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
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)
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 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
•

2
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

4
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。

5
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

6
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

7
•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

8
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