EKKO EK18RRL Electric Reach Truck Instruction Manual

EKKO EK18RRL Electric Reach Truck

Product Information

• Specifications
  • Model: Electric Reach Truck EK18RR / RRL
  • Main Components: Drive assembly, Operating handle assembly, Electrical assembly, Chain assembly, Door frame assembly, Pallet rack assembly
  • Hydraulic Oil Specifications: HVLP 32 for ambient temperature >25°C, HLP 46 for ambient temperature <25°C
  • Fuse Specifications: 10A fuse, 200A fuse

Product Usage Instructions

• Maintenance List
  • Refer to the maintenance list provided in the manual for regular upkeep of the reach truck.
  • a. Overview of Main Components
  • Understand the main components such as Drive assembly, Operating handle assembly, Electrical assembly, Chain assembly, Door frame assembly, and Pallet rack assembly.
  • b. Lubrication Point
  • Lubricate marked points with DIN 51825 standard grease, focusing on contact surfaces between the gantry and roller chain, hinge pin, guide rail, roller contact surface, and axle.
  • c. Check and Refill Hydraulic Oil
  • Use the recommended hydraulic oil model based on the ambient temperature. Ensure the oil level is maintained above the minimum required amount and refill if necessary.
  • d. Check the Fuse
  • Inspect and replace fuses as needed. Use a 10A fuse or a 200A fuse as per the specifications.
• Fault Analysis
  • If the reach truck encounters issues, refer to the fault analysis section for troubleshooting.
  • a. Common Fault Analysis
    • Follow the instructions in Chapter 6 of the manual for resolving common faults.

FAQs

• Q: What should I do if the reach truck malfunctions persist?
  • A: If the vehicle continues to malfunction, follow the instructions in Chapter 6 of the manual for further troubleshooting steps.

Maintenance List

| Interval (month)
---|---
1| 3| 6| 12
hydraulic system
1| Check the hydraulic cylinder, piston for damage noise and leakage|  | ·|  |
2| Check hydraulic connectors for damage and leakage|  | ·|  |
3| Check hydraulic oil level and refill if necessary|  | ·|  |
4| Fill hydraulic fluid after 12 months or 1500 hours of work|  |  |  | ·
5| Check and adjust the function of hydraulic valve (1500kg/2000kg +0/+10%)| |  |  | ·
mechanical system
6| Check the fork for deformation and breakage|  | ·|  |
7| Check chassis for deformation and cracking|  | ·|  |
8| Check that all screws are in place|  | ·|  |
9| Check push rod for deformation and damage|  | ·|  |
10| Check gear box for noise and leakage|  | ·|  |
11| Check wheel for deformation and damage|  | ·|  |
12| Lubricated steering bearing|  |  |  | ·
13| Check and lubricate the pivot points|  | ·|  |
14| Lubricating grease nozzle| ·|  |  |
Electric System
15| Check whether electrical wiring is damaged|  | ·|  |
16| Checking Electrical Connections|  | ·|  |
17| Check the emergency switch function|  | ·|  |
18| Check the electric drive system for noise and damage|  | ·|  |
19| Detection meter|  | ·|  |
20| Check that the correct fuse is used|  | ·|  |
21| Detection warning signal|  | ·|  |
22| Check the current contactor|  | ·|  |
23| Check frame for leakage (insulation test)|  | ·|  |
24| Check whether electrical wiring is damaged|  | ·|  |
25| Checking Electrical Connections|  | ·|  |
braking systems
26| Check brake performance and replace brake discs or adjust air gaps if|  | ·|  |
 | necessary|  |  |  |
---|---|---|---|---|---
storage battery
27| Check the voltage of the battery|  | ·|  |
28| Inspect terminals for corrosion and damage and lubricate terminals|  | ·| |
29| Check whether the battery cover is damaged|  | ·|  |
charger
30| Check the main cable for damage|  |  | ·|
31| Check the start-up protection program during the charging|  |  | ·|
function
32| Check horn function| ·|  |  |
33| Check the solenoid valve air gap| ·|  |  |
34| Detect emergency brake| ·|  |  |
35| Detect reverse braking and regenerative braking| ·|  |  |
37| Check steering function| ·|  |  |
38| Check lifting and descending functions| ·|  |  |
synthesize
40| Check all labels for clarity and completeness| ·|  |  |
41| Check the load-bearing pinion and adjust the height, replace if worn|  | ·|  |
42| Run a test run| ·|  |  |

Lubrication point

Lubricate marked points according to the maintenance list. Required grease specification: DIN 51825 standard grease。

Lubrication point.

Check and refill hydraulic oil

Recommended hydraulic oil model according to temperature::

Waste materials such as waste oil, waste batteries or other materials must be treated and recycled per national regulations and returned to the recycling company for recycling if necessary. The oil level should not be lower than the minimum amount required to start the vehicle. Fill up to the refuelling point if necessary。

Check the electrical fuse

Specification

List 2: Fuse specification

Fault Analysis

• a. Common fault analysis
  • If the vehicle continues to malfunction, follow the instructions in Chapter 6 of the manual.
  • list 3: fault analysis

Oil leakage caused by

suction

| Oil is too high| Reduce oily
Vehicle inoperable| The battery is charging|  | Fully charge the battery, then remove the main power plug from the power socket|
 | The battery is disconnected.|  |  | Connect batteries correctly|
The fuse is out of order|  | Check and eventually replace the fuse|
 | Battery discharge|  |  | The battery|

The emergency stop switch is activated

|  | Insert and pull the knob to eliminate the emergency stop switch function|
Moving in one direction| Accelerator and connector damage| Check the accelerator and connector
Traffic moves slowly|  | Battery discharge|  |  | Check the battery condition on the|
 |  |  | discharge monitor|
---|---|---|---|---
 | The electromagnetic brake has been activated|  |

Check electromagnetic brake

 | The handle wiring harness is not connected or damaged|  |  | Check handle wiring harness and connectors|

Electrical system overheating

|  | Discontinue use and cool the vehicle|

The thermal sensor is faulty

|  | Check and replace the heat sensor if necessary|
 | 400mm trigger sensor, stacker auto speed down|  |  | Check whether the sensor is normal|

The vehicle started suddenly

|  | Controller damage|  |  | Replacing a Controller|
 | The accelerator has not moved back to the middle position|  |

Repair or replace the accelerator

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

Fault code display Steering fault code

2.  The controller fails

13| Current Sense Fault| 1. The controller fails
14| Precharge Fault| 1. The controller fails
15| Controller Severe Undertemp|  | 1.  The controller runs in a low- temperature environment

2.  The temperature sensor is damaged

|
16| Controller Severe Overtemp|  | 1.  Vehicle overload

2.  The controller runs in an ultra-high temperature environment

3.  The controller is improperly fixed

|
17| Severe Undervoltage|  | 1.  The battery or battery cable is faulty

2.  There are other heavy loads connected to the battery

3.  The battery is dead or the model is different

|
18| Severe Overvoltage| 1.  In RegEN mode, the battery or battery cable resistance is too high

2.  The battery cable is disconnected during regen

21| Motor Temp Hot Cutback| 1.  Vehicle overload

2.  The controller runs in an ultra-high temperature environment

22| Controller Overtemp| 1.  Vehicle overload

2.  The controller runs in an ultra-high temperature environment

3.  The controller is improperly fixed

23| Motor Polarity Fault| 1.  The motor polarity is reversed

2.  The polarity of the position feedback device is reversed

24| 5V Output Failure| 1.5V output overload

2. The controller fails

31| Main Driver Fault| 1.  The internal relay coil is damaged

2.  The internal relay drives open or short

32| Relay Welded| 1.  Internal relays are adhered to

2.  The controller fails

33| Relay Did Not Close| 1.  The internal relay receives the pull-in instruction but fails to pull in

2.  Oxidation of internal relay patch

34| Hardware Fault| 1. A hardware fault is detected
 |  | 2.  The motor voltage is out of range

3.  The IIC communication is lost

4.  The power tube is short-circuited

---|---|---
35| Fault Output Failed|  | 1.  The output cable is improperly connected

2.  The controller fails

|
---|---|---|---|---
36| Motor Stalled| 1.  Motor is blocked

2.  The encoder of the steering motor fails or the cable is disconnected

3.  Cables to the steering motor are disconnected

4.  The parameters do not match the motor

37| Motor Open| 1.  Open cables to the steering motor

2.  The motor is incorrectly connected

3.  The controller fails

38| Motor Short| 1. The steering motor is short-circuited
41| Command Analog1 Out of Range| 1. Analog input 1 (J1-6) is out of range

2.  Low end of instruction (J1-14) out of range (for resistance type)

3.  The parameter Settings are incorrect

42| Command Analog2 Out of Range| 1. Analog input 2 (J1-13) is out of range

2. Analog quantities 1 and 2 fail to be cross-checked

3.  The parameter Settings are incorrect

43| Feedback Analog1 Out of Range| 1. Analog feedback input 1 (J1-11) is out of range

2.  The parameter Settings are incorrect

44| Feedback Analog2 Out of Range| 1. Analog feedback input 2 (J1-3) is out of range 2.J1-11 and J1-3 analog cross-check failed

3. The parameter Settings are incorrect

45| Parameter Change Fault| 1.  If the parameter value changes, you need to restart the system

2.  Restore the parameters to default values

46| EEPROM Failure| 1.  The verification calculation of storage parameters is incorrect

2.  The controller fails

47| Encoder Fault| 1.  The encoder data exceeds the allowable range

2.  Open A or B phase of the orthogonal encoder

3.  Polarity encoder phase B is open

53| Home Position Not Found| 1.  The Home switch fails

2.  The installation or cable connection is incorrect

62| Communication Fault| he communication s lost
63| Communication Lost| 1.  Cables to the Rx(J1-8) are faulty

2. A handheld programmer is being used on the walking controller

71| Software Fault| 1.  Software failure

2.  The controller fails

73| The following error| 1.  The parameter Settings are incorrect

2.  The position feedback device fails

3.  Steering motor failure

75| Parameter Conflict| 1.  The Home switch fails

2.  The installation or cable connection is incorrect

---|---|---
78| CAN bus Loading CAN| 1、 1. The CAN bus is abnormal

2、 2. Message sending is abnormal 3、

79| PDO Mapping Error| 1. Incorrect mapping data
81| Bad Calibrations| 1. Check data is out of range
82| |
84| Supervision| 1. Defects in monitoring procedures

Fault code of the walking controller

circuit

2.  Motor parameters do not match

3.  The controller is faulty

2| Current Sensor Fault| 1, motor U, V, W through the stator on the car body short circuit, resulting in leakage

2. The controller is faulty

3| Precharge Failed| 1. Negative load is connected to the positive end of the

capacitor, so that the capacitor can not be charged normally

4| Controller Severe

Undertemp

| 1. The working environment of the controller is too harsh
5| Controller Severe Overtemp| 1.  The working environment of the controller is too harsh

2.  Vehicle overload

3.  The controller is incorrectly installed

6| Severe Undervoltage| 1.  Battery parameters are incorrectly set

2.  Power consumption of non-controller system 3, the battery impedance is too large

4. The battery is disconnected

5, the fuse is disconnected, or the main contactor is not connected

7| Severe Overvoltage| 1.  Battery parameters are incorrectly set

2.  The battery impedance is too high

3. The battery connection is disconnected during regenerative braking

8| Controller Undertemp

Cutback

| 1. The controller works under restricted conditions

2, the controller working environment is harsh

9| Controller Overtemp Cutback| 1, the controller working environment is harsh

2.  Vehicle overload

3.  The controller is incorrectly installed

10| Undervoltage Cutback| 1.  The battery is low

2.  Battery parameters are incorrectly set

3.  Non-controller system runs out of power

4.  Excessive battery impedance

5.  The battery is disconnected

6.  Fuse is disconnected or main contactor is disconnected

---|---|---
11| Overvoltage Cutback| 1, regenerative braking process regenerative system The running current causes the battery voltage to rise

2. Battery parameters are incorrectly set 3, the battery impedance is too large

4. Battery connection is broken during regenerative braking

12| +5V Supply Failure| 1, the external load impedance is too low
13| Digital Out 6 Failure| 1, the external load impedance is too low
14| Digital Out 7

Overcurrent

| 1, the external load impedance is too low
15| Motor Temp Hot Cutback| 1.  The motor temperature reaches or exceeds the alarm temperature set by the program, resulting in the reduction of current output

2.The motor temperature parameters are incorrectly set

3.  If the motor does not use a temperature sensor, program parameters “Temp Compensation” and “Temp”

Cutback must be set to “OFF”

16| Motor Temp Sensor Fault| 1. The motor temperature sensor is incorrectly connected

If the motor does not use a temperature sensor, the programming parameters are “Temp Compensation and Temp”

Cutback must be set to “OFF”

17| Coil 1 Driver Open/Short| 1.  Connect load open or short

2.  The connecting pin is defiled

3.  Wrong wiring

18| Main Open/Short| 1.  Connect load open or short

2.  The connecting pin is defiled

3.  Wrong wiring

19| Coil2 Driver Open/Short| 1.  Connect load open or short

2.  The connecting pin is defiled

3.  Wrong wiring

20| EMBrake Open/Short| 1.  Connect load open or short

2.  The connecting pin is defiled

3.  Wrong wiring

21| Coil3 Driver Open/Short| 1.  Connect load open or short

2.  The connecting pin is defiled

3.  Wrong wiring

22| Coil4 Driver Open/Short| 1.  Connect load open or short

2.  The connecting pin is defiled

3.  Wrong wiring

23| PD Open/Short| 1. Connect load open or short
 |  | 2.  The connecting pin is defiled

3.  Wrong wiring

---|---|---
24| Encoder Fault| 1.  Motor encoder failure

2.  Wrong wiring

---|---|---
25| Motor Open| 1, motor phase deficiency

2. Wrong wiring

26| Main Contactor Welded| 1, main contactor contact fusion

2.  Motor U or V is disconnected or the phase is missing

3.  The circuit charging capacitor connected to the B+ terminal exists

27| Main Contactor Did Not Close| 1. The main contactor is not closed

2, the main contactor contact oxidation, melting Or the connection status is unstable

3.  The capacitor is charged by external devices

4.  The fuse is disconnected

28| Throttle Wiper High| 1, accelerator potentiometer output voltage is too high
29| Throttle Wiper Low| 1, accelerator potentiometer output voltage is too low
30| Pot2 Wiper High| 1, potentiometer 2 output voltage is too high
31| Pot2 Wiper Low| 1, potentiometer 2 output voltage is too low
32| Pot Low Overcurrent| 1， Potentiometer impedance is too low
33| EEPROM Failure EEPROM| 1Failed to write to the EEPROM storage. This may be caused by VCL writing to EEPROM storage, by CAN BUS, or by a parameter error programmed into the controller after the programmer parameters are

adjusted.

34| HPD/Sequencing Fault| 1. Incorrect setting of key start, interlock, direction and accelerator input sequence.

2, wiring, switch key, interlock, direction, or accelerator

input failure

35| Emer Rev HPD| 1. The emergency reverse operation has ended, but the accelerator, forward and reverse input and interlock have not

been reset.

36| Parameter Change Fault| 1. To ensure the safety of the vehicle, the modification of some specific parameters must take effect

after the key switch is restarted.

38| VCL RunTime Error| 1. The VCL code timed out
39| External Supply Out of Range| 1, the external load in 5V and 12V power source current is too large or too small

Checking Menu parameter error, e.g. “Exit Supply Max”, “Ext

Named “Supply” Min”

40| OS General| 1. The internal controller fails
41| PDO Timeout| 1. The CAN PDO message receiving time exceeds the PDO time

limit

42| Stall Detected| 1.  Motor blocking

2.  Motor encoder failure

3.  Wrong wiring

4. The power supply of the input motor encoder is faulty

43| Motor Characterization Fault| 1, in the motor matching process of modern code comparison: 0 = normal

1= The controller receives the encoder number,

But the impulse quantity is undefined. Please handset set Buy pulse value

2= Motor temperature sensor failure

3= High-temperature reaction failure of motor 4= motor overheating reaction failure

5= Low-temperature reaction failure of motor 6= Low voltage response failure

7= high-pressure reaction failure

8= The controller cannot detect the encoder message Alpha, the channel signal is down

9= Motor parameter setting exceeds the range

---|---|---
44| Motor Type Fault| 1. The motor type parameter value is out of range
45| VCl/OS Mismatch| 1. The VCL program in the controller does not match the OS

program

46| EM Brake Failed to Set| 1. The vehicle is still moving after the electromagnetic brake command is set.

2, electromagnetic brake braking force is too small

47| Encoder LOS (Limited Operating Strategy)| 1.  Due to motor blocking or encoder

The failure causes the restricted operating state to be The Activation

2.  Wrong wiring

3.  Traffic jams

48| Emer Rev Timeout| 1. The emergency reverse timeout is activated because the EMR Timer expires

2.  The emergency reverse switch is always in the On position

49| Illegal Model Number| 1.  The controller model cannot be identified

2.  Hardware and software do not match each other

3.  The controller is damaged

50| Dualmotor Parameter| The Enable parameter of dual motors is set to ON, and the

control Mode selection parameter is not set to (Speed Mode Express) or 1 (Speed Mode).

WIRING DIAGRAM

Hydraulic Principle Diagram
Hydraulic principle diagram

Hydraulic oil inspection

can

continue to use

Colour changes like milk| well| mixed with air and water| to separate moisture or replace

hydraulic fluid

The colour becomes dark brown| not

good

| for oxidation| replacement of hydraulic oil
Clear color but small black spots| good| mix with other particles| can be used after filtering
---|---|---|---

Disassembly Parts

Disassembly of main parts
Electromagnetic brake adjustment

Drive the disassembly diagram

Drive and balance wheel disassembly

Dismantling of frame and door frame

Mechanical part of door frame

Frame mechanical part Pressure regulation

Disassembling diagram of bearing wheel

Battery removal diagram

• Before taking out the battery, prepare a support platform of appropriate height.
• First, remove the battery baffle, then fix the battery side with the hook and slowly drag the battery to the support platform.
• After the battery is placed firmly on the support table, hook the hook position on both sides of the battery, and then place the battery in the appropriate position.
• The battery can be put into the car body in reverse order.
• Caution: Be careful during the operation, confirm the safety of the lifting device before lifting, and do not place body parts (such as feet) under the lifting object, to avoid heavy objects accidentally falling off and being injured.

CURTIS Hand-held unit Precautions for operation:

• The 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, to avoid vehicle and personal safety accidents.
• The hand-held unit will automatically save the modification parameters, just need to close the key switch, and restart.
• The CURTIS handheld unit can be connected in the event of a controller power or power failure

Vehicle fault reading process:

1. After connecting the handheld unit to 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. After connecting the handheld unit to the controller, open the key switch
2. According to the menu list of CURTIS handheld units, find: Monitor……
3. According to requirements, open the corresponding sub-item of the detection menu, run the vehicle, and observe the change of the hand-held value.

CURTIS Contents of the hand-held unit menu:

• The Curtis 1313 handheld programmer is used to configure the Curtis electric control system.
• Through this programmer, you can adjust and save the set parameters, and real-time monitoring of controller data and faults.

Warning: The control system can affect the vehicle’s acceleration rate, deceleration rate, hydraulic system and braking. A dangerous situation can occur if the vehicle control system is not programmed correctly or exceeds safety. Only the vehicle manufacturer or an authorized service agent can program the control system The programmer has two interfaces, one is used to communicate with the electric control, the other is used to communicate with the PC, the programmer has a battery box and a memory card slot

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.

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.

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. Expand the table through the grid option, enter a group of execution commands through the dialogue box option, and return to the upper menu regardless of the interface by pressing the left direction button. The names of all nine sub menus are shown in bold on 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.

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.

+ / – 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 option.

Power key

• When the programmer inserts a controller that has been powered on, the programmer does not have to press the power button to use it.
• The programmer will start up automatically.
• When you hold it down for a few seconds, the programmer will prompt you whether to turn it off.
• You can decide whether to turn it off by selecting the “Yes” and “No” represented by the function key.
• After closing the programmer, press for a few seconds and the programmer will restart. collection keys There are two ways to enter the Favorites menu. You can enter Favorites from the main menu or press this key.

Fault Diagnosis menu

• On the main menu, Select Diagnostics and press Select to access the Fault diagnosis menu. The Fault diagnosis menu contains Present Errors current faults Fault History historical faults
• Note: Sometimes a fault caused by a temporary event captured in the circuit is not a system fault. You can determine whether the fault exists by restarting the system and observing whether the fault disappears automatically.
• 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. A function key is highlighted only when there are historical failures in the historical failures folder and greyed 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. CPF file function in the programming menu to back up the currently set parameters. You can save as many.pdf files as you want, and you need to name each.pdf file differently
• Restore. CPF File (Restore.cpf File)
• Restore. CPF File The. CPF File saved earlier can be used to replace the. CPF File of the current controller. When the data recovery is complete, a dialogue box is

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

Read User Manual Online (PDF format)

Download This Manual (PDF format)

Download this manual  >>