EKKO EK20R User manual

Service Manual
Electric Forklift
EK20R/RL
Warning
You must understand the operation instructions in this manual
before using it.
Note:
Please check the last page of this document and nameplate for all
current product type identification.
Keep it for future use 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........................................................................................................................ 12
4.1 Driver Removal...............................................................................................................................12
4.2 Steering disassembly ....................................................................................................................14
4.3 Brake disassembly ........................................................................................................................16
4.4 Hydraulic disassembly................................................................................................................... 17
4.5 Removing the top guard ................................................................................................................20
4.6 Frame Disassembly .......................................................................................................................22
4.7 Removing the slide frame ..............................................................................................................25
4.8 Adjustment method of chain tightness ...........................................................................................26
5. Electric System........................................................................................................................................ 27
5.1 electrical schematic diagram .............................................................................................................. 27
5.2 Electronic assembly............................................................................................................................. 28
5.3instrument ............................................................................................................................................... 29
5.4 storage battery..................................................................................................................................... 32
5.5 Fault Diagnosis menu.......................................................................................................................... 33
6. CURTIS handhold unit 4......................................................................................................................3

1
Maintenance List
Overview of main components
list 1
:maintenance
Interval
(month)
1 3 6 12
Braking
1 Check the air gap of the electromagnetic brake •
Electric System
2
Check operating switches to display the functions of devices and components
•
3
Check alarm system and safety devices
•
4
Check whether the cable is damaged and whether the wiring terminal is firm
•
5
Check the function of microswitch Settings
•
6
Check the controller and EPS controller
•
7
Cable and motor fixation
•
energy supply
8
By looking at the battery
•
9
Visually inspect the battery charging plug
•
10 Check that battery cables are securely connected and grease the electrodes if
necessary
•
traveling system
11
Check the gearbox for abnormal sound
•
12 Check driving mechanism, grease and check the reset function of operating
handle
•
13
Check drive wheel and load wheel for wear and damage
•
14
Check wheel bearing and fastening condition
•
monolithic component
15
Check the frame for damage
•
16
Check signage for completeness
•
29
Check the fixing condition of lifting door frame
•
The hydraulic motor
30
Check the function of hydraulic system
•
31
Check hoses, piping and joints for tightness, sealing and damage
•
32
Inspect cylinder block and piston for damage, sealing and fixation
•
33
Check load chain Settings and re-tensioning if necessary
•
34
Visually inspect the door stand roller and inspect the roller surface for wear
•
35
Inspect forks and loading parts for wear and loss
•
36
Check oil level in fuel tank
•

2
37
Replacement hydraulic fluid
•
1. Lubrication point.
Lubricate marked points according to maintenance list. Required grease specification: DIN 51825 standard
grease
Pic1：transmission chain
Door frame inside
Chain lubrication

3
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 converted acco 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
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 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.
Wheel lubrication

4
a. Check fuse
List 2 : Fuse specification
specification
Fuse 1
10A
Fuse 01
300A
2 Fault analyses
If the vehicle continues to malfunction, follow the instructions of the manual.
Hand and foot break common faults and troubleshooting methods
Failure
cause
maintenance
Poor braking
Improper position of brake pedal
Adjust the
Leakage of brake system
Repair or replacement
There is air mixed in the brake system
exhaust
Brake shoe clearance is not properly
adjusted
Adjust the
Main pump sub pump bowl deformation,
damage or excessive wear
Check the cause of damage and
replace
There is oil stain on the surface of brake
Clean up
200A fuse
10A fuse

5
drum hole
Brake uneven
The surface of the friction plate is greasy
Cleaning and replacement
Brake drum hole deviation, large hole
different center
Bright hole, ensure roundness,
concentricity
Brake shoe clearance is not properly
adjusted
Adjust the
Brake shoe return spring damaged
replace
Points and pump failure
Repair or replacement
Self-adjusting mechanism fails Reset spring deformation, repair,
replacement
Brake noise
Friction plate surface hardening or
impurities
replace
The bottom plate is deformed or the
bolts are loose
repair
Brake shoe is deformed or improperly
installed
Replacement or repair
Excessive wear of friction plate
replace
Hub shaft is loose
replace
The handle is not in the operating area First move the handle to the braking
area
Other poor braking
Brake overheating
Brake Check for a skid
Impurities are mixed into the brake fluid Confirm strains are mixed into the
brake fluid
Hand brake position cable deformation,
joint off
Hand brake position cable
deformation, joint off
(1) Common faults of steering system and troubleshooting methods
Failure
cause
maintenance
To problem
There is air in the steering system
hydraulic line element
exhaust
Working oil level is too low, inhale air
Gas exhaust
The shunt valve hole is blocked and the
spool is stuck
Cleaning and replacement
Steering cylinder piston rod bent
Replace the piston rod
Knuckle and knuckle pin bite to death
Lift the rear axle to see if you can

6
Other steering when relative surface bite
dead
swing from side to side
Dismantle, repair
The steel ball in the steering valve body
fails and is blocked
Replacement spring
Steering gear reset failure, spring
breakage
Check piston seal ring and replace
Leakage in steering cylinder is too large
Adjust pressure and flow
There is air in the steering system
hydraulic line element
Use specified oil
Working oil level is too low, inhale air
replace
The shunt valve hole is blocked and the
spool is stuck
replace
Steering cylinder piston rod bent
exhaust
The spill
The joint was not pried tight
Pry tight
There are dirty joints between stator and
rear cover of valve body of steering gear
cleaning
Cylinder leakage
Check guide sleeve seal joint seal
Abnormal sound
Low oil level, hydraulic noise
Refueling and exhaust
Suction tank or oil filter blocked
Cleaning and replacement
(1) Common faults of lifting system and troubleshooting methods
fault
cause
maintenance
Lifting, falling is not
smooth, loud noise
The gap between the upper side roller of
the outer frame and the channel steel of
the inner frame is over 1mm
Reduce adjusting gasket
The gap between the lower side roller of
the outer frame and the channel steel of
the inner frame is over 1mm
Add adjusting gasket
The gap between the side roller of the
fork frame and the channel steel of the
inner door frame is over 1mm
Reduce adjusting gasket
The side roller shaft fastening bolt is
loose
fastening
There are broken objects in the channel
steel of sliding frame and inner door
frame
Yeah, oil on the tracks regularly

7
The cargo fork frame
is skewed
Pressure difference between left and
right
Air replenishment and air pressure
are consistent
Inconsistent tightness of left and right
chains
The tightness adjustment is
consistent
The oil channel in the speed limiting
valve is blocked
Cleaning and replacement
The oil inlet of the lifting cylinder is
partially blocked
Maintenance and cleaning
The left and right
elevations are not
synchronized
Left and right lifting cylinder stroke is
inconsistent
Use cylinder head 180 degree
adjustment
The height of the left and right cylinders
is inconsistent
Adjusting bolts on the oil cylinder
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
Insufficient working oil
Come on
The throttle orifice of the speed limiting
valve was blocked with stolen goods
Unpick and wash
The safety valve is sliding and jammed
Cleaning and repairing
Gas leakage of suction pipe weld at filter
screen in oil tank
Repair welding, bottom leakage
Loose pipe joint
Pry tight
Oil pump gear and pump body
excessive wear, clearance is too large
Check oil cleanliness, grade 9-11
required
The sealing ring in the lifting cylinder is
damaged or overwork and leaks too
much
Replace seal ring
Multi-way valve body and spool valve
gap is too large, the main valve pressure
is too low
Replacement and adjustment
The shunt valve shunt improperly
Adjust the

8
(1) Common faults of electrical system and troubleshooting methods
fault cause maintenance
Open key switch no
voltage
Turn over the hoist
The key switch is not in contact
bolt
The connector is in poor contact
Loose battery connector
Step on the
accelerator pedal and
the forklift will not
walk
bolt
The connector is in poor contact
Bad contact of direction switch
The SCR speed regulating device is
faulty
The lifting motor does
not work
Contactor coil is open or disconnected
The lifting switch does not work properly
bolt
Poor contact of connector
The contactor main contact is burned
out
The lifting motor
work longtime
The lifting switch does not work properly
The light is not
working properly
Fuse is broken
Poor contact of connector
The bulbs
Speakers don't ring
Poor contact of connector
Poor contact of horn switch
speaker
Long horn ring
Horn switch contact long
The reversing buzzer
doesn't work
Buzzer bad
Bad contact of reversing switch
The line is not properly connected

9
(1) Transmission failure causes and troubleshooting methods
fault cause maintenance
Decline in efficiency
1. 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.
dredge
The spill
1. The gasket is damaged.
Replace gasket
2. Rubber parts are aged or damaged.
Replacement parts
3. Parts are damaged and cracked.
replace
(1) Multi-way valve failure causes and troubleshooting methods
fault
cause
maintenance
External leakage
The sealing part of the lip is worn
Replace seal ring
The valve stem seal is damaged
Replace stem or disc sub assembly
The sealing part of the lip is embedded
with foreign matter such as paint and
dust
Clean the paint and other foreign
matters embedded in the lip sealing
part, pay attention to not damage
the valve stem and sealing surface
O-ring damaged (cut ring)
Replace the O-ring seal
The sealing ring between valve discs is
aged and deformed
Replace the new sealing ring
There is scratch (new valve) or foreign
matter in the sealing plane of valve disc
Remove foreign matter or replace
valve disc
Valve body hole and sealing ring slot
hole different (new valve)
Replace the valve plates
Back pressure exceeds allowable value Check the loop and lower the return
oil pressure to the specified value
The bolts between plates are not evenly
stressed or tightened
Tighten the stud bolts with specified
torque
Stem cannot be reset
The control mechanism is not flexible
Check the control lever
The stem was jammed with dirt Clean valves, fuel tanks and
pipelines
The return spring is deformed or broken Remove the back cover for
inspection and replace the spring
Stem deformation caused by external
Refit stem or replace valve sub

10
force
assembly
Uneven installation surface, deformation
of valve body, resulting in stuck valve
Adjust the installation plane
Stem heavy drop in
neutral position
(leakage out of
tolerance in neutral
position)
Stem and valve hole wear, gap increase
serious internal leakage
Reinstall stem
Stem or orifice scratched and increased
internal leakage
Refit stem or replace valve sub
assembly
Stem not returned to neutral position
Check reversing mechanism
Overload valve or overload valve plug
and valve body seal is not tight
Check whether the O-ring is cut. If
damaged, replace it with a new
O-ring
There is serious leakage in the cylinder Check the cylinder piston seal for
damage
The groove size of valve body
decreases the length of out-of-tolerance
sealing oil
Replace the valve plates
hard steering
The oil is not clean, and the shunt valve
core or the shunt safety valve core is
stuck by foreign matter
Clean shunt valve core or shunt
relief valve core and fuel tank and
pipeline
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
Oil pump underflow Check why the oil supply system of
the oil pump is insufficient
Steering gear failure
Replace the steering gear
No action of oil
cylinder (low pressure
or no pressure)
Foreign matter is stuck between main
spool and seat of overflow valve or
overload valve
Clean valves, fuel tanks, pipelines,
etc
Damping hole plugging Hydraulic oil pollution is serious,
clean the hydraulic system
Abnormal wear of the cone spool Inspect for wear and replace relief
valve assembly
Pressure regulating spring deformation
Check spring quality
The adjusting screw of the relief valve is
loose
After adjusting the pressure, tighten
the nut according to the specified

11
torque
Oil pump failure
Replace the oil pump
Relief valve vibration
Dynamic and noise
There is air in the hydraulic system The system will be discharged after
repeated operation for a while
Pump suction air
Check oil absorption test of oil pump
Suction pipeline resistance is too large;
The suction side of the oil pump
produces negative pressure
Check the cause of negative
pressure
The oil suction filter is blocked
Clean the oil filter and filter the oil
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
The oil is not clean, so that the forward
control small spool is stuck
Clean valves, fuel tanks, pipelines,
etc
Wrong oil mouth
Switch the wrong oil connection
The oil is not clean, so that the forward
control small spool is stuck
Clean valves, fuel tanks, pipelines,
etc
Wrong oil mouth
Switch the wrong oil connection
(1) Gear pump failure causes and troubleshooting methods
fault
cause
maintenance
The pump won't take
in the oil
Or oil absorption is
not smooth
The oil suction filter has a small flow
area or is blocked by foreign bodies
Replace the filter with a suitable flow
area or clean the blocked filter
The liquid level in the tank is low The tank is filled with hydraulic fluid
as required
Oil pump installation position is too high;
Suction range exceeds specified
According to the suction range of the
oil pump, it is within 500mm
Oil temperature is too low, oil viscosity is
too high
Change oil or heat oil seasonally
Suction tubing too thin or too long, too
much resistance
Change the large diameter tubing,
shorten the length of suction tubing
The oil seal of the oil pump is damaged
and air is inhaled
Replace the new oil seal
Oil pump rotation is not correct or the
speed is too high
Change the oil pump rotation, make
the speed to the specified value

12
Oil suction side leakage Check the oil absorption part and its
seal, and replace the failed seal
The discharge side of
the pump does not
produce oil
If not, the pump is damaged
The relief valve is damaged or jammed
by stolen goods, and the oil flows back
to the tank from the relief valve
Check and repair pumps or replace
pumps
Check and repair relief valve or
replace relief valve, filter oil or
replace oil
The oil outlet of the oil
pump discharges oil
but the pressure
cannot rise
The side plate of oil pump is seriously
worn and the volume efficiency is too
low
Repair or replace the oil pump
The spool of the relief valve is severely
worn
Replace the new cone spool
The overflow valve is jammed by stolen
goods and loosely closed
Filter oil and remove dirt
The pressure regulation of the relief
valve is too low
Adjust the overflow valve to the
specified value
The oil suction takes in air Check whether the sealing ring at
the oil suction port is damaged
Low volume efficiency
of oil pump
The seal inside the oil pump is damaged
Replace seal ring
Lateral plate wear
Replace the side panel
The oil pump contains stolen goods or
too large clearance
Remove stolen goods and filter oil;
Replacement of new oil pump
The oil pump speed is too low or too
high
Make the oil pump run within the
specified speed range
Negative pressure 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 oil
absorption filter blockage; 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
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
The oil viscosity is too high and the oil
temperature is too low
Choose oil with proper viscosity
according to the season, or heat it
up

13
The coaxial of the pump shaft and prime
mover shaft is too large
Adjust the coaxiality of the two axes
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
Pressure is too high, speed is too fast,
side plate burns
Properly adjust the overflow valve;
Reduce the speed to the specified
value; Repair the pump
Oil viscosity is too high or internal
leakage is serious
Change the appropriate oil and
check the seal
The back pressure of oil return is too
high
Eliminate the cause of high return
back pressure
The fuel tank is too small for heat
dissipation
Increase the fuel tank
(1) Drive axle failure reasons and troubleshooting methods
fault
cause
maintenance
Very noise
Bolts connecting drive axle and frame
are loose
fastening
Frame nut loose
fastening
Wear or damage inside hub
replace
Half shaft spine wear
replace
Bad lubrication
filling
Rough ride
Loose wheel nut
fastening
The wheel deformation
replace
Wear or damage inside hub
replace
Bolts connecting drive axle and frame
are loose
fastening
The tire pressure is abnormal
fastening
(1) Other common faults and troubleshooting methods
fault cause maintenance
Abnormal sound
during exercise
Hydraulic oil, gear oil and other oil does
not meet the requirements
Fuel until required
The front and rear hub bearings are
loose and broken
After tightening the bearing and
locking the nut, retract about 1/8
turn, and the hub should be free to

14
turn. Fracture will renew the bearing.
Gearbox, gear, friction plate damage
update
Differential and cross shaft damaged
update
Fastener loosening
Pry tight

15
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.
B、oil hydraulic circuit

16
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
1. Main parts disassembly
A、Drive axle assembly removed
Figure 8: Hydraulic circuit

17
B、Pump station to remove
No. Code Name Specificatio
ns
Quant
ity
Remar
ks
1 GB/T 70.1-2000 Hexagon socket head
screws
M8×20 2
2 GB/T 93-1987
Elastic washer
Φ8 2
3 GB/T 97.1-2002
Flat washer
Φ8 2
4 E15A-01.7.2 Multi - way valve oil inlet
steel pipe
1
5 GB/T 5781-2000 Hexagon head bolts full
thread
M10×35 2
6 GB/T 93-1987
Elastic washer
Φ10 6
7 GB/T 95-2002 Flat washer Φ10 6
8 E15A-01.7.3
Gear pump fitting (14.5cc)
1
9 GB/T 5781-2000 Hexagon head bolts full
thread
M10×40 4
10 1U141213-190
The oil pump motor
7.7kw 1
11 E25A-01.31
The motor gasket
4
12 GB/T 5783-2000 Hexagon head bolts full
thread
M10×30 4
13 GB/T 93-1987
Elastic washer
Φ10 4
14 GB/T 96.1-2002
The big washer
Φ10 4
15 E15A-01.7.1 Lifting motor mounting seat
welded
1

18
NO. code name Specifications quantit
y Remarks
1 GB/T 6170-2000
Hexagonal nut
M12 6
2 GB/T 93-1987
Elastic washer
Φ12 8
3 1R342357
Traction motor
1
4 GB/T 5782-2000
Hexagon head bolt
M12×70 2
5 GB/T 97.1-2002
Flat washer
Φ12 8
6 GB/T 5786-2000 Hexagon bolts, fine thread,
full thread
M10×1.5×30 10
7 GB/T 97.1-2002
Flat washer
Φ10 10
8 GB/T 93-1987
Elastic washer
Φ10 10
9 DCS15H6
Gear box
1
10 REF10510-1 Internal combustion drive
axle assembly
1
11 6.5-10-10PR
The front wheel
2
12 E15A-01.5.1
Gear box pad
2
13 GB/T 5782-2000
Hexagon head bolt
M12×60 6