EKKO EK18GS User manual

Electric Counterbalance Forklift Truck Series
EK18GS / EK18GSH / EK20GS / EK25GB / EK25GHB / EK30GB /
EK35GB
Operation and Maintenance Manual

Foreword
The EKKO counterbalance electric forklift trucks are new series of
products developed by our company to meet the market demand, based on the
advantages of electric forklift trucks at home and aboard and in combination with our
existing products and mature technologies. They are characterized by environmental
protection, maintenance-free, long service life, high efficiency and energy saving, high
safety, etc. They are especially suitable for loading and unloading, handling and
stacking of goods in stations, ports, freight yards, warehouses as well as food, textile
and general logistics industries. If equipped with various attachments, it can be used
more widely.
This product is not suitable for working in dusty, charged dusty,
high-temperature and highly corrosive environments! All components shall be
cleaned and maintained regularly for working in a less dusty (non-conductive)
environment!
Due to the new PI concept and ergonomic design, this product is equipped with
low-noise and high-efficiency integral drive axle, large-angle steering axle, wide-view
lifting system and structure body without tail frame and other advanced components. It
is also equipped with high-quality motor, battery, MOSFET electronic control and color
large-screen LCD combination instrument, hydraulic operation valve and full LED
lamp and other advanced components. Therefore, it has the advantages of superior
performance, convenient operation, wide visual field, flexible steering, reliable braking,
good dynamic performance, low noise, no pollution and aesthetic appearance.
This Manual mainly introduces the technical parameters, structure, working
principle, operation, maintenance and other aspects of this series of products. It can
help the operator to use the electric forklift truck correctly and give full play to its
efficiency. The operator and equipment management personnel shall read it carefully
before operating the forklift truck.

Please strictly abide by the regulations and precautions in this Manual in use, so
that your forklift will be in the best working condition.
This Manual describes standard and optional vehicles, and the real object shall
prevail for non-standard vehicles. In case of any technical questions, please consult the
manufacturer.
Due to the continuous improvement of technology or components, the relevant
contents in this manual will be changed without notice. Please understand.

Table of Contents
I. Driving, Operation and Safety Procedures of Forklift Truck .................................1
1
2
3
4
5
6
7
8
. Basic Principles................................................................................................1
. Transportation of Forklift truck .......................................................................1
. Storage of Forklift truck...................................................................................1
. Preparation before Use.....................................................................................1
. Operation of Forklift truck...............................................................................2
. Routine Maintenance of Forklift Truck ...........................................................4
. Description of Frame Number Printing Position .............................................5
.
Load Curve...................................................................................................6
Main Technical Parameters of Forklift Truck ...................................................10
III. Structure, Principle, Adjustment and Maintenance ...........................................15
II.
1
2
3
4
5
6
. Transmission System .....................................................................................15
. Brake System .................................................................................................18
. Steering System..............................................................................................34
. Electrical System ...........................................................................................41
. Hydraulic System...........................................................................................70
. Lifting System................................................................................................83

I. Driving, Operation and Safety Procedures of Forklift Truck
1
. Basic Principles
Forklift truck drivers and management personnel must keep in mind the concept of
"safety first", and carry out safe and standard operation according to the Operation and
Maintenance Manual and Driver's Manual of the forklift truck.
2
. Transportation of Forklift truck
Pay attention to the following matters when forklift trucks are transported by
automobiles:
(1) Apply the parking brake;
(2) The front and back of the mast and counterweight shall be fixed with steel
wire, and the corresponding positions of the front and rear tires shall be wedged;
(3) The lifting shall be carried out according to the position indicated on the
"lifting signs" of the forklift.
(4) Charge the forklift to 40% ~ 60% and press the emergency power-off switch.
3
. Storage of Forklift truck
(1) The mast is lowered to the lowest position;
(2) Turn off the key and start the parking brake;
(3) The front and rear tires shall be wedged;
(4) The painted surface shall be applied with antirust oil, and hoisting chains
shall be applied with lubricating oil;
(5) Charge the forklift to 40% ~ 60% or above, and press the emergency
power-off switch.
4
. Preparation before Use
(1) Do not check oil leakage, oil level and electrical instruments in places with
open fire, and do not refuel when the vehicle is working;
(2) Check the tire pressure; (this step is not required when a solid tire is
equipped)
1

(3) Check the sound, light and alarm devices: various lights, buzzers and horns
(including rear handle buttons);
(4) The drive and reverse gear handle shall be in the middle position (neutral
position);
(5) Check the state of each handle and pedal;
(6) Make preparations before startup;
(7) Release the parking brake;
(8) Perform test lifting, lowering, forward & backward tilting, turning and
braking of the door frame;
5
. Operation of Forklift truck
(1) The truck can only be driven by drivers who have been trained and have a
driver's license;
(2) Operators shall wear shoes, hats, clothing and gloves for safety protection
during operation;
(3) Check all control and alarm devices before driving, and operate after repair if
any damage or defect is found;
(4) During handling, the load shall not exceed the specified value, and the forks
shall be inserted under the pallet, and the pallet shall be evenly placed on the fork. It is
not allowed to use a single fork to pick up objects;
(5) Start, turn, drive, brake and stop smoothly, and slow down when steering on a
wet or slick road;
(6) When driving with goods, keep the goods as low as possible and tilt the mast
backward;
(7) Be careful when driving on a ramp. When driving on a ramp with a gradient
of more than 10%, drive forward when going uphill and reverse when going downhill.
Do not turn when going uphill or downhill. Do not load or unload when the forklift
track is going downhill.
2

(8) Pay attention to pedestrians, obstacles and potholes when driving, and pay
attention to the upper clearance of the forklift;
(9) No one is allowed to stand on the fork, and the truck shall not carry persons
other than the driver;
(10)
(11)
No one is allowed to stand or walk under the fork;
Do not operate the vehicle and attachments from a position other than the
driver's seat;
(12)
For a high-lift forklift truck with a lift more than 3 m, attention shall be
paid to the goods falling, and protective measures shall be taken when necessary;
(13) For high-lift forklift trucks, try to make the mast tilt backward, and it shall
tilt forward within the minimum range during the loading and unloading operations;
(14)
planking;
(15)
Be careful and drive slowly when driving on a wharf or temporary
When checking the battery or fuel tank level, the driver shall not be on the
vehicle and shall stop the vehicle stably;
(16)
When the forklift truck with attachments is operated without goods, it
shall be operated as a loaded forklift truck;
(17)
Do not handle unfixed or loosely stacked goods, and carefully handle
large-sized goods;
(18)
When leaving the vehicle, lower the fork to the ground, put the gear lever
to the neutral position, turn off the vehicle and disconnect the power supply. When
parking on a ramp, pull the parking brake device, and wedge the wheels when the
parking will be long;
(19)
The pressure of multi-way valves and safety valves of the forklift truck
has been adjusted before the truck leaves the factory, so users shall not adjust it at will
in use, so as to avoid damage of the whole hydraulic system and hydraulic components
caused by excessive high pressure adjusted;
3

(20)
pressure value specified on the "Tire Pressure" plate;
(21) The maximum noise value outside the forklift truck shall not be more than
0 dB(A), and the test method is stated in JB/T3300;
(22) Be familiar with and master the contents of various signs on the forklift.
If pneumatic tires are equipped, the tire inflation pressure shall be the
8
6
. Routine Maintenance of Forklift Truck
(1) Key points of starting
a) Amount of hydraulic oil: The oil level shall be in the middle of the scale of the
oil level gauge;
b) Check whether there is leakage or damage on the pipes, joints, pumps and
valves;
c) Check the service brake:
The idle stroke of brake pedal shall be 20~30 mm;
The gap between the front base plate and the pedal shall be greater than 20 mm.
d) Check the parking brake function: When the parking brake is started, the
forklift shall be stopped on the slope with specified gradient (no load);
e) Instruments and lighting fixtures, etc.: Check whether the instruments, lighting,
connectors, switches and electrical circuits work normally.
(2) Oil and grease for forklift truck
4

Filling volume
(L)
Name
Grade, code and service temperature
Viscosity
grade
Operating Normal temperature
condition environment
hydraulic oil 40#
Anti-freezing hydraulic
oil YYY-LPL-HS32
Cold storage
1
.5-2t (E):33
Hydraulic oil
2-2.5t: 42
3
-3.8t: 45
/
environment
Brake fluid
Grease
4604 synthetic brake fluid GB12891 HZY4
3
# general purpose lithium grease (-20°C~+120°C)
Or 2# L-XDCBB2 low-temperature grease
(-40°C~+120°C)
/
Viscosity
grade
Operating Normal temperature
condition environment
Heavy-duty
vehicle
Gear oil GL-5
85W/90
CLY-LP75W-90
1.5-2t (E): 5
2-2.5t: 6
3-3.5t: 7
Cold storage
environment
Note: The oil filling amount is the amount used for standard mast.
(3) Lubrication system diagram
7
. Description of Frame Number Printing Position
When the vehicle is delivered, a unique frame number (the same as the product
number) is marked on the vehicle body, and permanently stamped on the frame with a
steel seal. According to the number, the production, sales, maintenance and other
information of the vehicle can be traced. The frame number of the battery lifting model
5

is located in the middle-upper area on the right wall plate of vehicle body, and the frame
number of the battery side taking (side pulling and side shoveling) model is located in
the middle-upper area on the left wall plate of vehicle body, as shown in the following
figure.
Printing Position of Vehicle No. with Lifting Battery
Printing Position of Vehicle Number with Side Battery
8
. Load Curve
It is strictly prohibited to overload the forklift, otherwise serious accidents such as
structural parts damage and vehicle rollover may occur. If the vehicle is equipped with
attachments, such as side shifters and buckets, the actual capacity is lower than the
corresponding rated load. The actual capacity and rated load charts are shown below.
6

(2) Rated load chart of forklift
1
.5t Two-stage Mast
1.5t Three-stage Mast
1
.8t Two-stage Mast
1.8t Three-stage Mast
7

Small 2t Two-stage Mast
Small 2t Three-stage Mast
2
t Two-stage Mast
2t Three-stage Mast
2
.5t Two-stage Mast
2.5t Three-stage Mast
3
t (M type) Two-stage Mast
3t (M-type) Three-stage Mast
8

3
t (S-type) Two-stage Mast
3t (S-type) Three-stage Mast
3
.5t (M-type) Two-stage Mast
3.5t (M-type) Three-stage Mast
3
.5t (S-type) Two-stage Mast
3.5t (S-type) Three-stage Mast
3
.8t Two-stage Mast
3.8t Three-stage Mast
9

II. Main Technical Parameters of Forklift Truck
Outline Drawing of the Vehicle
1
0

List of Main Technical Parameters
Model
Configuration No.
Rated lifting capacity
Load center distance
Power type
A3H4-M/A5H4-M
1500 1800
EK18
EK18
1800
EK20
A5XH4-S
2000
A5H4-S
Q
c
kg
1500
500
mm
Battery
Driving mode
Seat type
Tire type
Pneumatic tire
6.50-10-10PR
Front wheel size
Rear wheel size
Wheel base
6.50-10-12PR
16x6-8-10PR
1475
y
mm
°
Inclination angle of mast,
forward/backward
Lift height (standard)
Body length (excluding
fork)
α/β
h3
l2
6/8
mm
mm
3000
2200
2205
Body width
b1
h6
mm
mm
1120
2140
Height of overhead guard
Travel speed (full load/no
load)
km/h
m/s
%
14.5/15
12/13
14.5/15
0.280/0.440
15/25
Lifting speed (full load/no
load)
0.290/0.440
0.270/0.400
Max. gradeability, full
load/no load
17/27
15/26
15/23
15/22
Power of drive motor
(S2-60 minutes)
kW
8
11

Lifting motor power
(S3-15%)
kW
10.6
Battery voltage/rated
capacity
V/Ah
kg
48/480
760
48/400
48/420
Battery weight
Total weight
700
705
3175/2395
3050/2345
3100/2395
3300/2585
kg
3125/2345
(with/without battery)
List of Main Technical Parameters
EK20
EK25
EK20
2000
EK25
Model
Configuration No.
A3H4-M/A5H4-M
A5H4-S
Rated lifting capacity
Load center distance
Power type
Q
c
kg
2000
2500
2500
mm
500
Battery
Driving mode
Seat type
Tire type
Pneumatic tire
7.00-12-14PR
18×7-8-14PR
1660
Front wheel size
Rear wheel size
Wheel base
y
mm
°
Inclination angle of mast,
forward/backward
Lift height (standard)
Body length (excluding fork)
Body width
α/β
6/10
h3
l2
mm
mm
mm
mm
km/
h
3000
2434
1180
2170
b1
h6
Height of overhead guard
Travel speed (full load/no load)
14.5/15
12/13
1
2

Lifting speed (full load/no load)
Max. gradeability, full load/no load
Power of drive motor (S2-60 min)
Lifting motor power (S3-15%)
m/s
%
0.290/0.440
17/26
0.260/0.400
15/25
15/25
15/25
kW
kW
V/A
h
11
12
Battery voltage/rated capacity
48/600
930
48/500
840
Battery weight
kg
Total weight (with/without battery)
kg
4030/3100 4190/3260 3940/3100 4100/3260
List of Main Technical Parameters
EK3 EK3
Model
EK30 EK35
EK38
0
5
A3H4-M/A5H4-
M
Configuration No.
A5H4-S
A5H4-S
3800
Rated lifting capacity
Load center distance
Power type
Q
kg
3000
3500
3000
3500
c
mm
500
Battery
Driving mode
Seat type
Pneumatic tire of Pneumatic tire
Pneumatic tire of
front wheel
Solid tire of rear
wheel
front wheel
Solid tire of rear
wheel
of front wheel
Solid tire of
rear wheel
Tire type
Front wheel size
Rear wheel size
28×9-15-14PR
28×12.5-15-24PR
200/50-10
18×7-8
1750
Wheel base
y
mm
°
1780
Inclination angle of mast,
forward/backward
α/β
6/10
1
3

Lift height (standard)
Body length (excluding
fork)
h3
l2
mm
mm
3000
2567
2572
2567
2572
2612
Body width
b1
h6
mm
mm
km/
h
1260
2180
1392
2185
Height of overhead guard
Travel speed (full load/no
load)
1
4.5/15
12/13
0.260/0.400
15/25 15/22
15
14.5/15
0.260/0.400
15/20
Lifting speed (full load/no
load)
m/s
%
0.290/0.440
Max. gradeability, full
load/no load
17/26
15/23
Power of drive motor
(S2-60 min)
kW
kW
Lifting motor power
(S3-15%)
16
Battery voltage/rated
capacity
V/A
h
8
0/480
80/400
1200
80/480
1310
Battery weight
kg
1310
Total weight
4995/3 5310/4 4900/3 5110/
685 000 700 3910
kg
5610/4300
(with/without battery)
1
4

III. Structure, Principle, Adjustment and Maintenance
1
. Transmission System
1
.1 Overview
The transmission system of the electric forklift truck consists of a drive axle (Fig.
-2) and a reducer (Fig. 1-3). The drive axle is used to support and bear the mast and
1
frame. The reducer is used to increase the input torque and reduce the speed of the
motor to meet the use requirements of the vehicle under different working conditions.
The driving gear of the reducer is directly connected with the traveling motor. It
transmits power to the gears at all levels in the reducer, to the axle shaft through the axle
shaft gear of the differential, and then to the hub. The drive axle tire is connected with
the hub to realize the power transmission. The traveling speed of the electric forklift
increases with the increase of motor speed, and the change of traveling direction is
realized by changing the rotation direction of the motor. In addition to the reduction
gears at all levels in the reducer, there is an important component -- differential.
1
.2 Differential assembly
The differential assembly is located at the end of the transmission system, so that
the left and right wheels can run at different speeds when the vehicle is turning or
running on a curve. The differential assembly is installed on the reducer housing
through bearings at both ends. The 1.5-3.8t differential is of left and right split structure
(as shown in Fig. 1-1), with two axle shaft gears and four planetary gears.
Fig. 1-1 Differential Assembly (1.5-3.8t)
1
5

1
.3 Drive axle assembly
The drive axle assembly is composed of axle housing, axle shaft, hub, brake and
wheel, and is installed in the front of the frame.
The 1.5-3.8t axle housing is of an integral casting structure. The hub is supported
on the axle housing by a conical roller bearing, and is connected to the tire with bolts
and nuts. The power is transmitted from the reducer to the axle shaft via the differential.
The axle shaft drives the hub to rotate the front wheels and only bears the torque
transmitted to the hub. Oil seals are installed inside the hub and on the axle shaft to
prevent lubricant from entering the brake or the drive axle from oil leakage. See Fig.
1
-2.
Refer to Table 1-1 for models and tire pressures of front wheel tires and rims.
Table 1-1
3.8t
Forklift
tonnage
1
.5t 1.8t
2t(E)
2t
2.5t
3t
3.5t
1
.5-1.8t：6.5-10-10PR
Tire
7.00-12-14PR 28×9-15-14PR 28×12.5-15-24PR
2
t：6.5-10-12PR
Rim
Tire
pressure
5.00F-10
1.5-1.8t：790kPa
5.00Sx12DT
000kPa
7.0T-15
970kPa
9.75-15
1
1000kPa
2t：1000kPa
Fig. 1-2 Drive Axle Assembly (1.5-3.8t)
1
6