EKKO EK15A-189LI Series User manual

1
The Specification
EK15A-189LI Series -3 Wheel Electric Forklift
Note: Before using please read this manual and the various warning label!
EKKO Material Handling Equipment Manufacturing,
Inc.

2
Contents
I. Introduction.....................................................................................................................................3
1.1 Summary...............................................................................................................................3
1.2 Parameter.............................................................................................................................3
II. Structure and working principle............................................................................................4
2.1 Basic structure....................................................................................................................5
2.2 Working principle.............................................................................................................6
2.3 Electrical principle............................................................................................................8
2.4 Hydraulic principle...........................................................................................................9
III、Safety operation and matters needing attention ..................................................... 10
3.1 General rule...................................................................................................................... 10
3.2 Storage and transportation........................................................................................ 11
3.3 Check before using......................................................................................................... 11
3.4 Operation specification................................................................................................ 12
3.5 Safe Operation Rules..................................................................................................... 15
IV.、Maintenance and Service Manual.................................................................................. 17
4.1 Repair and maintenance of safety procedures................................................... 17
4.2 Routine Maintenance (Before every shift)........................................................... 18
4.3 Professional Maintenance Manual .......................................................................... 18
4.4 Maintenance, Recharging and Replacement of the accumulator................ 21
V、Service Manual ...................................................................................................................... 27
5.1 Troubleshooting ............................................................................................................. 27
5.2 Preparation before repair........................................................................................... 28
5.3Check hydraulic oil level............................................................................................... 28
5.4 Use Preparation after maintenance or repairing .............................................. 28

3
I. Introduction
1.1 Summary
This manual combines the whole EK15A-189LI 3300lb three-wheel
counterbalanced electric forklift (hereinafter referred to as "forklift").
1.2 Parameter
EK15A-189LI

4
Model
EK15A-189LI
Load capacity
Power
Operator type
Seat
Load capacity
(lbs)
3300
Load center distance
(in)
23.6
Wheel base
(in)
43
Lifting height
(in)
189
Lowered mast height
(in)
83.54
Mast/Fork carriage tilt
forward/backward
(°)
2/5
Overall length
(in)
106.6
Overall width
(in)
36.1
Fork size,
Thickness/Width/Length
(in)
1.4/4/45.2
Fork adjust width
(in)
8.7-29
Turning radius
(in)
53
Max gradient performance,
laden/unladen
(%)
6/8
Lift speed, laden/unladen
(in/s)
4/5.5
Lowering speed, laden/unladen
(in/s)
5.3/4.7
Charger
24V/50A
Driving Motor
AC 24V/2.0kw
Lifting Motor
24V/2.5kw
Battery voltage
24V/350AH--LI(Side）
Service Weight
(lbs)
5560

5
II. Structure and working principle
2.1 Basic structure
The power source for this forklift is lead acid industrial batteries. This Forklift
uses electric and hydraulic system to control, driving, lifting and lowering, mast
tilt forward and backward, steering and other movements. The basic structure
shown in FIG.

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1. .Steering wheel 2. Combination Switch 3. Key Switch 4. .Lifting handle
5..Tilting handle 6. Side shift handle,7.Emergency stop switch 8.Accelerator
2.2 Working principle
2.2.1 Walking system
The batteries provide energy to forklift for driving. With a frequency
conversion system, it converts DC into AC, by controlling the AC motor drive on
drive wheels. AC motors through the gear box converts the high-speed low
torque into a low speed high torque, and ultimately by the drive wheel to
perform the action. Driving speed is controlled by frequency control motor with
an accelerator control.
Gear box is filled with enough gear box oil at straight from the factory.
Under normal circumstances, the gear box oil should be checked every 1000
hours.
If there is ever abnormal sound in within the gear box during use, the user
should immediately stop the forklift to determine whether the bearing or gear
short of fluid or is damaged. Continue to use only after refill or replacement.
2.2.2 Steering system
The steering of this forklift is controlled by the steering wheel through the
steering reduce gear unit, led by a steering sensor sending unit, sending a signal
to the steering motor. The steering column also has a steering shaft to tilt back
and forth at a 2- and 5-degree angle, to meet diverse needs positioning of the
load.
2.2.3 Braking system
The braking system on this forklift is combined with both the braking system
and the parking brake.
Braking meaning stopping or slowing down the truck during operation, by
compressing the foot brake.
When the brake cylinder is compressed, the same force of the main brake line
suppresses the brake drums until the top of brake pads compresses the fixing

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pins, the brake pads will move to the rotation direction of brake drum. The
friction between brake drum and friction plate is then increased.
Double brake pads are mounted on both sides of the drive axle. Brake consists of
two groups of brake pads, brake cylinder and regulator. One end of the brake pad
is in contact with the fixed pin, and the other end is in contact with the adjusting
calipers. The returning spring and compression spring rod suppress the parking
brake lever unit. In addition, the brake is also assembled with a parking brake
mechanism and automatic adjustment device.
Brake
1. Left baseboard 2. Brake shoe 3. Brake cylinder 4.adjustable Spring
5.return spring 6. Hand brake adjusting mechanism 7.hand brake return
spring 8.spring tab letting 9.pressure lever 10.tension spring 11.pull
rod stop block 12.Jaw dust cover
The parking brake should always be used for parking, to prevent accidents
caused by slippage and secure the forklift. Also equipped with a limit switch on
the parking brake, the control circuit is closed under a parking state. The parking
brake must be released before starting to drive, only after that the control circuit
can be switched on. The parking brake has adjustable elastic functions.
2.2.4 Operating system

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The main working part of the forklift is the forks. The forks recognize the
loading, unloading, stacking and short-distance transportation for pallets or
cargo.
The forks are mounted on the carriage, by chain drive or inner mast moving
up and down, the carriage and forks lifts the goods off the ground or to be
stacked on racks. The chain transmission and inner mast overall movement are
achieved by the extension of the lift cylinder. Forklift operation process is
achieved by extending of the control cylinders (including tilt action).
Cylinder movement is controlled by a physical valve stem, and the oil
pressure is provided by the hydraulic pump.
The controlled safety valves in the lifting cylinders and tilt cylinder will
slow down the speed of mast lifting, lowering or tilting to ensures safety.
2.3 Electrical principle
2.3.1 Electrical system
The forklift electrical system includes driving and operation control, and lighting.
The forklift implements Curtis Instrument Controllers and i.e. CURTIS1232 AC
control assembly.
The controller has the indicator for power display, slowing down of mast lifting,
parking and hour meter display function. When the battery power is may be low,
the power meter will cut off the control circuit of pump motor to protect its
battery life. The forklift will not lift however can still drive, which means the
forklift should be charged immediately.
The hydraulic pump motor is a DC motor therefore not recommended for long
continuous operations. The lifting movements should have intervals, should not
be continuous, otherwise it can cause the motor to overheat
Special Note: If the forklift is used for a continuous period, the pump motor may
lack performance. The lack of performance is that the starter may not lift
properly. The latter one is represented as no lifting with the multi-way valve
control lever, pump motor will keep turning. If this occurs the forklift should be
turned off. Disconnect the battery and allow time to dissipate the overload.

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The forklift is equipped with front headlights, rear lights, reversing warning horn
and other safety and lighting devices.
The switch groups
2.4 Hydraulic principle
Pump motor driven gear pump provides hydraulic power; Two lifting cylinders
are responsible for the forklift; a tilt cylinder is for the mast tilt movements. The
oil-way for Lift-lower and tilt is controlled by two handles on the double valve,
the lifting and lowering action is controlled by a single-acting oil-way on the
passage double valve, while tilt motion is controlled by a double-acting oil-way
on the double valve passage. The hydraulic system pressure for this forklift is
adjusted only on double valve, which is set at to factory specifications. If you’re
not our after-sales dealer or professional repair staff, it is not allowed to adjust,
to avoid accidents and warranty.

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Hydraulic principle FIG.
III、Safety operation and matters needing attention
3.1 General rule
3.1.1 The operator must have a forklift operation certificate or qualification
which proved by the relevant departments of the training before driving a
forklift.
3.1.2 The operator must read the instructions before use and understand the use
and operations of this forklift.
3.1.3 Forklift must never to be used to carry passengers.

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3.1.4 Operators should pay close attention to the environment, including other
pedestrians and nearby structures.
3.1.5 Without the manufacturer's approval, no one shall modify, add or remove
the any parts off the equipment.
3.2 Storage and transportation
3.2.1 Transporters should be qualified and pay attention of shipment:
○
1 Front and rear wheels should be wedged, use of parking system, to prevent
from sliding in the process of transportation;
○
2 Use of straps, must be placed on the frame or structure of the forklift;
○
3 When the forklift is being used, keep the forklift truck's center of gravity
in the intermediate position of the forks 24” load center.
3.2.2 If the forklift fails to work, it should be parked in a dry ventilated area:
○
1 Shut off all ignition, emergency switch, and unplug the power connector
from battery;
○
2 Pull the parking system, front and rear wheels with wedged blocks;
○
3 If discontinued for a long period without use, the battery should be
charged every 15 days.
3.3 Check before using
3.3.1 New forklifts should be checked for any damages during transit, please
don't be put into use if there are signs of damage, and promptly get in touch with
the dealer for proper process.
3.3.2 New forklifts from our factory are all properly inspected with all
lubricating oil, hydraulic oil, and batteries are filled to manufacturer
specifications.
3.3.3 All forklifts are equipped with batteries and charger. The batteries are
charged before leaving our facility. Before use, it is always recommended to pay

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attention to battery meter which whether a charge is required. Every day before
use, or before charging, you should open the battery covers to check the water
level, if it is ever lower than recommend, please add only distilled water into the
battery’s cells.
3.4 Operation specification
Before operating the forklift, please get familiar with the dashboard
functions of each switch/button.
3.4.1 Start, run and parking:
○
1 Insert the key into the key switch, turn to the right, the emergency power
safety switch should be lifted upwards to engage power.
○
2 Lift the forks at least 10cm from the ground to ensure no structure
interference.
○
3 Begin to disengage the parking system.
○
4 According to your desired direction, push the lever either forward or
reverse.
○
5 Start accelerating by stepping on the accelerator pedal slowly, until the
desired speed.
○
6 In case of an emergency or urgent need to stop, quickly cut off the power
supply by pressing down on the red emergency power switch.
○
7 When driving into a turn, reduce speed, where possible.
○
8 Forklift gradeability is 8%, so during an uphill slope, keep into
consideration when climbing the gradient to accelerate the pedal to maximus the
upward force.
○
9 Forklift in the process of downhill, let loose of the accelerator pedal, in
order to obtain the reverse braking current, if the reverse current can't control
the downhill braking speed. Please then apply the brake pedal at the same time,
to ensure safety.

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○
10 When not driving, always maintain the foot on the pedal of the brakes.
Put the pallet fork in the lowest position, keep hands in the forklift, press the
safety switch, pull out the key.(Note never leave without using the brake lever
forklift).
3.4.2 The steering wheel angle adjustment
According to the individuals operating comforts. The steering wheel angle can be
adjusted . Adjustment method is as follows: Loosen the left hand of direction
column, adjust the steering wheel to the right position, then lock regulating
handle.
3.4.3 Accelerator pedal operation
Determine the forklift direction either forward or reverse. Toggle left side handle
in place, right on the foot pedal accelerator to drive forward or backward.
Continue pressing down on the pedal to desired forklift speed. Never pressed
down the foot accelerator completely down unless as necessary in a incline.
3.4.4 Brake pedal operation
When the forklift needs to be parked or to slow down, you can either lift off the
accelerator foot pedal or press on the foot brakes to slow down or stop.
3.4.5 The using of emergency power safety switch
If the forklift ever loses control or there is a malfunction, please press the red
emergency switch on the right console to immediately shut off. Determine the
fault or reason of loss of control. If all is safe and secure continue use by pulling
the red button upwards to engage in full functions.
3.4.6 The use of reversing beeper
For the safety of operations and pedestrians, this forklift is equipped with
reverse beeper to allow others of your reverse movement. Also recommended to
press the horn while reversing or around obstructed corners from line of sight of
others.
3.4.7 The operation of the control handles

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Hydraulic control handles are for hydraulic diverse needs, there are two
functions including with the following functions:
(1) Forklift lever: a. fork to ascend (pull); b. fork to descend (push)
(2) Tilt lever: a. back tilt (pull); b. forward (push)
Each handle is used to operate a hydraulic circuit. Each handle has a micro
switch that will start the hydraulic pump motor rotating at the same time, the
output pressure of hydraulic oil, is related to each hydraulic component. In order
to ensure the safety of hydraulic system pressure, the hydraulic valve block is
equipped with pressure relief devices. The control valve will automatically
disburse the overflow.
Note: the pressure of the hydraulic valve block device, cannot be adjusted.
3.4.8 Battery capacity indicator
The battery capacity meter is located on the dashboard to display battery
reading and can also use to determine electricity time statistics (cumulative
hour).
3.4.9 Handling stacking operation
(1) How to transport the goods and stack loads
Driving the forklift with load always required to drive with ease and caution,
slowly. Forks should always be parallel to the ground. Inserted the forks into the
pallet with the load center of minimum of 24” from backrest. When the forks are
completely inserted into the pallet lift the forks off the ground to a minimum
height without obstruction to maneuver. Always maneuver a forklift with loads
at a minimum height to protect others and the loads with the mast tilted back.
（2）The weight on load
When ready to pile one load on top of the other. Pull up to the goods to be
stacked then lift the forks to the desired height. Move close to the pile of
deceleration, then line up the load you currently have on the fork with the load to
be stacked on top of. Adjust and raise the mast to the vertically, slowly drive the
forklift forward to pile on top. Use the hydraulic control lever slowly. Once
centered then tilt the forks parallel, then lower the load on top of each other.
After the load is stacked then carefully maneuver the forks out of the load.

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3.5 Safe Operation Rules
3.5.1 Requirements for drivers: The forklift must be operated by a trained and
certified operator.
3.5.2 Drivers’ rights, obligations and responsibilities: They are familiar of the
operations of this forklift, the operator must be clear of his rights and
obligations; and is familiar with the contents of the relevant operating
instructions. Safety gear should always be recommended.
3.5.3 Prohibit unauthorized personnel to operate: the driver is responsible
for the vehicle at work. They must prevent unauthorized persons from driving or
operating this truck. It is forbidden to use the vehicle to transport or lift
personnel.
3.5.4 Malfunctions and defects: If there is any malfunction or defect for the
forklift, they must immediately inform management. If the forklift cannot be
safely operated (e.g.: wheel wear or brake failure), then all use of this forklift
must be fully inspected for repairs before operation.
3.5.5 Safe operation and environmental protection: inspection and
maintenance must be performed in accordance with the time intervals on the
maintenance list.
Forklift parts cannot be changed without being a certified technician,
especially safety devices. The operating speed of the forklift is not allowed to
change.
To ensure the safety and reliability of the operation of this forklift, spare
parts should be EKKO’s spare parts to ensure reliability. The old parts, such as
oils and fuels must be handled in accordance with the relevant environmental
protection rules.
3.5.6 Hazardous area: Hazardous area usually refers to the following range:
forklift or its load lifting devices (e.g. fork or accessories) is dangerous for
personnel when running or lifting, or the ongoing regional transport loads.
Typically, this range extends to the load or vehicle accessories landing area.
3.5.7 Risk environment: When working in high-risk environment, you must
have a safety gear for protection.

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The vehicle was not specially designed for the high-risk environment.
3.5.8 Safety devices and warning signs: Safety devices, warning signs and
warning notes described in the previous operating instructions must be taken
seriously.
3.5.9 Driving in public places: the vehicle is forbidden to drive in public places
other than specific areas.
3.5.10 Distance between forklifts: Always operate the forklift with caution that
that another forklift in front of you could suddenly stop at any time, so please
keep an appropriate distance.
3.5.11 Headroom: When the headroom is below the cargo or mast, it is
prohibited in using this truck.
3.5.12 The use in the elevator and loading platform maneuvering: if there is
sufficient loading capacity, that does not affect the operation of the forklift, and
agreed by the operator of the forklift, lift and loading platform that can be used
for v transportation. Before entering the elevator or loading station, driver must
personally identify the area and weight load of area. The loads must be placed in
front and occupy an appropriate place, when the forklift enters the elevator, so
as not to contact with the walls of the elevator.
3.5.13 With access and working area: The vehicle must be operated on the
specified channel, all the non-related personnel must leave the work area, and
cargo should be stacked in designated places.
3.5.14 Operations Management: traveling speed must be adapted to local
conditions. When through the corners, narrow passage, swing doors and closed
place, the vehicle must slow down. Drivers must be able to visually an adequate
braking distance between the vehicle and the vehicle in front, and he must
remain in control of his vehicle. Sudden stop (unless urgent needs), rapid U-turn,
chased each other in the channel is not allowed in not smooth places. It is
forbidden to operate while the body is lean outside.
3.5.15 Visibility: The driver must look in the direction of travel, to ensure that
the front situation is clearly visible. When the vehicle is backing up with the
carriage of goods blocked the line of sight, there is must be a second person walk
in front of the vehicle to give appropriate guidance and warnings.

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3.5.16 via the ramp: Only known ramp was allowed to go through. While the
ramp should be clean, non-slip, and the vehicle technical specification includes
the ramp. The goods on the forks must face uphill. It is forbidden to turn back,
move diagonally or park on the ramp. The driver must slow down when going
through the ramp, and prepare to brake at any time.
3.5.17 ground load: Remember to check the load pressure of the body weight or
wheels on the ground does not exceed the capacity of the ground, when the
vehicle is in operation.
3.5.18 Vehicle Change: any possible changes or modifications for rated load,
stability or safe operation of the vehicle, must obtain prior written approval from
origin manufacturers or its successor. After vehicle manufacturer check and
approve the changes, nameplates, labels and markings of Operation and
Maintenance Manual must be modified as well.
IV. Maintenance and Service Manual
4.1 Repair and maintenance of safety procedures
Maintenance technician: The maintenance and service should only be
performed by special personnel trained by the manufacturer. After the
technician sent by after-sales department of the manufacturer completed
maintenance and servicing work, they should sign on the service log.
Cleaning Operation: Flammable liquid cannot be used for cleaning the forklift.
Before cleaning, take safety precautions to prevent electric sparks (e.g. sparks
caused by short circuit). When operating the accumulator, connectors on it must
be disconnected. Use soft air suction or compressed air, non-conductive and anti-
static brushes to clean electric and electronic components.
Operation of Electric System: Operation on the electric system should only be
performed by specially trained personnel. Before performing any operation on
the electric system, precautions must be made to prevent electric shock. When
operating the accumulator, connectors on it must be disconnected.
Installation: When repairing or replacing hydraulic components, electric and
electronic components, make sure to install them back to their original positions.

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Wheels: Quality of the wheels has significant effect on stability and driving
performance of the stacker. Modification on wheels can be performed only with
the approval from the manufacturer. When replacing wheels, ensure that the
stacker is levelled as delivery state(wheels must be replaced in pairs, i.e. replace
right wheel together with left one).
Lifting chain and rollers: Chain and rollers will be worn quickly without good
lubrication. Perform periodic lubrication according to following maintenance
table. Shorten the lubrication period under adverse operation conditions (such
as in dusty and hot environment).
Hydraulic oil pipe: The oil pipe must be changed every 6 years. When change
the hydraulic assembled parts, the oil pipe should be also changed.
4.2 Routine Maintenance (Before every shift)
4.2.1Check the liquid level of electrolyte in the accumulator.
The liquid level will be higher when being recharged.
4.2.2 Check every pole, every cable and their covers.
4.2.3 Check if the accumulator box is secured.
4.2.4 Check the forklift for oil leakage.
4.2.5 Check the chain, rollers, fork, oil pipes and horn.
4.2.6 Check the brake.
4.2.7 Check the wear and tear of drive wheels and loading wheels.
4.3 Professional Maintenance Manual
It is very important for safe operation of the forklift to perform overall
professional maintenance. Failure in performing maintenance according to
specified interval may cause malfunction of the forklift, and potential risk to
human and equipment.

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Maintenance periods listed in this manual apply to single shift a day under
normal operation conditions. If using in dusty environment, the ambient
temperature varies remarkably or in multi-shift situation, the maintenance
period has to be shortened.
Maintain the stacker according to following maintenance list. Maintenance
periods are as follows:
W1 = Every 50 work hours, but at least once a week.
M3 = Every 500 work hours, but at least once every three months
M6 = Every 1000 work hours, but at least once every six months
M12 = Every 2000 work hours, but at least once every 12 months
Additional operations should be performed in trial run period:
(In initial 50 –100 working hours or after two months)
—Check the nuts on the wheels, and tighten them if necessary.
—Check the hydraulic components for leakage, and tighten them if
necessary.
—Replace the hydraulic filter.

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Time interval of maintenance
Standard: ●
W
M
M
M
Cool storage:＃
1
3
6
9
Chassis & Main
frame
1.1
Check all bearing parts for damages
●
1.2
Check all bolt connections
●
Driver
2.1
Check the drive system for noise and leakage
●
2.2
Check oil level in drive system
●
2.3
Replace lubricant oil
＃
●
Wheels
3.1
Check for wear and tear
●
3.2
Check the bearings and make sure they fit well with the wheels
●
Steering system
4.1
Check the steering control
●
Braking system
5.1
Check the performance and adjust accordingly
＃
●
5.2
Check reset function of the air spring, and check for leakage and damages
●
5.3
Check the brake disk for wear
●
5.4
Check the connection of brake and adjust if necessary
●
Lifting Mechanism
6.1
Check performance and wear, and adjust accordingly
●
6.2
Visually inspect the loading wheels for blockage
●
6.3
Check fork tips and pallet support for wear and damages
＃
●
Hydraulic system
7.1
Check performance
＃
●
7.2
Check all connections for leakage and damages
＃
●
7.3
Check the cylinder for leakage and damages and if the accessories are safe and
secure
＃
●
7.4
Check the oil level.
＃
●
7.5
Replace hydraulic oil and the filter element
＃
●
7.6
Check the pressure regulator valve
＃
●
Electric system
8.1
Check performance
●
8.2
Check all cable connections for safety, reliability and damages
●
8.3
Check if the amperage of fuses is proper
8.4
Check if the switches and release cam mechanism is secure and functions
properly
●
8.5
Check the connectors and replace worn parts if necessary
Motor
9.1
Check the carbon brush for wear
●
9.2
Check safety of additional devices of motor
●
9.3
Use a vacuum to clean motor frame. Check the commutator for wear
＃
●
Accumulator
10.
1
Check the density of acid liquid, capacity and voltage of the accumulator
＃
●
10.
2
Check the safety devices on terminals and the grease
＃
●
10.
3
Clean the connector of accumulator and check the connection.
＃
●
10.
4
Check the cable for damages, replace if necessary
●
Lubricant oil
11.
1
Grease the stacker according to time table for filling up lubricant
＃
●
12.
1
Check the grounding connection of electric system
●
12.
2
Check the travelling speed and braking distance
●
List of maintenance