosis.

Speed Encoder Checking and Troubleshooting

Details checking, testing, and control circuit troubleshooting for the speed encoder.

6. Operating System

Left Control Assembly Service

Steps for removing and installing the left control assembly.

Right Control Assembly Service

Steps for removing and installing the right control assembly.

Button Switch Service and Testing

Procedures for button switch removal, installation, fault diagnosis, checking, and testing.

Button Switch Control Circuit Troubleshooting

Details control circuit troubleshooting for platform lifting and lowering buttons.

Storage Table Button Control Circuit Troubleshooting

Troubleshooting for storage table lifting and lowering button control circuits.

Horn Button Control Circuit and Checks

Troubleshooting for the horn button circuit and horn checks.

Travel Switch Service and Testing

Procedures for travel switch removal, installation, fault diagnosis, checking, and testing.

Enable Switch Service and Testing

Procedures for enable switch removal, installation, fault diagnosis, checking, and testing.

Enable Switch Control Circuit Troubleshooting

Troubleshooting for the enable switch control circuit.

Proximity Switch Control Circuit Troubleshooting

Troubleshooting for the right-hand proximity switch control circuit.

Stepper Motor Service and Testing

Procedures for stepper motor removal, installation, fault diagnosis, checking, and testing.

Stepper Motor Control Circuit Troubleshooting

Troubleshooting for the stepper motor control circuit.

Key Switch Service and Testing

Procedures for key switch removal, installation, fault diagnosis, checking, and testing.

Emergency Stop Switch Service and Testing

Procedures for emergency stop switch removal, installation, fault diagnosis, checking, and testing.

Emergency Stop Switch Control Circuit Troubleshooting

Troubleshooting for the emergency stop switch control circuit.

Charge Gauge Service and Testing

Procedures for charge gauge removal, installation, fault diagnosis, checking, and testing.

Charge Gauge Control Circuit Troubleshooting

Troubleshooting for the charge gauge control circuit.

7. Hydraulic System

Hydraulic System Overview and Components

General overview, hydraulic oil specifications, seals, and assembly instructions.

Hydraulic Schematic Diagram

Schematic diagram of the hydraulic system.

Pump and Motor Assembly Service

Steps for removing, installing, and identifying components of the pump and motor assembly.

Pump Motor Service and Faults

Procedures for pump motor removal, installation, and diagnosis of common faults.

AUX Pump Motor Service and Faults

Procedures for AUX pump motor removal, installation, and fault diagnosis.

Pump Motor Checking and Troubleshooting

Details checking, testing, and control circuit troubleshooting for the pump motor.

AUX Pump Motor Checking and Troubleshooting

Details checking, testing, and control circuit troubleshooting for the AUX pump motor.

Solenoid Valve Service and Testing

Procedures for solenoid valve fault diagnosis, checking, and testing.

Solenoid Valve Control Circuit Troubleshooting

Troubleshooting for the solenoid valve control circuit.

Cylinder Removal Precautions

Important safety precautions and steps before removing the hydraulic cylinder.

Cylinder Installation Precautions

Guidelines for proper cleaning, tool usage, and lubrication during cylinder installation.

Accumulator Service and Faults

Procedures for accumulator removal, installation, and diagnosis of common faults.

Hydraulic Troubleshooting

Table listing common hydraulic faults and their troubleshooting measures.

Hydraulic Symbol

Glossary of hydraulic system symbols used in diagrams.

8. Electrical System

Controller Functions and Diagram

Explanation of controller functions and a diagram illustrating control modules.

Traction Controller Interface Functions

Pin assignments and signal descriptions for the traction controller's A interface.

Steering Controller Interface Functions

Pin assignments and signal descriptions for the steering controller (EPS-DC0).

Controller Interfaces and Terminals

Details B interface, C interface (handheld), and terminal stud pin assignments.

CAN-Tiller Module Interface Functions

Pin assignments and signal descriptions for the CAN-Tiller module.

CAN-Tiller Module Interfaces (B & C)

Pin assignments for the CAN-Tiller module's B and C interfaces.

Fuse Overview and Location

Information on fuse functions, status, and physical locations on the vehicle.

Fuse Checking and Testing

Procedures for checking and testing fuses to ensure proper function.

Main Contactor Service and Faults

Procedures for main contactor removal, installation, and diagnosis of common faults.

Main Contactor Checking and Testing

Details on checking contactor surfaces, coils, and contacts for proper function.

Main Contactor Control Circuit Troubleshooting

Troubleshooting steps for the main contactor control circuit.

Limit Switch Service and Types

Procedures for limit switch removal, installation, and identification of different types.

Limit Switch Faults and Causes

Lists common faults and their causes for slack chain, lifting limit, speed reduction, and door safety switches.

Limit Switch Checking and Troubleshooting

Procedures for checking, testing, and troubleshooting limit switch control circuits.

Door Safety Switch Control Circuit Troubleshooting

Troubleshooting for the door safety switch control circuit.

Deadman Switch Service and Faults

Procedures for deadman switch removal, installation, and diagnosis of common faults.

Deadman Switch Checking and Troubleshooting

Details checking, testing, and control circuit troubleshooting for the deadman switch.

Tilt Switch Service and Testing

Procedures for tilt switch removal, installation, fault diagnosis, checking, and testing.

Tilt Switch Control Circuit Troubleshooting

Troubleshooting for the tilt switch control circuit.

Blue Light Service and Testing

Procedures for blue light removal, installation, fault diagnosis, checking, and testing.

Blue Light Control Circuit Troubleshooting

Troubleshooting for the blue light control circuit.

Flash Light Service and Testing

Procedures for flash light removal, installation, fault diagnosis, checking, and testing.

Flash Light Control Circuit Troubleshooting

Troubleshooting for the flash light control circuit.

Pressure-sensitive Switch Service and Testing

Procedures for pressure-sensitive switch removal, installation, fault diagnosis, checking, and testing.

Pressure-sensitive Switch Control Circuit Troubleshooting

Troubleshooting for the pressure-sensitive switch control circuit.

Button Switch Service and Faults

Procedures for button switch removal, installation, and diagnosis of common faults.

Button Switch Checking and Troubleshooting

Details checking, testing, and control circuit troubleshooting for button switches.

Platform Control Button Circuit Troubleshooting

Troubleshooting for platform lifting and lowering button control circuits.

LED Charging Indicator Service and Testing

Procedures for LED charging indicator removal, installation, fault diagnosis, checking, and testing.

LED Charging Indicator Control Circuit Troubleshooting

Troubleshooting for the LED charging indicator control circuit.

Tester Menu Parameters (Traction Controller)

Lists parameters and descriptions available in the tester menu for the traction controller.

Handheld Unit Connection and Menu Options

Steps for connecting the handheld unit and navigating its menu options.

Handheld Unit Settings and Adjustments

Guides for configuring options and adjusting parameters via the handheld unit.

Handheld Unit Adjustments

Step-by-step guide to changing various adjustments using the handheld unit.

Handheld Unit Parameter Change

Guide for modifying parameters using the handheld unit.

Controller Error Messages (Traction Controller)

Details error codes, causes, and solutions for the traction controller.

Controller Error Messages (Traction Controller - Cont.)

Lists additional error codes, causes, and solutions for the traction controller.

Steering Controller Error Messages

Lists error codes, causes, and solutions specific to the steering controller.

Steering Controller Error Messages (Cont.)

Lists additional error codes, causes, and solutions for the steering controller.

Cable Wiring Diagrams

Diagrams illustrating cable connections and wiring harnesses.

Electrical Schematic Diagrams

Electrical schematic diagrams of the vehicle systems.

Wiring Harness and Connectors

Diagrams showing wiring harnesses and connector layouts.

9. Troubleshooting

Common Fault Troubleshooting

A table detailing common faults, their symptoms, and recommended troubleshooting steps.

Hydraulic and Lift System Troubleshooting

Troubleshooting for hydraulic failures like platform lift issues and lift system faults.

Steering and Other System Troubleshooting

Troubleshooting for steering system faults and other issues like lights and horn.

A Service Manual - Mast

Three-Stage Mast Chain Service

Procedures for chain adjustment and replacement on the three-stage mast.

Three-Stage Mast Chain 2 Replacement and Installation

Procedures for replacing chain 2 and installing components on the three-stage mast.

Drag Chain Replacement Procedures

Detailed steps for replacing left and middle drag chains.

Drag Chain Harness Replacement

Procedures for replacing left and right drag chain harnesses.

Cylinder Removal and Installation

Detailed steps for removing and installing the hydraulic cylinder.

Cylinder Maintenance and Installation

Covers cylinder maintenance precautions, installation steps, and hydraulic oil procedures.

B Service Manual - Battery

Lead-acid Battery Service and Troubleshooting

Covers safety, usage, maintenance, storage, and troubleshooting for lead-acid batteries.

Maintenance-free Battery Service and Charging

Safety, usage, pre-use checks, discharging, and charging procedures for maintenance-free batteries.

Lithium Battery Safety, Usage, and Troubleshooting

Comprehensive guidelines for lithium-ion battery safety, usage, charging, and common problem resolution.

Lithium Battery Daily and Regular Maintenance

Details daily and regular maintenance, including checks for connections and casing.

Lithium Battery Common Problems and Solutions

Discusses common abnormal conditions in lithium-ion batteries and necessary actions.

Lead-acid Battery Fault Analysis (Part 1)

Analysis of battery faults related to charging and electrolyte issues with causes and methods.

Lead-acid Battery Fault Analysis (Part 2)

Analysis of battery faults including sulfation, shedding, overcharging, and over-discharge.

Lead-acid Battery Fault Analysis (Part 3)

Analysis of battery faults like short circuits, broken circuits, reverse electrodes, and leaks.

Maintenance-free Battery Supplementary Charging

Guidance on supplementary charging for maintenance-free batteries when not in use.

Maintenance-free Battery Daily and Supplementary Charging

Daily maintenance and supplementary charging procedures for maintenance-free batteries.

SAFETY WARNING

C Schedule

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