EKKO EK20R Service Manual Download | Manualshive

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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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Summary of Contents for EK20R

Page 1: ...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...

Page 2: ...gram 10 b Hydraulic circuit 11 4 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 F...

Page 3: ...lectrodes if necessary traveling system 11 Check the gearbox for abnormal sound 12 Check driving mechanism grease and check the reset function of operating handle 13 Check drive wheel and load wheel f...

Page 4: ...ement hydraulic fluid 1 Lubrication point Lubricate marked points according to maintenance list Required grease specification DIN 51825 standard grease Pic1 transmission chain Door frame inside Chain...

Page 5: ...emperature of electrolyte when measuring density Under the condition of normal working of charging function the density of 1 26 0 005 25 temperature below 30 sulfuric acid electrolyte into the battery...

Page 6: ...shooting methods Failure cause maintenance Poor braking Improper position of brake pedal Adjust the Leakage of brake system Repair or replacement There is air mixed in the brake system exhaust Brake s...

Page 7: ...wear of friction plate replace Hub shaft is loose replace The handle is not in the operating area First move the handle to the braking area Other poor braking Brake overheating Brake Check for a skid...

Page 8: ...leaning Cylinder leakage Check guide sleeve seal joint seal Abnormal sound Low oil level hydraulic noise Refueling and exhaust Suction tank or oil filter blocked Cleaning and replacement 1 Common faul...

Page 9: ...onsistent to exceed the cylinder head adjustment range Add adjusting gasket on lifting cylinder piston rod The over lift speed at full load cannot meet the requirements Or fail to lift Insufficient wo...

Page 10: ...ice is faulty The lifting motor does not work Contactor coil is open or disconnected The lifting switch does not work properly bolt Poor contact of connector The contactor main contact is burned out T...

Page 11: ...matters embedded in the lip sealing part pay attention to not damage the valve stem and sealing surface O ring damaged cut ring Replace the O ring seal The sealing ring between valve discs is aged and...

Page 12: ...shunt valve core or the shunt safety valve core is stuck by foreign matter Clean shunt valve core or shunt relief valve core and fuel tank and pipeline The opening and closing characteristics of the s...

Page 13: ...the forward control small spool is stuck Clean valves fuel tanks pipelines etc Wrong oil mouth Switch the wrong oil connection 1 Gear pump failure causes and troubleshooting methods fault cause mainte...

Page 14: ...fied value The oil suction takes in air Check whether the sealing ring at the oil suction port is damaged Low volume efficiency of oil pump The seal inside the oil pump is damaged Replace seal ring La...

Page 15: ...eat dissipation Increase the fuel tank 1 Drive axle failure reasons and troubleshooting methods fault cause maintenance Very noise Bolts connecting drive axle and frame are loose fastening Frame nut l...

Page 16: ...14 turn Fracture will renew the bearing Gearbox gear friction plate damage update Differential and cross shaft damaged update Fastener loosening Pry tight...

Page 17: ...s 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...

Page 18: ...d can continue to use Color changes like milk well mixed with air and water to separate moisture or replace hydraulic fluid The color becomes dark brown not good for oxidation replacement of hydraulic...

Page 19: ...Hexagon head bolts full thread M10 35 2 6 GB T 93 1987 Elastic washer 10 6 7 GB T 95 2002 Flat washer 10 6 8 E15A 01 7 3 Gear pump fitting 14 5cc 1 9 GB T 5781 2000 Hexagon head bolts full thread M10...

Page 20: ...ad bolt M12 70 2 5 GB T 97 1 2002 Flat washer 12 8 6 GB T 5786 2000 Hexagon bolts fine thread full thread M10 1 5 30 10 7 GB T 97 1 2002 Flat washer 10 10 8 GB T 93 1987 Elastic washer 10 10 9 DCS15H6...

Page 21: ...19 C Multiway Valve Assembly Removal...

Page 22: ...0 6 10 E15A 01 9 1 4 Support piece left 1 11 GB T 95 2002 Flat washer 10 5 12 GB T 889 1 2000 Hexagon lock nuts M10 1 13 GB 882 88 pin 8 26 3 14 GB T 91 2000 Cotter pin 3 2 20 3 15 E15A 01 9 2 Connect...

Page 23: ...EK20R H Hose hoops 16 25 2 33 E15A 01 9 4 7 Hollow bolt 1 34 GB982 77 16 combined gasket 2 35 E15A 01 9 3 Return pipe 1 36 Hose hoops 32 50 2 37 E25A 01 9 6 Right Angle connector 1 38 E25A 01 9 8 Rig...

Page 24: ...22 e Removal of roof guard frame...

Page 25: ...Side cover mounting support plate 2 8 GB T 93 1987 Elastic washer 8 6 9 GB T 5781 2000 Hexagon head bolt M8 16 6 10 GB T 5783 200 Hexagon head bolts full thread M10 20 4 11 GB T 93 1987 Elastic washer...

Page 26: ...24 19 GB T 41 2000 Hexagonal nut M16 4 20 E25A 03 4 Rubber plug 41 3 6 NO Code Name Specification Quanti ty Remark...

Page 27: ...screws M8 20 3 13 Q15GB 02 5 16 Joint 3 1 14 GB T 5783 2000 Hexagon head bolts full thread M6 12 3 15 GB T 93 1987 Elastic washer 6 3 16 GB T 95 2002 Flat washer 6 3 17 GB T 5783 2000 Hexagon head bo...

Page 28: ...2 3 8 Tie pin 6 39 GB T 91 2000 Cotter pin 6 40 E15A 06 2 Middle gantry assembly 1 41 LH1223 BL623 Plate chain 111 2 NO code Name Specificati on Quantit y Remark 1 E15A 05 3 2 Retaining rack welding 1...

Page 29: ...ontroller steering combination switch multi way valve block controller display instrument combination control switch instrument and light a Electrical schematic diagram 12 GB T 41 2000 Hexagonal nut M...

Page 30: ...3 GB T 93 1987 Elastic washer 6 8 4 GB T 95 2002 Flat washer 6 8 5 1232SE 2421 Ac controller 1 6 Article copper connection B 1 7 Article copper connection B 2 8 The fuse 300A 2 9 1232SE 2421 Ac contro...

Page 31: ...cription 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 Contro...

Page 32: ...on 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 Pre...

Page 33: ...on The controller is updating its software The yellow and red lights were flashing Controller is faulty CODE FAULT DISPALY POSIBILITY 1 2 Controller Overcurren 1 1 The U V or W phases of the motor are...

Page 34: ...nction of the controller takes effect 2 2 The controller works in the limit condition 3 View the controller temperature in the Monitoring menu 2 2 Controller Overtemp Cutback 1 1 The controller overhe...

Page 35: ...itoring menu If the thermostat is not used the temperature compensation and temperature cut off should be set to OFF 2 9 Motor Temp Sensor Fault 1 The motor temperature sensor is improperly connected...

Page 36: ...main contactor is not closed 2 2 The contact of the main contactor is burned or not in good contact 3 3 The external load in the capacitor bank B end prevents the capacitor bank from charging 4 B fuse...

Page 37: ...o see 6 8 VCL Runtime Erro VCL 1 4 1 VCL code runtime error 2 See 1311 Controller Monitoring menu VCL Error Module and VCL Error This failure can be likened to the runtime VCL module ID and error code...

Page 38: ...he 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 s...

Page 39: ...rd slot 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 control...

Page 40: ...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...

Page 41: ...n 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 Nine Menu Fault Diagnosis menu On the main menu...

Page 42: ...in the historical failures folder and grayed out when there are no historical failures Save cpf File Save cpf File Use the save CPF file function in the programming menu to back up the currently set p...

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