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

7
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