Baoli EP16-N01 User manual

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Service & Maintenance ManualService & Maintenance Manual

Pallet truck EP16-N01 EP20-N04Pallet truck EP16-N01 EP20-N04

WarningWarning
You must read the instructions in this manualYou must read the instructions in this manual
before using the manual.before using the manual.
Notice:Notice:

The The last last page page please please check check the fthe file aile andnd
all of the current product type all of the current product type on theon the
nameplate.nameplate.

Pay attention to keep for future Pay attention to keep for future use.use.

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CONTENTCONTENT
FOREWORDFOREWORD……………………..............………………………………………………………………………………………………………………………………………………..3..3
1 1 GENERAGENERAL .............................................................L ................................................................................................................................................................................................................. ................ 44
1.1 1.1 INTRODUCTIOINTRODUCTIONN
––MAINTENANCE MAINTENANCE SAFETY SAFETY PRECAUTIO PRECAUTIO ................................................................................................................ 44
1.2 1.2 MEASUREMEASUREMENT MENT CONVERCONVERSIONS .......................SIONS ................................................................................................................................................................ ..... 77
2 2 SPECIFICASPECIFICATION ........................................TION ........................................................................................................................Errore. Il segnalibro non è Errore. Il segnalibro non è definito.definito.
2.1 OVERVIEW OF 2.1 OVERVIEW OF MAIN COMPONENTS .....................MAIN COMPONENTS ...............................................Errore. Il segnalibro non è Errore. Il segnalibro non è definito.definito.
2.2 2.2 TECHNICATECHNICAL L PARAMETEPARAMETER R TABLE .....................TABLE ............................................................................................................................................................ 14... 14
2.3 2.3 LUBRICATIOLUBRICATION N ............................................................................................................................................................................................................................. 16......................... 16
3 3 ELECTRICAELECTRICAL L SYSTEM SYSTEM ............................................................................................................................................................................................................................. ................... 1717
3.1 3.1 ELECTRIC ELECTRIC DIAGRAM DIAGRAM .................................................................................................................................................................................................................... ............ 1717
3.2 3.2 ELECTRIC ELECTRIC INSTALLATIOINSTALLATION..................................N........................................................................................................................................................................... . 1818
3.3 3.3 DRIVING DRIVING WHEEL ...............WHEEL ............................................................................................................................................................................................................................ ... 2020
3.4 3.4 HYDRAULIC HYDRAULIC POWER POWER UNIT UNIT ...................................................................................................................................................................................................... 21........ 21
3.5 3.5 BATTERY BATTERY COMPONCOMPONENTS ........................................ENTS .......................................................................................................................................... 23.............................. 23
3.6 3.6 CONTROLLCONTROLLER ER ............................................................................................................................................................................................................................. ......................... 2424
3.7 3.7 BATTERY CHARGING BATTERY CHARGING AND AND REPLACEMEREPLACEMENT NT ........................................................................................................................................... 26....... 26
3.8 3.8 ELECTRICAELECTRICAL L COMPONECOMPONENTS NTS REPLACEMEREPLACEMENT NT ......................................................................................................................................... 31. 31
3.9 TOOL 3.9 TOOL FOR REPAIRING THE PIN FOR REPAIRING THE PIN OF ELECTRIC PLUG...........................................OF ELECTRIC PLUG......................................................... 37.............. 37
4 4 HYDRAULIC HYDRAULIC SYSTEM .........................................SYSTEM ........................................................................................................................................................................................... 38.............. 38
4.1 CLEANING TA4.1 CLEANING TANK AND FILTER.................................................................................NK AND FILTER...............................................................................................39..............39
4.4.2 CHANGE OF PUMP 2 CHANGE OF PUMP STATION..................................................................................................40STATION..................................................................................................40
4.3 REPLACE THE HYDRA4.3 REPLACE THE HYDRAULIC OIL...................................................ULIC OIL.............................................................................................41..........................................41
4.4 REPLACE THE FILTER.............................................................................................................424.4 REPLACE THE FILTER.............................................................................................................42
4.5 REPLACE CARBO4.5 REPLACE CARBON BRUSH.....................................................................N BRUSH....................................................................................................43...............................43
4.6 ADJUST THE PUMP PRESS4.6 ADJUST THE PUMP PRESSURE.............................................................................................45URE.............................................................................................45
5 DRIVING WHEEL.5 DRIVING WHEEL.................................................................................................................................46................................................................................................................................46
5.1 REPLACE THE DRIVE WHEE5.1 REPLACE THE DRIVE WHEELS.........................................................................................LS..............................................................................................47.....47
5.2 ADJUST THE BRAKE OF THE AIR GAP.................................................................................495.2 ADJUST THE BRAKE OF THE AIR GAP.................................................................................49
6 HAND SHANK.6 HAND SHANK......................................................................................................................................50.....................................................................................................................................50
6.1 REMOVE THE HANDLE............................................................................................................516.1 REMOVE THE HANDLE............................................................................................................51
6.2 REPLACE THE GAS SPRING6.2 REPLACE THE GAS SPRING..........................................................................................................................................................52............................................52
6.3 CHANGE THE INTERLOC6.3 CHANGE THE INTERLOCK SWITCH.......................................................................................53K SWITCH.......................................................................................53
6.4 REPLACE THE HANDLE HEA6.4 REPLACE THE HANDLE HEAD.....................................................D...............................................................................................55..........................................55
7 CASTER.7 CASTER...............................................................................................................................................57..............................................................................................................................................57 
7.1 CASTER OPERA7.1 CASTER OPERATION......................................................................................TION..............................................................................................................57........................57
8 8 LABELS LABELS ................................................................................................................................................................................................................................................................................................ 6060
9 9 MAINTENANCE MAINTENANCE LIST ...........................................LIST ........................................................................................................................................................................................................... 6262
10 10 FAULT FAULT ANALYSIANALYSIS S .......................................................................................................................................................................................................................................................... 6464
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FOREWORDFOREWORD
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.
This manual describes the different types of pallet truck usage, maintenance truck, please make sure theThis manual describes the different types of pallet truck usage, maintenance truck, please make sure the
model is consistent with your company.model is consistent with your company.
Please pay attention to keep for Please pay attention to keep for future use. If future use. If this manual or alert/warning label damaged or lost, pleasethis manual or alert/warning label damaged or lost, please
contact the local dealer to replace.contact the local dealer to replace.
The carrier in accordance with EN The carrier in accordance with EN 3691-1 (Industrial vehicles - safety requirements and validation, part3691-1 (Industrial vehicles - safety requirements and validation, part
1), EN 12895 (Industrial vehicles - electromagnetic compatibility),EN 12053 (The safety of industrial1), EN 12895 (Industrial vehicles - electromagnetic compatibility),EN 12053 (The safety of industrial
vehicles - test vehicles - test method of the method of the measuremenmeasurement noise emission),EN 1175 (Industrial vehicle safety - t noise emission),EN 1175 (Industrial vehicle safety - electricalelectrical
performance requirements) standard requirement, must ensure that the vehicle on the basis of theperformance requirements) standard requirement, must ensure that the vehicle on the basis of the
above purposes. Accordinabove purposes. According to EN g to EN 12053, driver's ear noise level is less than 12053, driver's ear noise level is less than 70dB (A).70dB (A).
NOTICENOTICE：：
 Waste pacWaste packaging shkaging should be ould be according according to the to the material cmaterial classification lassification in solid in solid waste box, waste box, collectioncollection
processing and specially by the local environmental protection bureau. To avoid pollution, optionalprocessing and specially by the local environmental protection bureau. To avoid pollution, optional
littering is littering is prohibiteprohibited.d.
 To avoid To avoid the spill the spill situation when situation when use the use the product, the product, the user should user should prepare some prepare some materials can materials can bebe
absorbed (waste wood chips or dry cloth) to absorb of absorbed (waste wood chips or dry cloth) to absorb of the leakage of oil in a the leakage of oil in a timely manner. To avoidtimely manner. To avoid
the secondary pollution of the environment, has been with absorbable materials shall be delivered tothe secondary pollution of the environment, has been with absorbable materials shall be delivered to
special department according to local authorities.special department according to local authorities.
 Continuous Continuous improvemenimprovement of t of our proour products, bducts, because ecause only in only in this manthis manual opeual operation/mainration/maintenance tenance truck,truck,
for the purpose of this for the purpose of this manual does not guarantee in addition to the special circumstances, pleasemanual does not guarantee in addition to the special circumstances, please
understand.understand.
NOTICE:NOTICE:
In this manual, the symbol on the In this manual, the symbol on the left if you don't follow that left if you don't follow that may result in death or serious injury,may result in death or serious injury,
warning and dangerous situation.warning and dangerous situation.
op yri h topyri ht

Copyright by this file last Copyright by this file last mentioned compamentioned company reserves on the CE ny reserves on the CE standard.standard.
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1. GENERAL1. GENERAL
1.1 INTRODUCTION1.1 INTRODUCTION ––MAINTENANCE SAFETY PRECAUTIOMAINTENANCE SAFETY PRECAUTIO
MaintenanMaintenance 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 theleast observing the
following.following. It is
It is of utmost importance that maintenance personnel pay strict attention to these warningsof utmost importance that maintenance personnel pay strict attention to these warnings
and precautions to avoid possible injury to themselves, others or damage to the and precautions to avoid possible injury to themselves, others or damage to the equipment. Aequipment. A
maintenanmaintenance program must be followed to ensure that the ce program must be followed to ensure that the machine is safe to machine is safe to operate.operate.
The specific precautions to be The specific precautions to be observed during maintenanobserved during maintenance are ce are inserted at the inserted at the appropriaappropriate point in te point in thethe
manual. These precautionmanual. These precautions are, for s are, for the most parts, those the most parts, those that apply when servicing hydraulic and largerthat apply when servicing hydraulic and larger
truck component partstruck component parts
MODIFICATION OF THE TRUCK WITHOUT CERTIFICATION BY A RESPONSIBLEMODIFICATION OF THE TRUCK WITHOUT CERTIFICATION BY A RESPONSIBLE
AUTHORITY THAT THE TRUCK IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED, IS AAUTHORITY THAT THE TRUCK IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED, IS A
SAFETY VIOLATION.SAFETY VIOLATION.
SINCE THE TRUCK MANUFACTURER HAS NO
SINCE THE TRUCK MANUFACTURER HAS NO
DIRECT CONTROL OVER THE FIELD INSPECTION ANDDIRECT CONTROL OVER THE FIELD INSPECTION AND
MAINTENANCE, SAFETY IN THIS AREA RESPONSIBIUTY OF THEMAINTENANCE, SAFETY IN THIS AREA RESPONSIBIUTY OF THE
OWNER OR OPERATOR.OWNER OR OPERATOR.
FAILURE TO COMPLY WITH SFAILURE TO COMPLY WITH SAFETY PRECAUTIONAFETY PRECAUTIONS,S,
LlSTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATHLlSTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH
AND IS A SAFETY VIOLATION.AND IS A SAFETY VIOLATION.
 Only Only speciallspecially y trained trained personnel personnel to to the the local local operation.operation.
 Please read it Please read it carefully before operation or maintenance vehiclecarefully before operation or maintenance vehicle
operation and maintenance manual.operation and maintenance manual.
 Read all the vehicles with preventive measures.Read all the vehicles with preventive measures.
 Make sure you fully Make sure you fully understand operation content. Maintenance vehiclesunderstand operation content. Maintenance vehicles
before preparing the necessary tool box parts are very important.before preparing the necessary tool box parts are very important.
 Maintenance vehicles is the first Maintenance vehicles is the first consideration when you and the safetyconsideration when you and the safety
of others. In the absence of mechanical equipment parts do not move.of others. In the absence of mechanical equipment parts do not move.
Please do not place heavy objects on the location of the instability. Improve equipment part; makePlease do not place heavy objects on the location of the instability. Improve equipment part; make
sure to provide enough support.sure to provide enough support.
 We should pay attention to the machine hydraulic system to We should pay attention to the machine hydraulic system to operateoperate
under the pressure of high risk. In any part of the disconnect orunder the pressure of high risk. In any part of the disconnect or
remove system before doing everything it can to reduce the remove system before doing everything it can to reduce the systemsystem
pressure. Through many times to stop and start the cycle controlpressure. Through many times to stop and start the cycle control
motor, reduce the system pressure.motor, reduce the system pressure.
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 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 workhelmet, safety shoes and work
clothes, wear protective glasses. In order to avoid the hurt byclothes, wear protective glasses. In order to avoid the hurt by
prominent parts of the vehicle, the staff must wear safety clothing.prominent parts of the vehicle, the staff must wear safety clothing.
Don't wear oily clothes. Check to remove battery when the plug-in.Don't wear oily clothes. Check to remove battery when the plug-in.
Do not wear loose clothing and tie, in case Do not wear loose clothing and tie, in case of clothing involved inof clothing involved in
equipment.equipment.
 During maintenance does not allow any During maintenance does not allow any unauthorized person standunauthorized person stand
near the machine.near the machine.
 Can't replace lamps and lanterns with flame. Don't use flame Can't replace lamps and lanterns with flame. Don't use flame leakleak
check, oil level or electrolyte.check, oil level or electrolyte.
 Immediately clean the grease of the operating area or hand, Immediately clean the grease of the operating area or hand, ifif
someone slipped on vehicle slip could be someone slipped on vehicle slip could be dangerous.dangerous.
 Use pure oil and clean container.Use pure oil and clean container.
 Oil is a kind Oil is a kind of dangerous substancesof dangerous substances, there is fire don't, there is fire don't
appear grease or oil. To do appear grease or oil. To do a good job of using firea good job of using fire
extinguishers and other firefighting equipment.extinguishers and other firefighting equipment.
 Keep battery away from fire hazards, the generated gasKeep battery away from fire hazards, the generated gas
explodes.explodes.
 Flammable things far away from the vehicleFlammable things far away from the vehicle，，and smoking isand smoking is
prohibited to work.prohibited to work.
 Disconnect the battery when you replace the electrical components.Disconnect the battery when you replace the electrical components.
 Using force recommended oil level, Using force recommended oil level, according to the environmentalaccording to the environmental
temperature choose oil viscosity.temperature choose oil viscosity.
 In a closed space in the In a closed space in the exhaust gas is very dangerous.exhaust gas is very dangerous.
 Avoid inhaling processAvoid inhaling processing components of ing components of dust, wear a mask wdust, wear a mask when necessary.hen necessary.
 At the top of the At the top of the vehicle is working, vehicle is working, be careful not to fallbe careful not to fall..
 In In the the operating operating area area warning warning labellabel ((such as "don't such as "don't start" "maintenancstart" "maintenance"e"))，，this can prevents this can prevents workersworkers
start or a moving vehicle.start or a moving vehicle.
 When When welding welding or or power power system system is wis working, orking, turn turn off off the the keykey
switch and unplug battery plug-in. The vehicle parking in solidswitch and unplug battery plug-in. The vehicle parking in solid
flat field. The goods fork fell to the flat field. The goods fork fell to the lowest level, stop the motorlowest level, stop the motor
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work. Park machine company, the ground.work. Park machine company, the ground.
 In the sulfuric acid toxic battery electrolyte, it can burn skin and clIn the sulfuric acid toxic battery electrolyte, it can burn skin and clothes ofothes of
corrosion. If splashed on your clothing or skin sulfate to rinse corrosion. If splashed on your clothing or skin sulfate to rinse immediatelyimmediately
with plenty of water.with plenty of water.
 For battery to work to wear goggles or safety glasses, For battery to work to wear goggles or safety glasses, if splashed into eyes,if splashed into eyes,
rinse immediately and go to a rinse immediately and go to a doctor.doctor.
 Metal object touch the battery Metal object touch the battery terminal may cause shortterminal may cause short
circuit and burn to you, tools to stay away from the batterycircuit and burn to you, tools to stay away from the battery
terminal.terminal.
 Fire, lit a match and Fire, lit a match and flame to stay away from the battery, batteryflame to stay away from the battery, battery
(hydrogen) gas explodes.(hydrogen) gas explodes.
 Disassembly and assembly of battery to make sure the batteryDisassembly and assembly of battery to make sure the battery
terminal (+, -) terminal (+, -) properly connected.properly connected.
 If the water into the electrical system, the operation will lead If the water into the electrical system, the operation will lead toto
failure. Don't use water on failure. Don't use water on sensors, connectors, and vehiclesensors, connectors, and vehicle
instrument.instrument.
 Don't deal with electrical equipment, wear wet gloves that could lead to electric Don't deal with electrical equipment, wear wet gloves that could lead to electric shocks.shocks.
 Work together with others, choose a Work together with others, choose a leader and work according leader and work according to his instructions. Don't to outsideto his instructions. Don't to outside
any maintenance work.any maintenance work.
 Unless you have special instructions, must the ability after the motor stopped for maintenance work.Unless you have special instructions, must the ability after the motor stopped for maintenance work.
If the motor run time If the motor run time for maintenance, you must have two technicians present: a for maintenance, you must have two technicians present: a piling car operation,piling car operation,
and another for maintenance work. In and another for maintenance work. In this case, do not touch any this case, do not touch any contact with any moving parts.contact with any moving parts.
 Before adjustment, lubrication and maintenance work, close all the Before adjustment, lubrication and maintenance work, close all the power switch.power switch.
 Remove containing O gaskets or seal parts, clean up the installationRemove containing O gaskets or seal parts, clean up the installation
surface and replace the new seal.surface and replace the new seal.
 Thoroughly clean the machine, particularly carefully clean Thoroughly clean the machine, particularly carefully clean oil componentsoil components
and in the area near and in the area near the oil dipstick. Be careful not to let the oil dipstick. Be careful not to let any dirt or dustany dirt or dust
into the system.into the system.
 Can only be used to allow the burning cleaning solvent.Can only be used to allow the burning cleaning solvent.
 When change hydraulic oil or filter, check the hydraulic oil When change hydraulic oil or filter, check the hydraulic oil and filter for excessand filter for excess
metal particles or other foreign material.metal particles or other foreign material.
 Use of manufacturers to provide spare parts for replacement, make sure Use of manufacturers to provide spare parts for replacement, make sure thatthat
the replacement of parts or components is the same as the original parts.the replacement of parts or components is the same as the original parts.
 Check the open gear box, there might be Check the open gear box, there might be a material falls into. Before remove the cover for ia material falls into. Before remove the cover for inspection,nspection,
to ensure that you have nothing in his pocket. Then carefully remove the nut.to ensure that you have nothing in his pocket. Then carefully remove the nut.
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1.2 MEASUREMENT CONVERSIONS1.2 MEASUREMENT CONVERSIONS
LengthLength
unit unit cm cm m m km km in in ft ft yd yd milemile
cm cm 1 1 0.01 0.01 0.00001 0.00001 0.3937 0.3937 0.03281 0.03281 0.01094 0.01094 0.0000060.000006
m m 100 100 1 1 0.001 39.37 0.001 39.37 3.2808 3.2808 1.0936 1.0936 0.000620.00062
km km 100000 100000 1000 1000 1 1 39370.7 39370.7 3280.8 3280.8 1093.6 1093.6 0.621370.62137
in in 2.54 2.54 0.0254 0.0254 0.000025 0.000025 1 1 0.08333 0.08333 0.02777 0.02777 0.0000150.000015
ft ft 30.48 30.48 0.3048 0.3048 0.000304 12 0.000304 12 1 1 0.3333 0.3333 0.0001890.000189
yd yd 91.44 91.44 0.9144 0.9144 0.000914 0.000914 36 36 3 3 1 1 0.0005680.000568
mile 160930 mile 160930 1609.3 1.6093 1609.3 1.6093 63360 63360 5280 5280 1760 1760 11
1mm=0.1cm, 11mm=0.1cm, 1m=0.001mmm=0.001mm
AreaArea
unit cmunit cm22 mm22 kmkm22 a a ftft22 ydyd22 inin22
cmcm22 1 0.00011 0.0001 –– 0.000001 0.000001 0.001076 0.001076 0.000012 0.000012 0.1550000.155000
mm22 10000 10000 1 1 0.000001 0.01 10.764 0.000001 0.01 10.764 1.1958 1.1958 1550.0001550.000
kmkm22 –– 1000000 1000000 1 1 10000 10000 1076400 1076400 11958001195800 ––
a a 0.01 0.01 100 0.0001 100 0.0001 1 1076.4 1 1076.4 119.58119.58 ––
ftft22 –– 0.092903 0.092903 –– 0.000929 1 0.000929 1 0.1111 0.1111 144.000144.000
ydyd22 –– 0.83613 0.83613 –– 0.008361 0.008361 9 9 1 1 1296.001296.00
inin22 6.4516 0.0006456.4516 0.000645 –– –– 0.006943 0.006943 0.000771 0.000771 11
1ha=100a, 1mile1ha=100a, 1mile22=259ha=2.59km=259ha=2.59km22
VolumeVolume
unitunit cm
cm33= = cc cc mm33llinin33ftft33ydyd33
cmcm33 = m= m l
l1 1 0.000001 0.000001 0.001 0.001 0.061024 0.061024 0.000035 0.000035 0.0000010.000001
mm331000000 1000000 1 1 1000 1000 61024 61024 35.315 35.315 1.307961.30796
ll1000 1000 0.001 0.001 1 1 61.024 61.024 0.035315 0.035315 0.0013080.001308
inin3316.387 16.387 0.000016 0.000016 0.01638 0.01638 1 1 0.000578 0.000578 0.0000210.000021
ftft3328316.8 28316.8 0.028317 0.028317 28.317 28.317 1728 1728 1 1 0.037040.03704
ydyd33764529.8 764529.8 0.76453 0.76453 764.53 764.53 46656 46656 27 27 11
1gal(US)=3785.41 cm1gal(US)=3785.41 cm33=231 in=231 in33=0.83267gal(US)=0.83267gal(US)
WeightWeight
unit
unit g kg kg g t t oz oz lblb
g g 1 1 0.001 0.001 0.000001 0.000001 0.03527 0.03527 0.00220.0022
kg kg 1000 1000 10 10 0.001 0.001 35.273 35.273 2.204592.20459
t t 1000000 1000000 1000 1000 1 1 35273 35273 2204.592204.59
oz oz 28.3495 28.3495 0.02835 0.02835 0.000028 0.000028 1 1 0.06250.0625
lb lb 453.592 453.592 0.45359 0.45359 0.000454 0.000454 16 16 11
1 tone (metric)= 1.1023 ton(US)=0.9842 ton(UK)1 tone (metric)= 1.1023 ton(US)=0.9842 ton(UK)
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PressurePressure
unit kgf/cm
unit kgf/cm22bar Pa=N/mbar Pa=N/m22kPa lbf/inkPa lbf/in22lbf/ftlbf/ft22
kgf/cmkgf/cm221 1 0.98067 0.98067 98066.5 98066.5 98.0665 98.0665 14.2233 14.2233 2048.162048.16
bar 1.01972 bar 1.01972 1 1 100000 100000 100 100 14.5037 14.5037 2088.62088.6
Pa=N/mPa=N/m220.00001 0.00001 0.001 0.001 1 1 0.001 0.001 0.00015 0.00015 0.020860.02086
kPa kPa 0.01020 0.01020 0.01 0.01 1000 1000 1 1 0.14504 0.14504 20.88620.886
lbf/inlbf/in220.07032 0.07032 0.0689 0.0689 6894.76 6894.76 6.89476 6.89476 1 1 144144
lbf/ftlbf/ft220.00047 0.00047 0.00047 0.00047 47.88028 47.88028 0.04788 0.04788 0.00694 0.00694 11
kgf/cmkgf/cm22=735.56 Torr(mmHg)=0.96784atm=735.56 Torr(mmHg)=0.96784atm
STANDARD TIGHTENING TORQUESTANDARD TIGHTENING TORQUE
The following charts give the standard tightening torques of bolts and nuts.The following charts give the standard tightening torques of bolts and nuts.
METER TABLEMETER TABLE
Classification Classification 4T, 4T, 5T 5T 10T10T
Bolt typeBolt type
Bolt Bolt size size Torque Torque kgf kgf · · m m (lbf (lbf · · ft) ft) Torque Torque kgf kgf · · m m (lbf (lbf · · ft)ft)
M4 M4 0.2 0.2 ± ± 0.02 0.02 0.4 0.4 ± ± 0.040.04
M5 M5 0.3 0.3 ± ± 0.03 0.03 0.8 0.8 ± ± 0.080.08
M6 M6 0.5 0.5 ± ± 0.05 0.05 1.4 1.4 ± ± 0.140.14
M8 M8 1.2 1.2 ± ± 0.12 0.12 3.3 3.3 ± ± 0.30.3
M10 M10 2.3 2.3 ± ± 0.23 0.23 6.5 6.5 ± ± 0.70.7
M12 M12 4.0 4.0 ± ± 0.4 0.4 11.3 11.3 ± ± 1.11.1
M14 M14 6.4 6.4 ± ± 0.6 0.6 17.9 17.9 ± ± 1.81.8
M16 M16 9.5 9.5 ± ± 0.9 0.9 26.7 26.7 ± ± 2.72.7
M18 M18 13.5 13.5 ± ± 1.4 1.4 38.0 38.0 ± ± 3.83.8
M20 M20 18.6 18.6 ± ± 1.9 1.9 52.2 52.2 ± ± 5.25.2
M22 M22 24.7 24.7 ± ± 2.5 2.5 69.4 69.4 ± ± 6.96.9
M24 M24 32.1 32.1 ± ± 3.2 3.2 90.2 90.2 ± ± 9.09.0
M30 M30 62.6 62.6 ± ± 6.3 6.3 176.1 176.1 ± ± 17.617.6
M36 M36 108.2 108.2 ± ± 10.8 10.8 304.3 304.3 ± ± 30.430.4
M42 M42 171.8 171.8 ± ± 17.2 17.2 483.2 483.2 ± ± 48.348.3
M45 M45 211.3 211.3 ± ± 21.1 21.1 594.3 594.3 ± ± 50.450.4
10.910.9
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
 99
INCH TABLEINCH TABLE
4T, 4T, 5T 5T 10T10T
Classification Bolt typeClassification Bolt type
Bolt Bolt size size Torque Torque kgf kgf · · m m (lbf (lbf · · ft) ft) Torque Torque kgf kgf · · m m (lbf (lbf · · ft)ft)
1/4 1/4 0.6 0.6 ± ± 0.06 0.06 1.7 1.7 ± ± 0.20.2
5/16 5/16 1.2 1.2 ± ± 0.12 0.12 3.0 3.0 ± ± 0.30.3
3/8 3/8 2.0 2.0 ± ± 0.20 0.20 5.6 5.6 ± ± 0.50.5
7/16 7/16 3.2 3.2 ± ± 0.32 0.32 8.9 8.9 ± ± 0.90.9
1/2 1/2 4.7 4.7 ± ± 0.47 0.47 13.4 13.4 ± ± 1.31.3
9/16 9/16 6.8 6.8 ± ± 0.68 0.68 19.0 19.0 ± ± 1.91.9
5/8 5/8 9.3 9.3 ± ± 0.93 0.93 26.1 26.1 ± ± 2.62.6
3/4 3/4 16.0 16.0 ± ± 1.60 1.60 45.1 45.1 ± ± 4.54.5
7/8 7/8 25.5 25.5 ± ± 2.55 2.55 71.6 71.6 ± ± 7.27.2
1 1 38.0 38.0 ± ± 3.80 3.80 106.9 106.9 ± ± 10.710.7
1-1/8 1-1/8 54.1 54.1 ± ± 5.41 5.41 152.2 152.2 ± ± 15.215.2
1-1/4 1-1/4 74.2 74.2 ± ± 7.42 7.42 208.9 208.9 ± ± 20.920.9
1-3/4 1-3/4 98.8 98.8 ± ± 9.88 9.88 277.8 277.8 ± ± 27.827.8
1-1/2 1-1/2 128.2 128.2 ± ± 12.82 12.82 360.7 360.7 ± ± 36.136.1
The torque in above table shall not be applied to nylon or nonferrous bolts or washer. The same is validThe torque in above table shall not be applied to nylon or nonferrous bolts or washer. The same is valid
for not for not standardizstandardized ones.ed ones.
H Newton meter : 1 Nm = 0.1kgfmH Newton meter : 1 Nm = 0.1kgfm
Split flange bolt tightening torqueSplit flange bolt tightening torque
The following table torque applied to split flange boltsThe following table torque applied to split flange bolts
DiameterDiameter
(mm)(mm)
Flat widthFlat width
(mm)(mm)
TorqueTorque
kgf·m N·mkgf·m N·m
10 10 14 14 6.7 6.7 ± ± 0.7 0.7 66.7 66.7 ± ± 6.86.8
12 12 17 17 11.5 11.5 ± ± 1 1 112 112 ± ± 9.89.8
16 16 22 22 28.5 28.5 ± ± 3 3 279 279 ± ± 2929
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
 1010
PF PF THREAD THREAD OO––ring ring PlugPlug
Thread Thread Torque Torque (kgf·m)(kgf·m)
1/8 1/8 1.1 1.1 ± ± 0.10.1
1/4 1/4 2.6 2.6 ± ± 0.20.2
3/8 3/8 4.6 4.6 ± ± 0.30.3
1/2 1/2 8.5 8.5 ± ± 0.40.4
3/4 3/4 19 19 ± ± 1.01.0
1 1 33 33 ± ± 2.02.0
With rotate the nut torque o-ringsWith rotate the nut torque o-rings
Connector OConnector O––ring ring SwivelSwivel––nut nut hosehose
Tube O.D (inch)Tube O.D (inch) Thread (in)Thread (in) Torque (kgf·m)Torque (kgf·m)
1/2 1/2 UN UN 13/16 13/16 - - 16 16 9.5 9.5 ± ± 0.950.95
3/4 3/4 UN UN 1 1 3/16 3/16 - - 12 12 18 18 ± ± 1.81.8
1 1 UN UN 1 1 7/16 7/16 - - 12 12 21 21 ± ± 2.12.1
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
 1111
APPROXIMATE CONVERSIONSAPPROXIMATE CONVERSIONS

SI SI Conv Conv NonNon––SI SI Conv Conv SISI
Unit Unit Factor Factor Unit Unit Factor Factor UnitUnit
TorqueTorque
Newton meter (N·m)Newton meter (N·m) ×× 8.9 8.9 = ln·in= ln·in ×× 0.113 0.113 = N·m= N·m
Newton meter (N·m)Newton meter (N·m) ×× 0.74 0.74 = lb·ft.= lb·ft. ×× 1.36 1.36 = N·m= N·m
Newton meter (N·m)Newton meter (N·m) ×× 0.102 0.102 = kg·m= kg·m ×× 7.22 7.22 = lb·ft.*= lb·ft.*
Pressure (Pa = N/mPressure (Pa = N/m22))
kiloPascal (kPa)kiloPascal (kPa) ×× 4.0 4.0 = = in. in. HH22OO ×× 0.249 0.249 = kPa= kPa
kiloPascal (kPa)kiloPascal (kPa) ×× 0.30 0.30 = = in. in. HgHg ×× 3.38 3.38 = kPa= kPa
kiloPascal (kPa)kiloPascal (kPa) ×× 0.145 0.145 = psi= psi ×× 6.89 6.89 = kPa= kPa
(bar)(bar) ×× 14.5 14.5 = psi= psi ×× 0.069 0.069 = bar*= bar*
(kg/cm(kg/cm22)) ×× 14.22 14.22 = psi= psi ×× 0.070 0.070 ==
kgf/cmkgf/cm22**
Newton/mmNewton/mm22 ×× 145.04 145.04 = psi= psi ×× 0.069 0.069 = bar*= bar*
MegaPascal (MPa)MegaPascal (MPa) ×× 145 145 = psi= psi ×× 0.00689 0.00689 = MPa= MPa
(Pa=N·m(Pa=N·m22))
Power r (W = J/s)Power r (W = J/s)
kiloWatt (kW)kiloWatt (kW) ×× 1.36 1.36 = = PS PS (cv)(cv) ×× 0.736 0.736 = kW= kW
kiloWatt (kW)kiloWatt (kW) ×× 1.34 1.34 = HP= HP ×× 0.746 0.746 = kW= kW
kiloWatt (kW)kiloWatt (kW) ×× 0.948 0.948 = Btu/s= Btu/s ×× 1.055 1.055 = kW= kW
Watt (W)Watt (W) ×× 0.74 0.74 = ft·lb/s= ft·lb/s ×× 1.36 1.36 = = WW
(W=J/s)(W=J/s)
Energy (J = N·m)Energy (J = N·m)
kiloJoule (kJ)kiloJoule (kJ) ×× 0.948 0.948 = Btu= Btu ×× 1.055 1.055 = kJ= kJ
Joule (J)Joule (J) ×× 0.239 0.239 = calorie= calorie ×× 4.19 4.19 = = JJ
(J=N·m)(J=N·m)
Velocity and Velocity and AccelerationAcceleration
meter per secmeter per sec22(m/s(m/s22)) ××3.283.28 = ft/s= ft/s22 ×× 0.305 0.305 = m/s= m/s22
meter per sec (m/s)meter per sec (m/s) ×× 3.28 3.28 = ft/s= ft/s ×× 0.305 0.305 = m/s= m/s
kilometer per hour (km/h)kilometer per hour (km/h) ×× 0.62 0.62 = mph= mph ×× 1.61 1.61 = km/h= km/h
Horse Power/TorqueHorse Power/Torque
BHPBHP ×× 5252 5252 R.P.M. R.P.M. = = TQ TQ (lb·ft) (lb·ft) TQ TQ Z Z R.P.M. R.P.M. 5252 5252 = = B.H.P.B.H.P.
TemperatureTemperature
°C = (°F°C = (°F––32) 32) ÷ ÷ 1.8 1.8 °F= °F= (°C (°C Z Z 1.8) 1.8) + + 3232
Flow RateFlow Rate
liter/min (dmliter/min (dm33/min)/min) ×× 0.264 0.264 = = US US gal/minZ3.7gal/minZ3.785 85 = = l/minl/min
Note Note : : ( ( ) ) NonNon––SI UnitSI Unit
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
 1212
2. 2. SPECIFICASPECIFICATIONTION
2.1 OVERVIEW OF MAIN COMPONENTS2.1 OVERVIEW OF MAIN COMPONENTS
1. 1. Electrical Electrical box box cover cover 11 11 Driving Driving wheelwheel
2. 2. Discharge Discharge indicator, indicator, LED LED chargingcharging
indicatorindicator
12 12 Steering Steering wheel wheel partsparts
3. 3. handle handle shank shank 13 13 hydraulic hydraulic oil oil cylindercylinder
4. 4. Drive Drive control control switch switch (switch)(switch)
butterflybutterfly
1414
5. 5. Safety Safety switch switch button/belly button/belly 1515
6. 6. Instrument Instrument panel panel cover cover 1616
7. 7. Joint Joint emergency emergency button button 1717
8 8 Key Key switch switch 1818
9 9 Pallet Pallet fork fork chassis chassis 1919
10 10 Load Load wheel wheel 2020
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
 1313
CONTROL HANDLECONTROL HANDLE
5 5 Safety Safety switch switch 15 15 Lifting Lifting switchswitch
4 4 Drive Drive control control switchswitch
14 14 horn horn buttonbutton
55
44
1414
1515
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
 1414
2.2 TECHNICAL PARAMETER TABLE2.2 TECHNICAL PARAMETER TABLE
Depending on the type of industrial Depending on the type of industrial vehicles VDI 2198 standard tablevehicles VDI 2198 standard table
ffeeaattuurreess
1.21.2 typetype EP16-N01EP16-N01
Fixed Fixed the the pedal pedal Folding Folding pedalspedals
1.31.3 Power (electric, diesel, gasoline, liquefied petroleumPower (electric, diesel, gasoline, liquefied petroleum
gas, electrical)gas, electrical)gas, electrical)gas, electrical)
electricelectric
1.41.4 Driving mode (manual type, walk, stand driving, carDriving mode (manual type, walk, stand driving, car
type, choose type)type, choose type)
standing steer
standing steer
typetype
standing steerstanding steer
typetype
1.51.5 Load CapacityLoad Capacity Q Q (t) (t) 2.52.5
1.61.6 Load center distanceLoad center distance C C (mm) (mm) 600600
1.81.8 Front overhangFront overhang X X (mm) (mm) 965965
1.91.9 Wheel baseWheel base Y Y (mm) (mm) 15951595
wweeiigghhtt
2.12.1 Weight (including battery)Weight (including battery) kg kg 1085 1085 950950
2.22.2 When the full bridge load driver side/bearing sideWhen the full bridge load driver side/bearing side kg kg 1555/2030 1555/2030 1370/20801370/2080
2.32.3 When the full bridge load driver side/bearing sideWhen the full bridge load driver side/bearing side kg kg 885/200 885/200 730/220730/220
wwhheeeell
3.13.1 TyreTyre Polyurethane (PU)Polyurethane (PU)
3.23.2 Wheel Wheel size size driving driving sideside x w (mm)x w (mm) 82X8282X82
3.33.3 Wheel Wheel size size Bearing Bearing sideside x w (mm)x w (mm) 250X82250X82
3.43.4 Steering wheel sizeSteering wheel size x w (mm)x w (mm) 124X60124X60
3.53.5 Number of wheels (x = drive wheel )drive side/bearingNumber of wheels (x = drive wheel )drive side/bearing
sideside
1×+2/41×+2/4
3.63.6 Wheel Wheel base( base( front) front) driving driving sideside bb1010 (mm) 530(mm) 530
3.73.7 Wheel Wheel base base (behind) (behind) Bearing Bearing sideside bb1111 (mm) 367/512(mm) 367/512
ssiizzee
4.44.4 Hoisting Hoisting height height hh33 (mm) 120(mm) 120
4.94.9 The height of the operating lever in the neutral positionThe height of the operating lever in the neutral position hh1414 (mm) (mm) 1235 1235 1005/14451005/1445
4.154.15 Goods Goods fork fork minimum minimum height height hh1313 (mm) 85(mm) 85
4.194.19 Overall Overall length length ll11 (mm) (mm) 2667 2667 21222122
4.204.20 Body Body length length ll22 (mm) (mm) 1516 1516 971971
4.214.21 overall overall width width bb11 (mm) 790(mm) 790
4.224.22 Pallet Pallet fork fork size size s/e/l s/e/l (mm) (mm) 60/173/115060/173/1150
4.254.25 Pallet Pallet fork fork out out wide wide bb55 (mm) 540/685(mm) 540/685
4.324.32 The The minimum minimum clearance clearance from from the the ground ground mm22 (mm) 25(mm) 25
4.334.33
Work channel width,1000X1200Work channel width,1000X1200 pallet
 pallet (1200 (1200AcrossAcross
the pallet fork placed)the pallet fork placed) Ast (mm) Ast (mm) 3084 3084 25502550
4.344.34 Work channel width,800X1200Work channel width,800X1200pallet
pallet(1200(1200Fork placedFork placed
along the goods)along the goods) Ast (mm) Ast (mm) 2945 2945 24102410
4.354.35 turn turn radius radius Wa Wa (mm) (mm) 2520 2520 19801980
pprrooppeerrttyy
5.15.1 running running speed speed Full/empty Full/empty km/h km/h 9/12 9/12 9.5/12.59.5/12.5
5.25.2 hoisting hoisting speed speed Full/empty Full/empty m/s m/s 0.038/0.0580.038/0.058
5.35.3 rate rate of of descend descend Full/empty Full/empty m/s m/s 0.050/0.0480.050/0.048
5.85.8 Maximum Maximum gradeability gradeability Full/empty Full/empty % % 8/10 8/10 8/158/15
5.105.10 brake brake Electromagnetic Electromagnetic brakebrake
mmoottoorr
6.16.1 Drive Drive motor motor power power kW kW 2.72.7
6.26.2 Lifting Lifting Motor Motor Power Power kW kW 2.22.2
6.36.3 Battery, Battery, according according to to DIN DIN 43531/35/36 43531/35/36 A, A, B, B, C, C, top top mm mm B,3PzSB,3PzS
6.46.4 Battery Battery voltage/capacity voltage/capacity V/ V/ Ah Ah 24/37524/375
6.56.5 Battery Battery weight weight kg kg 300300
6.66.6 Energy Energy consumption consumption (VDI (VDI cycle) cycle) kWh/h kWh/h 1.83 1.83 1.751.75
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
 1515
ootthheerr
8.18.1 Drive Drive control control Ac Ac speed speed controlcontrol
8.48.4 According to the EN12053 According to the EN12053 driver's ear noise levdriver's ear noise level el dB(A) dB(A) 6969
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
 1616
2.3 LUBRICATION2.3 LUBRICATION
HYDRAULIC OILHYDRAULIC OIL
The hydraulic oil must have the
The hydraulic oil must have the anti-wear propertieanti-wear properties, and it s, and it is forbidden to different brandsis forbidden to different brands
or types of oil or types of oil are mixed together, because their additives or comparable viscosity valuesare mixed together, because their additives or comparable viscosity values
may be different.may be different.
THICKENING OF THE HYDRAULIC OILTHICKENING OF THE HYDRAULIC OIL
Viscosity Viscosity #40 #40 #30#30
Features UnitFeatures Unit
ViscosityViscosity
At 40At 40OOCC
mmmm22/s/s
5757
At 50At 50OOC 40C 40
Viscosity indexViscosity index ≥≥150150 ≥≥150150
Cleveland open cupCleveland open cup OOCC ≥≥160160 ≥≥160160
Pour Pour point point MaximumMaximum OOCC ≤≤-35-35 ≤≤-35-35
Density 15Density 15OOC kg/mC kg/m33 861.5 861.5
Copper corrosion(100Copper corrosion(100OOC, C, 3h) 3h) LevelLevel ≤≤11 ≤≤11
Foaming (93.5Foaming (93.5OOC) C) ml ml / / mlml ≤≤30/030/0 ≤≤30/030/0
D D type type vane vane pump pump test test Biggest Biggest lossloss mgmg ≤≤100 15.3100 15.3
Wear points of diameter 1200 r/min, 294N, 30min, 75Wear points of diameter 1200 r/min, 294N, 30min, 75OOC mmC mm ≤≤0.50.5 ≤≤0.50.5
GEAR BOX OILGEAR BOX OIL
Extreme pressure lithium greaseExtreme pressure lithium grease 1#1#
Features UnitFeatures Unit
Penetration Penetration 0.1mm 0.1mm 310--340310--340
Drop pointDrop point OOCC ≥170≥170
Extreme Extreme pressure pressure (Timken (Timken OK) OK) NN ≥177≥177
Similar Similar viscosity viscosity (-10(-10OOC, 10sC, 10s-1-1) ) PPa.a.ss ≤250≤250
Corrosion resistance performance (52
Corrosion resistance performance (52OOCC, 48h) , 48h) Level Level 11
Line some oil (100Line some oil (100OOC, C, 24h) 24h) %% ≤10≤10
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
 1717
3 ELECTRICAL SYSTEM3 ELECTRICAL SYSTEM
3.1 ELECTRIC DIAGRAM3.1 ELECTRIC DIAGRAM
Electric diagramElectric diagram
FUSE01 : 150AFUSE01 : 150A
FUSE02 : 80 AFUSE02 : 80 A
FUSE1 : 10 AFUSE1 : 10 A
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
 1818
3.2 ELECTRIC INSTALLATION3.2 ELECTRIC INSTALLATION
Electrical assembly
Electrical assembly
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
 1919
ELECTRICAL ASSEMBLYELECTRICAL ASSEMBLY
NO NO Name Name Quantity Quantity RemarksRemarks
1 1 Dc Dc power power supply supply switch switch 1 1 ZDK32-350ZDK32-350
22 Dc power supply switch Dc power supply switch ZDK32-350 microZDK32-350 micro
switchswitch 11
33 cross recessed pan head screwcross recessed pan head screw 2 M4×252 M4×25
4 4 Micro Micro switch switch cover cover 11
5 5 Micro Micro switch switch 1 1 RZ-15GW2S-B3RZ-15GW2S-B3
66 hexagon socket cap screwshexagon socket cap screws 2 M6x122 M6x12
7 7 Standard Standard spring spring washer washer 4 4 66
8 8 Limit Limit switch switch mounting mounting plate plate 11
9 9 Dc Dc power power supply supply switch switch 11 ZDK32-350ZDK32-350
mushroommushroom
headhead
1010 cross recessed pan head screwcross recessed pan head screw 2 M3×252 M3×25
11 11 Type Type I I hexagonal hexagonal nut nut 2 2 M3M3
12 12 General General key key switch switch 1 1 LKS-101A LKS-101A keykey
13 13 General General key key switch switch 1 1 LKS-101ALKS-101A
14 14 voltameter voltameter 1 1 CURTIS CURTIS 803803
1515 hexagon socket cap screwshexagon socket cap screws 2 M5×162 M5×16
16 16 Standard Standard spring spring washer washer 2 2 55
17 17 Flat Flat washer washer class class C C 2 2 44
18 18 Standard Standard spring spring washer washer 9 9 44
1919 cross recessed pan head screwcross recessed pan head screw 5 M4×125 M4×12
20 20 AMP AMP core core 2 2 connectors connectors 44
21 21 Plug-in Plug-in bending bending plate plate 11
2222 hexagon socket cap screwshexagon socket cap screws 4 M4x124 M4x12
23 23 Excessive Excessive plug-in plug-in board board 11
24 24 Plug Plug seat seat 33
2525 hexagon socket cap screwshexagon socket cap screws 2 M6×202 M6×20
2626 hornhorn 1 DC24V1 DC24V
2727 hexagon socket cap screwshexagon socket cap screws 1 M8×161 M8×16
28 28 Standard Standard spring spring washer washer 5 5 88
29 29 Line Line socket socket 11
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
 2020
3.3 DRIVING WHEEL3.3 DRIVING WHEEL
FIGURE 14 ROTARY-DRIVEN ASSEMBLYFIGURE 14 ROTARY-DRIVEN ASSEMBLY
NO NO Name Name Quantity Quantity RemarksRemarks
1 1 ElectromagnElectromagnetic etic brake brake 11
22 hexagon socket cap screwshexagon socket cap screws
8 M8x408 M8x40
3 3 Standard Standard spring spring washer washer 9 9 88
4 4 Driving Driving wheel wheel seat seat 11
55

hehexaxa on on sosockcket et ca ca scscrerewsws
1 M8x161 M8x16
6 6 Small Small washer washer A-class A-class 1 1 88
77 handle seathandle seat 11
88 hehexaxa on on sosockcket et ca ca scscrerewsws
4 M10x204 M10x20
9 9 Standard Standard spring spring washer washer 4 4 1010
10 10 Elastic Elastic cylindrical cylindrical pin pin heavy heavy 2 2 8x268x26
1111 Vertical communication driveVertical communication drive
assemblyassembly 11
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