EKKO EB12E-119 User manual

Service Manual
Walkie Electric Stacker
EB12E-119/138, EB12E-98Li, EB13E-119/138
EB13ES-145Li, EB13E-119/138/145 Li
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 point .................................................................................... 3
C. Check and refill hydraulic oil.................................................................. 5
D. Check electrical fuses ........................................................................... 6
2. Failure analysis........................................................................................ 7
A. Common failure analysis ....................................................................... 7
B. Controller fault code display .................................................................. 8
C. Troubleshooting for common faults........................................................ 9
3. Wiring/circuit diagram..............................................................................11
A. Circuit diagram .................................................................................... 14
B. Oil hydraulic circuit .............................................................................. 14
C. Hydraulic oil inspection........................................................................ 16
4. Disassembly of main parts ..................................................................... 17
a. Electromagnetic brake adjustment ...................................................... 17
bDisassembly of driving assembly......................................................... 17
c. Disassembly of electromagnetic brake ................................................ 18
d. Drive internal gears and bearing.......................................................... 18
e. Operating handle assembly................................................................. 19
f. The mechanical part of electric stacker ............................................... 19
g. Pump motor ....................................................................................... 20
5. CURTIS handle programmer manual content ........................................ 21

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
(2600lbs/3300lbs+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, replace the brake disk or adjust
the air gap if necessary
•
Battery
27
Check the battery voltage
•
28
Check the terminals for corrosion and damage and lubricate the
terminals
•

2
29
Check whether the battery cover is damaged
•
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, replace if it is
worm.
•
42
Perform a test run
•

B. Lubrication point
Lubricate the marked points according to the maintenance list. The required grease
specification is DIN51825 standard Grease.
Pic.1: Lubrication point
Tapered bearing
Butter filler

4
Sliding way in the mast
Chain Lubrication

5
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
1.5 L
Waste materials such as waste oil, 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.
Shaft lubrication

6
D. Check electrical fuses
Table 2: Fuse specification
Specification
Fuse 1
10A
Fuse 01
200A
200A Fuse
10A fuse

7
2. Failure analysis
A. Common failure analysis
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.
The battery is disconnected
Connect batteries correctly
Fuse failure
Check and replace the fuse
Low battery
Charge the battery
The emergency switch is activated
Turn the emergency switch
clockwise
The handle is not in normal working
Angle
First move the handle to the
braking area
If the truck breaks down and cannot 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.

8
B. Controller fault code display
Table 4: 1212P fault code
Programmer
display
Code
Failure phenomenon
Troubleshooting
BATTERY
DISCONNECT
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
HARDWARE
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.
MAIN FAULT
2.3
Main contractor fault
1) Main contractor welded or stuck
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

9
C. Troubleshooting for common faults
Code 4.5 battery is not connected
Step 1: Check if the truck cable terminal is loosened or not. Shown as below picture
Step 2: Use a multimeter to measure the cell voltage of the battery under load, Shown
below:
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
At the cable connection (including other fastening
point), check whether it is loosened

10
Code 3.4 and 3.2 Electromagnetic brake cable issue or electromagnetic brake failure
Use a multimeter to measure the resistance of the two-core plug-in on the controller.
Shown below
Code 4.1 Motor 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, there is a motor issue. If the motor rotates normally, the controller
should be issue.
Code 3.5 and 3.1 Operation sequence failure
1. Under normal conditions of the interlock switch, use a Multimeter to measure the
voltage between J1-6 and negative pole on the 14-core plug-in of the controller when bend
the handle to operating handle there is a voltage of about 24V.
2.If not, Check the interlock switch. For example, you can observe whether the switch light
is on or not whether the signal pass through wire to controller.
Code 4.2 Motor Voltage can’t match the accelerator input, The motor or motor ring short
circuit and controller failure. Troubleshooting operations as below steps.
Battery cell with load measurement, Cell voltage
drop should between 2-3V.
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 40Ω if no
resistance tested
there is a problem
with the brake
circuit, or the brake
coil is short-circuited

11
Please replace the controller If the voltage of the accelerator changes normally .
D. Quick determine controller 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. No walking. Then need 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. Short-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, Remove the brake (keep the brake cable connected) turn the
accelerator after restarting the truck to see if it is normal
4. Remove the brake disc (keep the brake cable connected) Connected The motor M1
and M2 directly to the positive and negative poles of the battery. And observe whether
the motor rotates normally. If not, is 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
The unit isn’t lifting up & lowering down or oil cylinder lowered itself, Troubleshooting
operations as below steps:
1.
2. Press the lower button. The red light of the lower solenoid valve signal should be
steady on.
If the oil cylinder is lowered after being lifted to the top.
Check whether the red mark of the lower solenoid valve
core is loose or not. If not clean or replace it .
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 pls check whether the metal button is
well connected
The red light is signal light of lowering solenoid valve. If this light is not
On, measure whether the connection between Line 16 and the
handle is well connected

13
3.If the truck can’t lift goods normally. For example. the truck with 1.5T loading capacity but
can only lift goods less than 1T, then we can adjust the oil pump pressure to reach 1.5T
loading capacity. But the operation must be carried out carefully.
P.S.: Don’t adjust the hydraulic pressure exceed the rated load. If so, the frame may be
deformed. The operating step as below:
Unscrew the pressure screw cap with a wrench.
Use an allen wrench to adjust the Hydraulic pressure

14
3. Wiring/circuit diagram
A. Circuit diagram

15

16
B. Oil hydraulic circuit
C. 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. You
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
Lifting cylinder
Lowering valve
Hydraulic power unit
(Motor or oil pump)
Oil tank
Throttle valve
Pressure controller
valve

17
4. Disassembly of main parts
A. Electromagnetic brake adjustment
B. Disassemble of Driving
Adjust nut
The electromagnetic brake gap is about 25-
35CM, 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.
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 brake and driving wheel
D. Driving internal gears and bearings
This manual suits for next models
6
Table of contents
Other EKKO Lifting System manuals