EKKO Walkie EB16EA User manual

Service manual
Full-electric stacker
EB16EA
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.

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 .......................................................................................................................................................................................1
. 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
4.8Adjustment method of chain tightness...........................................................................................24
5. CURTIS handhold unit......................................................................................................................23

1
1. Maintain List
a. Main part overview
Table 1 : Maintain List
Time Interval
（Month）
1 3 6 12
Hydraulic System
1 Check hydraulic cylinder and piston for damage, noise and leakage. •
2 Check hydraulic connector for damage and leakage. •
3 Check hydraulic oil level and refill it if necessary. •
4 Refill hydraulic oil after 12 months or 1500 hours. •
5 Check and adjust the function of the hydraulic value. (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 whether all screws are fastened. •
9 Check whether the push rod is deformed or damaged. •
10 Check the gearbox for noise and leakage. •
11 Check whether the wheel rod is deformed or damaged. •
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 Check the emergency switch function. •
18 Check electric rive system for noise damage. •
19 Check electricity meter. •
20 Check whether the correct fuse is used. •
21 Detection warning signals. •
22 Check the contactor •
23 Check the leak in the frame(insulation test) •
24 Check the function and wear of the drive controller •
25 Check the electric system of the drive motor. •
Brake system
26 Check the brake ferformance. Replace the brake disc or adjust the air gap if necessary. •
Battery
27 Check the battery voltage. •
28 Check the terminal for corrosion and damage and lubricate the terminal. •
29 Check whether the battery cover is damaged. •
Charger
30 Check whether the main cable is damaged. •
31 Check startup protection program in the process of charging. •

2
Function
32 Check the horn function. •
33 Check air gap of solenoid value. •
34 Detect emergency braking. •
35 Detect the reverse braking and regenerative braking. •
36 Check the emergency reverse switch function. •
37 Check steering function. •
38 Check lifting and lowering function. •
39 Check the handle proximate switch function. •
Comprehensive
40 Check whether all labels are clear and complete. •
41 Check the bearing wheels and adjust the height, replace if it is worn. •
42 Perform a test run. •
b.Lubrication point
Lubricate the marked point according to the maintain list. The required grease specification is the DIN 51825
standard grease.
Picture.1: Lubrication point
Door frame
guide rail and
contact surface.
Chain

3
c. Check and refill hydraulic oil
According to the temperature, we recommend the type of hydraulic oil as following:
Temperature –5℃~25℃ >25℃
Model HVLP 32，
DIN 51524
HLP 46，
DIN 51524
Viscosity 28.8-35.2 41.4 - 47
Oil volume 14~15L
Wasted material such as waste oil, waste battery or other material must be processed and recycled in accordance
with the national regulation. And if necessary, they need to be handed over to recycle companies to recycle.
The oil level should not be lower than the minimum amount of oil required when the vehicle start out.
If necessary, please add the oil to the filling points.
Idler wheel
&guide rail
contact surface
Bearing shaft

4
d.Check electric fuses
Table 2:
fuse specification
specification
Fuse 1 10A
Fuse 01 200A
2. Malfunction Analysis
a.Common malfunction analysis
If the vehicle still in problems, please follow the chapter 6 in this manual.
Table 3: Malfunction analysis
Malfunction
Cause
Solution
Goods can’t be lifted up
Over load Only lift the maximum capacity show
on nameplate.
Battery discharge
Charge the battery
Lift fuse damaged
Check and replace the fuse
Low hydraulic oil level Check and refill hydraulic oil
Oil leakage Detect the sealing condition of
oil cylinder.
Suction leak High oiliness Reducing oiliness
200A Fuse
10A Fuse

5
The vehicle can’t be
operated
Battery is charging
Full charge the battery, then unplug
the main power plug from the outlet.
Battery disconnected Connect battery correctly.
Fuse malfunction Check and replace the fuse.
Low battery Charge the battery
Emergency switch is activate Unplug the emergency switch
The handle is not in operating area
Move the handle to the braking
area.
The vehicle drive to one
direction Accelerator and connector are damaged Check the accelerator and connector
The vehicle move slowly
Battery discharging
Check the battery condition on the
discharge monitor
The electromagnetic brake has been
activated. Check the electromagnetic brake
The handle wiring harness isn’t connected
or damaged
Check the handle wiring harness and
connector
At the 400mm altitude, the speed decreases
and the sensor fails Check the sensor
Electric system overheated Stop using and cool the vehicle
The thermal sensor fails
Check, replace the thermal sensor if
necessary
The vehicle suddenly
start
Controller damage Change the controller
The accelerator has not moved back to the
middle place. maintain or replace accelerator
If the vehicle malfunction and can’t operate outside work area, please hold up the vehicle, and place a load
handing device under the vehicle and make sure it is secure , then move the vehicle from channel.
b.Fault code display
1、Steering fault code

6
code malfunction name Possible cause
12 Controller Overcurrent
控制器过流
1.steering motor wiring short
2.controller fail
13 Current Sense Fault
电流传感器故障
1.controller fail
14 Precharge Fault
预充电故障
1.controller fail
15 Controller Severe Undertemp
控制器严重低温
1.the controller runs in ultra-low temperate environment
2.temperature sensor damage
16 Controller Severe Overtemp
控制器严重过温
1.vehicle overload
2.the controller runs in ultra-high temperate environment
3.the controller is improperly fixed
17 Severe Undervoltage
严重欠压
1.battery or battery cable connection is faulty
2.there are other large loads attached to the battery
3.battery no power and wrong model
18 Severe Overvoltage
严重过压
1.in regen, the battery and battery cable resistance is too high
2.battery cable disconnected during the regen procedure.
21 Motor Temp Hot Cutback
电机温度过高削减
1.vehicle overload
2.the controller runs in ultra-high temperate environment
22 Controller Overtemp
控制器过温
1.vehicle overload
2.the controller runs in ultra-high temperate environment
3.the controller is improperly fixed
23 Motor Polarity Fault
电机极性故障
1.the motor polarity is reversed
2.position feedback device has reversed polarity
24 5V Output Failure
5V 输出故障
1.5V output overload
2.controller failure
31 Main Driver Fault
主接触器故障
1.the internal relay coil is damaged
2.the internal relay drive open or short
32 Relay Welded
继电器粘连
1.the internal relay adhesion
2.controller failure
33 Relay Did Not Close
继电器未吸合
1.the internal relay receives close command but fails to close
2.internal relay patch oxidation
34 Hardware Fault
硬件故障
1.a hardware fault was detected
2.motor voltage is out of range
3.IIC communication is lost
4.power tube short circuit
35 Fault Output Failed
故障输出失效
1.the fault output cable is incorrect connected
2.controller failure
36 Motor Stalled
电机堵转
1.Motor stalled
2.the encode of the steering motor fails or the cable is disconnected
3.the steering motor is disconnected.
4.parameter do not match the motor
37 Motor Open
电机开路
1. steering motor wiring open
2.the wrong motor connection
3.controller failure

7
38 Motor Short 1.steering motor wiring short
41 Command Analog1 Out of
Range
模拟量 1指令超出范围
1.command analog input 1(J1-6) is out of range
2.low command (J1-14)out of range(for resistive type)
3.parameter settings are incorrect.
42 Command Analog2 Out of
Range
模拟量 2指令超出范围
1.command analog input 2 (J1-13)out of range
2.analog1 and analog 2 fail to be cross- checked
3.parameter settings are incorrect.
43 Feedback Analog1 Out of
Range
模拟量 1反馈超出范围
1.feedback analog input 1(J1-11) is out of range
2.parameter settings are incorrect
44 Feedback Analog2 Out of
Range
模拟量 2反馈超出范围
1.feedback analog input 2(J1-3) is out of range
2.analogJ1-11 and analog J1-3 fail to be cross-check
3.parameter settings are incorrect
45 Parameter Change Fault
参数更改故障
1.parameter change,need to restart.
2.parameter are restored to default
46 EEPROM Failure
存储器故障
1.memory parameter verification calculation error
2.controller failure
47 Encoder Fault
编码器故障
1.the encode date exceeds the allowable range.
2.orthogonal encoder A phase or B phase open
3.polarity encoder B phase open
53 Home Position Not Found
没找到 Home 位置
1.Home switch failure
2.installation or cable connection error
62 Communication Fault
通讯故障
1.communication lost during walking
63 Communication Lost
通讯丢失
1.Rx(J1-8) cable connection error
2.there is a handheld programmer being used on the walk controller.
71 Software Fault
软件故障
1.app failure
2.controller failure
73 Following Error
跟随故障
1.parameter setting is incorrect
2.position feedback device failure
3.steering motor failure
75 Parameter Conflict
参数冲突
1.parameter setting and other parameters conflict
2、Fault code of walking controller

8
code
Malfunction name
Possible cause
1 Controller Overcurrent 1，motor external U,V or W connection short circuit
2，motor parameter isn’t match
3，controller malfunction
2 Current Sensor Fault
1，motor U,V,W through the stator on the car body short circuit,resulting in
leakage.
2，controller malfunction
3 Precharge Failed
1，the positive end of the capacitor is connected with negative load,so that the
capacity can not be charged normally
4 Controller Severe
Undertemp 1，the operating environment of the controller is too harsh
5 Controller Severe
Overtemp 1，the operating environment of the controller is too harsh 2，vehicle overload
3，controller installation incorrect
6 Severe Undervoltage 1，battery parameter setting mistake
2，power consumption for non-controller system
3，excessive battery impedance
4，the battery is disconnected
5，the fuse is not connected ,or the main contactor is not connected.
7 Severe Overvoltage
1，battery parameter setting is incorrect.
2，excessive battery impedance
3，battery connection disconnected during regenerative brake
8 Controller Undertemp
Cutback 1、the controller operate under the restricted conditions 2、the operating environment of the controller is too harsh
9 Controller Overtemp
Cutback 1, the operating environment of the controller is too harsh 2，vehicle overload
3，controller installation incorrect
10 Undervoltage Cutback 1，low battery
2，battery parameter setting incorrect
3，non-controller system runs out of power
4, excessive battery impedance
5, the battery disconnected
6，the fuse is not connected ,or the main contactor is not connected.
11 Overvoltage Cutback 1，the regenerative braking current increase the battery voltage during the
regenerative braking
2，battery parameter setting incorrect
3，excessive battery impedance
4，battery connection disconnected during regenerative brake
12 +5V Supply Failure
1，the impedance of external load is too low
13 Digital Out 6 Failure
1，the impedance of external load is too low
14 Digital Out 7
Overcurrent 1，the impedance of external load is too low
15 Motor Temp Hot
Cutback 1，the motor temp reaches or exceeds the alarm temp set by program,
resulting in reduced current output
2，motor temp parameter setting incorrect

9
3，If the motor does not use a temperature sensor, the programming
parameters “Temp Compensation and Temp Cutback” must be set to OFF.

10
16 Motor Temp Sensor
Fault 1，motor temp sensor connects incorrectly 2，If the motor does not use a temperature sensor, the programming
parameters “Temp Compensation and Temp Cutback” must be set to OFF.
17 Coil 1 Driver Open/Short 1，load connection to be open or short
2，the connection pin is dirty
3，wrong connection
18 Main Open/Short 1，load connection to be open or short
2，the connection pin is dirty
3，wrong connection
19 Coil2 Driver Open/Short 1. load connection to be open or short
2. the connection pin is dirty
3. wrong connection
20 EMBrake Open/Short 1，load connection to be open or short
2，the connection pin is dirty
3，wrong connection
21 Coil3 Driver Open/Short 1，load connection to be open or short
2，the connection pin is dirty
3，wrong connection
22 Coil4 Driver Open/Short
1，load connection to be open or short
2，the connection pin is dirty
3，wrong connection
23 PD Open/Short 1，load connection to be open or short
2，the connection pin is dirty
3，wrong connection
24 Encoder Fault 1，Motor encoder failure
2，wrong connection
25 Motor Open 1，Motor Open phase
2，wrong connection
26 Main Contactor Welded
1，main contactor contact fusion
2，motor U or V disconnected or missing phase.
3，the circuit capacitor connected to the B+ terminal is charged
27 Main Contactor Did Not
Close 1，main contactor is not closed 2，primary contactor junction oxidation, melting, or unstable connection
3，the capacitor is charged by external device.
4，the fuse is disconnected
28 Throttle Wiper High 1，the output voltage of accelerator potentiometer is too high.
29 Throttle Wiper Low
1，the output voltage of accelerator potentiometer is too low.
30 Pot2 Wiper High 1，pot 2 output voltage is too high
31 Pot2 Wiper Low 1，pot 2 output voltage is too low
32 Pot Low Overcurrent 1，pot impedance is too low
33 EEPROM Failure
EEPROM 1，fail to write the EEPROM storage. This may caused by VCL writing to
EEPROM storage, or by CAN BUS,or by a parameter error programmed into
the controller after the programmer parameters are adjusted.

11
34 HPD/Sequencing Fault 1，key start,interlock, orientation and accelerator input sequence are
incorrectly set.
2，wiring,switch key,interlock, orientation or accelerator input failure.
35 Emer Rev HPD 1，the emergency reverse operation is over,but the accelerator, forward and
reverse input and interlock have not been reset.
36 Parameter Change Fault 1，In order to ensure the safety of the vehicle, certain parameter changes must
be reactivated after the key switch.
38 VCL RunTime Error
1，the VCL code timed out
39 External Supply Out of
Range 1，the 5Vnad 12vV source currents are too large or too small 2，parameter error in Checking Menu，such as“ExtSupply Max”,“Ext Supply
Min”
40 OS General 1，internal controller failure
41 PDO Timeout 1，CAN PDO message receiving time exceeded the PDO time limited.
42 Stall Detected motor stalling
2，motor encode failure
3，wrong wiring connection
4，Power supply of the input motor encoder is faulty
43 Motor Characterization
Fault 1, in the motor matching process of modern code comparison:
0 = normal
1= The controller receives the encoder number,
But the impulse quantity is undefined.Please hand set
Buy pulse value
2= Motor temperature sensor failure
3= High temperature reaction failure of motor
4= motor overheating reaction failure
5= Low temperature reaction failure of motor
6= low voltage response failure
7= high pressure reaction failure
8= The controller cannot detect the encoder message
Alpha, channel signal is down
9= Motor parameter setting exceeds the range
44 Motor Type Fault 1. The motor type parameter value is out of range
45 VCl/OS Mismatch 1. The VCL program in the controller does not match the OS program
46 EM Brake Failed to Set 1. The vehicle is still moving after the electromagnetic brake command is set.
2, electromagnetic brake braking force is too small
47 Encoder LOS (Limited
Operating Strategy)
1. Due to motor blocking or encoder
The failure causes the restricted operating state to be
The activation
2. Wrong wiring
3. Traffic jams
48 Emer Rev Timeout 1. The emergency reverse timeout is activated because the EMR Timer
expires
2. The emergency reverse switch is always in the On position
49 Illegal Model Number
1. The controller model cannot be identified
2. Hardware and software do not match each other

12
3. The controller is damaged
50 Dualmotor Parameter The Enable parameter of dual motors is set to ON, and the control Mode
selection parameter is not set to (Speed Mode Express) or 1 (Speed Mode).

13
3. Circuit/circuit diagram
a. Circuit

14
b. Hydraulic circuit
Hydraulic circuit diagram（with lateral）

15
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 good 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
4. Disassembly of main parts
a. electromagnetic brake adjustment
Adjusting nut
Electromagnetic brake clearance is about
0.25-0.35mm, about the thickness of a piece of
paper.Need to be adjusted carefully repeatedly,
ensure that three adjustment surface clearance is
consistent, electricity will give out a crisp sound.
Note: electromagnetic brake
can't pull properly when it is
powered on in free state, it
needs external force or
installation to pull

16
c. Drive the disassembly diagram
Electromagnetic brak
Drive motor
Steering
motor
Driving whee
Gear case

17
d. Handle assembly
Accelerator button
Belly switch
Horn button
Accelerator
Tortoise speed switch

18
e. Dismantling of frame and door frame
f. Mechanical part of door frame
The clearance between
the door frames is
adjusted by adjusting the
tightness of the adjusting
screws
After removing the axle seat
cover and bolt, the door
frame can be separated
from the frame. Note: the
body and door frame shall
be fixed with external
objects during disassembly
to avoid safety accidents in
the process of disassembly.
bolt