EKKO EB18E Bedienungsanleitung

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. 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. •

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

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

d. Check electric fuses

Table 2: fuse specification

specification

Fuse 1 10A

Fuse 01 200A

200A fuse

10A fuse

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.

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

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

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

Main Contactor Did Not

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

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

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）

3、Circuit/circuit diagram

a、Circuit

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