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Service Manual
Pallet Truck
EPE20LI/EPE18LI/EP15SLI/EP18SLI series EP15LI
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
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Table of Contents
Related Manuals for EKKO EPE20LI Series
Summary of Contents for EKKO EPE20LI Series
- Page 1 Service Manual Pallet Truck EPE20LI/EPE18LI/EP15SLI/EP18SLI series EP15LI 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.
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Page 2: Table Of Contents
Table of Contents Maintain list ..........................1 Main part overview ........................1 Lubrication points ........................3 Check and refill hydraulic oil ..................... 4 Check electrical fuses ........................ 5 Failure analysis ..........................6 Common failure analysis ......................6 Controller fault code display ...................... 7 Troubleshooting for common faults ................... -
Page 3: Maintain List
Maintain list A. Main part overview Table 1: Maintain list Time interval (Month) Hydraulic system • Check the hydraulic cylinder and the piston for damage, noise and leakage. • Check the hydraulic connector for damage and leakage. • Check the Hydraulic oil level and refill if necessary. •... - Page 4 Charger • Check whether the main cable is damaged. • Check the startup protection program during charging Function • Check the horn function • Check the air gap of the solenoid valve • Detect Emergency braking • Detection of reverse braking and regenerative braking. •...
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Page 5: Lubrication Points
B. Lubrication point Lubricate the marked points according to the maintenance list. T h e required grease specification is DIN51825 standard Grease Pic.1: Lubrication point Shaft lubrication... -
Page 6: Check And Refill Hydraulic Oil
Bearing lubrication Butter filler C. Check and refill hydraulic oil – >25℃ According to the temperature, the 5℃~25℃ recommended hydraulic oil type as below: Temperature Model HVLP 32， HLP 46， DIN 51524 DIN 51524 Viscosity 28.8-35.2 41.4 - 47 Oil volume 0.4 L Waste materials such as waste oil, Waste 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... -
Page 7: Check Electrical Fuses
D. Check electrical fuses 100A fuse 10A fuse Table 2: Fuse specification Specification Fuse 1 Fuse 01 100A... -
Page 8: Failure Analysis
Failure analysis A. Common failure analysis If the truck still in problem, please follow the instruction in Chapter 6 in this manual Table 3: Failure analysis Malfunction Cause Solution Only lifting max capacity shown on Overload name plate Battery discharge Charge the battery Check and replace the lifting fuse if Goods can’t be... -
Page 9: Controller Fault Code Display
B. Controller fault code display Programmer display Code Failure phenomenon Troubleshooting 1) Battery not connected BATTERY Battery disconnected 2) Poor connection to battery DISCONNEC T FAULT terminals 1) Electromagnetic brake coil BRAKE OFF FAULT BRAKE OFF FAULT shorted 2) Electromagnetic brake driver open 1) Electromagnetic brake coil open BRAKE ON FAULT... - Page 10 1) Main contractor welded or stuck MAIN FAULT Main contractor fault open 2) Main contractor driver fault MAIN OFF FAULT Main contractor driver 1) Main contractor driver failed open off fault MAIN ON FAULT Main contractor driver on 1) Main contractor driver failed fault Closed 1) battery voltage >31V...
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Page 11: Troubleshooting For Common Faults
C. Troubleshooting for common faults • Code 4.5 battery is not connected 1) Check if the truck cable terminal is loosened or not. Shown as below picture:... - Page 12 Use a Multimeter to measure the voltage of the battery under load 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. the step as below Unplug 2-core plug in of the controller.
- Page 13 • Code 4.2 Motor Voltage If the motor voltage can’t match the accelerator input, The motor or motor ring short circuit and controller failure. Troubleshooting operations as below steps: Turn the Multimeter to 24V DC, insert the pin into J1- 1(Accelerator 0-5v speed signal)2(Negative).
- Page 14 The product can’t lift and lower down or oil cylinder lower itself. Troubleshooting operations as below steps: Hand lowering ： 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.
- Page 15 Electric lowering： No lifting. the principle is same as Hand lowering truck. Electric lowering adds a lifting Limit switch to the lifting circuit. If there is no lift, in addition to the above steps for troubleshooting, you can check whether the limit switch work properly or not 2、No lowering. can be check as below steps: This is plug for drop solenoid valve.
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Page 16: Wiring/Circuit Diagram
3. Wiring/circuit diagram A. Circuit diagram Wiring diagram... -
Page 18: Hydraulic Circuit
B. Hydraulic circuit Oil cylinder Lowering Valve Pressure control Throttle valve valve Hydraulic power unit (motor and oil pump) Tank FIC.8: Hydraulic circuit Hydraulic oil inspection Exterior Smell Condition Result Clear and no color Good Good Can be used Check the viscosity. Transparent Good Mixed with other oil... -
Page 19: Disassembly Of Main Parts
4. Disassembly of main parts A. Electromagnetic brake adjustment Adjust nut The electromagnetic brake gap is about 25-35 CM, about one hundred yuan in thickness. It needs to be carefully and Note: The electromagnetic brake can't be carefully adjusted to ensure that the gaps of the three properly connected when it is energized adjustment surfaces are consistent, and the power will give a in the free state. -
Page 20: Disassembly Of Electromagnetic Brake
C. Disassembly of Electromagnetic brake D. Driving internal gears and bearings... -
Page 21: Operating Handle Assembly
E. Operating handle assembly 5. CURTIS Handle programmer Operation precautions： Handle programmer the main function is to facilitate truck inspection and maintenance. Without the approval of the truck manufacturer, it is not allowed to adjust the controller parameters to avoid truck and personal safety accidents. - Page 22 The truck signal detection Connect Handle programmer to controller then turn on the key switch According to the menu list of CURTIS Handle programmer, find: Monitor. If necessary, Open the corresponding sub-item of the detection menu. R u n the truck and observe the change of value CURTIS Handle programmer Manual content Curtis 1313 handheld programmer is used to configure the Curtis electronic control system.
- Page 23 Function keys Since the functions of these three buttons are determined according to the specified content, these three buttons are blank. At any given time, the function of the button will be displayed on the upper LCD screen. Arrow keys The displayed information can be selected up, down, left, and right through the 4 Arrow keys.
- Page 24 Menu structure The main menu consists of nine sub-menus, each of which is displayed with a specific icon, and each item in the sub-menu is arranged hierarchically. Some menus only contain one item of information, but most menus contain multiple pieces of information. You can enter the next submenu by opening each folder.
- Page 25 Fault diagnosis menu In the main menu, select the "Diagnostics" fault diagnosis icon, and press the corresponding function key of Select to enter the fault diagnosis menu. The fault diagnosis menu includes two folders: "Present Errors" current fault and "Fault History" historical fault Note: Sometimes the fault caused by the temporary event captured in the circuit is not a system fault.
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