Ekko Ek18a User manual

Service Manual

EK18A

Three Wheel Electric 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 identification.

Keep it for future use

Manual

1. Maintenance List.........................................................................................................................................................................................1

a. Overview of main components ........................................................................................................................................................2

b. Lubrication point ....................................................................................................................................................................................3

c. Check and refill hydraulic oil.............................................................................................................................................................4

d. Check the fuse ..........................................................................................................................................................................................5

2. Fault Analysis.................................................................................................................................................................................................6

a. Common Fault analysis......................................................................................................................................................................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 assembly disassembly............................................................................................................................................... 13

c. Drive brake disassembly ...................................................................................................................................................... 14

d. Drive internal gear bearings............................................................................................................................................... 15

e. Handle assembly...................................................................................................................................................................... 16

f. Frame breakdown ................................................................................................................................................................... 18

g. Pump station motor ............................................................................................................................................................... 26

5、CURTIS Handheld Unit...............................................................................................................................................................................19

1 Regular maintenance

Only qualified and trained personnel should perform maintenance work on this vehicle.

Before maintenance, remove the cargo from the fork and lower the fork to the lowest position.

If you need to lift the vehicle, use the specified lashing or jacking equipment.Before operation, place safety

devices (such as designated jacks, wedges or wood blocks) under the vehicle to prevent accidental drop,

movement or sliding.

Use the original parts approved and released by your dealer.

Please consider that hydraulic fluid leakage may lead to machine failure and accidents.

Pressure valve adjustment is only allowed by trained service technician.

If you need to replace wheels, casters must be round and free of abnormal wear.

Check the items on the maintenance list.

1.1 Maintenance List

Interval

(month)

3 6

The hydraulic system

1.1

Check the function of hydraulic system

•

1.2

Check hoses, piping and joints for tightness, sealing and damage

•

1.3

Inspect cylinder block and piston for damage, sealing and fixation

•

1.4

Visually inspect the door stand roller and inspect the roller surface for wear

•

1.5

Inspect forks and loading parts for wear and loss

•

1.6

Check load chain Settings and re-tensioning if necessary

•

1.7

Check oil level in fuel tank

•

1.8

Replacement hydraulic fluid

•

Mechanical systems

2.1

Check the fork for deformation and breakage

•

2.2

Check chassis for deformation and cracking

•

2.3

Check that all screws are in place

•

2.4

Check gear box for noise and leakage

•

2.5

Check wheel for deformation and damage

•

2.6

Lubricated steering bearing

•

2.7

Check and lubricate the pivot points

•

2.8

Lubricating grease nozzle

•

Electrical system

3.1

Check whether power cables are damaged

•

3.2

Check the electrical connections

•

3.3

Check the function of the emergency switch

•

3.4

Check whether the power drive system is noisy or damaged

•

3.5

Test electricity meter

•

3.6

Check whether the correct fuse is used

•

3.7

Detect warning signals

•

3.8

Check the current contactor

•

3.9

Check frame for leakage (insulation test)

•

3.10

Check the function and wear of the drive controller

•

3.11

Check the electrical system that drives the motor

•

traveling system

4.1

Check the gearbox for abnormal sound

•

4.2

Check the driving mechanism and grease it

•

4.3

Inspect 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 and left and right movement of the

door frame

•

4.7

Check and adjust braking effect

•

Energy supply

5.1

Check the voltage of the battery

•

5.2

Check that battery cables are securely connected and grease the electrodes if

necessary

•

5.3

Check whether the battery cover is damaged

•

5.4

Check the main cable for damage

•

5.5

Check the start up protection program during charging

•

Monolithic Construction

6.1

Check all labels for clarity and completeness

•

6.2

Check the frame for damage

•

6.3

Check the fixing condition of lifting door frame

•

6.4

Run a test run

•

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

Pic3：Drive axle clamp

1.3 Check and refill hydraulic oil

Recommended hydraulic oil model according to temperature::

Ambient

temperature

–5℃~25℃

>25℃

mark

HVLP 32

，

DIN 51524

HLP 46

，

DIN 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 the recycling company for recycling if necessary.

The oil level should not be lower than the minimum amount required to start the vehicle.

Fill up to refueling point if necessary。

A. Check the electrical fuse

List 2:

Fuse specification

specification

Fuse 1

10A

Fuse 01

300A

2 Fault analysis

If the vehicle continues to malfunction, 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 of brake pedal

Adjust

2. Brake system leaks oil

Repair or replacement

3. Air is mixed in the brake system

exhaust

10Aelectrical fuse

300A fuse

4. The brake shoe clearance is not

adjusted well

Adjust

5, the total pump pump bowl

deformation, damage or excessive

wear

Check the cause of damage and

replace

6. There are oil stains on the surface of

brake drum hole

Clean up

Brake uneven

1. There are oil stains on the surface of

the friction plate

Cleaning and replacement

2. The brake drum hole is partial, and

the big hole is different

Bright hole, ensure roundness,

concentricity

3. The brake shoe clearance is 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

1, friction plate surface hardening or

impurities

replace

2. Bottom plate deformation or bolt

loosening

repair

3, brake shoe deformation or

installation is not correct

Replacement or repair

4. Excessive wear of friction plate

replace

5. Hub shaft is loose

replace

Other poor

braking

1. Brake overheating

Check for skid

2. Impurities are mixed into the brake

fluid

Check and replace brake fluid

3, hand brake position cable

deformation, joint off

Repair, replacement

•2.1.2

Steering system common faults and troubleshooting methods

Failure

cause

maintenance

steering

hydraulic

system problem

1. There is air in the hydraulic pipeline

components of the steering system

exhaust

2, the working oil oil level is too low,

inhale air

Gas exhaust

3. The shunt valve hole is blocked and

the spool is stuck

Cleaning and replacement

4. The piston rod of the steering

cylinder is bent

Replace the piston rod

5, knuckle and knuckle pin bite

Check method: lift the rear axle to see

whether the swing is flexible

Dismantle, repair

6, other steering when the relative

surface bite

7. The steel ball in the valve body of

the 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 flow

10, the shunt valve pressure is lower

than the working pressure, the flow is

too low

Use specified oil

11. The viscosity of oil is too large

replace

12, spool, valve body excessive wear,

clearance is too large

replace

13. Excessive wear of oil pump

exhaust

oil leak

1, the joint is not pry tight

Pry tight

2. There is dirt on the joint surface of

the stator and rear cover of the valve

body of the steering gear

cleaning

3, oil cylinder leakage

Check guide sleeve seal joint seal

Abnormal

sound

1, the oil level of the tank is too low,

hydraulic noise

Refueling and exhaust

2. Suction tank or oil filter is blocked

Cleaning and replacement

2.1.3 Lifting system common faults and troubleshooting methods

Failure

cause

maintenance

Lifting, falling

is not smooth,

loud noise

1. The gap between the upper side

roller of the outer door frame and the

channel steel of the inner door frame

is too large > 1mm

Reduce adjusting gasket

2. The gap between the lower side

roller of the outer frame and the

channel steel of the inner frame is too

large > 1mm

Add adjusting gasket

3. The gap between the side roller of

the fork frame and the channel steel of

the inner door frame is too large >

1mm

Reduce adjusting gasket

4. Fastening bolts of side roller shaft

are loose

fastening

5. There are debris in the channel

steel of the sliding 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

2. The tightness of the left and right

chains is inconsistent

The tightness adjustment is consistent

3. The oil channel in the speed limiting

valve is blocked

Cleaning and replacement

4. The oil inlet of the lifting cylinder is

partially blocked

Maintenance and cleaning

The left and

right

elevations are

not

synchronized

1, the left and right lifting cylinder

stroke is inconsistent

Use cylinder head 180 degree

adjustment

2. The height of the left and right

cylinders is inconsistent

Adjusting bolts on the oil cylinder

3, the left and right cylinder stroke is

too inconsistent to exceed the cylinder

head adjustment range

Add adjusting gasket on lifting

cylinder piston rod

The over lift

speed at full

load cannot

meet the

requirements

Or fail to lift

1. Insufficient amount of working oil

Come on

2, speed limit valve throttle hole is

blocked by stolen goods

Unpick and wash

3, the safety valve slide blocked, stuck

Cleaning and repairing

4. Leakage of suction pipe weld at the

filter screen in the tank

Repair welding, bottom leakage

5. The pipe joint is loose

Pry tight

6, oil pump gear and pump body

excessive wear, clearance is too large

Check oil cleanliness, grade 9-11

required

7, lifting cylinder sealing ring damage

or excessive wear internal leakage

Replace seal ring

8, multi-way valve body and spool

valve gap is too large, the main valve

pressure is too low

Replacement and 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 contact of key switch

2, break

3. Poor contact of the connector

4. The battery connector is loose

Step on the accelerator pedal

and the forklift will not walk

1, disconnect

2. Poor contact of the connector

3, the direction switch contact is poor

4, thruster speed regulating device failure

The lifting motor does not

work

1. Contactor coil is open or open

2. The lifting switch does not work normally

3, disconnect

4. Poor contact of connectors

5. The main contact of contactor is burned out

Turn over the hoist

1. The lifting switch does not work normally

The light is not working

properly

1, the fuse is broken

2. Poor contact of connectors

3. Light bulbs are broken

Speakers don't ring

1. Poor contact of connectors

2, the horn switch contact is poor

The speaker is broken

Long horn ring

1, horn switch contact long

The reversing buzzer doesn't

work

1. The buzzer is broken

2. Poor contact of reversing switch

3. Poor line connection and plug

2.1.5Gearbox fault causes and troubleshooting methods

Failure

Fault cause and elimination method

efficiency decrease

1. The friction plate is stuck or worn. Check for gluing,

uneven contact or warping of the friction plate

2, bearing damage. Replace the bearing

3. Check whether the lubricating oil road is blocked

oil leak

1. The sealing pad is damaged. Replace gasket

2. Rubber parts are aging or damaged. Replacement parts

3, parts damage crack. replace

•2.1.6 Multi-way valve fault causes 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. Foreign bodies such as paint and

dust are embedded in the lip sealing

part

Clean the paint and other foreign

matters embedded in the lip sealing

part, pay attention to not damage the

valve stem and sealing surface

4, O-ring damage (cut ring)

Replace the O-ring seal

5. Aging and deformation of sealing

ring between valve discs

Replace the new sealing ring

6. The sealing plane of the valve plate

is scratched (new valve) or there are

foreign bodies

Remove foreign matter or replace

valve disc

7, valve body hole and sealing ring slot

hole different heart (new valve)

Replace the valve plates

8. Back pressure of oil return exceeds

allowable value

Check the loop and lower the return

oil pressure to the specified value

9. The bolts between pieces are not

evenly stressed or tightened

Tighten the stud bolts with specified

torque

Stem cannot be

reset

1, the control mechanism is not

flexible

Check the control lever

2, the valve stem is squeezed by dirt

Clean valves, fuel tanks and pipelines

3, return spring deformation or

fracture

Remove the back cover for inspection

and replace the spring

4. Stem deformation caused by

external force

Refit stem or replace valve sub

assembly

5, the installation surface is uneven,

the valve body deformation, resulting

in stuck valve

Adjust the installation plane

Stem heavy

drop in

neutral

position

(leakage out

of tolerance in

neutral

position)

1, stem and valve hole wear, gap

increase serious internal leakage

Rein stall stem

2, stem or valve hole scratch internal

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 not

strict

Check whether the O-ring is cut. If

damaged, replace it with a new O-ring

5. Serious leakage in the cylinder

Check the cylinder piston seal for

damage

6. The groove size of valve body is out

of tolerance and the length of sealing

oil becomes smaller

Replace the valve plates

hard steering

1, the oil is not clean, the shunt valve

core or the shunt safety valve core is

stuck

Clean shunt valve core or shunt relief

valve core and fuel tank and pipeline

2. The opening and closing

characteristics of the shunt safety

valve are not good or the pressure

regulation of the shunt safety valve is

low

Replace the shunt relief valve or

readjust the shunt relief valve

pressure

3. Insufficient flow of oil pump

Check why the oil supply system of the

oil pump is insufficient

4. Steering gear failure

Replace the steering gear

No action of

oil cylinder

(low pressure

or no

pressure)

1. There is foreign matter stuck

between the overflow valve or

overload valve main spool and valve

seat

Clean valves, fuel tanks, pipelines, etc

2. The damping hole is blocked

Hydraulic oil pollution is serious,

clean the hydraulic system

3, the cone spool has abnormal wear

Inspect for wear and replace relief

valve assembly

4, pressure regulating spring

deformation

Check spring quality

5. The adjustment screw of the relief

valve is loose

After adjusting the pressure, tighten

the nut according to the specified

torque

6. Oil pump failure

Replace the oil pump

The relief valve

has vibration

and dynamic

and noise

1, the hydraulic system has air

The system will be discharged 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 pressure

Check the cause of negative pressure

4. The oil suction filter is blocked

Clean the oil filter and filter the oil

5, the relief valve has a pressure point

vibration and noise

Adjust relief valve, slightly raise or

lower pressure gauge 1 ~ 2 scale grid

There is no

self-lock in

forward tilt or

the self-lock

in forward tilt

exceeds the

standard

1, the oil is not clean, so that the

forward control small spool stuck

Clean valves, fuel tanks, pipelines, etc

2, the wrong oil port

Switch the wrong oil connection

•2.1.7 Gear pump failure reasons and troubleshooting methods

Failure

cause

maintenance

Pump suction

oil or oil

1. The flow area of the oil suction filter

is small or blocked by foreign bodies

Replace the filter with a suitable flow

area or clean the blocked filter

absorption is

not smooth

2. The tank level is too low

The tank is filled with hydraulic fluid

as required

3. The installation position of the oil

pump is too high; Suction range

exceeds specified

According to the suction range of the

oil pump, it is within 500mm

4, the oil temperature is too low, the

oil viscosity is too high

Change oil or heat oil seasonally

5, suction tubing is too thin or too

long, too much resistance

Change the large diameter tubing,

shorten the length of suction tubing

6. The oil seal of the oil pump is

damaged and the air is inhaled

Replace the new oil seal

7. The rotation of the oil pump is not

correct or the speed is too high

Change the oil pump rotation, make

the speed to the specified value

8, oil suction side leakage

Check the oil absorption part and its

seal, and replace the failed 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 pump

2. The cone spool of the relief valve is

severely worn

Replace the new cone spool

3. The overflow valve is stuck by

stolen goods and loosely closed

Filter oil and remove dirt

4. The pressure regulation of relief

valve is too low

Adjust the overflow valve to the

specified value

5, oil suction air

Check whether the sealing ring at the

oil suction port is damaged

Low volume

efficiency of

oil pump

1. The sealing parts in the oil pump

are damaged

Replace seal ring

2, side plate wear

Replace the side panel

3. There are stolen goods or too large

clearance in the oil pump

Remove stolen goods and filter oil;

Replacement of new oil pump

4. The oil pump speed is too low or too

high

Make the oil pump run within the

specified speed range

5. Negative pressure appears in the

tank

Increase the capacity of air filters

Oil pump

noise

1. Most cases are caused by

insufficient oil absorption of oil pump,

such as blockage of oil absorption

filter; Oil level is too low; Inhalation of

air; Suction air at oil seal, etc

Keep oil level high and seal must be

reliable to prevent oil contamination

2. The return pipe is higher than the

oil level, and there are a lot of bubbles

in the oil

Immerse the return pipe below the oil

level

3. The viscosity of oil is too high and

the oil temperature is too low

Choose oil with proper viscosity

according to the season, or heat it up

4. The coaxial of the pump shaft and

prime mover shaft is too large

Adjust the coaxiality of the two axes

5. After maintenance, the driven gear

is inverted, and the meshing area

becomes smaller

Disassemble the oil pump and turn the

driven gear

Oil 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. The oil viscosity is too high or the

internal leakage is serious

Change the appropriate oil and check

the seal

3. The back pressure of oil return is

too high

Eliminate the cause of high return

back pressure

4, the fuel tank is too small, poor heat

dissipation

Increase the fuel tank

2.1.8 Other common faults and troubleshooting methods

Failure

cause

maintenance

Abnormal

sound during

exercise

1, hydraulic oil, gear oil and other oil

does not meet the requirements

Fuel until required

2, front and rear hub bearings loose,

broken

After tightening the bearing and

locking the nut, retract about 1/8 turn,

and the hub should be free to turn.

Fracture will renew the bearing

3, gearbox, gear, friction plate damage

replace

4, differential and cross shaft damage

replace

5. Fasteners are loose

Pry tight

1、Walk and lift controller fault code

Code Fault name Possible cause

Controller Over

current

1, motor external U,V or W connection short circuit

2. Motor parameters do not match

3. The controller is faulty

Current Sensor Fault

1, motor U, V, W through the stator on the car body short circuit,

resulting in leakage

2. The controller is faulty

Precharge Failed

1. Negative load is connected to the positive end of the capacitor, so

that the capacitor can not be charged normally

Controller Severe

Under temp

1The operating environment of the controller is too harsh

Controller Severe

Over temp

1. The working environment of the controller is too harsh

2. Vehicle overload

3. The controller is incorrectly installed

Severe Under voltage

1. Battery parameters are incorrectly set

2. Power consumption of non-controller system

3, the battery impedance is too large

4. The battery is disconnected

5, the fuse is disconnected, or the main contactor is not connected

Severe Over voltage

1. Battery parameters are incorrectly set

2. The battery impedance is too high

3. Battery connection is disconnected during regenerative braking

Controller Under temp

Cutback

1. The controller works under restricted conditions

2, the controller working environment is harsh

Controller Over temp

Cutback

1, the controller working environment is harsh

2. Vehicle overload

3. The controller is incorrectly installed

Under voltage Cutback

1. The battery is low

2. Battery parameters are incorrectly set

3. Non-controller system runs out of power

4. Excessive battery impedance

5. The battery is disconnected

6. Fuse is disconnected or main Contactor is disconnected

Over voltage Cutback

1, regenerative braking process regenerative system

The running current causes the battery voltage to rise

2. Battery parameters are incorrectly set

3, the battery impedance is too large

4. Battery connection is disconnected during regenerative braking

+5V Supply Failure

1, the external load impedance is too low

Digital Out 6 Failure

1, the external load impedance is too low

Digital Out 7

Over current

1, the external load impedance is too low

Motor Temp Hot

Cutback

1. The motor temperature reaches or exceeds the alarm temperature

set by the program, resulting in the reduction of current output

2. The motor temperature parameters are incorrectly set

3. If the motor does not use a temperature sensor, program

parameters "Temp Compensation" and "Temp"

Cutback must be set to OFF.

Motor Temp Sensor

Fault

1. The motor temperature sensor is incorrectly connected

If the motor does not use a temperature sensor, the programming

parameters are "Temp Compensation and Temp"

Cutback must be set to "OFF"

Coil 1 Driver

Open/Short

1. Connect load open or short