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Summary of Contents for EKKO EK18RF
- Page 1 Service Manual EK18RF/RFL Stand Up Forklift 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
Manual Maintenance List ......................................Overview of main components ................................ 2 Lubrication point ....................................3 Check and refill hydraulic oil ................................4 Check the fuse ......................................5 Fault Analysis ........................................ Common Fault analysis ..................................7 The fault code is displayed ................................. 8 Wiring/circuit Diagram ..................................... - Page 3 1. Regular maintenance Only qualified and trained personnel should perform maintenance work on this vehicle. Before maintenance, remove the cargo from the fork and lower the fork to the lowest position. If you need to lift the vehicle, use the specified lashing or jacking equipment. Before operation, place safety devices (such as designated jacks, wedges or wood blocks) under the vehicle to prevent accidental drop, movement or sliding.
- Page 4 Check that all screws are in place • Check gear box for noise and leakage • Check wheel for deformation and damage • Lubricated steering bearing • Check and lubricate the pivot points • Lubricating grease nozzle • Electrical system Check whether power cables are damaged •...
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Page 5: Lubrication Point
Energy supply Check the voltage of the battery • Check that battery cables are securely connected and grease the electrodes if • necessary Check whether the battery cover is damaged • Check the main cable for damage • Check the start up protection program during charging •... - Page 6 Pic2：The rail of gantry Pic3： Drive axle clamp...
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Page 7: Check And Refill Hydraulic Oil
Recommended hydraulic oil model according to temperature: 4. Check and refill hydraulic oil Ambient –5℃~25℃ >25℃ temperature mark HVLP 32， HLP 46， DIN 51524 DIN 51524 Viscosity 28.8-35.2 41.4 - 47 19-20L Waste materials such as waste oil, waste batteries or other materials must be treated and recycled in accordance with national regulations and returned to the recycling company for recycling if necessary. - Page 8 Follow the procedure listed in the The vehicle is not running "Vehicle cannot Move" fault There's too little hydraulic fluid Check hydraulic oil Fuse damage Check fuse The cargo Load overweight Note rated load cannot be raised Check the hydraulic oil and clean the or lowered Dirty oil clogs the control valve control valve and replace the hydraulic...
- Page 9 7. Display of fault code Steering failure code CODE fault cause Controller Overcurrent 1. The steering motor is short-circuited Current Sense Fault 2. The controller fails Pre-Charge Fault 1. The controller fails Controller Severe Undertemp 1. The controller fails Controller Severe Overtemp 1.
- Page 10 Relay Welded 1. In RegEN mode, the battery or battery cable resistance is too high Relay Did Not Close 2. The battery cable is disconnected during regen Hardware Fault 1. Vehicle overload Fault Output Failed 2. The controller runs in an ultra-high temperature environment Motor Stalled 1.
- Page 11 Encoder Fault 2. Analog quantities 1 and 2 fail to be cross-checked Home Position Not Found 3. The parameter Settings are incorrect Communication Fault 1. Analog feedback input 1 (J1-11) is out of range Communication Lost 2. The parameter Settings are incorrect Software Fault 1.
- Page 12 8. Fault code of the walking controller CODE fault cause Controller Over 1, motor external U, V or W connection short circuit current Current Sensor Fault 2. Motor parameters do not match Precharge Failed 3. The controller is faulty Controller Severe 1, motor U, V, W through the stator on the car body short circuit, Undertemp resulting in leakage...
- Page 13 Coil 1 Driver If the motor does not use a temperature sensor, the programming Open/Short parameters are "Temp Compensation and Temp" Main Open/Short Cutback must be set to "OFF" Coil2 Driver 1. Connect load open or short Open/Short EMBrake Open/Short 2.
- Page 14 External Supply Out of 2. The connecting pin is defiled Range OS General 3. Wrong wiring PDO Timeout 1. Motor encoder failure Stall Detected 2. Wrong wiring Motor 1, motor phase deficiency Characterization Fault Motor Type Fault 2. Wrong wiring VCl/OS Mismatch 1, main contactor contact fusion EM Brake Failed to Set...
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Page 15: Wiring/Circuit Diagram
9. Wiring/circuit diagram A. Electrical schematic diagram 3.2 hydraulic principle diagram... - Page 16 10. Hydraulic oil inspection Appearance odor condition results Clear not discoloration good good can be used check viscosity, if qualified can color transparency good with other oil mix continue to use to separate moisture or replace Color changes like milk well mixed with air and water hydraulic fluid...
- Page 17 1. Controller 2. Rotating steering wheel 3.Electromagnetic braking 5. Steering motor 6. Reducer 7. Tires When the vehicle is moving forward, rotate the steering wheel in the direction of S, then the vehicle rotation direction is S; If the steering wheel is rotated in the N direction, the whole vehicle rotates in the N direction.
- Page 18 The braking system Operating handle diagram...
- Page 19 1. Roll forward button 2. Roll back button 3. The left button 4. Right move button 5. Horn button 6. Safety switch button Insert the key into the key switch, turn to the right, turn the emergency stop switch in accordance with the direction indicated by the arrow above the button, and open the control circuit.
- Page 20 a. Hydraulic system The hydraulic system consists of main oil pump, valve group, lifting cylinder, inclined cylinder and oil circuit. The oil pump motor drives the gear pump to provide hydraulic power, the lifting cylinder is responsible for the lifting of the fork, the inclined cylinder completes the forward and backward tilt of the door frame, and the lateral cylinder completes the left and right-side movement of the tray frame.
- Page 21 1, solenoid valve 2, proportional valve 3, check valve 4, countercurrent valve 5, throttle valve...
- Page 22 13. Schematic drawing of lifting cylinder and tilting cylinder...
- Page 23 1. Piston rod 2. Dust ring 3. Cylinder head 4. Bearing 6. Cylinder block 7. Separator 8. Hole retaining ring 9. Supporting ring 10. Sealing ring 11. Retainer ring 12. Safety globe valve 13. Cylindrical pin 14. Buffer sleeve 16. Piston 1.
- Page 24 1. Oil cup 2. Cylinder block 3. Piston 5. Sealing ring for hole 6. Supporting ring for hole 7. Piston rod 9. Guide sleeve 10. Bearing 11. O-ring 12. Seal ring for shaft 13. Dust ring 14. Nut 15. Plain bearings Elastic retainers for hole 8 Lifting system...
- Page 25 The lifting system consists of internal and external door frame, cargo fork frame, retaining shelf, lifting cylinder, inclined cylinder, lifting chain and so on. It is the holding mechanism of forklift truck for loading and unloading operations. Forklifts are standard with a three-stage wide view frame. 8.1 Internal and external door frames The three-level wide view frame is composed of an outer frame that cannot be lifted and lowered and two inner and middle frames that can be telescoped up and down.
- Page 26 Fault indicator light 9. Lifting lock indicator light 10. Foot switch indicator light 11. Battery alarm lamp 9.2 the battery First use an inner hexagonal wrench to unscrew the screw, take out the battery baffle, and then slowly pull out the battery from the side to replace, to ensure that the lifting equipment has enough load capacity.
- Page 27 Vehicle fault reading process: 1. After connecting the handheld unit with the controller, open the key switch 2, From the menu list of CURTIS handheld 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.
- Page 28 The programmer is powered on The connection line of the handheld programmer can be connected to the controller by inserting the programming port of the controller. After connecting the controller, the handheld programmer will be powered on automatically and the control information will be displayed on the programmer.
- Page 29 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.
- Page 30 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.
- Page 31 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. 。 “Clear All is used to Clear historical fault folders. function highlighted only when there are historical failures in the historical...
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