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Service Manual
Electric Forklift
EK20R/RL
Warning
You must understand the operation instructions in this manual
before using it.
Note:
Please check the last page of this document and nameplate for all
current product type identification.
Keep it for future use current product type identification.
Keep it for future use.
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Table of Contents
Related Manuals for EKKO EK20R
Summary of Contents for EKKO EK20R
- Page 1 Service Manual Electric Forklift EK20R/RL Warning You must understand the operation instructions in this manual before using it. Note: Please check the last page of this document and nameplate for all current product type identification. Keep it for future use current product type identification.
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Page 2: Table Of Contents
Manual Maintenance List ............................1 Overview of main components ......................2 Lubrication point ............................ 3 Check and refill hydraulic oil ........................4 Check the fuse ............................5 Fault Analysis ............................6 Common Fault analysis ........................7 The fault code is displayed ........................8 Wiring/circuit Diagram .......................... -
Page 3: Maintenance List
Maintenance List Overview of main components list 1 :maintenance Interval (month) 1 3 6 Braking • Check the air gap of the electromagnetic brake Electric System • Check operating switches to display the functions of devices and components • Check alarm system and safety devices •... -
Page 4: Lubrication Point
• Replacement hydraulic fluid Lubrication point Lubricate marked points according to maintenance list. Required grease specification: DIN 51825 standard grease Pic1：transmission chain Door frame inside Chain lubrication... - Page 5 Wheel lubrication A. Check and correct electrolytes The electrolyte density is based on 25 ℃.Therefore, when m easuring, if the tem perature of the electrolyte is higher or lower than 25℃, every 1℃ higher, should be measured from the actual density value plus 0.0007;On the contrary, lower than 25 ℃, every 1℃...
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Page 6: Check The Fuse
a. Check fuse 200A fuse 10A fuse List 2 : Fuse specification specification Fuse 1 Fuse 01 300A 2 Fault analyses If the vehicle continues to malfunction, follow the instructions of the manual. Hand and foot break common faults and troubleshooting methods Failure cause maintenance... - Page 7 drum hole The surface of the friction plate is greasy Cleaning and replacement Brake drum hole deviation, large hole Bright hole, ensure roundness, different center concentricity Brake shoe clearance is not properly Adjust the Brake uneven adjusted Brake shoe return spring damaged replace Points and pump failure Repair or replacement...
- Page 8 Other steering when relative surface bite swing from side to side dead Dismantle, repair The steel ball in the steering valve body Replacement spring fails and is blocked Steering gear reset failure, spring Check piston seal ring and replace breakage Leakage in steering cylinder is too large Adjust pressure and flow There is air in the steering system...
- Page 9 Pressure difference between left and Air replenishment and air pressure right are consistent Inconsistent tightness of left and right The tightness adjustment is The cargo fork frame chains consistent is skewed The oil channel in the speed limiting Cleaning and replacement valve is blocked The oil inlet of the lifting cylinder is Maintenance and cleaning...
- Page 10 (1) Common faults of electrical system and troubleshooting methods fault cause maintenance The key switch is not in contact Open key switch no voltage bolt Turn over the hoist The connector is in poor contact Loose battery connector bolt Step on the The connector is in poor contact accelerator pedal and the forklift will not...
- Page 11 (1) Transmission failure causes and troubleshooting methods fault cause maintenance 1. The friction plate is stuck or worn. Check for gluing, uneven contact or warping of the friction plate. Decline in efficiency 2. Bearing damage. Replace the bearing 3. Check whether the lubricating oil road dredge is blocked.
- Page 12 force assembly Uneven installation surface, deformation Adjust the installation plane of valve body, resulting in stuck valve Stem and valve hole wear, gap increase Reinstall stem serious internal leakage Stem or orifice scratched and increased Refit stem or replace valve sub internal leakage assembly Stem not returned to neutral position...
- Page 13 torque Oil pump failure Replace the oil pump The system will be discharged after There is air in the hydraulic system repeated operation for a while Pump suction air Check oil absorption test of oil pump Suction pipeline resistance is too large; Check the cause of negative Relief valve vibration The suction side of the oil pump...
- Page 14 Check the oil absorption part and its Oil suction side leakage seal, and replace the failed seal Check and repair pumps or replace If not, the pump is damaged pumps The discharge side of The relief valve is damaged or jammed the pump does not Check and repair relief valve or by stolen goods, and the oil flows back...
- Page 15 The coaxial of the pump shaft and prime Adjust the coaxiality of the two axes mover shaft is too large After maintenance, the driven gear is Disassemble the oil pump and turn inverted and the meshing area becomes the driven gear smaller Properly adjust the overflow valve;...
- Page 16 turn. Fracture will renew the bearing. Gearbox, gear, friction plate damage update Differential and cross shaft damaged update Fastener loosening Pry tight...
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Page 17: B、 Hydraulic Circuit
If the vehicle is malfunctioning and cannot be operated outside the work area, lift the vehicle up, place a load handling device under the vehicle and secure the vehicle, then remove the vehicle out of the channel. B、oil hydraulic circuit... -
Page 18: Main Parts Disassembling
Figure 8: Hydraulic circuit Hydraulic oil inspection Clear not discoloration good good can be used Appearance odor condition results 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 19 B、Pump station to remove Specificatio Remar Code Name Quant Hexagon socket head GB/T 70.1-2000 M8×20 screws GB/T 93-1987 Φ8 Elastic washer GB/T 97.1-2002 Φ8 Flat washer Multi - way valve oil inlet E15A-01.7.2 steel pipe Hexagon head bolts full GB/T 5781-2000 M10×35 thread GB/T 93-1987...
- Page 20 quantit code name Specifications Remarks GB/T 6170-2000 Hexagonal nut GB/T 93-1987 Φ12 Elastic washer 1R342357 Traction motor GB/T 5782-2000 M12×70 Hexagon head bolt GB/T 97.1-2002 Φ12 Flat washer Hexagon bolts, fine thread, GB/T 5786-2000 M10×1.5×30 full thread GB/T 97.1-2002 Φ10 Flat washer GB/T 93-1987 Φ10...
- Page 21 Multiway Valve Assembly Removal...
- Page 22 quan remar code name specification tity outso urcin DF-CCSB-003 Move the handle sideways outso urcin DF-CCSB-003 Tilting handle outso urcin DF-CCSB-003 Lifting handle E15A-01.9.1.3 Side shift lever welded E15A-01.9.1.2 Inclined handle bar welding E15A-01.9.1.1 Lifting handle bar is welded E15A-01.9.1.5 Support shaft E15A-01.9.1.3 Support block right...
- Page 23 Q25GB-01.4.8 Directly to the head Z-15GW22-B Micro switch Q15GB-01.4.7 Right Angle adjustable joint E15A-01.9.4.3 Turn to oil return adapter E15A-01.9.4.6 Diverter outlet pipe EK20R.H Φ16-25 Hose hoops E15A-01.9.4.7 Hollow bolt GB982-77 φ 16 combined gasket E15A-01.9.3 Return pipe Φ32-50 Hose hoops E25A-01.9.6...
- Page 24 e、Removal of roof guard frame...
- Page 25 F、Door frame assembly removed SPECIFICATIO QUANT REMA CODE NAME Top guard frame E15A-04.1 welding 1KG fire extinguisher holder Cross recessed pan GB/T 818-2000 M6×16 head screws 1 kg of fire extinguisher HS200×110 Rear view mirror Spring snap nut Side cover mounting E15A-04.2 support plate GB/T 93-1987...
- Page 26 GB/T 41-2000 Hexagonal nut Quanti Code Name Specification Remark E25A-03.4 Φ41.3 Rubber plug...
- Page 27 E15A-06.9.2 Lifting hose Hexagon thin nuts with GB/T 6173-2000 M22×1.5 fine teeth Q15GB-04.7.5 joint E15A-06.9.1 Steel pipe E15A-06.9.3 Steel pipe E15A-06.5 Lift cylinder assembly GB892-77 Φ22 Combination gasket E15A-05.6.2 High pressure hose E15A-06.9.7 Tee joint E10GS-01.11.8 Through joint XSF-F16L-60-1.5T The speed limit valve Hexagon socket GB/T 70.3-2000 M8×20...
- Page 28 E15A-01.19 ZG310-570 Front axle clamp under GB/T 97.1-2002 Φ14 Flat washer GB/T 93-1987 Φ14 Elastic washer Hexagon head bolts full GB/T 5783-2000 M14×70 thread E15A-0.7 Tilting cylinder assembly Inclined cylinder pin shaft Q15GB-01.12 welding GB/T 95-2002 Φ8 Flat washer GB/T 93-1987 Φ8 Elastic washer Hexagon head bolts full...
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Page 29: Electric System
GB/T 41-2000 Hexagonal nut E15A-05.7 The chain tension bar Q15GB-02.3.8 Tie pin GB/T 91-2000 Φ3×20 Cotter pin GB/T 91-2000 Φ3×20 Cotter pin 5. Electric System The electrical system mainly includes battery, traction motor, pump motor, traction motor controller and pump motor controller, steering combination switch, multi-way valve block controller, display instrument, combination control switch, instrument and light a. -
Page 30: Electronic Assembly
b. Electronic assembly Intelligent instrument Specificati Quantit Code Name Remark δ/10 Aluminum plate Hexagon socket head GB/T 70.1-2000 M6×16 screws GB/T 93-1987 Φ6 Elastic washer GB/T 95-2002 Φ6 Flat washer 1232SE-2421 Ac controller Article copper connection Article copper connection 300A The fuse 1232SE-2421 Ac controller... - Page 31 Function Description 1. Vehicle running timing 2. Vehicle speed 3. Battery capacity 4. Maintenance countdown (no setting) 5. Turning Angle (EPS configuration) 6. Setting button 7. Vehicle speed range 8. Speed mode 1 9. Controller fault code...
- Page 32 2. View the current fault information 1. Press confirm to enter the fault information screen 2. When the language of the meter is set to English, the English fault information is displayed. When the language of the meter is set to Chinese, fault information in Chinese is displayed. 1.
- Page 33 d.Fault Diagnosis menu 1232SEProgrammable fault diagnosis menu and status display LED fault diagnosis table There are two luminous LED lights, red and yellow, on the controller shell. Different flashing conditions represent different fault conditions, as shown in the following table: According to situation On behalf of the meaning Neither light is on...
- Page 34 调速器不工作；满制动输入） The controller works under the limit temperature Controller Severe Overtemp condition (higher than 95℃). 控制器工作在超温保护温度之上 1，6 Vehicle overload. （主接触器、电机、电磁制动器、 The controller is improperly installed. 调速器不工作；满制动输入） 4. View the controller temperature in the Monitoring menu. 1. 1. Battery voltage parameters are incorrectly set. 2.
- Page 35 2. Battery voltage parameters are incorrectly set. 3. The battery resistance is too high when the regenerative braking current is generated. 4. Open battery connection during regenerative braking. View the capacitor voltage under the programmer monitor menu. 1. 1. External load resistance connected to +5V supply +5V Supply Failure (pin26) is too low.
- Page 36 驱动 3 连接的线圈开路/短路 11. 2. The connection terminal is contaminated. （驱动 3 无输出） The cable harness is damaged or incorrectly connected. Coil 4 Driver Open/Short 12. 1. The connected load is open or short. 13. 2. The connection terminal is contaminated. 3，4 驱动...
- Page 37 比例阀均不工作，满制动输入） 1. 1. Incorrect key switch, interlock, direction and accelerator input sequence. HPD/Sequencing Fault 2. 2. Key switch, interlock, direction and accelerator input HPD/操作顺序错误 connection is not good or switch failure. （调速器不工作） 3. View the programmer monitor menu input. 4，7 Emer Rev HPD 1.
- Page 38 Encoder Characterization Fault 1. The description of the encoder is incorrect. 编码器特征描述错误（主接触器、 8，8 2. Motor encoder pulse frequency is not a standard value 调速器、电磁制动器和电机不工 (32,48,64,80 PPR) 作，） Motor Type Fault 电机型号参数错误（主接触器、 8，9 1. The motor model parameter value exceeds the range. 调速器、电磁制动器和电机不工...
- Page 39 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 Warning: The control system can affect the vehicle's fault diagnosis acceleration rate, deceleration rate, hydraulic system...
- Page 40 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.
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Page 41: Fault Diagnosis Menu
The menu structure 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. - Page 42 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. 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 Save.cpf File (Save.cpf File) Use the save.
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