EKKO EK18A, Service Manual

Page 1: ...lectric Forklift Warning You must understand the operation instructions in this manual before using it Note Please check the last page of this document and name plate for all current product type iden...

Page 2: ...sis 7 b The fault code is displayed 8 3 Wiring circuit Diagram 9 a Schematic diagram and wiring diagram 10 b Hydraulic circuit 11 4 Main parts disassembling 2 a Battery brake adjustment 12 b Drive ass...

Page 3: ...tems on the maintenance list 1 1 Maintenance List Interval month 1 3 6 12 The hydraulic system 1 1 Check the function of hydraulic system 1 2 Check hoses piping and joints for tightness sealing and da...

Page 4: ...pect driving and steering wheels for wear and damage 4 4 Check wheel bearing and fastening condition 4 5 Check the air gap of the electromagnetic brake 4 6 Check the lifting forward and backward tilt...

Page 5: ...1 2 Lubrication point Lubricate marked points according to maintenance list Required grease specification DIN 51825 standard grease Pic1 transmission chain Pic2 The rail of gantry...

Page 6: ...N 51524 Viscosity 28 8 35 2 41 4 47 Oil 1 5 L Waste materials such as waste oil waste batteries or other materials must be treated and recycled in accordance with national regulations and returned to...

Page 7: ...lfunction follow the instructions of the manual 2 1 Common fault analysis 2 1 1 Hand and foot brake common faults and troubleshooting methods Failure cause maintenance Poor braking 1 Improper position...

Page 8: ...s not adjusted well Adjust 4 brake shoe return spring damage replace 5 Sub pump failure Repair or replacement 6 self adjusting mechanism failure Reset spring deformation repair replacement Brake noise...

Page 9: ...e steering gear fails and is blocked Replacement spring 8 steering reset failure spring fracture Check piston seal ring and replace 9 Leakage in the steering cylinder is too large Adjust pressure and...

Page 10: ...ing frame and the inner door frame Yeah oil on the tracks regularly The cargo fork frame is skewed 1 the left and right tire pressure is inconsistent Air replenishment and air pressure are consistent...

Page 11: ...adjustment 9 the shunt valve shunt improperly Adjust 2 1 4 Common faults and troubleshooting methods of electrical system Failure Fault cause and elimination method Open key switch no voltage 1 Poor...

Page 12: ...ses and troubleshooting methods Failure cause maintenance External leakage 1 lip sealing parts wear Replace seal ring 2 The valve stem sealing part is damaged Replace stem or disc sub assembly 3 Forei...

Page 13: ...ernal leakage increase Refit stem or replace valve sub assembly 3 Stem is not restored to neutral position Check reversing mechanism 4 overload valve or overload valve plug and valve body seal seal is...

Page 14: ...ged after repeated operation for a while 2 The pump inhales air Check oil absorption test of oil pump 3 suction pipeline resistance is too large or the suction side of the oil pump produces negative p...

Page 15: ...iled seal The oil outlet of the oil pump discharges oil but the pressure cannot rise 1 The side plate of the oil pump is severely worn and the volume efficiency is too low Repair or replace the oil pu...

Page 16: ...il pump temperature rises too high 1 the pressure is too high the speed is too fast the side plate burns Properly adjust the overflow valve Reduce the speed to the specified value Repair the pump 2 Th...

Page 17: ...ted 7 Severe Over voltage 1 Battery parameters are incorrectly set 2 The battery impedance is too high 3 Battery connection is disconnected during regenerative braking 8 Controller Under temp Cutback...

Page 18: ...ng pin is defiled 3 Wrong wiring 20 EMBrake Open Short 1 Connect load open or short 2 The connecting pin is defiled 3 Wrong wiring 21 Coil3 Driver Open Short 1 Connect load open or short 2 The connect...

Page 19: ...Time Error 1 The VCL code timed out 39 External Supply Out of Range 1 the external load in 5V and 12V power source current is too large or too small Checking Menu parameters are incorrect for example...

Page 20: ...Model Number 1 The controller model cannot be identified 2 Hardware and software do not match each other 3 The controller is damaged 50 Dualmotor Parameter The Enable parameter of dual motors is set t...

Page 21: ...the switch with the limitation of walking function According to the schematic diagram it can be found that seat switch 1A9 and handbrake switch 1A14 as shown below This type of switch can be measured...

Page 22: ...21 3Circuit circuit diagram 3 1Electrical schematic diagram Speed mode H...

Page 23: ...22 3 2...

Page 24: ...lor but small black spots good mix with other particles can be used after filtering 4 drive system The moving of forklift truck is powered by batteries and the direct current is converted into alterna...

Page 25: ...the axle housing so only bear the torque of driving wheel axle shaft inside the wheel is equipped with oil seal Prevent water and dust from entering and oil leakage 1 Brake assembly left 2 Inner hexa...

Page 26: ...smitted to the differential Maintenance permanent lubrication of rotary platform 1 Bolt 2 Gasket 3 Bearing cover 4 O ring 5 Deep groove ball bearing 6 Box assembly 7 Lock plate of bearing seat 8 Deep...

Page 27: ...3 Differential structure drawing 1 Deep groove ball bearing 2 Nut 3 Left differential case 5 Washer 6 Gear 7 Shaft 8 Half shaft gear 9 Half shaft washer 10 Right differential housing 11 Gear ring 12 B...

Page 28: ...pin before and after the fixed plate by damping pad bolted to the frame on the tail at the back of the shelf make bridge physical swing around the pin shaft steering axle sides of a steering knuckle h...

Page 29: ...lve a return spring and a main leather bowl piston and auxiliary leather bowl The end is fixed with a stop washer and a stop steel wire and the exterior is protected by a rubber dust cover The piston...

Page 30: ...ump so that the sub pump leather bowl is placed correctly to prevent oil leakage and eliminate the possible air resistance phenomenon during emergency braking 1 Lock nut 2 Push rod 3 Dust cover 4 Stop...

Page 31: ...rol of lifting tilting and lateral oil passage is controlled by three handles on the triplet valve the lifting action is controlled by the single acting oil passage on the triplet valve and the tiltin...

Page 32: ...ief valve The valve body is assembled together by bolts and nuts The pressure of the main safety valve has been adjusted before leaving the factory Users are not allowed to adjust it casually 1 safety...

Page 33: ...drawing of lifting cylinder and tilting cylinder 1 Dust ring 2 Cylinder head 3 O ring 4 Cylinder block 6 piston 7 steel wire retainer 8 support ring 9 Sealing ring 10 Baffle 11 Buffer sleeve 12 Cylind...

Page 34: ...ock 3 Piston 5 Sealing ring for hole 6 Supporting ring for hole 7 Piston rod 9 Guide sleeve 10 Bearing 11 O ring 12 Seal ring for shaft 13 Dust ring 14 Nut 15 Joint bearings 17 Elastic retainers for h...

Page 35: ...the roller side roller to bear the longitudinal and transverse load and make the frame with smooth movement 8 2 fork arm carrier Fork frame is equipped with rollers and adjustable gap side rollers so...

Page 36: ...strument function key 9 Function selection key Up 10 Function selection key Down 11 Parameter Adjustment key Down 12 Parameter Adjustment button Up 13 Exit button 14 Battery indicator 9 2 The battery...

Page 37: ...er open the key switch 2 From the menu list of CURTIS hand held units find Faults 3 When the vehicle is running and the hand held cursor flashes there will be English fault content which can be interp...

Page 38: ...inserting the programming port of the controller After connecting the controller the hand held programmer will be powered on automatically and the control information will be displayed on the program...

Page 39: ...eft by four directional buttons buttons You can add and subtract parameters by using these two keys In addition can mean Yes and can mean No In some cases it can also be used as a scrolling option Pow...

Page 40: ...n the main menu and below the icon When entering the stepped menu the name of the sub menu or the path you are in is displayed at the top of the screen Nine menu Fault Diagnosis menu On the main menu...

Page 41: ...l failures folder and grayed out when there are no historical failures Save cpf File Save cpf File Use the save CPF file function in the programming menu to back up the currently set parameters You ca...