Service manual

Full-electric stacker
EB16EA

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 ferformance. 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. •
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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

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 Idler wheel
&guide rail
contact surface

Bearing shaft

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， HLP 46，
DIN 51524 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.

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 d. Check electric fuses

10A Fuse 200A Fuse

Table 2: fuse specification

specification
Fuse 1 10A
Fuse 01 200A

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
Only lift the maximum capacity show
Over load
on nameplate.
Battery discharge Charge the battery
Goods can’t be lifted up Lift fuse damaged Check and replace the fuse
Low hydraulic oil level Check and refill hydraulic oil
Detect the sealing condition of
Oil leakage
oil cylinder.
Suction leak High oiliness Reducing oiliness

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 Full charge the battery, then unplug
Battery is charging
the main power plug from the outlet.
Battery disconnected Connect battery correctly.
The vehicle can’t be Fuse malfunction Check and replace the fuse.
operated Low battery Charge the battery
Emergency switch is activate Unplug the emergency switch
Move the handle to the braking
The handle is not in operating area
area.
The vehicle drive to one
Accelerator and connector are damaged Check the accelerator and connector
direction
Check the battery condition on the
Battery discharging
discharge monitor
The electromagnetic brake has been
Check the electromagnetic brake
activated.
The handle wiring harness isn’t connected Check the handle wiring harness and
The vehicle move slowly or damaged connector
At the 400mm altitude, the speed decreases
Check the sensor
and the sensor fails
Electric system overheated Stop using and cool the vehicle
Check, replace the thermal sensor if
The thermal sensor fails
necessary
Controller damage Change the controller
The vehicle suddenly
start The accelerator has not moved back to the
maintain or replace accelerator
middle place.

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

1、Steering fault code
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code malfunction name Possible cause
12 Controller Overcurrent 1.steering motor wiring short
控制器过流 2.controller fail
13 Current Sense Fault 1.controller fail
电流传感器故障
14 Precharge Fault 1.controller fail
预充电故障
15 Controller Severe Undertemp 1.the controller runs in ultra-low temperate environment
控制器严重低温 2.temperature sensor damage
16 Controller Severe Overtemp 1.vehicle overload
控制器严重过温 2.the controller runs in ultra-high temperate environment
3.the controller is improperly fixed
17 Severe Undervoltage 1.battery or battery cable connection is faulty
严重欠压 2.there are other large loads attached to the battery
3.battery no power and wrong model
18 Severe Overvoltage 1.in regen, the battery and battery cable resistance is too high
严重过压 2.battery cable disconnected during the regen procedure.
21 Motor Temp Hot Cutback 1.vehicle overload
电机温度过高削减 2.the controller runs in ultra-high temperate environment
22 Controller Overtemp 1.vehicle overload
控制器过温 2.the controller runs in ultra-high temperate environment
3.the controller is improperly fixed
23 Motor Polarity Fault 1.the motor polarity is reversed
电机极性故障 2.position feedback device has reversed polarity
24 5V Output Failure 1.5V output overload
5V 输出故障 2.controller failure
31 Main Driver Fault 1.the internal relay coil is damaged
主接触器故障 2.the internal relay drive open or short
32 Relay Welded 1.the internal relay adhesion
继电器粘连 2.controller failure
33 Relay Did Not Close 1.the internal relay receives close command but fails to close
继电器未吸合 2.internal relay patch oxidation
34 Hardware Fault 1.a hardware fault was detected
硬件故障 2.motor voltage is out of range
3.IIC communication is lost
4.power tube short circuit
35 Fault Output Failed 1.the fault output cable is incorrect connected
故障输出失效 2.controller failure
36 Motor Stalled 1.Motor stalled
电机堵转 2.the encode of the steering motor fails or the cable is disconnected
3.the steering motor is disconnected.
4.parameter do not match the motor
37 Motor Open 1. steering motor wiring open
电机开路 2.the wrong motor connection
3.controller failure
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38 Motor Short 1.steering motor wiring short
41 Command Analog1 Out of 1.command analog input 1(J1-6) is out of range
Range 2.low command (J1-14)out of range(for resistive type)
模拟量 1 指令超出范围 3.parameter settings are incorrect.
42 Command Analog2 Out of 1.command analog input 2 (J1-13)out of range
Range 2.analog1 and analog 2 fail to be cross- checked
模拟量 2 指令超出范围 3.parameter settings are incorrect.
43 Feedback Analog1 Out of 1.feedback analog input 1(J1-11) is out of range
Range 2.parameter settings are incorrect
模拟量 1 反馈超出范围
44 Feedback Analog2 Out of 1.feedback analog input 2(J1-3) is out of range
Range 2.analogJ1-11 and analog J1-3 fail to be cross-check
模拟量 2 反馈超出范围 3.parameter settings are incorrect
45 Parameter Change Fault 1.parameter change,need to restart.
参数更改故障 2.parameter are restored to default
46 EEPROM Failure 1.memory parameter verification calculation error
存储器故障 2.controller failure
47 Encoder Fault 1.the encode date exceeds the allowable range.
编码器故障 2.orthogonal encoder A phase or B phase open
3.polarity encoder B phase open
53 Home Position Not Found 1.Home switch failure
没找到 Home 位置 2.installation or cable connection error
62 Communication Fault 1.communication lost during walking
通讯故障
63 Communication Lost 1.Rx(J1-8) cable connection error
通讯丢失 2.there is a handheld programmer being used on the walk controller.
71 Software Fault 1.app failure
软件故障 2.controller failure
73 Following Error 1.parameter setting is incorrect
跟随故障 2.position feedback device failure
3.steering motor failure
75 Parameter Conflict 1.parameter setting and other parameters conflict
参数冲突

2、Fault code of walking controller

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 code Malfunction name Possible cause
1 Controller Overcurrent 1， motor external U,V or W connection short circuit
2， motor parameter isn’t match
3， controller malfunction
2 Current Sensor Fault 1，motor U,V,W through the stator on the car body short circuit,resulting in
leakage.
2，controller malfunction
3 Precharge Failed 1，the positive end of the capacitor is connected with negative load,so that the
capacity can not be charged normally
4 Controller Severe 1，the operating environment of the controller is too harsh
Undertemp
5 Controller Severe 1，the operating environment of the controller is too harsh
Overtemp 2，vehicle overload
3，controller installation incorrect
6 Severe Undervoltage 1， battery parameter setting mistake
2， power consumption for non-controller system
3， excessive battery impedance
4， the battery is disconnected
5， the fuse is not connected ,or the main contactor is not connected.
7 Severe Overvoltage 1， battery parameter setting is incorrect.
2， excessive battery impedance
3，battery connection disconnected during regenerative brake
8 Controller Undertemp 1、 the controller operate under the restricted conditions
Cutback 2、 the operating environment of the controller is too harsh
9 Controller Overtemp 1, the operating environment of the controller is too harsh
Cutback 2，vehicle overload
3，controller installation incorrect
10 Undervoltage Cutback 1，low battery
2，battery parameter setting incorrect
3，non-controller system runs out of power
4, excessive battery impedance
5, the battery disconnected
6， the fuse is not connected ,or the main contactor is not connected.
11 Overvoltage Cutback 1， the regenerative braking current increase the battery voltage during the
regenerative braking
2，battery parameter setting incorrect
3，excessive battery impedance
4，battery connection disconnected during regenerative brake
12 +5V Supply Failure 1， the impedance of external load is too low
13 Digital Out 6 Failure 1， the impedance of external load is too low
14 Digital Out 7 1， the impedance of external load is too low
Overcurrent
15 Motor Temp Hot 1， the motor temp reaches or exceeds the alarm temp set by program,
Cutback resulting in reduced current output
2，motor temp parameter setting incorrect
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3， If the motor does not use a temperature sensor, the programming
parameters “Temp Compensation and Temp Cutback” must be set to OFF.

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16 Motor Temp Sensor 1，motor temp sensor connects incorrectly
Fault 2， If the motor does not use a temperature sensor, the programming
parameters “Temp Compensation and Temp Cutback” must be set to OFF.
17 Coil 1 Driver Open/Short 1， load connection to be open or short
2，the connection pin is dirty
3， wrong connection
18 Main Open/Short 1， load connection to be open or short
2， the connection pin is dirty
3， wrong connection
19 Coil2 Driver Open/Short 1. load connection to be open or short
2. the connection pin is dirty
3. wrong connection
20 EMBrake Open/Short 1，load connection to be open or short
2， the connection pin is dirty
3， wrong connection
21 Coil3 Driver Open/Short 1，load connection to be open or short
2， the connection pin is dirty
3， wrong connection
22 Coil4 Driver Open/Short 1，load connection to be open or short
2， the connection pin is dirty
3， wrong connection
23 PD Open/Short 1，load connection to be open or short
2， the connection pin is dirty
3， wrong connection
24 Encoder Fault 1， Motor encoder failure
2， wrong connection
25 Motor Open 1，Motor Open phase
2，wrong connection
26 Main Contactor Welded 1， main contactor contact fusion
2， motor U or V disconnected or missing phase.
3，the circuit capacitor connected to the B+ terminal is charged
27 Main Contactor Did Not 1， main contactor is not closed
Close 2， primary contactor junction oxidation, melting, or unstable connection
3， the capacitor is charged by external device.
4， the fuse is disconnected
28 Throttle Wiper High 1，the output voltage of accelerator potentiometer is too high.

29 Throttle Wiper Low 1，the output voltage of accelerator potentiometer is too low.

30 Pot2 Wiper High 1，pot 2 output voltage is too high

31 Pot2 Wiper Low 1，pot 2 output voltage is too low
32 Pot Low Overcurrent 1，pot impedance is too low
33 EEPROM Failure 1，fail to write the EEPROM storage. This may caused by VCL writing to
EEPROM EEPROM storage, or by CAN BUS,or by a parameter error programmed into
the controller after the programmer parameters are adjusted.
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34 HPD/Sequencing Fault 1， key start,interlock, orientation and accelerator input sequence are
incorrectly set.
2，wiring,switch key,interlock, orientation or accelerator input failure.
35 Emer Rev HPD 1，the emergency reverse operation is over,but the accelerator, forward and
reverse input and interlock have not been reset.
36 Parameter Change Fault 1，In order to ensure the safety of the vehicle, certain parameter changes must
be reactivated after the key switch.
38 VCL RunTime Error 1，the VCL code timed out
39 External Supply Out of 1，the 5Vnad 12vV source currents are too large or too small
Range 2， parameter error in Checking Menu，such as“ExtSupply Max”,“Ext Supply
Min”
40 OS General 1，internal controller failure
41 PDO Timeout 1，CAN PDO message receiving time exceeded the PDO time limited.
42 Stall Detected motor stalling
2，motor encode failure
3，wrong wiring connection
4，Power supply of the input motor encoder is faulty
43 Motor Characterization 1, in the motor matching process of modern code comparison:
Fault 0 = normal
1= The controller receives the encoder number,
But the impulse quantity is undefined.Please hand 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, 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 1. Due to motor blocking or encoder
Operating Strategy) 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
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 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).

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3. Circuit/circuit diagram
a. Circuit

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 b. Hydraulic circuit

Hydraulic circuit diagram（with lateral）

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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 good mixed with air and water
hydraulic fluid
Not
The color becomes dark brown for oxidation replacement of hydraulic oil
good
Clear color but small black spots good mix with other particles can be used after

4. Disassembly of main parts

a. electromagnetic brake adjustment
Adjusting nut

Note: electromagnetic brake

can't pull properly when it is Electromagnetic brake clearance is about
powered on in free state, it 0.25-0.35mm, about the thickness of a piece of
needs external force or paper.Need to be adjusted carefully repeatedly,
installation to pull ensure that three adjustment surface clearance is
consistent, electricity will give out a crisp sound.

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 c. Drive the disassembly diagram

Electromagnetic brak

Steering
motor
Drive motor

Driving whee

Gear case

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 d. Handle assembly

Belly switch

Tortoise speed switch

Horn button

Accelerator
Accelerator button

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e. Dismantling of frame and door frame

After removing the axle seat

cover and bolt, the door
frame can be separated
from the frame. Note: the
bolt body and door frame shall
be fixed with external
objects during disassembly
to avoid safety accidents in
the process of disassembly.

f. Mechanical part of door frame

The clearance between

the door frames is
adjusted by adjusting the
tightness of the adjusting
screws

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 The door frame can be
raised by loosening the
adjusting screw

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Door frame with side sliding

Multistage door
frame

Measuring instrument
carriage

fork

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f. Frame mechanical part
Pressure regulation diagram

The relief value is

used to adjust the oil
pressure, which
should be adjusted to
avoid excessive
pressure causing
damage to the car
body

Disassembly drawing of adjustable leg bearing wheel（Model with slide shift）

Bolt Straight pin

bearing

axle

Pressing plate Connecting plate

Wheel bearing

Car leg

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

Vehicle fault reading process:

1. After connecting the hand held unit with the controller, open the key switch
2. From the menu list of CURTIS hand held 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 hand held unit with the controller, open the key switch
2, According to the menu list of CURTIS hand held unit, 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 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 fault diagnosis

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

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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 controller, the hand held programmer will be powered on automatically and the
control information will be displayed on the programmer.

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 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.

Collect keys

There are two ways to enter the Favorites menu. You can

enter Favorites from the main menu or press this key

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 dialog 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.

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nine menu

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 and 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 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

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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.cpf files as you want, and you need to name
each.cpf 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 dialog box is displayed asking
you to restart the system.

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