EKKO EPE20LI Series User manual

Service Manual
Pallet Truck
EPE20LI/EPE18LI/EP15SLI/EP18SLI series EP15LI
WARNING
You must understand the operation instructions in this
manual before using it.
Attention:
•Please check the last page of this document and all
the current product type identification on the name
plate.
•Keep it for future use

Table of Contents
1. Maintain list ..................................................................................................................................1
a. Main part overview....................................................................................................................1
b. Lubrication points......................................................................................................................3
c. Check and refill hydraulic oil .....................................................................................................4
d. Check electrical fuses ................................................................................................................5
2. Failure analysis..............................................................................................................................6
a. Common failure analysis ............................................................................................................6
b. Controller fault code display ......................................................................................................7
c. Troubleshooting for common faults...........................................................................................9
3. Wiring/circuit diagram................................................................................................................14
a. Circuit diagram........................................................................................................................14
b. Hydraulic circuit......................................................................................................................16
4. Disassembly of main parts...........................................................................................................17
a. Electromagnetic brake adjustment ............................................................................................17
b Disassembly of driving assembly .............................................................................................17
c. Disassembly of Electromagnetic brake .....................................................................................18
d. Drive internal gear, Bearing ...................................................................................................... 18
e. Operating handle assembly .......................................................................................................19
5. CURTIS Hand programmer ..........................................................................................................19

1
1. Maintain list
A. Main part overview
Table 1: Maintain list
Time interval
(Month)
1
3
6
12
Hydraulic system
1
Check the hydraulic cylinder and the piston for damage, noise and leakage.
•
2
Check the hydraulic connector for damage and leakage.
•
3
Check the Hydraulic oil level and refill if necessary.
•
4
Refill hydraulic oil after 12 Months or 1500 hours working time
•
5
Check and adjust the function of the hydraulic valve (1500kg/2000kg+0/+10%)
•
Mechanical system
6
Check whether the fork is deformed or broken.
•
7
Check whether the chassis is deformed or broken.
•
8
Check if all screws are fastened
•
9
Check whether the push rod is deformed or broken.
•
10
Check the gearbox for noise and leakage
•
11
Check whether the wheel rod is deformed or broken.
•
12
Lubricate steering bearings
•
13
Check and lubricate the pivot point
•
14
Grease nipple
•
Electrical system
15
Check whether the power wiring is damaged
•
16
Check The electrical connection
•
17
Detect Emergency switch function
•
18
Check the electric rive system for noise damage
•
19
Check the Electricity meter
•
20
Check if the correct fuse is used
•
21
Detection warming signal
•
22
Check the contactor
•
23
Check for leaks in the frame (Insulation test)
•
24
Check the function and wear of the drive controller
•
25
Check the electrical system of the drive motor
•
Brake system
26
Check the brake performance.replacethe brake dis or adjust the air gap if necessary
•
Battery
27
Check the battery voltage
•
28
Check theterminals for corrosion and damage and lubricate the terminals
•
29
Check whether the battery cover is damaged
•

2
Charger
30
Check whether the main cable is damaged.
•
31
Check the startup protection program during charging
•
Function
32
Check the horn function
•
33
Check the air gap of the solenoid valve
•
34
Detect Emergency braking
•
35
Detection of reverse braking and regenerative braking.
•
36
Check the Emergency reverse switch function
•
37
Check the steering function.
•
38
Check the lifting and lowering functions
•
39
Check the handle proximity switch function
•
Comprehensive
40
Check that all labels are clear and complete
•
41
Check the bearing wheel and adjust the height,replaceif it is worm.
•
42
Perform a test run
•

3
B. Lubrication point
Lubricate the marked points according to the maintenance list. The required grease specification
is DIN51825 standard Grease
Pic.1: Lubrication point
Shaft lubrication

4
Bearing lubrication
Butter filler
C. Check and refill hydraulic oil
According to the temperature, the
recommended hydraulic oil type as below:
Temperature
–
5℃~25℃
>25℃
Model
HVLP 32，
DIN 51524
HLP 46 ，
DIN 51524
Viscosity
28.8-35.2
41.4 - 47
Oil volume
0.4 L
Waste materials such as waste oil, Waste batteries or other materials must be processed and recycled in
accordance with national regulations .and if necessary, they must be handed over to recycling companies
for recycling.
The oil level should not be lower than the minimum amount of oil required to start the truck.
If necessary. Please add oil to the filling points.

5
D. Check electrical fuses
100Afuse
10Afuse
Table 2: Fuse specification
Specification
Fuse 1
10A
Fuse 01
100A

6
2. Failure analysis
A.Common failure analysis
If the truck still in problem, please follow the instruction in Chapter 6 in this manual
Table 3: Failure analysis
Malfunction
Cause
Solution
Goods can’t be
lifted up
Overload
Only lifting max capacity shown on
name plate
Battery discharge
Charge the battery
Lift fuse damaged
Check and replace the lifting fuse if
necessary
Low hydraulic oil level
Check and refill hydraulic oil if
necessary
Oil leakage
Check the sealing condition of the
oil cylinder
Suction leak
High oiliness
Reduce oiliness
The truck can’t
operate
Battery is charging
Fully charge the battery, then
unplug the main power plug from
the outlet
Battery disconnected
Connect the battery correctly
Fuse is damaged
Check and replace the lifting fuse if
necessary
Low battery
Charge the battery
Emergency switch is activated
Turn the emergency switch clockwise
The handle is not in operating area
Bend the handle to operating area.
If the truck breaks down and can’t be operated outside of the working area, Jack up the truck and place a
load handing device under the truck to ensure the safety of the truck, and then move the truck to of the
tunnel

7
B. Controller fault code display
Programmer display
Code
Failure phenomenon
Troubleshooting
BATTERY
DISCONNEC
T FAULT
4.5
Battery disconnected
1) Battery not connected
2) Poor connection to battery
terminals
BRAKE OFF FAULT
3.4
BRAKE OFF FAULT
1) Electromagnetic brake coil
shorted
2) Electromagnetic brake driver
open
BRAKE ON FAULT
3.2
BRAKE ON FAULT
1) Electromagnetic brake coil open
2) Electromagnetic brake driver
shorted
CURRENTSENSE
FAULT
4.1
CURRENTSENSE out of
range
1) Short in motor or in motor
wiring
2) Controller failure
EEPROM
CHECKSUM
FAULT
4.3
EEPROM fault
1) EEPROM failure or fault
HARDWAR
E FAILSAFE
4.2
Motor voltage out of
range
1) Motor voltage does not
correspond to Throttle request
2) Short in motor or in motor
wiring
3) Controller failure
HPD FAULT
3.5
HPD fault
1) Improper sequence of throttle
and KSI, push or inhibit inputs
2) Misadjusted throttle pots.

8
MAIN FAULT
2.3
Main contractor fault
1) Main contractor welded orstuck
open
2) Main contractor driver fault
MAIN OFF FAULT
2.1
Main contractor driver
off fault
1) Main contractor driver failed open
MAIN ON FAULT
2.4
Main contractor driver on
fault
1) Main contractor driver failed
Closed
OVERVOLTAGE
FAULT
1.5
Battery voltage too high
1) battery voltage >31V
2) Truck operating with charger
attached
3) intermittent battery connection
PRECHARGE
FAULT
3.3
Pre-charge fault
1) Controller failure
2）Battery low voltage
SPEED POT FAULT
1.3
Speed limited pot wiper out
of range
1) Speed limit pot wire(s)broken or
shorted
2) Speed limit pot wire(s)open
THERMAL FAULT
1.1
Over-/under-temperature cut
back
1) temperature>80℃or <-10℃
2) Excessive load on truck
3) Operating in extreme
environment
4) Electromagnetic brake not
releasing
THROTTLE FAULT
1.2
Pot low and/or pot wiper out
of range
1)Throttle input wire open or shorted
2) throttle port defective
3) wrong throttle type selected.
UNDERVOLTAGE
FAULT
1.4
Batter voltage too low
1) Batter voltage<17V
2) bad connection at battery or
controller

9
C.Troubleshooting for common faults
•Code 4.5 battery is not connected
1) Check if the truck cable terminal is loosened or not. Shown as below picture:

10
Use a multimeter to measure the resistance of the two-core plug-in on the controller.the step as
below Unplug 2-core plug in of the controller. Turn the
multimeter to 200Ω, and measure the resistance between the
two wires on the plug-in
Normally it should be
around 40 Ωifno
Resistance tested. There
is aproblem with the
brake circuit, or the
brake coil is short-
circuited
2) Use aMultimeter to measure the voltage of the battery under load
•Code 3.4 and 3.2 Electromagnetic brake cable issue or electromagnetic brake Failure
•Code 4.1Motor or motor wire shot circuit or Controller failure.
Remove the motor brake disc (the brake cable is still connected), Connect the motor M1 and M2
to the positive and negative pole of the battery, and observe whether the motor rotates
normally, If not, the motor failure,
If the motor rotates normally, the controller should be Failure.
•Code 3.5 and 3.1 Operationsequence failure
1. Under normal conditions of the interlock switch, use aMultimeter to measure the voltage
between J1-6 and negative pole on the 14-core plug-in of the controller. whenbend the handle to
operating handle. there is avoltage of about 24V.
2. If not, checkthe interlock switch,forexample you can observe whether the switch light on or
not, whether the signal pass through wire to controller.

11
•Code 4.2 Motor Voltage
Ifthemotorvoltagecan’t match the accelerator input, The motor or motor ring short circuit and controller
failure. Troubleshooting operations as below steps:
Please replace the controller If the voltage of the accelerator changes normally.
Quickdeterminecontroller failure.
Pull out the plug of the accelerator.If the controller still reports a fault after power on.Then there is fault
controller
Controller fault light is always on.Nowalking.Thenneed to check below step one by one:
1、Measure whether there is voltage output 0-5V from the accelerator (Between J1-1 and Negative pole)
2、2Short-circuit the J1-6 on the 14-pin plug of the controller with the 7th line on the 5th pin, and turn the
accelerator after restarting the truck to see if there is walking
3、The brake locked,Removethe brake (keep the brake cable connected)turnthe accelerator after
restarting the truck to see if it is normal
4、Remove the brake disc (keep the brake cable connected)ConnectedThe motor M1 and M2 directly to
the positive and negative poles of the battery. And observe whether the motor rotates normally. If not.
The motor Failure
5、After all above test finished and all result are normal, then it should be controller problem.
Turn the Multimeter to 24V DC, insert the pin into J1-
1(Accelerator 0-5v speed signal)2(Negative). Turn the
accelerator after Power-on. And observe whether the
Multimeter reading has a linear change of 0-5v voltage

12
2、手动下降
Here is the coil wiring of the lifting contractor (wire No.5 &
No.15) After power on, Press lifting button and then
measure whether there is a voltage about 24V from these
two places. If yes, and there is no sound of the contractor,
then should be Contractor Failure. If there is no 24
Voltage. Then check whether the metal button is well
connected
Theproduct can’t lift and lower down or oil cylinder lower itself.
Troubleshooting operations as below steps:
Hand lowering ：
Pressure adjustment
valve, note: This valve
should not be over-
adjusted to avoid
deformation of the
frame caused by
overload.
This is a descending valve.
If it descends slowly or
automatically, adjust the
tightness of the
descending chain, or check
the spool

13
Electric lowering：
No lifting. the principle is same as Hand lowering truck. Electric lowering adds a lifting Limit switch to
the lifting circuit. If there is no lift, in addition to the above steps for troubleshooting, you can check
whether the limit switch work properly or not 2、No lowering. can be check as below steps:
This is plug for drop solenoid valve. Use Multimeter to
Measure Whether there is a24V voltage between grays line
&black line when you press the down Button. If yes, it
should be the lowering valve body failure, replace it. If
there is no voltage. Please measure whether the down
button works properly or not.
The truck cannot power on, measure the battery voltage if normal or not.
Follow steps below:
1.
2. Observe whether the fuse is blown.
Battery charging:
1. Measure the voltage between these
two-part shown on the red circle. it is
for battery voltage. Check if the
voltage normal or not
2. If there is no voltage. Then pull the
battery plug out .and measure the
battery voltage from the plug
(positive pole & Negative pole.
When charging. This switch needs to be
turned on. If the battery fails to charge,
measure whether the battery voltage is
normal.

14
3 . Wiring/circuit diagram
A. Circuit diagram
Wiring diagram

15

16
B. Hydraulic circuit
Oil cylinder Lowering
Valve
Pressurecontrol
valve
Throttle valve
Hydraulic power unit (motor
and oil pump)
Tank
FIC.8: Hydraulic circuit
Hydraulic oil inspection
Exterior
Smell
Condition
Result
Clear and no color
Good
Good
Can be used
Transparent
Good
Mixed with other oil
Check the viscosity.
Y o u can use it
If qualified
Color changed like milk
Good
Mixed with air and
water
Separate water or replace
New hydraulic oil
Color becomes dark brown
Not
good
Oxidation
Replace New hydraulic oil
Color is clear but with small
black spots
Good
Mixed with other
particles
Use after filtering

17
The electromagnetic brake gap is about 25-35 CM, about
one
hundred yuan in thickness. It needs to be carefully
and
carefully adjusted to ensure that the gaps of the
three
adjustment surfaces are consistent, and the power will give
a
crisp sound.
Adjust nut
4. Disassembly of main parts
A. Electromagnetic brake adjustment
B. Disassemble ofDriving
Note: The electromagnetic brake can't be
properly connected when it is energized
in the free state. It needs to be pulled by
external force or installed.

18
C. Disassembly of Electromagnetic brake
D. Drivinginternal gears and bearings