Baoli EP16-N01 User manual

Service & Maintenance Manual
Pallet truck EP16-N01 EP20-N04
Warning
You must read the instructions in this manual
before using the manual.
Notice:
The last page, please check the file and
all of the current product type on the
nameplate.
Pay attention to keep for future use.

2
CONTENT
FOREWORD………….......………………………………………………………………………..3
1 GENERAL............................................................................................................................................... 4
1.1 INTRODUCTION–MAINTENANCE SAFETY PRECAUTIO........................................................ 4
1.2 MEASUREMENT CONVERSIONS.............................................................................................. 7
2 SPECIFICATION................................................................................Errore. Il segnalibro non è definito.
2.1 OVERVIEW OF MAIN COMPONENTS ..................................Errore. Il segnalibro non è definito.
2.2 TECHNICAL PARAMETER TABLE.......................................................................................... 14
2.3 LUBRICATION ........................................................................................................................... 16
3 ELECTRICAL SYSTEM........................................................................................................................ 17
3.1 ELECTRIC DIAGRAM................................................................................................................ 17
3.2 ELECTRIC INSTALLATION....................................................................................................... 18
3.3 DRIVING WHEEL....................................................................................................................... 20
3.4 HYDRAULIC POWER UNIT....................................................................................................... 21
3.5 BATTERY COMPONENTS........................................................................................................ 23
3.6 CONTROLLER........................................................................................................................... 24
3.7 BATTERY CHARGING AND REPLACEMENT......................................................................... 26
3.8 ELECTRICAL COMPONENTS REPLACEMENT ..................................................................... 31
3.9 TOOL FOR REPAIRING THE PIN OF ELECTRIC PLUG......................................................... 37
4 HYDRAULIC SYSTEM ......................................................................................................................... 38
4.1 CLEANING TANK AND FILTER...............................................................................................39
4.2 CHANGE OF PUMP STATION..................................................................................................40
4.3 REPLACE THE HYDRAULIC OIL.............................................................................................41
4.4 REPLACE THE FILTER.............................................................................................................42
4.5 REPLACE CARBON BRUSH....................................................................................................43
4.6 ADJUST THE PUMP PRESSURE.............................................................................................45
5 DRIVING WHEEL.................................................................................................................................46
5.1 REPLACE THE DRIVE WHEELS..............................................................................................47
5.2 ADJUST THE BRAKE OF THE AIR GAP.................................................................................49
6 HAND SHANK......................................................................................................................................50
6.1 REMOVE THE HANDLE............................................................................................................51
6.2 REPLACE THE GAS SPRING...................................................................................................52
6.3 CHANGE THE INTERLOCK SWITCH.......................................................................................53
6.4 REPLACE THE HANDLE HEAD...............................................................................................55
7 CASTER...............................................................................................................................................57
7.1 CASTER OPERATION..............................................................................................................57
8 LABELS................................................................................................................................................ 60
9 MAINTENANCE LIST........................................................................................................................... 62
10 FAULT ANALYSIS ............................................................................................................................. 64

3
FOREWORD
The handling car operation, please read the manual carefully and fully understand the use of the car,
improper operation easily lead to danger.
This manual describes the different types of pallet truck usage, maintenance truck, please make sure the
model is consistent with your company.
Please pay attention to keep for future use. If this manual or alert/warning label damaged or lost, please
contact the local dealer to replace.
The carrier in accordance with EN 3691-1 (Industrial vehicles - safety requirements and validation, part
1), EN 12895 (Industrial vehicles - electromagnetic compatibility),EN 12053 (The safety of industrial
vehicles - test method of the measurement noise emission),EN 1175 (Industrial vehicle safety - electrical
performance requirements) standard requirement, must ensure that the vehicle on the basis of the
above purposes. According to EN 12053, driver's ear noise level is less than 70dB (A).
NOTICE：
Waste packaging should be according to the material classification in solid waste box, collection
processing and specially by the local environmental protection bureau. To avoid pollution, optional
littering is prohibited.
To avoid the spill situation when use the product, the user should prepare some materials can be
absorbed (waste wood chips or dry cloth) to absorb of the leakage of oil in a timely manner. To avoid
the secondary pollution of the environment, has been with absorbable materials shall be delivered to
special department according to local authorities.
Continuous improvement of our products, because only in this manual operation/maintenance truck,
for the purpose of this manual does not guarantee in addition to the special circumstances, please
understand.
NOTICE: In this manual, the symbol on the left if you don't follow that may result in death or serious injury,
warning and dangerous situation.
Copyright
Copyright by this file last mentioned company reserves on the CE standard.

4
1. GENERAL
1.1 INTRODUCTION –MAINTENANCE SAFETY PRECAUTIO
Maintenance work may cause injuries. Always take care to perform work safe, at least observing the
following. It is of utmost importance that maintenance personnel pay strict attention to these warnings
and precautions to avoid possible injury to themselves, others or damage to the equipment. A
maintenance program must be followed to ensure that the machine is safe to operate.
The specific precautions to be observed during maintenance are inserted at the appropriate point in the
manual. These precautions are, for the most parts, those that apply when servicing hydraulic and larger
truck component parts
MODIFICATION OF THE TRUCK WITHOUT CERTIFICATION BY A RESPONSIBLE
AUTHORITY THAT THE TRUCK IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED, IS A
SAFETY VIOLATION.
SINCE THE TRUCK MANUFACTURER HAS NO
DIRECT CONTROL OVER THE FIELD INSPECTION AND
MAINTENANCE, SAFETY IN THIS AREA RESPONSIBIUTY OF THE
OWNER OR OPERATOR.
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS,
LlSTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH
AND IS A SAFETY VIOLATION.
Only specially trained personnel to the local operation.
Please read it carefully before operation or maintenance vehicle
operation and maintenance manual.
Read all the vehicles with preventive measures.
Make sure you fully understand operation content. Maintenance vehicles
before preparing the necessary tool box parts are very important.
Maintenance vehicles is the first consideration when you and the safety
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; make
sure to provide enough support.
We should pay attention to the machine hydraulic system to operate
under the pressure of high risk. In any part of the disconnect or
remove system before doing everything it can to reduce the system
pressure. Through many times to stop and start the cycle control
motor, reduce the system pressure.

5
Maintenance vehicles when remove rings, watches and jewelry.
Drill grinding or hammer to wear a helmet, safety shoes and work
clothes, wear protective glasses. In order to avoid the hurt by
prominent parts of the vehicle, the staff must wear safety clothing.
Don't wear oily clothes. Check to remove battery when the plug-in.
Do not wear loose clothing and tie, in case of clothing involved in
equipment.
During maintenance does not allow any unauthorized person stand
near the machine.
Can't replace lamps and lanterns with flame. Don't use flame leak
check, oil level or electrolyte.
Immediately clean the grease of the operating area or hand, if
someone slipped on vehicle slip could be dangerous.
Use pure oil and clean container.
Oil is a kind of dangerous substances, there is fire don't
appear grease or oil. To do a good job of using fire
extinguishers and other firefighting equipment.
Keep battery away from fire hazards, the generated gas
explodes.
Flammable things far away from the vehicle，and smoking is
prohibited to work.
Disconnect the battery when you replace the electrical components.
Using force recommended oil level, according to the environmental
temperature choose oil viscosity.
In a closed space in the exhaust gas is very dangerous.
Avoid inhaling processing components of dust, wear a mask when necessary.
At the top of the vehicle is working, be careful not to fall.
In the operating area warning label (such as "don't start" "maintenance")，this can prevents workers
start or a moving vehicle.
When welding or power system is working, turn off the key
switch and unplug battery plug-in. The vehicle parking in solid
flat field. The goods fork fell to the lowest level, stop the motor

6
work. Park machine company, the ground.
In the sulfuric acid toxic battery electrolyte, it can burn skin and clothes of
corrosion. If splashed on your clothing or skin sulfate to rinse immediately
with plenty of water.
For battery to work to wear goggles or safety glasses, if splashed into eyes,
rinse immediately and go to a doctor.
Metal object touch the battery terminal may cause short
circuit and burn to you, tools to stay away from the battery
terminal.
Fire, lit a match and flame to stay away from the battery, battery
(hydrogen) gas explodes.
Disassembly and assembly of battery to make sure the battery
terminal (+, -) properly connected.
If the water into the electrical system, the operation will lead to
failure. Don't use water on sensors, connectors, and vehicle
instrument.
Don't deal with electrical equipment, wear wet gloves that could lead to electric shocks.
Work together with others, choose a leader and work according to his instructions. Don't to outside
any maintenance work.
Unless you have special instructions, must the ability after the motor stopped for maintenance work.
If the motor run time for maintenance, you must have two technicians present: a piling car operation,
and another for maintenance work. In this case, do not touch any contact with any moving parts.
Before adjustment, lubrication and maintenance work, close all the power switch.
Remove containing O gaskets or seal parts, clean up the installation
surface and replace the new seal.
Thoroughly clean the machine, particularly carefully clean oil components
and in the area near the oil dipstick. Be careful not to let any dirt or dust
into the system.
Can only be used to allow the burning cleaning solvent.
When change hydraulic oil or filter, check the hydraulic oil and filter for excess
metal particles or other foreign material.
Use of manufacturers to provide spare parts for replacement, make sure that
the replacement of parts or components is the same as the original parts.
Check the open gear box, there might be a material falls into. Before remove the cover for inspection,
to ensure that you have nothing in his pocket. Then carefully remove the nut.

7
1.2 MEASUREMENT CONVERSIONS
Length
unit
cm
m
km
in
ft
yd
mile
cm
1
0.01
0.00001
0.3937
0.03281
0.01094
0.000006
m
100
1
0.001
39.37
3.2808
1.0936
0.00062
km
100000
1000
1
39370.7
3280.8
1093.6
0.62137
in
2.54
0.0254
0.000025
1
0.08333
0.02777
0.000015
ft
30.48
0.3048
0.000304
12
1
0.3333
0.000189
yd
91.44
0.9144
0.000914
36
3
1
0.000568
mile
160930
1609.3
1.6093
63360
5280
1760
1
1mm=0.1cm, 1m=0.001mm
Area
unit
cm2
m2
km2
a
ft2
yd2
in2
cm2
1
0.0001
–
0.000001
0.001076
0.000012
0.155000
m2
10000
1
0.000001
0.01
10.764
1.1958
1550.000
km2
–
1000000
1
10000
1076400
1195800
–
a
0.01
100
0.0001
1
1076.4
119.58
–
ft2
–
0.092903
–
0.000929
1
0.1111
144.000
yd2
–
0.83613
–
0.008361
9
1
1296.00
in2
6.4516
0.000645
–
–
0.006943
0.000771
1
1ha=100a, 1mile2=259ha=2.59km2
Volume
unit
cm3 = cc
m3
l
in3
ft3
yd3
cm3 = m l
1
0.000001
0.001
0.061024
0.000035
0.000001
m3
1000000
1
1000
61024
35.315
1.30796
l
1000
0.001
1
61.024
0.035315
0.001308
in3
16.387
0.000016
0.01638
1
0.000578
0.000021
ft3
28316.8
0.028317
28.317
1728
1
0.03704
yd3
764529.8
0.76453
764.53
46656
27
1
1gal(US)=3785.41 cm3=231 in3=0.83267gal(US)
Weight
unit
g
kg
t
oz
lb
g
1
0.001
0.000001
0.03527
0.0022
kg
1000
10
0.001
35.273
2.20459
t
1000000
1000
1
35273
2204.59
oz
28.3495
0.02835
0.000028
1
0.0625
lb
453.592
0.45359
0.000454
16
1
1 tone (metric)= 1.1023 ton(US)=0.9842 ton(UK)

8
Pressure
unit
kgf/cm2
bar
Pa=N/m2
kPa
lbf/in2
lbf/ft2
kgf/cm2
1
0.98067
98066.5
98.0665
14.2233
2048.16
bar
1.01972
1
100000
100
14.5037
2088.6
Pa=N/m2
0.00001
0.001
1
0.001
0.00015
0.02086
kPa
0.01020
0.01
1000
1
0.14504
20.886
lbf/in2
0.07032
0.0689
6894.76
6.89476
1
144
lbf/ft2
0.00047
0.00047
47.88028
0.04788
0.00694
1
kgf/cm2=735.56 Torr(mmHg)=0.96784atm
STANDARD TIGHTENING TORQUE
The following charts give the standard tightening torques of bolts and nuts.
METER TABLE
Classification
4T, 5T
10T
Bolt type
Bolt size
Torque kgf · m (lbf · ft)
Torque kgf · m (lbf · ft)
M4
0.2 ± 0.02
0.4 ± 0.04
M5
0.3 ± 0.03
0.8 ± 0.08
M6
0.5 ± 0.05
1.4 ± 0.14
M8
1.2 ± 0.12
3.3 ± 0.3
M10
2.3 ± 0.23
6.5 ± 0.7
M12
4.0 ± 0.4
11.3 ± 1.1
M14
6.4 ± 0.6
17.9 ± 1.8
M16
9.5 ± 0.9
26.7 ± 2.7
M18
13.5 ± 1.4
38.0 ± 3.8
M20
18.6 ± 1.9
52.2 ± 5.2
M22
24.7 ± 2.5
69.4 ± 6.9
M24
32.1 ± 3.2
90.2 ± 9.0
M30
62.6 ± 6.3
176.1 ± 17.6
M36
108.2 ± 10.8
304.3 ± 30.4
M42
171.8 ± 17.2
483.2 ± 48.3
M45
211.3 ± 21.1
594.3 ± 50.4
10.9

9
INCH TABLE
4T, 5T
10T
Classification Bolt type
Bolt size
Torque kgf · m (lbf · ft)
Torque kgf · m (lbf · ft)
1/4
0.6 ± 0.06
1.7 ± 0.2
5/16
1.2 ± 0.12
3.0 ± 0.3
3/8
2.0 ± 0.20
5.6 ± 0.5
7/16
3.2 ± 0.32
8.9 ± 0.9
1/2
4.7 ± 0.47
13.4 ± 1.3
9/16
6.8 ± 0.68
19.0 ± 1.9
5/8
9.3 ± 0.93
26.1 ± 2.6
3/4
16.0 ± 1.60
45.1 ± 4.5
7/8
25.5 ± 2.55
71.6 ± 7.2
1
38.0 ± 3.80
106.9 ± 10.7
1-1/8
54.1 ± 5.41
152.2 ± 15.2
1-1/4
74.2 ± 7.42
208.9 ± 20.9
1-3/4
98.8 ± 9.88
277.8 ± 27.8
1-1/2
128.2 ± 12.82
360.7 ± 36.1
The torque in above table shall not be applied to nylon or nonferrous bolts or washer. The same is valid
for not standardized ones.
H Newton meter : 1 Nm = 0.1kgfm
Split flange bolt tightening torque
The following table torque applied to split flange bolts
Diameter
(mm)
Flat width
(mm)
Torque
kgf·m
N·m
10
14
6.7 ± 0.7
66.7 ± 6.8
12
17
11.5 ± 1
112 ± 9.8
16
22
28.5 ± 3
279 ± 29

10
PF THREAD O –ring Plug
Thread
Torque (kgf·m)
1/8
1.1 ± 0.1
1/4
2.6 ± 0.2
3/8
4.6 ± 0.3
1/2
8.5 ± 0.4
3/4
19 ± 1.0
1
33 ± 2.0
With rotate the nut torque o-rings
Connector O –ring Swivel –nut hose
Tube O.D (inch)
Thread (in)
Torque (kgf·m)
1/2
UN 13/16 - 16
9.5 ± 0.95
3/4
UN 1 3/16 - 12
18 ± 1.8
1
UN 1 7/16 - 12
21 ± 2.1