EP Equipment HPL152 User manual

Service Manual
Electric Pallet Truck
HPL152/HPL152Z

Service Manual
Electric Pallet Truck
HPL152/HPL152Z

Release Date Version No. Changes (Serial number)
2020-08-15 SM-1128 08.20 EP V1.0
This manual applies to:
Model Specications
HPL152 1,500 kg Capacity
*If there are any changes, revised version will be published once every 12 months;
if there is no change, please follow the most recent version.
*Please refer to the corresponding version of the service manual against the purchase time
of your vehicle.
*If you need the latest versions of the manual, please contact our service department or
dealer to obtain.

EP Equipment Co., Ltd.
EP Industrial Park, Xiaquan Village,
Dipu Town, Anji County, Zhejiang Province, P.R.China
www.ep-ep.com
Safety signs and instructions:
Please strictly adhere to these safety instructions to avoid personal injury.
Please pay attention to the important safety instructions.
Instructions.
FOREWORD
This Service Manual can help readers learn more about the truck system components,
maintenance and troubleshooting, and other related information. The operation and
maintenance personnel must read this Manual carefully before using the product. And when
vehicle is in use, be sure to follow the complete operation and maintenance information in
this Manual for vehicle maintenance.
Before using, please check if the pages of the Manual are clear and complete, so as not
to a󰀨ect your normal use because of incomplete information. If the contents of the Manual
have been illegible or damaged, which may a󰀨ect reading, please contact our company or
dealer for replacement.
With the constant update and improvement of our products, the equipment you are using
may be slightly di󰀨erent from what has been described in this Manual, therefore, we must
reserve the right to modify the appearance, conguration and technical specications. If you
have any questions, please contact our sales department or dealer.
i
Copyright
Copyright of Service Manual belongs to EP Equipment Co., Ltd.
REV. SM-1128 08.20

REV. 08/2020
TABLE OF CONTENTS
TABLE OF CONTENTS
1. INFORMATION & SPECIFICATIONS..............................1
1.1 After-sales Service Platform .........................................3
1.2 Introduction...................................................................4
1.3 Common Tools..............................................................5
1.4 General Tightening Torques .........................................6
2. MAINTENANCE...............................................................9
2.1 Overview..................................................................... 11
2.2 Maintenance............................................................... 12
2.2.1 Cleaning ........................................................................12
2.2.2 Inspection ......................................................................12
2.2.3 Lubrication.....................................................................16
3. STRUCTURE & FUNCTIONS........................................ 19
3.1 Structure & Functions................................................. 21
3.1.1 Travel Switch .................................................................21
3.1.2 Horn Switch ...................................................................21
3.1.3 Start-stop Switch ...........................................................21
3.1.4 Emergency Reverse Switch ..........................................21
3.1.5 Crawl Speed Switch ......................................................22
3.1.6 Manual Lowering Lever .................................................22
3.1.7 Emergency Stop Switch ................................................22
3.1.8 LED Lights.....................................................................23
3.1.9 Charger..........................................................................23
3.1.10 Horn.............................................................................23
3.1.11 Controller .....................................................................23
3.1.12 Fuse.............................................................................24
3.1.13 Interlock Switch ...........................................................24
3.1.14 Hydraulic Station .........................................................24
4. CHASSIS SYSTEM........................................................ 27
4.1 Load Wheel ................................................................ 29
4.1.1 Removal and Installation ...............................................29
4.1.2 Faults and Causes.........................................................30
4.2 Cover.......................................................................... 30
4.2.1 Removal and Installation ...............................................30
4.3 Lifting Mechanism....................................................... 31
4.3.1 Fork Inspection..............................................................31
4.3.2 Connecting Rod Adjustment ..........................................32
4.3.3 Removal and Installation ...............................................32
SECTION PAGE
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TABLE OF CONTENTS
5. DRIVE SYSTEM............................................................. 35
5.1 Drive Assembly........................................................... 37
5.1.1 Removal and Installation ...............................................38
5.2 Electromagnetic Brakes.............................................. 39
5.2.1 Removal and Installation ...............................................39
5.2.2 Faults and Causes.........................................................40
5.2.3 Checking and Testing ....................................................40
5.2.4 Control Circuit Troubleshooting .....................................41
5.3 Drive Wheel................................................................ 42
5.3.1 Removal and Installation ...............................................42
5.3.2 Faults and Causes.........................................................42
5.4 Drive Motor................................................................. 43
5.4.1 Removal and Installation ...............................................43
5.4.2 Faults and Causes.........................................................43
5.4.3 Checking and Testing ....................................................44
5.5 Gearbox...................................................................... 45
5.5.1 Removal and Installation ...............................................45
5.5.2 Faults and Causes.........................................................45
6. OPERATING SYSTEM................................................... 47
6.1 Control Lever.............................................................. 49
6.2 Button Switch.............................................................. 50
6.2.1 Removal and Installation ...............................................50
6.2.2 Faults and Causes.........................................................50
6.2.3 Checking and Testing ....................................................50
6.2.4 Control Circuit Troubleshooting .....................................52
6.3 Travel Switch .............................................................. 54
6.3.1 Removal and Installation ...............................................54
6.3.2 Faults and Causes.........................................................54
6.3.3 Checking and Testing ....................................................54
6.3.4 Control Circuit Troubleshooting .....................................55
7. HYDRAULIC SYSTEM................................................... 57
7.1 Overview..................................................................... 59
7.1.1 Hydraulic Schematic Diagram ......................................60
7.2 Hydraulic Station ........................................................ 61
7.2.1 Removal and Installation ...............................................61
7.2.2 Component....................................................................61
7.3 Cylinder ...................................................................... 62
7.3.1 Cylinder Removal Precautions ......................................62
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TABLE OF CONTENTS
7.3.2 Cylinder Installation Precautions ...................................63
7.3.3 Removal and Installation ...............................................63
7.4 Hydraulic Troubleshooting .......................................... 65
7.5 Hydraulic Symbol........................................................ 66
8. ELECTRICAL SYSTEM ................................................. 67
8.1 Controller.................................................................... 69
8.1.1 Removal and Installation ...............................................69
8.1.2 Controller Interface Function .........................................70
8.2 Fuse............................................................................ 72
8.2.1 Location of Fuses ..........................................................72
8.2.2 Checking and Testing ....................................................73
8.3 Emergency Stop Switch ............................................. 73
8.3.1 Removal and Installation ...............................................73
8.3.2 Faults and Causes.........................................................73
8.3.3 Checking and Testing ....................................................74
8.4 Interlock Switch .......................................................... 74
8.4.1 Removal and Installation ...............................................74
8.4.2 Faults and Causes.........................................................74
8.4.3 Checking and Testing ....................................................75
8.4.4 Control Circuit Troubleshooting .....................................75
8.5 Battery ........................................................................ 76
8.5.1 Removal and Installation ...............................................76
8.5.2 Faults and Causes.........................................................76
8.5.3 Checking and Testing ....................................................77
8.6 LED Lights........................................................................78
8.6.1 Removal and Installation ...............................................78
8.6.2 Faults and Causes.........................................................78
8.6.3 Checking and Testing ....................................................79
8.6.4 Control Circuit Troubleshooting .....................................79
8.7 Handheld Unit (Optional)............................................ 80
8.7.1 Handheld Unit Connection.............................................80
8.7.2 Handheld Unit Main Menu.............................................80
8.7.3 Parameter Settings........................................................81
8.7.4 TESTER Menu ..............................................................83
8.8 Controller Error Message ........................................... 84
8.8.1 Traction Controller .........................................................84
8.9 Electrical Schematic Diagrams................................... 87
8.10 Cable Wiring Diagrams............................................. 88
8.11 Wiring Harness and Connectors............................... 89
3-4
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TABLE OF CONTENTS
9. TROUBLESHOOTING................................................... 91
9.1 Preparation Before Troubleshooting........................... 93
9.1.1 Check the Voltage of Battery.........................................93
9.2 Troubleshooting Solutions of Common Faults............ 94
APPENDIX ..................................................................... 97
B SERVICE MANUAL - BATTERY................................... 99
B1 Lithium Battery.......................................................... 101
B1-1 Safety and Warnings.............................................. 101
B1-2 Use of Battery ........................................................ 101
B1-2.1 Pre-use Checks ........................................................101
B1-2.2 Discharging...............................................................101
B1-2.3 Charging ...................................................................102
B1-3 Maintenance & Care ............................................ 102
C SCHEDULE ................................................................. 105
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SECTION PAGE

SAFETY WARNING
For your own safety and that of others, please observe the following safety instructions:
Thorough and normative maintenance is one of the most important prerequisites to ensure
stable and reliable operation of truck. Neglecting regular maintenance could easily lead
to the truck malfunction and failure, and potential threats to staff and operational safety.
Therefore, there must be adequate maintenance equipment, professional maintenance
personnel and a comprehensive maintenance plan in place.
Please perform the maintenance and inspections according to the following provisions:
To strictly enforce the truck maintenance, lubrication and inspection plans.
Truck maintenance, lubrication and inspection personnel must be approved by accredited
certication or evaluation agency.
The following operations shall be performed before you leave the truck:
- No parking on slopes.
- Fully lower the forks.
- Cut o󰀨 the power supply.
- Turn the switch lock to “STOP” and remove the key.
Prior to truck maintenance:
- Raise the drive wheel o󰀨 the ground, or cut o󰀨 the power supply connection.
- Use wooden wedges or other e󰀨ective xtures.
- When performing maintenance underneath the vehicle, make sure that the lifting device
or jack leg is secure.
- Park your vehicle in a safe and secure area.
Never use an open ame to check level of electrolyte, other oils or uids for leaks.
Keep the parking lot clean, well-ventilated and dry.
Regular checks and maintenance should be conducted to braking, steering, control, warning
and safety devices to keep them in good condition.
All nameplates and safety signs on the truck should be cleaned regularly to make them
clearly visible.
Regular checks and maintenance should be conducted to all the devices of lifting system to
ensure them to be safe for use.
The hydraulic system should be checked regularly based on usage. Hydraulic cylinders,
hydraulic valves and other hydraulic components should be ensured to be without leakage.
Regular checks and maintenance should be conducted to batteries, motors, controllers,
limit switches, protective devices, wires and connectors, and so on. Please pay particular
attention to the electrical insulation.
Park the truck in a clean environment to minimize the risk of re.
Without the permission of the manufacturer, users are not allowed to change or increase
the capacity of the truck. After having been changed under permission, the nameplates and
safety signs on the truck should also be changed accordingly.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

1
1
1. INFORMATION & SPECIFICATIONS

2
NOTE:

3
REV. 08/2020
INFORMATION & SPECIFICATIONS
1
1.1 After-sales Service Platform
Claims/Replacement Parts Service Platform:
In order to provide you with a fast and ecient
after-sales service, when you claim / order spare
parts or after-sales service upon maintenance,
please provide accurate truck model, vehicle
body serial number and part number.
After-sales Maintenance Service Platform:
iNOTE

REV. 08/2020
INFORMATION & SPECIFICATIONS
1
4
No. Name
1 Control Lever
2 Manual Lowering Lever
3 Hydraulic Station
4 Drive Wheel
No. Name
5 Drive Motor
6 Load wheel
7 Charger Connector
8 Emergency Stop Switch
9 Battery Plug
1.2 Introduction

5
REV. 08/2020
INFORMATION & SPECIFICATIONS
1
This series are electric pallet trucks. Its import-
ant structure is as shown in Fig1128-00003SM.
-Please refer to the nameplate for rated load
capacity of the vehicle.
- The vehicle can only be used on the level gro-
und indoors, never use it on mezzanine or
balcony area.
WARNING
Truck can only be operated by single operator;
other personnel is forbidden from riding.
1.3 Common Tools
No. Name Remark
1 Hex Wrench 2#~6# One Set
2 Hex Head Socket Wrench 8#~19# One Set
3 Phillips Screwdriver 2# One Piece
4 Slotted Screwdriver 2# One Piece
5 Circlip Pliers One for holes and one for shaft
6 Hammer One Piece
7 Spreader, Crane One Pair
8 Diagonal Pliers One Piece
9 Grease Gun One Piece
10 Tiger Tooth Wrench 22#/27# One of Each
WARNING

REV. 08/2020
INFORMATION & SPECIFICATIONS
1
6
Table 1.4.1 Screws/Bolts Performance Levels
Performance Level Material Specication (mm)
5.8 grade Low carbon steel M6 ~ M48
8.6 grade Quenched and tempered medium
carbon steel M6 ~ M48
10.9 grade Quenched and tempered medium
carbon alloy steel M6 ~ M48
12.9 grade Quenched and tempered medium
carbon alloy steel M6 ~ M48
12.9
10.9
8.6
5.8
1.4 General Tightening Torques
Screws or bolts used on the truck are of 8.6
grade or higher performance level.
When you are conducting truck maintenance,
you can refer to Table 1.4.1 and Table 1.4.2 to
select the suitable screws or bolts for replace-
ment.
-
-
CAUTION
The performance levels of screws or bolts are
marked on the heads of the screws or bolts.
If you nd the screws or bolts used on certain
position are not marked with performance
level, please select spare parts with perform-
ance level of at least 8.6 grade or higher level
forreplacement.

7
REV. 08/2020
INFORMATION & SPECIFICATIONS
1
Table 1.4.2 Metric Screws/Bolts Tightening Torque Table (n•m)
Nominal Diameter
(mm)
Performance Level
5.8 8.6 10.9 12.9
Proof Stress (MPa)
380 600 830 970
M6 7~8 10~12 14~17 17~20
M8 16~18 25~30 34~41 41~48
M8×1 17~20 27~32 37~43 43~52
M10 31~36 49~59 68~81 81~96
M10×1 35~41 55~66 76~90 90~106
M12 55~64 86~103 119~141 141~167
M12×1.5 57~67 90~108 124~147 147~174
M14 87~103 137~164 189~224 224~265
M14×1.5 144~170 149~179 206~243 243~289
M16 136~160 214~256 295~350 350~414
M16×1.5 144~170 228~273 314~372 372~441
M18 186~219 294~353 406~481 481~570
M18×1.5 210~247 331~397 457~541 541~641
M20 264~312 417~500 576~683 683~808
M20×1.5 294~345 463~555 640~758 758~897
M22 360~431 568~680 786~941 918~1099
M22×1.5 395~473 624~747 803~1034 1009~1208
M24 457~547 722~864 998~1195 1167~1397
M24×2 497~595 785~940 1086~1300 1269~1520
M27 669~801 1056~1264 1461~1749 1707~2044
M27×2 723~865 1141~1366 1578~1890 1845~2208
M30 908~1087 1437~1717 1984~2375 2318~2775
M30×2 1005~1203 1587~1900 2196~2629 2566~3072
M36 1587~1900 2506~3000 3466~4150 4051~4850
M36×3 1680~2011 2653~3176 3670~4394 4289~5135
M42 2538~3039 4088~4798 5544~6637 6479~7757
M42×3 2731~3269 4312~5162 5965~7141 6921~8345
M48 3813~4564 6020~7207 8327~9969 9732~11651
M48×3 4152~4970 6556~7848 9069~10857 10598~12688

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INFORMATION & SPECIFICATIONS
1
8

9
2
2. MAINTENANCE

10
NOTE: