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