EP JX 1 Electric Order Picker Service Manual – PDF DOWNLOAD

EP JX 1 Electric Order Picker Service Manual – PDF DOWNLOAD

FILE DETAILS:

EP JX 1 Electric Order Picker Service Manual – PDF DOWNLOAD

Language : English
Pages : 184
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

EP JX 1 Electric Order Picker Service Manual – PDF DOWNLOAD

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 17
3 STRUCTURE & FUNCTIONS 21
3 1 Structure & Functions 23
3 1 1 Travel Switch 23
3 1 2 Emergency Stop Switch 23
3 1 3 Key Switch 23
3 1 4 Horn Button 23
3 1 5 Loading Rack Lowering Switch 24
3 1 6 Loading Rack Lifting Switch 24
3 1 7 Instrument 24
3 1 8 Horn 24
3 1 9 Lowering / Door Buzzer 25
3 1 10 Tilt Buzzer 25
3 1 11 Tilt Switch 25
3 1 12 Door Safety Switch 25
3 1 13 Warning Light 26
3 1 14 Lifting Limit Switch 26
3 1 15 Speed Reduction Switch 26
3 1 16 Main Contactor 26
3 1 17 AC0 Controller (Traction Controller) 27
3 1 18 EPS-AC0 Controller 27
3 1 19 Fuse 1 27
3 1 20 Fuse 2 27
3 1 21 Pump Motor 28
3 1 22 Gear Pump 28
3 1 23 Pump Contactor 28
3 1 24 Accumulator 28
3 1 25 Solenoid Valve / Manual Pressure Relief Valve 29
3 1 26 Foot Switch 29
3 1 27 Stepper Motor 29
4 CHASSIS SYSTEM 31
4 1 Load Wheel 33
4 1 1 Removal and Installation 33
4 1 2 Faults and Causes 33
4 2 Caster 34
4 2 1 Removal and Installation 34
5 DRIVE SYSTEM 35
5 1 Drive Wheel 38
5 1 1 Removal and Installation 38
5 1 2 Faults and Causes 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 Motor 42
5 3 1 Removal and Installation 42
5 3 2 Faults and Causes 43
5 3 3 Checking and Testing 43
5 3 4 Control Circuit Troubleshooting 44
5 4 Gearbox 46
5 4 1 Removal and Installation 46
5 4 2 Faults and Causes 46
5 5 Proximity Switch 47
5 5 1 Removal and Installation 47
5 5 2 Faults and Causes 47
5 5 3 Checking and Testing 48
5 5 4 Control Circuit Troubleshooting 48
5 6 Steering Motor 49
5 6 1 Removal and Installation 49
5 6 2 Faults and Causes 49
5 6 3 Checking and Testing 50
5 6 4 Control Circuit Troubleshooting 51
6 OPERATING SYSTEM 53
6 1 Left Control Lever 55
6 2 Right Control Panel 55
6 3 Button Switch 56
6 3 1 Removal and Installation 56
6 3 2 Faults and Causes 56
6 3 3 Checking and Testing 56
6 3 4 Control Circuit Troubleshooting 56
6 4 Travel Switch 58
6 4 1 Removal and Installation 58
6 4 2 Faults and Causes 58
6 4 3 Checking and Testing 58
6 4 4 Control Circuit Troubleshooting 59
6 5 Stepper Motor 60
6 5 1 Removal and Installation 60
6 5 2 Faults and Causes 60
6 5 3 Checking and Testing 60
6 5 4 Control Circuit Troubleshooting 60
6 6 Key Switch 61
6 6 1 Removal and Installation 61
6 6 2 Faults and Causes 61
6 6 3 Checking and Testing 61
6 6 4 Control Circuit Troubleshooting 61
6 7 Emergency Stop Switch 62
6 7 1 Removal and Installation 62
6 7 2 Faults and Causes 62
6 7 3 Checking and Testing 62
6 7 4 Control Circuit Troubleshooting 62
7 HYDRAULIC SYSTEM 63
7 1 Overview 65
7 1 1 Hydraulic Schematic Diagram 66
7 2 Pump and Motor Assembly 67
7 2 1 Removal and Installation 67
7 2 2 Component 67
7 3 Pump Motor 68
7 3 1 Removal and Installation 68
7 3 2 Faults and Causes 68
7 3 3 Checking and Testing 69
7 4 Pump Contactor 70
7 4 1 Faults and Causes 70
7 4 2 Checking and Testing 70
7 4 3 Control Circuit Troubleshooting 71
7 5 Solenoid Valve 72
7 5 1 Faults and Causes 72
7 5 2 Checking and Testing 72
7 5 3 Control Circuit Troubleshooting 73
7 6 Reach Cylinder 74
7 6 1 Cylinder Removal Precautions 74
7 6 2 Cylinder Installation Precautions 75
7 7 Accumulator 76
7 7 1 Removal and Installation 76
7 7 2 Faults and Causes 76
7 8 Hydraulic Troubleshooting 77
7 9 Hydraulic Symbol 78
8 ELECTRICAL SYSTEM 79
8 1 Controller 81
8 1 1 Removal and Installation 82
8 1 2 Controller Interface Function 83
8 2 Fuse 87
8 2 1 Location of Fuses 87
8 2 2 Checking and Testing 88
8 3 Main Contactor 89
8 3 1 Removal and Installation 89
8 3 2 Faults and Causes 89
8 3 3 Checking and Testing 90
8 3 4 Control Circuit Troubleshooting 90
8 4 Limit Switch 91
8 4 1 Removal and Installation 91
8 4 2 Connection Mode 91
8 4 3 Faults and Causes 92
8 4 4 Checking and Testing 92
8 4 5 Control Circuit Troubleshooting 93
8 5 Foot Switch 95
8 5 1 Removal and Installation 95
8 5 2 Faults and Causes 95
8 5 3 Checking and Testing 96
8 5 4 Control Circuit Troubleshooting 96
8 6 Tilt Switch 97
8 6 1 Removal and Installation 97
8 6 2 Faults and Causes 97
8 6 3 Checking and Testing 97
8 6 4 Control Circuit Troubleshooting 97
8 7 Warning Light 98
8 7 1 Removal and Installation 98
8 7 2 Faults and Causes 98
8 7 3 Checking and Testing 98
8 7 4 Control Circuit Troubleshooting 98
8 8 Instrument 99
8 8 1 Instrument Operation Schematics 100
8 8 2 Tester Menu Operation Schematics 101
8 8 3 Parameter Settings 114
8 8 4 TESTER Menu 115
8 9 Controller Error Message 117
8 9 1 Traction Controller 117
8 9 2 Steering Controller (EPS-ACO) 122
8 10 Cable Wiring Diagrams 131
8 11 Electrical Schematic Diagrams 132
8 12 Wiring Harness and Connectors 134
9 TROUBLESHOOTING 137
9 1 Preparation Before Troubleshooting 139
9 1 1 Check the Voltage of Battery 139
9 2 Troubleshooting Solutions of Common Faults 140
APPENDIX 145
A SERVICE MANUAL – MAST 147
A1 Two-stage Mast 149
A1-1 Lifting Chains 149
A1-1 1 Chain Adjustment 149
A1-1 2 Chain Replacement 151
A1-2 Lift Cylinder 151
A1-2 1 Cylinder Removal 151
A1-2 2 Cylinder Maintenance 152
A1-2 3 Cylinder Installation 152
A2 Three-stage Mast 153
A2-1 Lifting Chains 153
A2-1 1 Chain Adjustment 153
A2-1 2 Chain Replacement 153
A2-1 2 1 Mast Chains 153
A2-1 2 2 Loading Rack Chains 153
A2-2 Full Free Lift Cylinder 157
A2-2 1 Cylinder Removal 157
A2-2 2 Cylinder Maintenance 157
A2-2 3 Cylinder Installation 158
A2-3 Lift Cylinder 158
A2-3 1 Cylinder Removal 158
A2-3 2 Cylinder Maintenance 159
B SERVICE MANUAL – BATTERY 161
B1 Lead-acid Battery 163
B1-1 Safety and Warnings 163
B1-2 Use of Battery 163
B1-2 1 Pre-use Checks 163
B1-2 2 Discharging 163
B1-2 3 Charging 164
B1-2 4 Temperature 164
B1-3 Maintenance & Care 164
B1-3 1 Daily Maintenance 164
B1-3 2 Weekly Maintenance 164
B1-3 3 Monthly Maintenance 165
B1-3 4 Care 165
B1-4 Storage 166
B1-5 Troubleshooting 166
B2 Maintenance-free Battery 169
B2-1 Safety and Warnings 169
B2-2 Use of Battery 169
B2-2 1 Pre-use Checks 169
B2-2 2 Discharging 169
B2-2 3 Charging 170
B2-3 Maintenance & Care 170
C SCHEDULE 171