EKKO EB18E User manual

Service manual
Full-electric stacker
EB18E/EB20E
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
4.8 Adjustment 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 performance. 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. •

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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
Bearing shaft

4
d. Check electric fuses
Table 2: fuse specification
specification
Fuse 1 10A
Fuse 01 200A
200A fuse
10A fuse

5
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
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.

6
b.Fault code display
code English name 中文名称
12 Controller Overcurrent 控制器过流
13 Current Sensor 电流传感器故障
14 Precharge Failed 预充失败
15
Controller Severe
Undertemp
控制器温度过低
16 Controller Severe Overtemp 控制器过温
17 Severe B+ Undervoltage B+欠压
17 Severe KSI Undervoltage KSI 欠压
18 Severe B+ Overvoltage 过压
19 Speed Limit Supervision 最大速度受限
1A Travel Control Supervision 行走控制监控异常
22
Controller Overtemp
Cutback
控制器过温导致性能降低
23 Undervoltage Cutback 控制器欠压导致性能降低
24 Overvoltage Cutback 控制器过压导致性能降低
25 Ext 5V Supply Failure 5V电源故障
26 Ext 12V Supply Failure 12V电源故障
28 Motor Temp Hot Cutback 电机过热导致性能降低
29 Motor Temp Sensor 电机温度传感器故障
31 Main Driver 主接触器驱动异常
32 EM Brake Driver 电磁刹车驱动异常
35 Pdoportional Driver 比例阀驱动异常
36 Encoder Fault 电机编码器故障
37 Motor Open 电机开路
38 Main Contactor Welded 主接触器主触点粘连
39
Main Contactor Did Not
Close
主接触器不吸合
42 Throttle Input 加速器输入异常
46 NV Memory Failure 控制器存储异常
47 HPD Sequencing （上电）操作顺序故障
47 EMER Rev HPD 紧急反向操作顺序故障
49 Parameter Change 参数修改故障
4A EMR Switch Redundancy 紧急反向开关冗余异常
51 User_1_Fault （上电）紧急反向有效
52 User_2_Fault （上电）互锁有限
53 User_3_Fault BMS 报文超时
54 User_4_Fault 锂电故障
55 User_5_Fault 锂电过温告警
56 User_6_Fault 锂电过温故障
57 User_7_Fault 锂电漏液告警
58 User_8_Fault 锂电漏液故障

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59 User_9_Fault 前拓CAN仪表通讯故障
61 User_10_Fault 前拓CAN仪表低电量
62 User_11_Fault 前拓CAN仪表继电器开路
68 VCL Run Time Error 程序或参数设置异常
72 PDO Timeout PDO超时
73 Stall Detected 电机堵转
77 Supervision （外部）监控故障
87
Motor Characterization
Error
电机匹配故障
88 Encoder Pulse Error 电机编码器脉冲异常
89 Parameter Out Of Range 参数超限
92 EM Brake Failed To Set 电磁刹车松闸失败
94 Emer Rev Timeout 紧急反向超时
99 Parameter Mismatch 参数不匹配
A1 Driver 1 Fault 驱动1故障（下降电磁阀）
A2 Driver 2 Fault 驱动 2故障 （电磁刹车）
A3 Driver 3 Fault 驱动3故障（主接触器）
A4 Driver 4 Fault 驱动4故障
A5 Driver 5 Fault 驱动 5故障（起升接触器）

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3、Circuit/circuit diagram
a、Circuit