EKKO EP20LI Series User manual

EP20LI
Service Manual
Warning
You must read the operation instruction before
using the manual:
•Please check the last page of this
document and all the current product
type identification on the nameplate.
•Keep it for future use.

目录
1. 维修清单 .............................................................................................Error! Bookmark not defined.
a. 主要零部件概述............................................................................................................................... 0
b. 润滑点 ............................................................................................................................................. 3
c. 检查再加注液压油 ........................................................................................................................... 4
d. 检查电器保险丝...............................................................................Error! Bookmark not defined.
2. 故障分析 .............................................................................................Error! Bookmark not defined.
a. 常见故障分析................................................................................................................................... 5
b. 仪表故障代码显示 ...........................................................................Error! Bookmark not defined.
3. 接线/电路图.........................................................................................Error! Bookmark not defined.
a. 电路图 .............................................................................................Error! Bookmark not defined.
b. 液压回路........................................................................................................................................ 13
4. 主要零部件拆解 ..................................................................................Error! Bookmark not defined.
a. 电池刹车调整...................................................................................Error! Bookmark not defined.
b驱动总成拆解...................................................................................Error! Bookmark not defined.
c. 驱动刹车拆解...................................................................................Error! Bookmark not defined.
d. 驱动内部齿轮 轴承 .........................................................................Error! Bookmark not defined.
e. 手柄总成..........................................................................................Error! Bookmark not defined.
f. 车架分解..........................................................................................Error! Bookmark not defined.
g. 泵站电机..........................................................................................Error! Bookmark not defined.
5. CURTIS 手持单元 ............................................................................................................................. 14
1Regular maintenance
Only qualified and trained personnel should perform maintenance work on this

1
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. Maintain List
Time Interval
（Month)
1
3
6
12
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 system
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
•
Electric System
3.1
Check whether electrical wiring is damaged
•
3.2
Checking Electrical Connections
•
3.3
Check emergency switch function
•
3.4
Check electric drive system for noise and damage
•

2
3.5
Detection meter
•
3.6
Check that the correct fuse is used
•
3.7
Check alarm system and safety devices
•
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 driving 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 startup protection program during charging
•
monolithic component
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
•

3
1.2 Lubrication points
Lubricate marked points according to maintenance list. Required grease specification: DIN 51825
standard grease.
Figure 1: Steering drive gear
Drive the oil injection
port

4
1.3Check and refill hydraulic oil
Recommended hydraulic oil model according to temperature:
Temperature
–5℃~25℃
>25℃
Model
HVLP 32，
DIN 51524
HLP 46，
DIN 51524
Viscosity
28.8-35.2
41.4 - 47
Oil volume
2L-2.5L
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.
1.4Check the electrical fuse
Bearing shaft

5
10A fuse
fuse specification
specification
Fuse 1
10A
Fuse 01
200A
2. Malfunction Analysis
If the vehicle continues to malfunction, follow the instructions in the manual.
2.1Common fault analysis
Fault
Cause
Processing method
Vehicles
cannot move
The battery connector is not
connected
Check the battery connector and
connect it if necessary
The electric lock switch is in
"OFF" position
The electric lock switch is placed in
the "0" position
The emergency stop switch is
not on
Turn on the emergency stop switch
Battery running out
Check the charging status of the
battery and recharge it if necessary
The forklift is charging
Interrupt charging process
Fuse damage
Check fuse
Cargo cannot
be lifted
The vehicle is not running
Follow the procedure listed in the
"Vehicle cannot Move" fault
There's too little hydraulic fluid
Check hydraulic oil
Fuse damage
Check fuse
Load overweight
Note rated load
The lift micro switch is in bad
Check fuse
200A fuse

6
contact or damaged
Goods cannot
be lowered
Dirty oil clogs the control valve
Check the hydraulic oil and clean the
control valve and replace the
hydraulic oil if necessary
The descent solenoid valve is
not open or damaged
Check the drop solenoid or replace it
can't stop when
go up
The lifting micro switch
is damaged
Cut off the power supply and
replace the lifting micro
switch
Moving in one
direction
Contact between micro
switch and connecting
cable is not good
Check the micro switch and
connecting cable in the control
handle
Traffic moves
slowly
The battery power is low
or the corresponding
cable is in poor contact
Check the battery indicator and
corresponding cables
The vehicle
started
suddenly
Controller damage
Replacing a Controller
Control forward and backward
handle is not reset
To restore or replace
2.2 Display of fault code
Table 4:1212P fault codes
Programmer display
code
The fault
phenomenon
fault diagnosis
BATTERY DISCONNECT
FAULT
4.5
Battery disconnection
1) Battery disconnection
2) Poor contact of battery end
BRAKE OFF FAULT
3.4
Brake closing fault
1)Electromagnetic brake coil short
circuit

7
2)Electromagnetic brake drive open
circuit
BRAKE ON FAULT
3.2
Brake opening failure
1) Electromagnetic brake coil open
2)Electromagnetic brake drive short
circuit
CURRENTSENSE FAULT
4.1
Current detection fault
1) Short circuit of motor or motor
wiring
2)The controller is faulty
EEPROM CHECKSUM
FAULT
4.3
EEPROM failure
1) EEPROM failure or invalid
HARDWARE FAILSAFE
4.2
Motor voltage is out of
range
1) Motor voltage cannot match
accelerator input
2) Short circuit of motor or motor
matching ring
3) The controller is faulty
HPD FAULT
3.5
HPD fault
1) Accelerator, key switch, promotion
or prohibition
Input several actions out of order
2) Wrong adjustment of accelerator
MAIN FAULT
2.3
The main contactor is
faulty
1) Main contactor adhesion or open
2) Main contactor coil drive error
MAIN OFF FAULT
2.1
Main contactor coil drive
'off' failure
1) Wrong opening of main contactor coil
MAIN ON FAULT
2.4
Main contactor coil drive
'on' failure
1) The main contactor coil is closed
incorrectly
OVERVOLTAGE FAULT
1.5
Battery voltage is too
high
1) Battery voltage >31V
2) The charger is still connected when
the vehicle is running
3) Poor battery contact
PRECHARGE FAULT
3.3
Pre charge failure
1) The controller is faulty
2) Low battery voltage
SPEED POT FAULT
1.3
The speed limiting
potentiometer is faulty
1) Open or short circuit connection of
speed limiting potentiometer
2) Open speed limiting potentiometer
THERMAL FAULT
1.1
Over/under temperature
cut-off
1) Temperature >80℃or <-10℃
2) Vehicle overload
3) Operate in extremely harsh
environment

8
4) The electromagnetic brake is not
released normally
THROTTLE FAULT
1.2
Potentiometer slip end
or low
1) Accelerator input is open or short
2) Accelerator potentiometer failure
3) Wrong selection of accelerator type
UNDERVOLTAGE FAULT
1.4
The terminal voltage is
out of range
1) Battery voltage <17V
2) The battery or controller is
not connected properly
Methods for troubleshooting common faults.
Code 4.5 The battery is not connected.
1. Check whether the fastening of cable terminals of the car body is loose, as shown below:
1、Use a multimeter to measure the monomer voltage of the battery with load. The specific operation is
shown as follows:
Check whether the cable connection (including other secured parts) is
loose
Cell with load measurement, cell voltage drop should be
between 2 and 3V