Vestil EPT-2745-45 User manual

Service & Maintenance Manual
Electric Pallet Truck
EPT-2745-45
WARNING
Do not use the pallet truck before reading and
understanding these operating instructions.
NOTE:
Please check the designation of your
present type at the last page of this
document as well as on the ID-plate.
Keep for future reference.
Version 05/2019

TABLE OF CONTENTS
1
.
REGULAR MAINTENANCE .............................................................................................................2
a. Maintenance checklist...................................................................................................................2
b. Lubricating points..........................................................................................................................3
c. Check and refill hydraulic oil..........................................................................................................4
d. Checking electrical fuses ..............................................................................................................4
TROUBLE SHOOTING.....................................................................................................................5
a. Common trouble shooting .............................................................................................................5
b. Fault code .....................................................................................................................................5
WIRING/ CIRCUIT DIAGRAM ........................................................................................................12
a. Electrical circuit diagram .............................................................................................................12
b. Hydraulic circuit...........................................................................................................................20
MAINTENANCE OF MAIN COMPONENTS ...................................................................................21
a. Battery replacement....................................................................................................................21
b. Battery difference between PTE15N and PTE20N......................................................................21
c. Outer-appearance parts ..............................................................................................................22
d. Tiller ............................................................................................................................................23
2.
3.
4.
1

1. REGULAR MAINTENANCE
a. Maintenance checklist
Table 1: Maintenance checklist
Interval(Month)
1
3
6
12
Hydraulic
1
2
3
4
5
Check the hydraulic cylinder(s), piston for damage noise and leakage
Check the hydraulic joints for damage and leakage
Inspect the hydraulic oil level, refill if necessary
Refill the hydraulic oil ( 12 month or 1500 working hours )
Check and adjust function of the pressure valve (1500kg/2000kg +0/+10%)
Mechanical system
6
7
8
9
Inspect the forks for deformation and cracks
Check the chassis for deformation and cracks
Check if all screws are fixed
Check the push rods for deformation and damages
1
0 Check the gearbox for noise and leakage
11 Inspect the wheels for deformation and damages
1
1
1
2 Inspect and lubricate the steering bearing
3 Inspect and lubricate the pivot points
4 Lubricate the grease nipples
Electrical system
1
1
1
1
1
2
2
2
2
2
2
5 Inspect the electric wiring for damage
6 Check the electric connections and terminals
7 Test the Emergency switch function
8 Check the electric drive motor for noise and damages
9 Test the display
0 Check, if correct fuses are used
1 Test the warning signal
2 Check the contactor(s)
3 Check the frame leakage (insulation test)
4 Check function and mechanical wear of the accelerator
5 Check the electrical system of the drive motor
Braking system
6 Check brake performance, if necessary replace the brake disc or adjust the air gap
Battery
2
2
2
2
7 Check the battery voltage
8 Clean and grease the terminals and check for corrosion and damage
9 Check the battery housing for damages
Charger
3
3
0 Check the main power cable for damages
1 Check the start-up protection during charging
Function
2

3
3
3
3
3
3
3
3
2 Check the horn function
3 Check the air gap of the electromagnetic brake
4 Test the emergency braking
5 Test the reverse and regenerative braking
6 Test the safety (belly) button function
7 Check the steering function
8 Check the lifting and lowering function
9 Check the tiller arm switch function
General
4
4
4
0 Check if all decals are legible and complete
1 Inspect the castors, adjust the height or replace these if worn out.
2 Carry out a test run
b. Lubricating points
Lubricate the marked points according to the maintenance checklist. The required grease specification is:
DIN 51825, standard grease.
Fig. 1: Lubricating points
3

c. Check and refill hydraulic oil
It is recommended to use hydraulic oil in connection with average temperature:
Environment temperature
Type
–5℃~25℃
HVLP 32，
DIN 51524
28.8-35.2
>25℃
HLP 46，
DIN 51524
41.4 - 47
Viscosity
Amount
0.4L
Waste material like oil, used batteries or other must be probably disposed and recycled according to the
national regulations and if necessary brought to a recycling company.
The oil level height shall be in the not lifted position min. 0.3L to 0.5L.
If necessary add oil at the filling point.
d. Checking electrical fuses
Fig. 2: EPT-2745-30 Location of fuses
Fig. 3: EPT-2745-45 Location of fuses
Table 2: Size of the fuses
Rate
FU 1
10A
70A
FU 01
4

2. TROUBLE SHOOTING
a. Common trouble shooting
If the truck has malfunctions follow the instructions, mentioned in chapter 6.
Table 3: Trouble shooting
TROUBLE
CAUSE
REPAIR
Load weight too high
Battery discharged
Lift only the max. capacity, mentioned on the ID-plate
Charge the battery
Load can’t be Lifting fuse faulty
Check and eventually replace the lifting fuse
Check and eventually refill hydraulic oil
lifted
Hydraulic oil level too
low
Oil leakage
Repair the sealing of the cylinder
Oil leakage
from air
Excessive quantity of oil. Reduce oil quantity.
breathing
Charge the battery completely and then remove the
Battery is charging
main power plug form the electrical socket.
Connect the battery correctly
Check and eventually replace fuses
Charge the battery
Battery not connected
Fuse faulty
Truck not
starts
Low battery
operating
Emergency switch is
activated
Turn the emergency clockwise
Tiller in the operating
Move the tiller firstly to the braking zone.
If the truck has malfunctions and can’t be operated out of the working zone, jack the truck up and go with
a load handler under the truck and safe the truck securely. Then move truck out of the aisle.
b. Fault code
When
is on, means there is fault of the truck, you can remove the code on LCD with
the help of following table.
5

Table 4: EPT-2745-30 Fault code list
PTE15N Fault Code List
Fault
Source of
failure
Description
code
Possible reasons
0
LOW BDI
Low battery power
Controller
Lifting or lowering switch is activated earlier
than key switch
1
PUMP SRO FAULT
Controller
Controller
Operation sequence of direction, inter-lock and
key switch is not correct.
2
3
SRO FAULT
HPD FAULT
Operation sequence of inter-lock and
accelerator is not correct; or accelerator is not
returned to neutral position after emergency
button is activated.
Controller
Accelerator:
4
5
WAITING FAULT
1. Misadjusted throttle.
Controller
Controller
2. Broken throttle pot or throttle mechanism.
Accelerator wiring:
THROTTLE FAULT
1. Throttle input wire open or shorted.
2. Throttle pot defective.
6
7
PRECHARGE FAULT
MAIN DRIVER FAULT
Controller doesn’t work
Controller
Controller
Internal relay coil is broken, replace controller.
1
2
1
. Internal relay welded.
8
MAIN RELAY WELDED
Controller
. Controller defective.
. Internal relay was commanded to be close
9
MAIN RELAY DNC
and it did not.
Controller
2
1
2
. Internal relay tips are oxidized.
. Electromagnetic brake driver open.
. Electromagnetic brake coil shorted.
1
1
1
0
1
2
BRAKE OFF FAULT
Controller
Controller
Controller
MOTOR OVER TEMPERATURE Motor overheating
1
2
1
2
. Battery not connected.
BATTERY DISCONNECT FAULT
. Poor connection to battery terminals.
. Electromagnetic brake driver shorted.
. Electromagnetic brake coil open.
1
3
4
BRAKE ON FAULT
Controller
Controller
1
CURRENT SENSE FAULT
Controller doesn’t work
. Motor voltage does not correspond to throttle
request.
1
1
5
6
HARDWARE FAULT
SOFTWARE FAULT
Controller
Controller
2
1
2
1
. Controller failure.
. Software defective.
1
. Controller defective.
.One parameter value is changed that requires
a power cycle (such as Throttle Type, Interlock
Type, Driver Type, EMR Type, Pump SRO
Type, AUX Switch Input Type)
1
7
PARAMETER CHANGE FAULT
Controller
2. Parameters are restored
6

to the default settings
Motor short circuit
18
19
20
21
MOTOR SHORT
MOTOR OPEN
Controller
Controller
Controller
Controller
1
. Motor wires open.
2. Faulty motor cable wiring.
. Controller defective.
CONTROLLER OVERCURRENT Controller defective.
3
1. Excessive load on vehicle.
MOTOR TEMP HOT CUTBACK
2. Controller is operating in extreme high
temperature.
CONTROLLER OVERTEMP
CUTBACK
1. Excessive load on vehicle.
2. Controller is operating in high temperature.
2
2
2
2
2
3
4
5
Controller
Controller
Controller
Controller
1
. Controller is operating in extreme low
temperature.
. The temperature sensor is broken.
CONTROLLER UNDERTEMP
2
CONTROLLER SEVERE
OVERTEMP
1. Excessive load on vehicle.
2. Controller is operating in high temperature.
1. Battery voltage >Overvoltage Cutback point.
OVERVOLTAGE CUTBACK
SEVERE OVERVOLTAGE
2. Vehicle operating with charger attached.
3
. Intermittent battery connection.
. Battery voltage >34.0V
1
2
6
2. Vehicle operating with charger attached.
Controller
3
1
2
. Intermittent battery connection.
. Battery voltage <16.8V
2
7
8
UNDERVOLTAGE CUTBACK
SEVERE UNDERVOLTAGE
Controller
Controller
. Bad connection at battery or controller.
2
Battery voltage <13.8V
. The CRC of the parameters does not
calculate correctly.
. Controller defective.
1
2
9
PARAMETER FAULT
Controller
2
Communication between the 1212C and the
CAN tiller has halted.
3
2
PDO TIMEOUT
Controller
3
3
4
LIFT DRIVER FAULT
Lifting contactor is open or shorted.
Lowering electromagnetic is open or shorted.
Communication between the 1212C and the
BMS has halted.
Controller
Controller
3
LOWER DRIVER FAULT
3
6
BMS PDO TIMEOUT
Controller
1
. Emergency button is activated before truck is
turned on.
. Micro switch inside the emergency button is
defective.
. Cable from micro switch to controller is
2
37
EMR SEQUENCING FAULT
Controller
3
broken.
Vertical driving is activated earlier than key
switch or when vertical driving is closed,
inter-lock switch from ON to OFF
Turtle button doesn’t work
3
9
COAST SRO FAULT
Controller
80
1
Mode fault
Lift fault
Tiller
Tiller
8
Lifting button doesn’t work
7

8
2
3
Lower fault
Lowering button doesn’t work
Tiller
Tiller
Lithium battery communication has halted:
1
2
3
. BMS failure.
8
BMS Communication Outage
. Cable from lithium battery to tiller is broken.
. Communication module of tiller is defective.
High battery voltage:
. Overcharging.
2. BMS failure.
. Big current from motor during driving down
1
Lithium
battery
90
Over Voltage
3
from ramp.
Battery over discharged.
1. Battery is not used for long time.
Lithium
battery
9
9
9
1
2
3
Over Discharge
2. Overused.
Lithium
battery
Communication Outage
Under Voltage
Battery communication has halted.
Battery low voltage:
1. Discharged.
Lithium
battery
2
. Battery cell defective.
Overcorrect:
. Unapproved adjustment of default
parameters.
. Wrong parameter after replacement of
controller.
. Current detection failure of lithium battery.
1
Lithium
battery
94
Over Current
2
3
Lithium
battery
Lithium
battery
9
5
6
Over Temperature Protect
Temperature Protect
Extremely high battery temperature
High battery temperature
9
Table 5: EPT-2745-45 Fault code list
EPT-2745-45 Fault Code List
Fault
Description
code
Possible reasons
Source
Turtle button is activated before truck is turned
0
1
2
Mode fault
Lift fault
Tiller
Tiller
Tiller
on.
Lifting button is activated before truck is turned
on.
Lowering button is activated before truck is
turned on.
Lower fault
Lithium battery communication problem:
1
. BMS failure.
3
BMS Communication Outage
2. Cable between lithium battery and tiller is
broken.
Tiller
3
. Tiller communication module failure.
8

Accelerator is not in neutral position before
password is typed.
4
throttle_FAULT
Tiller
SEVERE
1226BL-415
3 controller
1226BL-415
3 controller
1226BL-415
3 controller
1226BL-415
3 controller
1
2
2
3
3
Extremely low voltage
Extremely low voltage
Extremely high voltage
Extremely high voltage
UNDERVOLTAGE
UNDERVOLTAGE
CUTBACK
1
1
1
SEVERE
OVERVOLTAGE
OVERVOLTAGE
CUTBACK
CONTROLLER
OVERTEMP
1
226BL-415
controller
1
4
Controller high temperature
3
CUTBACK
CONTROLLER
SEVERE UNDERTEMP
CONTROLLER
SEVERE OVERTEMP
MOTOR TEMP
SENSOR
1226BL-415
3 controller
1226BL-415
3 controller
1226BL-415
3 controller
1226BL-415
3 controller
1
1
1
1
2
4
4
5
5
1
Controller extremely low temperature
Controller extremely high temperature
Motor temperature sensor failure
Motor over temperature protection
MOTOR TEMP HOT
CUTBACK
1
226BL-415
controller
THROTTLE
Accelerator failure
3
Operation sequence of inter-lock and
accelerator is not correct; or accelerator is not 1226BL-415
2
1
HPD SEQUENCING
returned to neutral position after emergency
button is activated.
3 controller
MAIN CONTACTOR
WELDED
1226BL-415
3 controller
1226BL-415
3 controller
2
2
2
2
2
2
2
2
2
2
2
3
3
4
Controller failure
Controller failure
Controller failure
Controller failure
Speed sensor failure
Motor failure
MAIN CONTACTOR
DID NOT CLOSE
1
1
1
1
1
226BL-415
MAIN DRIVER FAULT
PRECHARGE FAILED
ENCODER
3
controller
226BL-415
3
controller
226BL-415
3
controller
226BL-415
STALL DETECTED
MOTOR OPEN
3
controller
226BL-415
Motor open circuit
3
controller
Electromagnetic brake driver failure:
1. Controller port J3-12- is broken.
EMBRAKE DRIVER
FAULT
1226BL-415
3 controller
2
5
2
. Brake cable is broken.
9

3
. Brake failure(short ircuit/open circuit)
EM BRAKE FAILED TO
SET
1226BL-415
3 controller
3
3
3
3
1
1
2
2
Electromagnetic brake failure
Emergency reverse timeout
1
226BL-415
controller
EMER REV TIMEOUT
EMER REV HPD
EMR SRO
3
Emergency button not returned to neutral
position
1226BL-415
3 controller
Emergency button is not closed before truck is 1226BL-415
powered on
3 controller
Pump contactor driver failure:
1
. Controller port J3-11- is broken.
2. Brake cable is broken.
. Pump contactor failure(short ircuit/open
1
226BL-415
3
3
3
3
4
5
PUMP DRIVER FAULT
PUMP SRO
3
controller
3
circuit)
Lifting button is not closed before truck is
powered on
1226BL-415
3 controller
Valve driver failure:
1
. Controller port J3-2- is broken.
2. Brake cable is broken.
. Pump contactor failure(short ircuit/open
VALVE DRIVER
FAULT
1226BL-415
3 controller
3
circuit)
Lowering button is not closed before truck is
powered on
1226BL-415
3 controller
1226BL-415
3 controller
1226BL-415
3 controller
1226BL-415
3 controller
3
4
4
4
4
4
6
1
1
1
2
2
VALVE SRO
FIVE V SUPPLY
FAILURE
Replace controller
Replace controller
Replace controller
CAN overloaded
FIFTEEN V SUPPLY
FAILURE
EXTERNAL SUPPLY
OUT OF RANGE
1
226BL-415
CAN BUS LOADING
PDO TIMEOUT
3
controller
1
226BL-415
CAN communication timeout
3
controller
Communication between
the 1212C and the CAN
tiller has halted.
PDO MAPPING
ERROR
1226BL-415
3 controller
4
4
2
3
1
. Motor voltage does not
correspond to throttle
request.
1226BL-415
3 controller
HW FAILSAVE
2
1
2
. Controller failure.
. Software defective.
. Controller defective.
1226BL-415
3 controller
4
4
4
7
SW FAULT
LOW_BDI
1
226BL-415
controller
Battery low power
3
10

1
226BL-415
controller
4
8
8
8
8
9
1
1
3
4
STEERING_SENSOR
Steering sensor failure
Wrong parameter
3
PARAMETER
MISMATCH
PARAMETER
CHANGE
1226BL-415
3 controller
1226BL-415
3 controller
Parameter adjustment failure
Replace controller
1
226BL-415
NV FAILURE
3
controller
1
226BL-415
SUPERVISION
Replace controller
3
controller
Battery high voltage:
1
. Over charged.
2. BMS failure.
. Big current from motor during driving down
Lithium
battery
9
0
Over Voltage
3
from ramp.
Battery over discharged.
1.Battery is not used for long time.
Lithium
battery
9
9
9
1
2
3
Over Discharge
2
.Overused.
Lithium
battery
Communication Outage
Under Voltage
Battery communication has halted.
Battery low voltage:
1.Discharged.
Lithium
battery
2
.Battery cell defective.
Overcurrent:
.Unapproved adjustment of default
parameters.
.Wrong parameter after replacement of
controller.
.Current detection failure of lithium battery.
1
Lithium
battery
9
4
Over Current
2
3
Lithium
battery
Lithium
battery
9
9
5
6
Over Temperature Protect
Temperature Protect
Extremely high battery temperature
High battery temperature.
11

3. WIRING/ CIRCUIT DIAGRAM
a. Electrical circuit diagram
Without speed reduction on curves EPT-2745-30
FU 1 : 10A
Fig. 4: Electric diagram EPT-2745-30 without speed reduction on curves
FU 01 : 70A
12

Table 6: Description of electrical diagram
Code
GB
Et
Item
Code
B
Item
Battery
CAN tiller
Controller
SA
Proximity switch
Traction motor
Electromagnetic brake
10A fuse
Mp
Pump motor
Pump contactor
Emergency button
Electromagnetic valve
Micro switch
Mt
KMp
SM
YV
YB
FU1
FU01
70A fuse
SU
13

With speed reduction on curves EPT-2745-30
Fig. 5: Electric diagram EPT-2745-30 with speed reduction on curves
FU1 : 10A
FU01 : 70A
14

Table 7: Description of electrical diagram
Code
GB
Et
Item
Code
B
Item
Battery
CAN tiller
Controller
SA
Proximity switch
Traction motor
Electromagnetic brake
10A fuse
Mp
Pump motor
Pump contactor
Emergency button
Electromagnetic valve
Micro switch
Mt
KMp
SM
YV
YB
FU1
SE
Proximity switch
70A fuse
SU
FU01
15

Without speed reduction on curves EPT-2745-45
Fig. 6: Electric diagram EPT-2745-45 without speed reduction on curves
FU1 :10A
FU01 : 70A
16

Table 8: Description of electrical diagram
Code
GB
Et
Item
Battery
Code
B
Item
CAN tiller
Controller
SA
Proximity switch
Traction motor
Electromagnetic brake
10A fuse
Mp
Pump motor
Mt
KMp
SM
YV
Pump contactor
Emergency button
Electromagnetic valve
Micro switch
YB
FU1
FU01
HA
70A fuse
SU
Buzzer
17

PTE20N with speed reduction on curves
FU1 :10A
Fig. 7: Electric diagram EPT-2745-45 with speed reduction on curves
FU01 : 70A
18