EKKO EK18A-189LI Service manual

Operating and Service Manual
EK18A-189LI / EK18A-212Li

Foreword
To meet the demand of the market, based on the absorption the advantage of
battery forklift truck both at home and abroad, combined with the company to
introduce advanced technology at home and abroad and the development of new
products, our company developed the battery powered counterbalance forklift truck.
They are particularly suitable for railway stations, ports, freight yard, warehouse and
food, light textile industry, as well as general industrial goods loading and unloading,
transporting, stacking, etc.
This truck is not suitable for dusty, electrify dust, high temperature, high
corrosion environment! For the work in a small amount of dust (non-conductive)
environment, regular cleaning and maintenance of the components is necessary!
Because of this product adopts the new PI concept and man-machine engineering
design, it has low noise and high efficiency double-drive bridge, large angle steering
bridge, wide view lifting system, tailless frame structure body and other advanced
components. It is also equipped with high quality motor, battery, MOSFET electronic
control and large color screen combination instrument, hydraulic operating valve, full
suspension seat and multi-function armrest, full LED lamps and other advanced
components. Therefore, it has superior performance, easy to operate, wide field of
vision, flexible steering, reliable braking, good dynamic performance, small noise,
pollution-free, beautiful appearance and other advantages.
This manual mainly introduces the technical parameters of this series of products,
the main components of the structure, working principle and operation, maintenance
and other aspects of the content. It can help operators to use the battery forklift
correctly, so that it can make the maximum efficiency. Hope that operators and
equipment manager can read carefully before operating the forklift.
To keep your forklift in the best working condition, please follow the rules and
precautions in this manual strictly.
This manual is the description of standard and optional trucks. Non-standard
trucks shall prevail in kind. If you have any technical questions, please consult the
manufacturer.
This manual content might not correspond with the actual condition because of
the improving of our products. Our products are subject to improvements and changes
without notice.

CONTENTS
I. Safety regulations for driving and operation of forklift truck.....................................1
1. Fundamental principle........................................................................................1
2. The delivery of the truck....................................................................................1
3. The storage of the truck......................................................................................1
4. Preparations before use ......................................................................................1
5. Operation of forklift truck..................................................................................2
6. Daily maintenance of forklift truck....................................................................3
". Primary Parameters of Forklift Truck........................................................................6
რ. The Structure, Principle, Adjustment and Maintenance of Forklift Truck................9
1. Transmission system..........................................................................................9
2. Braking system.................................................................................................15
3. Steering system ................................................................................................21
4. Electric system.................................................................................................29
5. Hydraulic system............................................................................................136
6. Lifting system.................................................................................................149

1
I. Safety regulations for driving and operation of forklift truck
1. Fundamental principle
Drivers and superiors of the truck should always keep “SAFTY FIRST” in mind.
Operate according to the OPERATION & SERVICE MANUAL and OPERATOR’S
MANUAL.
2. The delivery of the truck
Pay attention to the following items when delivering the forklift truck by car:
(1) Pull up the hand brake;
(2) Fix the mast and the counter weight with rope and wedge the four wheels
well;
(3) Sling points should be the positions specified in sling decal when hoisting up
the forklift truck.
3. The storage of the truck
(1) Lower the mast to the lowest point;
(2) Close the key and start the parking brake;
(3) Wedge the four wheels well;
(4) Apply anti-rust to the surface of the unpainted surface and lubrication oil to
the lifting chains.
4. Preparations before use
(1) Don’t check fuel leakage and lever or instruments where there is open flame.
Never fill the fuel tank with the engine running;
(2) Check the tire pressure; (this step is omitted when the solid tire is fitted)
(3) Check for sound, light and alarm devices: various lights, buzzers and horns
(including rear handle buttons);
(4) The forward and backward gear handle should be in the middle position (zero
position);
(5) Check the condition of the knobs and the pedals;

2
(6) Complete the preparation work before starting;
(7) Loose the parking brake;
(8) Carry out the operation of mast lifting and lowering, forward and backward
tilting, steering and braking.
5. Operation of forklift truck
(1) Only trained and authorized operator shall be permitted to operate the truck;
(2) Wear safety guards such as shoes, helmet, clothing and gloves while
operating the truck;
(3) Inspect the control devices and alarming devices and operate after repairing if
there is damage or fault;
(4) Overloaded operation is strictly prohibited. The fork should insert completely
under the cargo and make the cargo placed on it evenly. Do not raise an object with
one fork end;
(5) The starting, turning, driving, braking and stopping operation of the truck
should be done smoothly. When steering on the humid or low friction road, the truck
should be decelerated;
(6) Lower the goods as possible and tilt the mast when travelling with load;
(7) Be careful when travelling on a slope. If the gradient is more than 10%, drive
forward when going up the slope and backward when down the slope. Never steer on
a slope in preventing of overturning. Do not load or off-load goods when descending;
(8) Take care of the pedestrian, obstacle, bumpy road and clearance above the
forklift truck;
(9) Persons are prohibited to stand on the forks or be carried on the truck;
(10) Never walk or stand under the raised fork;
(11) Never operate the truck or accessories out of the driver’s seat;
(12) Be care with the goods falling if the lifting height is over 3m. Take
protective measures if necessary;

3
(13) Tilt the mast backward as possible if the lifting height is high. Load or
unload with mast slightly forward or backward tilt;
(14) Slow down and be more careful when travelling on dock or bridge plate;
(15) When checking the battery or fuel tank level the driver should not be on the
truck and make the truck shut down and stop steadily;
(16) Truck with accessories without load should be operated as truck with load;
(17) Do not carry unsecured or loosely stowed cargo, and handle larger cargo
with care;
(18) Lower the fork to the ground, and put the knob in the neutral gear and shut
off the engine or disconnect the battery when leaving the truck. Pull up the parking
brake and wedge the four wheels if the truck stops on a slope;
(19) The pressure of the control valve, safety valve is regulated and can not be
adjusted by users at will in preventing of damaging the hydraulic system or unit;
(20) For those trucks are fitted with pneumatic tires, Inflate the tire according to
the tire pressure decal;
(21) The maximum noise outside the forklift shall not be greater than 80dB(A),
and the test method shall be according to JB/T3300;
(22) Be familiar with and master the contents of various plates on the forklift.
6. Daily maintenance of forklift truck
(1) Starting Method
a) Oil content of hydraulic oil: the oil level should be in the middle of the oil
level scale;
b) Inspect pipes, joints, pumps and valves for leakage and damage;
c) Check the service brake:
The free travel of the brake pedal should be 20~30 mm;
The clearance between the front bottom and the pedal shall be greater than
20mm.

4
d) Check parking brake function: when parking brake starts, stop on the ramp
with specified slope (no load);
e) Instruments and lighting fixtures, etc. : check whether all parts of instruments,
lighting, connectors, switches and electrical lines work normally.
(2) Oil and grease for the truck
Name
Original brand
Mark, code and service temperature
Hydraulic
oil
Changcheng
Viscosity grade
L-HM32
antiwear
hydraulic oil
L-HV32 low
temperature
anti-wear
hydraulic oil
Operating
temperature (℃)
≥-5
≥ -20 (The
outdoor cold
region )
Brake fluid
Fuchs TITAN
ATF 4000
Conform to ZF TE-ML 17C.
Lubricating
grease
Changcheng
3 # General lithium lubricating grease(- 20 ℃～+
120 ℃)
Gear oil
Conform to ZF
TE-ML 17A
Viscosity grade
85W/90 GL-5
80W/90 GL-5
Operating
temperature (℃)
-15～+49
-25～+49
Note: the conductive disc on the steering wheel acting on the horn switch contact
shall use NYOGEL 782G as lubricating grease.

5
(3) The figure of Lubrication System

6
". Primary Parameters of Forklift Truck

7
Primary Parameters
Specialty
Model code
EK18A-LI
Configuration
GE1(2/6)LI
Rated load weight
Q
lbs.
4000
Load center distance
c
Inch
20
Power source
Battery
Operation type
Sit-on truck
Tire
Tire type
Super elastic solid tire
Size of front tire
200/50-10
Size of rear tire
16X6-8
Dimension parameter
Angle of mast,
front/rear
α/β
°
5/7
Wheel base
y
Inch
55.1
Lift height (Standard)
h3
Inch
130
Overhead guard height
h6
Inch
80.3
Overall Length (without
Fork)
l2
Inch
81
Overall Width/Wheel
width
b1
Inch
41.7/44
Outside Steering Radius
Wa
Inch
66
Performance parameter
Travel Speed (Full
Load/No Load)
mph
10/10
Lift Speed (Full
Load/No Load)
m/s
0.41/0.6
Descent Speed (Full
Load/No Load)
m/s
0.58/0.5
Max. Gradeability(Full
Load/No Load)
%
22/30
Battery
Battery voltage/
capacity ( K5 )
V/Ah
80/202
Weight of battery
(min/max)
kg
260/320
Drive motor power
(S2-60min)
kW
5.5x2
Lifting motor Power
( S3-15% )
kW
14

8
Main detachable parts dimensions and weights
Truck configuration
Item
Unit
EK18A-LI
GE1(2/6)LI
Drive axle
Max external
dimension
mm
485x230x370
Weight
kg
80
Counterweig
ht
Max external
dimension
mm
1060×611×
775
Weight
kg
1295
Overhead
guard
Max external
dimension
mm
1550×950×1540
Weight
kg
95
Mas ( t M300,
excluding
fork and
tilting
cylinder)
Max external
dimension
mm
1010×420×2080
Weight
kg
495

9
რ. The Structure, Principle, Adjustment and Maintenance of
Forklift Truck
1. Transmission system
1.1 General description
The drive system of this series of electric forklift adopts the drive unit produced
by German ZF Company, which is left and right drive units and arranged
symmetrically. The drive system is mainly composed of two sets of wheel side
reducer, two sets of AC asynchronous drive motors, one set of driving brake and
parking system, the brake system is oil-cooled disc brake. Its outline and main
dimensions are shown in Figure 1-1.
Fig.1-1 Drive axle dimensions
1.2 Drive wheel
The drive wheel is made up of solid tire and rim. See the following for the
specifications of solid tire and rim:
1.3 Drive unit
1.3.1 Transport of Drive unit
The drive unit must be transported carefully or it may injure the person or the
axle itself. When slinging, special slinging equipment must be used to sling from the
slinging area (note: single driving unit and oil weight of about 80kg); During
transportation, the drive unit must be fixed on a special pallet for transportation.
Item
1.5-1.6t
1.8-2t
Tire
18x7-8
200/50-10
Rim
4.33R-8
6.50F-10

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Fig.1-2 Transport of drive axle
1. Sling position 2.Wheel hub bolt
1.3.2 Storage of drive axle
After the drive axle stored for 6 months, the starting motor works at
approximately 1000rpm maintained for 2 minutes, so that the gear oil inside the drive
axle is fully agitated and reactivated to ensure that each part is lubricated. Repeat
every six months for long-term storage.
If the drive axle is stored for more than 12 months at a time, the gear oil should
be completely replaced before use. When adding gear oil again, the gear oil must
conform to the provisions, specifications are specified in the preceding provisions.
1.3.3 Oil-way of drive axle
The drive axle has a total of three different oil way, independent of each other.
●One oil-way is gear box;
●One oil-way is hydraulic service brake
●One oil-way is hydraulic parking brake;
Gearbox oil-way is maintenance-free, while hydraulic oil circuit needs regular
maintenance. The service brake and parking brake is realized by hydraulic oil-way,
which apply force on a wet disc brake.

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Fig.1-3 Position of each oil hole
1. Oil filling port of gear box 2. Oil drain hole of Gear box
1.3.4 The brake connection of the drive axle
Fig.1-4 Position of brake oil port
1. Breathing cap connector 2. External braking hydraulic oil connector (M10X1)
3. External parking brake hydraulic oil connection (M10X1)
1.3.5 Electrical connection of the drive axle
Fig.1-5 Electrical connection position
1.UVW binding post 2.UVW binding post 3.Speed encoder interface

12
Incorrect connections may cause personal injury or damage to parts. Be sure to
follow the electrical wiring diagram for proper connection. Maximum tightening
torque of nuts on UVW binding posts is 8Nm. If connected according to the
distribution of U, V and W, the rotation direction of the motor is clockwise (look from
the input side of the motor).
1.3.6 Maintenance of drive axle
Perform the following checks during maintenance: wheel installation, leakage,
damage, oil level.
1.3.6.1 Reduction gearbox
On both sides of the gearbox, the oil usually needs to be replaced every 4000
working hours. Replace gear oil according to the following operation:
1. Oil drainage
(1) Clean the area around the drain plug thoroughly;
(2) Place a suitable container under the drain plug to receive the oil;
(3) Remove the oil plug and seal ring with tools;
(4) Drain the old gear oil completely into the container.
2. Refuel
(1) Clean the iron dust on the oil drain plug;
(2) Use a new sealing ring and tighten the drain plug with 16Nm torque;
(3) Use appropriate equipment (such as funnel, pipe, etc.) to add unused new
gear oil; (The gear oil must meet the requirements.)
(4) Check the oil level, until it reach required; (The correct oil level is reached
when the oil reaches the bottom edge of the filling hole. 0.35L on each side.)
(5) Use a new copper sealing ring and tighten the oil plug with 16Nm torque.
1.3.6.2 Braking
The middle brake normally needs to be replaced with brake oil every 1000
working hours. Replace the brake oil according to the following operation:

13
(1) Oil drainage
a) Clean the area around the drain plug thoroughly;
b) Place a suitable container under the drain plug to receive the oil;
c) Remove the oil plug and seal ring with tools;
d) Drain the old oil completely into the container.
(2) Refuel
a) Clean the iron dust on the oil drain plug;
b) Use a new sealing ring and tighten the drain plug with 16Nm torque;
c) Use appropriate equipment (such as funnel, pipe, etc.) to add unused new
brake oil; (The brake oil must meet the requirements.)
d) Check the oil level, until it reach required; (The correct oil level is reached
when the oil reaches the bottom edge of the filling hole. Oil mass is 3L.)
e) Use a new copper sealing ring and tighten the oil plug with 16Nm torque.
1.3.6.3 Waste disposal
Waste disposal should be conducive to environmental protection and comply
with relevant local laws and regulations.
1.3.7 The drive axle is connected to the frame and wheels
The drive axle is mounted on the frame by 7 sets of bolts M14x1.5x70 (10.9S),
the bolts shall add thread anti-loosening adhesive. The wheels are mounted on the
drive axle by 5 groups of hub nuts of the left and right, bolts must add thread locking
glue. The above fastening bolts shall be inspected regularly and the torque shall be
rechecked to prevent loosening.
The tightening torque of the above bolts is marked in accordance with Fig.1-6
below.

14
Fig.1-6 The drive axle and external connection
1.Hub nut 2. Bolts M14x1.5x70

15
2. Braking system
2.1 General description
Service brake system is mainly hydraulic power brake, mainly by the brake pedal,
brake pump, oil cup and wet brake composition, wet brake integrated in the drive axle.
Parking brake adopts pedal brake, By stepping on the brake pedal, the cable drives the
left and right brake sub-pumps to realize parking braking.
2.2 Brake pedal
The driving brake system mainly consists of brake pedal, main pump, sub-pump
and brake. The principle of service brake is shown in figure 2-1, and the structure of
brake pedal is shown in figure 2-2, which is installed on the support assembly through
pin shaft.The pedal and the mounting frame are kept in position by a tension spring.
The pedal force on the pedal is connected to the push rod of the brake master
cylinder and the pedal, and the pedal force is transferred to the brake master cylinder,
the brake master cylinder outputs the oil pressure, which is then conveyed to the oil
port on the drive axle through the brake tubing assembly.
Fig. 2-1 Principle diagram of service brake

16
Fig.2-2 Service brake device
2.3 Brake pedal adjustment
(1) Shorten the push rod on the brake main pump;
(2) Adjust the stop bolt. As shown in the figure below, adjust the pedal height,
which is about 60-75-mm; After stepping the pedal, the gap between the pedal and the
front bottom plate should be greater than 20 mm;
(3) Step the brake pedal and lengthen the push rod until the front end of the push
rod contacts the piston of the main pump;
(4) Tighten the push rod lock nut.
Fig.2-2 Brake pedal adjustment

17
2.4 Brake master pump
The master pump consists of a seat, a one-way valve, a return spring, and a
leather bowl, piston and auxiliary leather bowl. The ends are secured with stop
washers and stop wire, the exterior is protected by a rubber dust cap, and the master
pump piston is actuated by a push rod with the help of an operating brake pedal.
When step the brake pedal, push rod pushing the piston forward, the brake fluid in the
pump body back to the storage tank through the return oil port , until the packing
leather block the return oil port, after the main packing leather pushing through the
return oil port, The brake fluid in the front chamber of the main pump is compressed
and the one-way valve is opened, and flow to the sub-pump through the brake pipe, in
this way, each sub-pump piston juts out to make brake shoe friction plate and drum
brake contact, to achieve the effect of the deceleration or braking, at this point, after
the piston back cavity supplement by the brake fluid from the return oil port. When
releasing the brake pedal, the piston is pressed back to the original position by the
return spring. Meanwhile, the brake fluid in each brake sub-pump is also compressed
by the return spring of the brake shoe, so that the brake fluid returns to the main pump
(piston front chamber) through the one-way valve, and the piston returns to the
original position. The brake fluid in the master pump flow back to the fuel tank
through the oil return port, adjust the one-way valve pressure into a certain proportion
with residual pressure in the brake pipe and brake sub-pump ,makes the brake fluid in
the sub-pump flow back to the fuel tank through the oil return port, adjust the
one-way valve pressure into a certain proportion with residual pressure in the brake
pipe and brake sub-pump, make sub-pump packing leather placed correctly in case of
oil spill, and eliminate the gas resistance phenomenon may appear when emergency
braking.