Electric Stacker

ES12(10)-12(10)ES
——After-sales Training Handouts
CATALOGUE
Part 1. Appearance and parameters

Part 2. Main parts and functions

Part 3. Circuit diagram

Part 4. Handset and parameters

Part 5. Error code and processing

Part 6. Daily Maintenance

Part 1. Appearance and parameters

ES12(10)-12(10)ES
Electrical stacker
Economic stacker
Capacity 1200kg（1000kg）
 Express Name ES12-12ES Unit Remarks
Main parameters (part)
Q Rated capacity 1200 kg

c Load center distance 600 mm

Travel speed, laden/ unladen 3.5/4 km/ h

Lifting speed, laden/ unladen 0.12/0.22 m/ s

Max gradeability, laden/unladen 3/10 %

Service weight (include battery) 661 kg

Battery voltage/nominal capacity 2×12/ 105 V/ Ah

l1 Overall length 1740 mm

m2 Ground clearance 30 mm
Aisle width for pallets Including safety
Ast 2225 mm
1000×1200 crossways distance a = 7.87 in
Aisle width for pallets Including safety
Ast 2150 mm
800×1200 lengthways distance a = 7.87 in
See operation
manual or product Wa Outer turning radius 1408 mm
sample to find all
parameters. Type of drive control DC
Part 2. Main parts and functions

Frame system

Operation system

Driving system

Hydraulic system

Lifting system

Electrical system
Frame
system

Load wheel Caster assembly Cover

Load Wheel
From EP parts manual
Caster Assembly
（Notice: Different from the caster part in EPT10-22MM ）
Operation
system

Accelerator BDI Tiller switch

 Negative
Accelerator Of battery
Rev (10)
Controller

Technical specification:
• Curtis brand—ET165MCU
• In controller , the type of
throttle is set to 2
• Input voltage: 24V
• Output voltage: 0~5V
• Backward direction control
through single wire No.11
Attention: please ensure the right
installation position of two different
bolts. Wrong installation will break
accelerator.
 HANDSET
CURTIS
Accelerator detection
Through handset
Monitor Throttle Swing accelerator knob and see parameter change
in handset
 If item “throttle” has a change between 0-100%, the accelerator is normal.
 If it can’t rise to 100%, the accelerator needs an adjustment.
 If no change in handset, the accelerator has a problem, please check the wire
harness or change a new one.
Status of accelerator Normal Abnormal
Operation Display on handset

Swing it forward Forward input off/on change off/on no change

Swing it reverse Reverse input off/on change off/on no change

 BDI

Function:
1) Calculate and display
battery electricity
independently
(Always red light)

2) Calculate and display the

working hours (option)
It starts counting when the
tiller switch is closed
 Analysis of failure examples about BDI

1) The BDI shows electricity still has 70%, but the truck moves very slowly, and no
error code?
Solution:
① Check the battery electricity through handset and multimeter, if it shows the
battery electricity is already less than 20%, then the BDI has fault , replace it;
② If it is the same as the BDI shows, you need to check other parts especially
accelerator 、electromagnetic brake, which will be introduced in the following;

2) The former three lattices of BDI (100%→70%）drop very quickly after full
charged?
Solution:
Take the battery charge after the battery electricity is less than 30% , otherwise this
phenomenon may happen;
 Battery charge

LED light mode of battery charger:

Note: About “How to replace battery
• Red light : Under charging
• Constant green light: Full charge charger or Battery “, you can watch the

• Constant yellow light: Battery fault video in EP APP—Training folder;

• Yellow light flash: Battery charger fault
 brake

Tiller switch

Open

brake
 Normally open contact

Normally close contact

CMD(+24V) Multimeter

1st: 2nd : 3rd :

1) Use handset Monitor 1) Disconnect the 1)Take off the tiller
inhibit. Press/release tiller harness as the picture
Tiller switch

switch wire 1 and 8;

detection

switch, see off/on status in shows;

2) Press/release active 2) press/release active
handset:
end of the switch and end of the switch and
2) if off/on change, tiller measure on-off status
switch and the relative measure on-off status
between wire 1 and
harness is normal ; wire 8 with a of the part with a
3) Otherwise, go to step 2; multimeter. multimeter.
Driving
system DC Motor Butter hole

Electromagnetic
Brake
Junction box

Gear case
 A、B：Carbon brush
Motor (DC)

Video of “Driving wheel and motor carbon brush change” is in the EP APP—Training folder
Daily maintenance of the driving motor

1. Detection and change of carbon brush

• Measure the residual length of the carbon brush , if it is
less than 1/3 original value, replace it; （Different
specification different residual length, mainly depends
on the length of pre-embedded wire and spring）;
Just schematic pictures , not from
• The new carbon brush must be the same as the old this truck
ones , including mark and size ;

2. The contact surface of new carbon brush should

be grinded to be close to the commutator;
• Use 0# glass paper grind it as the picture shows ;
• Then, drive motor at low speed to polish the contact
surface of carbon brush
 Commutator Surface Inspection
The commutator must be repaired once it has nick
or damage on the surface, otherwise it will damage
the motor or speed up the wear and tear of the carbon
brush.
① Checking the surface of the commutator regularly:
clear out the carbon powder on the surface and
inside of the trough.
② When there is scratch, roughness and burn, polish
the commutator or finishing turning the top circle.
Use the number”0” glass emery cloth to polish. commutator
When finishing the top circle, put the bearing in
the central frame and process it with the purpose bearing
of insuring the same shaft angle for the
commutator and axes of the armature.
Dismantle gear case and driving wheel

This video is available in EP APP—Training folder

Electromagnetic brake

a. Mechanism: current-
coil-magnetic field-
platen-drive;
b. Air gap: 0.2~0.3mm by
feeler;
c. What’s the result if the
air gap is not right?
Electromagnetic brake detection

Measure the resistance Take off the plate, Check brake spring’s
of brake coil, normal check resin above elasticity, and ensure
value is around 20Ω. If the brake coil. If the every spring has same
the value is too big or resin thawed, length. If not, replace
too small, replace a replace a new brake. the springs.
new brake.
Analysis of failure examples about EB

Brakes does not release

Air gap more than 0.25mm Brake temperature above 140℃ Handset check the status of brake,
If ON/OFF change with operating
Check air gap Adjust brake air gap No Yes
or change brake disk
Check the wire from
controller. if there is output Check
with multimeter air gap
No
Yes
Check Check brake coil resistance,
power normal it be should 20Ω.
and
controller No
Yes
Change
Adjust or change
brake disk Check brake coil plug
 24V DC
Pump motor

Hydraulic
system
Pump contactor
Coupler

Adapter

Pump

Return pipe
Suction pipe

Oil filter
Adapter details
Oil filter

Check valve

Connect to cylinder
Safety valve

Throttle valve
Solenoid valve
Hydraulic System Diagram
Lifting process:

Lifting cylinder oil tank→oil filter→pump→Check

valve→cylinder;

Lowering process:
Solenoid valve
cylinder→solenoid
Check valve
valve→Throttle→oil tank
Relief valve
Throttle valve
Pump motor

Oil filter

Tank
Hydraulic oil and lubricating grease

Oil type quantity

Hydraulic
46# ~3.5L
oil
Grease
Lubricating
Contain Till overflow
grease MuS2
Pump contactor detection

Fault
Trouble shooting
phenomenon

Normal circuit,
but pump motor Running means contact is on,
is running all replace a new contactor.
the time

① Use multimeter resistance

channel to measure
contactor coil’s resistance, if
the resistance is infinit, that
Normal circuit,
means the coil is break,
but pump can’t
replace the contactor.
run
② When the resistance is Connected to coil
around 22Ω , that means the
contactor is normal, there is
fault in pump motor.
Pump motor detection

① Take off pump motor cables, measure

on/off status of pump motor’s connectors
with a multimeter’s pin A & pin B.

② If status is on, the motor is normal. If

status is off, the carbon brush is wore or
circuit break in rotor coil.

③ Separate pump motor and replace

carbon brush, check whether there has
circuit break in rotor coil. Replace motor if
circuit break.

④ Check if commutator is burn.

⑤ Check if two bearings are locked where Separate bracket, check whether
the arrow shows. carbon brush is wore seriously.
Analysis of failure examples about Hydraulic system
In case of normal battery, controller and circuit, the main trouble of hydraulic system
is no lifting, detection method is:

Step 1: Lowering the vehicle to the minimum height, check the oil level in tank.

Step 2: Separate oil pipe, put pipe head into a container with hydraulic oil, then
running pump and motor, if there is no oil comes out, the pump maybe broken. If
there is oil comes out, measure the pressure of pipe.

Step 3: If the pressure is abnormal, the pump maybe wore or the spool is blocked.

Step 4: If the spool is blocked, separate it and

clean it. If not blocked, check spool spring is
normal or not. If abnormal, replace it. If normal,
Coil
measure pipe pressure again. Spool
Step 5: If pipe pressure is abnormal, maybe the pump is wore, replace a new
pump.

Installation Gear pump tail

Valve body
flange
Fixation bolts

Pressure
sheetmetal
Seal

Driven gear Drive gear

 Noisy pump

Low oil supply Oil too heavy Air leak in inlet hose

Add oil to Change oil

suitable Inlet hose
level

Replace
or repair
 Pump or oil overheating

Oil is too thin Pump cavitation System relief valve bypassing

or contaminated oil

Change
oil
Relief valve

Check whether
the inlet hose and
outlet hose tight Replace or repair

Add oil to
right level
 The truck can not lift

Hydraulic system fault Electric circuit fault

(see next page)

Solenoid valve fault Relief valve have leaking. Oil pump fault

If the o-ring is ok? Adjust the No Change control No

Change oil pump
No adjustment nut valve
Yes Replace Ok Ok

Remove the o-ring then Carefully adjust Over

launder the solenoid the adjustment nut to
valve lower for test full load
Ok
No Over
Change the solenoid No
valve lower and o-ring
Ok
Over
 Electric circuit fault

Check fuse 10A and

Lifting switch fault Lifting limit switch fault Lifting contactor fault Lifting motor fault

Open the operation Remove number 2 Press down the lifting Check if the motor
handle box, disconnect and 5 wire , check if switch then measure brush is ok
plug, press down the lifting limit switch is voltage between No.5 No
lifting switch, measure ok and B- wire, normal it
the resistance between should be 24V Change the motor
No Ok
number 1 and 2 wire, No
normal it should be 0 Ω Change Yes
Check wire
harness Measure resistance
No
of contactor coil
Change normally it should
Yes
be around 22Ω

No Yes
Change the contactor
 The truck can not lower

Solenoid valve switch fault Lower switch fault

No
If the o-ring is ok? Replace Open the operation handle box, disconnect plug ,
press down the lower switch, measure the
Remove the o-ring then launder Ok resistance between number 1 and 3
Over wire ,normal it should be 0 Ω
the solenoid valve lower for test
No No Yes
Ok Check plug and Change
Change the solenoid valve lower and o-ring Over
Wire harness
No
Measure the resistance of solenoid valve No
Over
lower, normally it should be 32.5Ω
Yes
Check above item again
Lifting
system

Fix Cylinder
Replace the sealing of lifting cylinder
Take down wiper and seal,
Take down lifting cylinder’s head. and replace them.
①
③

Take down piston rod.

Replacing method is similar with this in
other same type cylinders.
Electrical
system Exchange M1&M2,
you can change the
vehicle’s running
direction

J3 brake
connector Battery terminals
J1 logic
connector Note
You can’t exchange
B﹢&B﹣, which will
burn controller. Motor
Motor terminals short circuit will burn
controller, too. It’s not
allowed.
J2 handset connector/
Charger connector
Technical specification
No. Name Specification No. Name Specification
1 Normal input voltage 24V 11 BDI output resistance 10KΩ
2 PWM working frequency 15.6KHZ 12 Speed control signal 0-5KΩ/0-5V
Insulating strength with heat
3 ＞500V 13 Spee control type Single-ended/Wiggle
sink
4 B+ B- logic current ＜9A 14 Working temperature -25 - 50℃
5 KSI input current ＜150mA 15 Storage temperature -40 - 65℃

High temperature
6 Logic input current ＜1mA 16 80℃ limit, 105℃ cut off
current limit

Low temperature -10℃ limit, -25℃ cut to

7 Alarm output current 15mA 17
current limit 50%

8 BDI output voltage 0-5V 18 Seal IPX5

9 LED driving current 15mA 19 Weight 0.3Kg
Electromagnetic brake
10 32-200Ω 20 Size 72×131×39 mm
resistance
Connectors and cables’ details

M1 Motor negative
M2 Motor positive

B－ Battery negative

B＋ Battery positive
Controller detection

Step a, Step b,
discharge controller with a detection items is in the following table.
resistance (30Ω, 5W), which
connect to B+ and B-.

Test every item three times at least.

Note
Test value is normal can’t not ensure controller normal.
To test polarity values, turn multimeter to ON/OFF channal.
Part 3. The circuit diagram
Note: Only when all
conditions of arrows which
point to one part are ok, this
part will work
 The truck can not move Check If lift is ok

No Yes

Check the Key switch fault DC Motor check Tiller switch check Accelerator check Brake check
voltage
of battery
Disconnect plug, Use multimeter Use handset check Use Disconnect brake
open key switch, check the voltage the status of tiller handset plug, press down the
Normal measure resistance of DC motor (M1、 switch; check the Handle and rotate
between No.0 and 1 M2）while status of accelerator, measure
No
wire (key switch operate truck accelerator the voltage between
Check the normally No.6 wire and B-,
side), normally it Disconnect plug,
fuse No normally it should
should be 0Ω. press down the
And the be around 24V.
handle, measure
emergency No Normal
resistance between Check the
switch No Yes
No.1 and 8 wire, no.1(24V)
Change key Change the normally it should and
switch DC motor Check Check brake
be 0Ω. no.10(0~5V) inside coil resistance,
Ok wire or the truck normally it
No
replace the wire should be
Over accelerator around 20Ω
Replace
the
No
tiller
switch
Change the brake
Controller fault
 The truck can only move forward or backward

No.11 Wire check Emergency switch

check
With rotating the
Use multimeter Check continuity
accelerator, no
check the of the No.11 Check if the
voltage signal
voltage of No.11 wire emergency switch is
comes out from
wire shortcircuit
No.11 wire

No matter if
rotate the
accelerator or
Replace the Replace the
not, always
accelerator controller
voltage signal
comes out from
No.11 wire
Part 4. Handset and parameters

Menu select

Value increase
Navigation
Value decrease

Power Help

Main menu
Favorite
4.1 Parameters
Brief introduction of main parameters usage scenarios

Used to adjust the acceleration and

deceleration
CASE 1. Clients use this truck to
transport fragile goods like glass, he
may complain his truck accelerates
too fast and decelerate too abruptly
which make his goods in danger.

Used to adjust the maximum forward

and backward speed of mode 1(normal
driving state), respectively

The speed in mode 2 is often set smaller,

which is used when the speed reduced
switch is active
Based on the type of throttle, this truck normally is 2
CASE2: after used for a long time, the neutral area of
the throttle becomes bigger than initial value, and
then the truck always report “incorrect start”. Then
this parameter should be adjusted;
In case 2, the error “incorrect start” is from this HPD

Used to adjust the maximum current of the truck

CASE 3: clients want to use this truck in narrow space

place like container、carriage, so it’s not convenient
to press down handle, two methods are available
through this menu, 1) set type 2 to type 5 2) set
speed to 100% or other number not 0% ;
Note: this menu is not used to control the BDI real part, it’s a BDI function inside controller;
So our truck has two ways to display and calculate the battery electricity independently;

Define the start and finish charge voltage

CASE 4. Clients complain he already get the

battery charged for 3 hours, but the truck still
move slowly like no enough power (Normally,
full battery charged needs around 6 hours);
So, only when the voltage of battery exceed
the value(reset voltage), controller will reset
its calculator, return to 100% ; Otherwise, the
value will not change, and the truck stay in
“Low BDI level”;

Battery protection function: When the residual battery

electricity is less than 30% (Low BDI level) , the max driving
speed will be reduced to the value(Low BDI MAX speed)
4.1.1 Parameters → Drive menu
4.1.2 Parameters → Speed menu
4.1.3 Parameters → Throttle menu
4.1.4 Parameters → Current menu
4.1.5. Parameters → Inhibit menu
4.1.6 Parameters → Brake menu
4.1.7 Parameters → Horn menu
4.1.8 Parameters → Motor menu
4.1.9 Parameters → BDI menu
4.1.10 Parameters → Compensation & Miscellaneous menu
4.2 Monitor
Part 5. Error code and processing

There are two ways you can get the error code from controller.

First way: connect your handset to controller, enter “Diagnostics” menu

to see error list.

Second way: get a error code through observing flashing times of diagnostic
LED. A normal vehicle’s diagnostic LED is on all the time. When there is a fault,
diagnostic LED will flash in different phase, that is the error code.
The following figure shows error code 1,4.
Part 6. Daily Maintenance
W = Every 50 service hours, at least weekly
A = Every 250 operating hours
B = Every 500 operating hours, or at least annually
C = Every 2000 operating hours, or at least annually
W service intervals are to be performed by the customer.
 Name Type Quantity Period

Hydraulic oil 46# ~3.5L 2000 h

Lubricating Grease
Till overflow 250 h
grease (contain MuS2)