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