EKKO EK07S Series User manual

SERVICE MANUAL
EK07S Series Counter Balanced Stacker

Manual
1. Maintenance List............................................................................................................................................. 1
a. Overview of main components ............................................................................................................ 2
b. Lubrication point......................................................................................................................................... 4
c. Check and refill hydraulic oil.................................................................................................................. 4
d. Check the fuse ............................................................................................................................................... 6
2. Fault Analysis..................................................................................................................................................... 6
a. Common Fault analysis........................................................................................................................... 7
b. The fault code is displayed...................................................................................................................... 8
3. Wiring/circuit Diagram ..............................................................................................................................15
a Schematic diagram and wiring diagram ................................................................................................15
b Hydraulic circuit .............................................................................................................................................17
C Hydraulic Oil Inspection .............................................................................................................................18
4. Dis assembly of main parts ......................................................................................................................18
a. Removal of handle assembly .........................................................................................................18
b. Removal of electric control component.............................................................................................20
C. Hydraulic assembly Removal.................................................................................................... 22
d. Outer Mast ..................................................................................................28
e. Internal door frame assembly removed ............................................................................................22
f. Removing slide frame assembly ................................................................................................29
5. CURTIS handhold unit .................................................................................................................................30

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1. Maintenance List
a. Overview of main components
List:1. Maintenance Lis t
Interval
(month)
1 3 6 12
The hydraulic system
1 Check the hydraulic cylinder, piston for damage noise and leakage •
2 Check hydraulic fittings and tubing for damage and leakage •
3 Check hydraulic oil level and refill if necessary •
4 Refill with hydraulic fluid (12 months or 1500 working hours) •
Mechanical systems
5 Check the fork for deformation and cracks •
6 Check the base for deformation and cracks •
7 Check that all screws are properly fastened •
8 Inspect door frame and chain for corrosion, deformation or damage and replace if
necessary
•
9 Check gear box for noise and leakage •
10 Check wheel for deformation and damage and replace if necessary •
11 Lubricated steering bearing •
12 Check and lubricate the pivot points •
13 Lubricating grease nozzle •
14 If the protection and/or protection plate is damaged, replace it •
Electric System

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15 Check for damaged wires •
16 Check electrical connections and terminals •
17 Test emergency stop switch function •
18 Check the electric drive motor for noise and damage •
19 Detection display •
20 Check that the correct fuse is used and replace it if necessary •
21 Check the buzzer •
22 Check the current contactor •
23 Check frame for leakage (insulation test) •
24 Check accelerator function and wear •
25 Check the electrical system driving the motor •
Driving system
26 Check braking performance •
storage battery
27 Checking the Battery voltage •
28 Clean and grease terminals and inspect for corrosion and damage •
29 Check whether the battery casing is damaged •
Charger
30 Check whether the main power cable is damaged •
31 Check the startup protection program during charging •
function
32 Check the buzzer •

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33 Check the air gap of the electromagnetic brake •
34 Test emergency brake function •
35 Test reverse braking and regenerative braking functions •
36 Check steering function•
37 Check lifting and descending functions •
38 Check whether the key switch is damaged and functional •
39 Detection speed limit switch (lifting height >~400mm) •
synthesize
40 Check all labels for clarity and completeness •
41 Check that the guard plate and/or guard are not damaged •
42 Check casters, if worn height adjustment or replacement •
43 Run a trial run •

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B. lubrication points
Lubricate marked points according to maintenance list.Required grease specification: DIN 51825
standard grease.
Chain lubrication
Door frame track
lubrication

5
A. Check and correct electrolytes
The electrolyte density is based on 25℃.Therefore, when measuring, if the temperature of the electrolyte
is higher or lower than 25℃, every 1℃ higher, should be measured from the actual density value plus
0.0007;On the contrary, lower than 25℃, every 1℃, should be minus 0.0007;If the temperature difference
is large,
Can be corrected by pressing the following formula:
Standard temperature of electrolyte (25℃) D ensity is co nverted a cco rding to the following form ula :
D25 = Dt + 0.0007(T-25)
D25 -- electrolyte density at 25℃
Dt -- T ℃ measured electrolyte density
T -- Temperature of electrolyte when measuring density
Axle lubrication

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Under the condition of normal working of charging function, the density of 1.26±0.005(25℃) temperature
below 30℃ sulfuric acid electrolyte into the battery, liquid level requirements higher than the protection
plate 0.6 ~ 1.0 in.
Leave the battery to rest for 3-4 hours, no more than 8 hours.Initial charging can be carried out only
when the liquid temperature drops below 35℃.If the electrolyte level drops after standing, the electrolyte
should be replenished.
The discarded batteries must be recovered and stored in the specified environmental protection area or
the specified waste disposal area in accordance with the local laws and regulations, and the work must
be carried out by qualified professional companies.
d. Check fuse
List 2: Fuse specification
specification
Fuse 1
10A
Fuse 01
300A
200Afuse

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Fault analyses
If the vehicle continues to malfunction, follow the instructions of the manual.
2.1 Common fault analysis
•2.1.1Hand and foot brake common faults and troubleshooting methods
fault cause maintenance
Cargo cannot be lifted
Excessive cargo weight
Lift only the maximum load as
shown on the nameplate
Battery discharge
The battery
The lift fuse has failed
Check and replace the lift fuse
The hydraulic oil level is too low
Check and finally fill with hydraulic
fluid
The spill
Check tubing and/or cylinder for
tightness
Sensor failure
Check the sensor on the door rack
Oil leakage caused by
suction Oil is too high Reduce oily
Stacker cannot
operate
The battery is charging
Fully charge the battery, then unplug
the main power plug from the power
supply
The battery is disconnected.
Connect batteries correctly
The fuse is out of order
Check and eventually replace the
fuse
Battery discharge
The battery
The emergency stop switch is activated Insert and pull knob to eliminate
emergency stop switch function
The handle is in the operating area First move the handle to the braking
area
Traffic is going in one
direction only Traffic is going in one direction only Check accelerator and connector

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The forklift suddenly
started
Controller damage
Replacing a Controller
The accelerator has not moved back to
the middle position
Repair or replace the accelerator
Other poor braking
Battery discharge
Check the battery condition on the
discharge monitor
The electromagnetic brake has been
activated
Check electromagnetic brake
The h
andle wiring harness is not
connected or damaged
Check handle wiring harness and
connectors
At 400mm altitude, the speed decreases
and the sensor fails
Check sensor
Electrical system overheating
Discontinue use and cool the vehicle
The thermal sensor is faulty Check and replace the heat sensor if
necessary
If the vehicle is malfunctioning and cannot be operated outside the work area, lift the vehicle up, place a
load handling device under the vehicle and secure the vehicle, then remove the vehicle out of the
channel.
Fault code display
Table 4:1212P fault codes
Programmer display code The fault phenomenon fault diagnosis
BATTERY
DISCONNECT
FAULT
4.5
Battery don't answer 1) The battery is not connected
BRAKE OFF FAULT
3.4
Brake closing fault 2) Poor contact of battery end
BRAKE ON FAULT
3.2
Brake opening failure
1) Electromagnetic brake coil short
circuit

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CURRENTSENSE
FAULT
4.1
Current detection fault
2) Electromagnetic brake drive open
circuit
EEPROM CHECKSUM
FAULT
4.3
EEPROM failure 1) Electromagnetic brake coil open
HARDWARE FAILSAFE
4.2
Motor voltage is out of
range
2) Electromagnetic brake drive short
circuit
HPD FAULT
3.5
HPD fault 1) Short circuit of motor or motor wiring
MAIN FAULT
2.3
The main contactor is
faulty
2) The controller is faulty
MAIN OFF FAULT
2.1
Main contactor coil drive
'off' failure
1) EEPROM is faulty or invalid
MAIN ON FAULT
2.4
Main contactor coil drive
'on' failure
1) Motor voltage cannot match
accelerator input
OVERVOLTAGE FAULT
1.5
Battery voltage is too
high
2) Short circuit of motor or motor
matching ring
PRECHARGE FAULT
3.3
Precharge failure 3) The controller is faulty
SPEED POT FAULT
1.3
The speed limiting
potentiometer is faulty
1) Accelerator, key switch, promotion or
prohibition
THERMAL FAULT
1.1
Over/under temperature
cut-off
Input several actions out of order

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THROTTLE FAULT
1.2
Potentiometer slip end
or low
2) Wrong adjustment of accelerator
UNDERVOLTAGE
FAULT
1.4
The terminal voltage is
out of range
1) Main contactor adhesion or open
一、Methods for troubleshooting common faults
1、Code 4.5 Battery is not connected
Check whether the fastening of cable terminals of the car body is loose, as shown below:
2. Use a multimeter to measure the monomer voltage of the battery with load. The specific operation is
shown as follows:
Check whether the cable connection (including other secured
parts) is loose

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1、Codes 3.4 and 3.2 Electromagnetic brake line problems, or electromagnetic brake failure
Use a multimeter to measure the resistance of the two cores on the controller to the plug-in. The specific
operations are as follows:
Code 4.1 Motor or motor line short circuit or controller failure
1. Remove the motor brake disc (the brake line is still connected), connect the motor M1
M2 directly to the positive and negative poles of the battery, observe whether the motor
rotates normally, if not, the motor will fail.
2. If the motor turns normally, the controller should be replaced.
Operation sequence failure in 3.5 and 3.1
1, interlock switch under normal circumstances, use a multimeter to measure the controller
14 core plug-in between J1-6 and the negative pole, when the handle rod is in the switch
working area, there is about 24V voltage. If not, check the interlock switch. For example,
check whether the interlock switch is normal and whether the signal cable of the switch is
connected to the controller.
4.2 Motor voltage cannot match accelerator input, motor or motor ring short circuit and
controller fault, troubleshooting operations are shown as follows:
Normally, it should be
about 40 ω. If no
resistance is displayed,
there is a problem with
the brake line or a short
circuit of the brake coil.

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If the voltage change of accelerator is normal, replace the controller.
Six, determine the controller fault
Unplug the accelerator docking plug, if the controller is still reported fault after powering on (in addition to
the above faults), the controller is faulty.
7. If the controller fault is steady on and there is no walking, the troubleshooting steps are as follows:
1. Measure whether there is voltage output of accelerator 0--5V (between J1-1 and negative electrode)
2. Short-circuit j1-6 on the 14-core plug of the controller with line 7 on the 5-pin. After restarting, turn the
accelerator to see if there is a walk.
3. The brake is locked, remove the brake (the brake line is still connected), restart and turn the
accelerator to check whether it is normal.
4, remove the motor brake disc (brake line is still connected), connect the motor M1 M2 directly to the
battery positive and negative poles, observe whether the motor is normal rotation, if not, the motor
failure.
5. If all the above tests are normal, judge the controller problem.
Viii. If there is no lifting and dropping or the cylinder drops automatically, the troubleshooting method is
as follows:
Switch the multimeter to 20V DC, insert the pen j1-1
(accelerator 0-5V speed signal) and 2 (negative pole)
respectively, turn the accelerator after power on, and

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2、Press down button, down solenoid valve signal red light should be steady on
•
1. If the vehicle cannot be lifted normally, for example, the original 3300
lbs. vehicle can only be lifted less than 2200 lbs., then the oil pump
pressure can be adjusted, but this operation must be carefully, if the
hydraulic pressure is adjusted so that the vehicle load exceeds the rated,
it may make the frame deformation. Specific operations are as follows:
The wrench unscrewed the pressure nut.
•
1.Here is the coil wiring of the lifting contactor (line numbers
are 2 and 15). After powering on, press the lifting button to
measure whether there is a voltage of about 24V at these two
places. If so, and there is no sound of pulling on the contactor,
then the contactor is faulty. If there is no 24V voltage, then line
15 at the measuring handle is connected to line 15 at this point.

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Using an inner hexagon wrench, adjust the pressure.

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a、Schematic diagram, and wiring diagram
EK05S Electrical Schematic diagram

EK07S Electrical Schematic diagram

B、Hydraulic circuit
Hydraulic circuit

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Hydraulic oil inspection
Appearance odor condition results
Clear not discoloration good good can be used
color transparency good with other oil mix check viscosity, if qualified can
continue to use
Color changes like milk well mixed with air and water to separate moisture or replace
hydraulic fluid
The color becomes dark brown not
good for oxidation replacement of hydraulic oil
Clear color but small black spots good mix with other particles can be used after filtering
4、Dissassembly of main parts
A、Removal of handle assembly