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）

8
3、Circuit/circuit diagram
a、Circuit

9
B、Hydraulic circuit

10
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
Note: electromagnetic brake
can't pull properly when it is
powered on in free state, it
needs external force or
installation to pull

11
B、Drive the disassembly diagram
Electromagnetic brak
drive motor
driving wheel gear case

12
C、Handle assembly
D、Dismantling of frame and door frame
Accelerator button
Belly switch
horn button
accelerator
Tortoise
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 w
ith external
objects during disassembly
to avoid safety accidents in
the process of disassembly.
bolt

13
E、Mechanical part of door frame
The clearance between
the door frames is
adjusted by adjusting the
tightness of the adjusting
screws
The door frame can
be raised by
loosening the
adjusting screw

14
F、Frame mechanical part
Pressure regulation diagram
The relief value is
used to adjust the
oil pressure, which
should be adjusted
to avoid excessive
pressure causing
damage to the car
body

15
5、CURTIS Hand held unit
Precautions for operation:
The attention function of the hand-held unit is to facilitate vehicle inspection and maintenance. It is not
allowed to adjust the controller parameters without the approval of the vehicle manufacturer, so as to avoid
vehicle and personal safety accidents.
The hand-held unit will automatically save the modification parameters, just need to close the key switch,
restart.
The CURTIS hand held unit can be connected in the event of a controller power or power failure
Vehicle fault reading process:
1. After connecting the hand held unit with the controller, open the key switch
2. From the menu list of CURTIS hand held units, find: Faults...
3. When the vehicle is running and the hand-held cursor flashes, there will be English fault content, which
can be interpreted by referring to the fault code table
Vehicle signal detection:
1. After connecting the hand held unit with the controller, open the key switch
2. According to the menu list of CURTIS hand held unit, find: Monitor......
3. According to requirements, open the corresponding sub-item of the detection menu, run the vehicle, and
observe the change of the hand-held value.
CURTIS Contents of hand held unit menu:
The Curtis 1313 hand held programmer is used to configure the Curtis electric control system. Through this
programmer, you can adjust and save the set parameters, real-time monitoring of controller data and fault diagnosis
The programmer has two interfaces, one is used to
communicate with the electric control, the other is used to communicate with the PC, and the programmer has a battery
box and a memory card slot
Warning: The control system can affect the vehicle's
acceleration rate, deceleration rate, hydraulic
system and braking. A dangerous situation can
occur if the vehicle control system is not
programmed correctly or exceeds safety. Only the
vehicle manufacturer or an authorized service agent
can program the control system

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The programmer is powered on
The connection line of the hand held programmer can be connected to the controller by inserting the programming port
of the controller. After connecting the controller, the hand held programmer will be powered on automatically and the
control information will be displayed on the programmer.

17
The main menu consists of nine sub-menus, and each sub-menu is
displayed with a specific icon. Each item in the sub-menu is
arranged by hierarchy.
Some menus contain only one item of information, but most menus contain more than one item of information, and
open each item folder to access the next level of sub menus. Expand the table through the grid option, enter a group of
execution commands through the dialog box option, and return to the upper menu regardless of the interface by pressing
the left direction button.
The names of all nine sub menus are shown in bold on the main menu and below the icon. When entering the stepped
menu, the name of the sub menu or the path you are in is displayed at the top of the screen.
The function keys
Since the function of the three keys is determined by the
specified content, the three keys are blank.At any given time,
the function of the button is displayed on the LCD screen
above.
Direction arrow key
The displayed information can be selected up, down, or left
by four directional buttons.
+ / - buttons
You can add and subtract parameters by using these two
keys.In addition, "+" can mean "Yes" and "-" can mean
"No".In some cases, it can also be used as a scrolling option.
Power key
When the programmer inserts a controller that has been
powered on, the programmer does not have to press the
power button to use it. The programmer will start up
automatically.When you hold it down for a few seconds, the
programmer will prompt you whether to turn it off. You can
decide whether to turn it off by selecting the "Yes" and "No"
represented by the function key.After closing the
programmer, press for a few seconds and the programmer
will restart.
Collect keys
There are two ways to enter the Favorites menu. You can
enter Favorites from the main menu or press this key

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Nine menus
Fault Diagnosis menu
On the main menu, Select Diagnostics and press Select to access the Fault diagnosis menu. The Fault diagnosis menu
contains Present Errors current faults and Fault History historical faults
Note: Sometimes a fault caused by a temporary event captured in the circuit is not a system fault. You can determine
whether the fault exists by restarting the system and observing whether the fault disappears automatically.
The historical faults folder lists all faults encountered after the last historical fault is cleared. By clearing the fault
content in the entire folder, you can record the historical faults again.
Programming menu
On the main menu, Select The Programming icon and press Select to access the menu. Save and restore parameter
Settings files (.cpf files) through programming menus
Clear all is used to Clear historical
fault folders. A
function key is
highlighted only when there are
historical failures in the historical
failures folder and grayed out when
there are no historical failures.