EKKO EK18RF User manual

SPECIFICATION
Counter balanced Electric forklift
EK18RF & EK18RFL

Introduction
In order to meet the needs of the national environmental protection request, To
reduce industrial pollution and improve productivity, we develop new series of
EK18RF & EK18RFL Type Counter Balanced Electric Forklift . on the basis of
absorption of the advantages of domestic & overseas battery truck, they are
especially suitable for cargo loading and unloading, handling, stacking, etc. for
food, bank, light textile, station, port, logistics and other enterprises.
This forklift uses advanced structures such as wide-view door frame system, EPS
steering system, new AC controller, open-type light guard, and is equipped with
high-quality motors, traction batteries and high-power pump station motors.
Therefore, it has the characteristics of superior performance, convenient
operation, wide vision, flexible steering, reliable braking, good power, low noise,
no pollution, and beautiful appearance.
This manual describes the technical parameters of the Electric Forklift, working
principle and operation, maintenance, and other aspects. It can help operators
use the truck more reasonable, make its maximum effect.
It is hoped that Operator strictly abide the regulations and the precautions in this
manual when using the truck .Carefully use them so that your truck can be in the
best working condition for long period of time to maximize its effectiveness. And
create better economic benefits.

The Statement
Our company production model EK18RF & EK18RFL Type 3960LBS Counter
Balanced Electric Forklift is a special motor vehicle used in factory ,tourist
attractions ,amusement places which is specified by “special equipment safety
supervision regulations”.

Contents
1.The General Introduction....................................................................................1
2.Proper usage ............................................................................................................2
3.Introduction of the product................................................................................4
3.1 Overview of main components.............................................................................. 4
3.2Model Overview ........................................................................................................... 4
3.3Truck schematic diagrame & Model parameters ............................................ 5
4.Operating Mechanism diagram.........................................................................7
5.Operating principle ...............................................................................................8
5.1Operation handle diagram ..................................................................................... 8
5.2Start, Traveling and stop........................................................................................... 8
5.3Lifting & Lowering....................................................................................................... 9
5.4Fork shift left & right ..............................................................................................10
5.5Fork tilt forward & backward ..........................................................................10
5.6Steering .......................................................................................................................10
5.7Emergency situations ..........................................................................................11
5.8The use of Horn and reversing Horn .............................................................11
5.9Monitor .....................................................................................................................11
5.10Operation ...............................................................................................................12
6.Electrical Schematic diagram.............................................................................. 13

7.Hydraulic Schematic diagram ............................................................................. 14
8、Maintenance and care instructions........................................................................15
8.1 Repair and Maintenance.........................................................................................15
8.2. Routine Maintenance.............................................................................................16
8.3 Professtional Maintenance Manual ....................................................................16
8.4Battery maintenance, charging and maintenance ........................................19
9.Safety Caution..............................................................................................................................28
9.1 General rule ......................................................................................................................28
9.2 Storage and transportation ........................................................................................28
9.3 Check before using.........................................................................................................29
9.4Safety operation regulation.........................................................................................29
10.Service Manual..........................................................................................................................33
10.1 Troubleshooting.............................................................................................................33
10.2 Preparation before repair ........................................................................................34
10.3 Check the amount of hydraulic oil ........................................................................34
11.4 Complete repair,the preparation before using ................................................34
11.After-sales service ............................................................................................ 35

1
1.The General Introduction
EK18RF & EK18RFL Type Counter Balanced Electric Forklift uses a battery
as the power source and AC motor as power to drive the truck through gear
transmission, The lifting of the fork and tilt forward & backward is driven by the
AC motor hydraulic drive to push the cylinder to lift and lower the cargo, Tilt the
cargo forward & backward and side shift . As the truck Electric motor for Lifting
and Driving .Then it has the characteristics of labor saving, high efficiency, stable
cargo operation, simple operation, safety and reliability, low noise and no
pollution.
The biggest advantage of the Counter balanced Electric Forklift is that it
adopted the optimized designed of wide view door frame, the mast and the hose
pulley group are more compact; it is not easy to block the operator's sight, the
opening size of the fork frame is enlarged, and the view is wide. The large-arc
roof guard and the optimal angle grid increase the driver’s upper vision. The
arrangement of the right-mounted joystick fully reflects the ergonomics,
improves the comfort of operation, and reduces the labor intensity of the
operators.
The service environment：
a. Altitude does not exceed 3937 ft；
b. Indoor room temperature at +5℃to +40℃；

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c. When environment temperature at +40℃,the relative humidity can’t over
50%,at low temperature ,allow bigger relative humidity
d. Firm, Flat ground 。
e. It is forbidden to use this car in corrosive environment such as flammable
and explosive or acid base
2. Proper use
Please using the Counter Balanced Electric Forklift according to this
specification.
This is a stand on type Counter Balanced Electric Forklift With solenoid
valve to control truck lifting & lowering, Tilt forward and backward, and side
shift
Improper use can cause personal injury or machine damage. Operators or
operating companies need to ensure proper using,
The Truck needs to be used on a firm ,flat ,intact surface and suitable surface
the truck is designed for indoor use at room temperature from+5°C to +40°C
Use under light load without using permanent barriers or pits ,it is
forbidden to operate on the slopes .During Operation ,the goods must be placed
approximately at the center of the truck’s load center
Lifting or Carrying people is strictly prohibited , if carried goods .The goods
must fall on the lifting point 。
It is prohibited to use this truck on lifting or loading ramps.
The rated capacity is marked on the capacity label or nameplate. And the
operator must pay attention to the warming signs and safety instructions.
Operating lighting must be at least 50LUX
Modification
Any modification that may affect the truck rated capacity, stability, or safety
operations must be approved in advance by the Truck’s original manufacturer or
Its authorized Manufacturer or its successor. This includes the effects of changes
such as Braking ,steering ,Visibility, and the addition of removable accessories.

3
After the manufacturer or its successor approves the modification or change ,the
capacity name plate ,Label, identification marks, operation and maintenance
manual must be changed accordingly
Truck damage caused by not following Instruction will lose its warranty.

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3.Introduce of the product
3.1 Overview of main components
The walking of the forklift is powered by the battery, and the DC power is
converted into AC power by the frequency conversion system, which is realized
by controlling the AC motor on the driving wheel. The AC motor converts
high-speed and low-torque into low-speed and high-torque through a gear
reducer, and finally the drive wheels perform actions. The speed of walking is
realized by the frequency conversion control of the motor speed, which is
controlled by the operating handle.
1.Main frame 2.Rotating warning light 3.Overhead guard 4.Headlight
5.Rearview mirror 6.Door frame 7.Front wheel 8.Battery
9.Driving assembly

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3.2 Model overview
This manual brings together the EK18RF & EK18RFL 3960lbs counterbalanced
Electric forklift (hereinafter referred to as "forklift").
The forklift model "EK18RF & EK18RFL-18 with a rated load of 3960lbs" meets
the requirements of JB/T8452-1996 "Battery Forklift Model Preparation
Method", and "RF" is the product code.
3.3Truck schematic diagram & Model parameters

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Model
EK18RFL
EK18RF
Power unit
Electric
Electric
Operation Type
Rider
Rider
Loading capacity
Q (lbs)
3960
3960
Load centre
c (Inch)
19.68
19.68
Axle centre to fork face
x (Inch)
11.5
11.5
Wheel base
y (Inch)
48.8
48.8
Service weight with battery
lbs
7870
7940
Wheels type
Solid wheel
Solid wheel
Front wheel size
Φ×w(Inch)
Φ×w(Inch)
16×7-10.5
（15.98*7.01*10.51）
16×7-10.5
（15.98*7.01*10.51）
Rear wheel size
Φ×w(Inch)
13.5×5.2
13.5×5.2
Wheels, number front/rear (x =
driven)
1×/2
1×/2
Track width
b10 (Inch)
35.04
35.04
Mast/Fork carriage
tilt ,Forward/back wardheight
a/b (°)
3/5
3/5
Lowered mast height
h1 (Inch)
82.6
91.77
Free lift height
h2 (Inch)
52.17
61.34
Lift height
h3 (Inch)
188.98
216.54
Extended mast height
h4 (Inch)
220.87
248.43
Height of overhead guard
(cabin)
h6 (Inch)
90.08
90.08
Height of seat/stand-on
platform
h7 (Inch)
9.06
9.06
Overall length
l1 (Inch)
117.78
117.78
Length to fork face
l2 (Inch)
72.52
72.52
Overall width
b1/ b2 (Inch)
42.52/42.13
42.52/42.13
Fork dimensions
s/e/l (Inch)
1.58/4.72/45.28
1.58/4.72/45.28
Width of forks
b3 (Inch)
36.22
36.22
Ground clearance under mast
m1 (Inch)
2.95
2.95
Min.Ground clearance
m2 (Inch)
3.86
3.86
Aisle width with pallet
39.37*47.24 across forks
Ast (Inch)
117.24
117.24
Aisle width with pallet 31.5 x
47.24 along forks
Ast (Inch)
125.12
125.12
Min.Turning radius
Wa (Inch)
58.5
58.5
Travel speed,laden/unladen
(km/h)
12/13
12/13
Lifting speed, with/without load
(mm/s)
250/400
250/400
Lowering speed, with/without
load
(mm/s)
240/258
240/258
Climbing ability, with/without
load
(%)
6/10
6/10
Service brake
Electromagnetic
Electromagnetic
Drive motor, 60 minute rating
(kW)
6
6
Lift motor rating at S3 15%
(kW)
7.7
7.7
Battery according to DIN
43531/35/36 A,B,C,no
no
no
Battery voltage/rated capacity
(V/Ah)
48/420
48/420
Battery weight (± 5%)
(LBS)
1570
1570
Power consumption according
to VDI cycle
38*18.1*29.53
38*18.1*29.53
Type of drive control
AC
AC
Noise level at operator‘s ear
(dB(A))
≤70
≤70

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steering type
EPS
EPS
4.Operating Mechanism diagram
The Truck with battery as power producer and Use electric and hydraulic
pressure to control, realize walking, fork lifting lowering, mast tilting, forward &
backward and other actions. Schematic diagram of operating mechanism:
1.Instrument 2.Steering wheel 3.Grip type operating
handle 4.Emergency stop switch 5.Key switch
6.Switch group 7.Foot switch

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5.Operating principle
Please familiarize yourself with the functions of the switches/buttons on the
dashboard before operating the forklift.
5.1 Operation handle diagram
1.Tilt Forward button 2.Tilt backward button
3.Left shifter button 4.Right Shifter button
5.Horn button 6.Safety switch buttton
5.2Start, Traveling and stop
Insert the key into the key switch, turn it to the right, and turn the
emergency stop switch in the direction indicated by the arrow above the
button to bounce, and the control circuit is opened. Slowly depress the foot
switch. Rotate the steering wheel in the required direction (forward or
backward). Hold the handle lever (must hold down the safety switch) and
move to the B direction, and the forklift will move forward. Hold the
handle lever (must hold down the safety switch) to the F direction, and the
forklift will move backwards. Observe the road surface and adjust the
driving speed through the handlebar. When the forklift stops, slowly pull
the handle lever to the middle of position and leave the foot switch with
your right foot to stop the forklift completely. Put the fork to the lowest
position, press the safety switch, and pull out the key.

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5.3 Lifting & Lowering
Step on the foot switch when driving, lower the fork to the ground
completely, hold the handle lever (must hold down the safety switch) and move
to the B direction until it reaches your desired lifting height.
If the fork is on the shelf, first carefully move the truck with the pallet rack
or separate the truck from the shelf. Hold the handle lever (must hold the safety
switch) carefully to the F direction to lower the fork away from the pallet rack,
and then carefully drive the truck away from the cargo.

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5.4 Fork shift left & right
Step on the foot switch, press the button(3) on the handle joystick, and the fork
moves to the left.
Step on the foot switch, press the button(4) on the handle joystick, and the fork
moves to the right.
5.5 Fork tilt forward & backward
Step on the foot switch, press the button(1) on the handle joystick, and the fork
tilt forward . Step on the foot switch, press the button(2) on the handle joystick,
and the fork tilt backward
5.6 Steering
The steering of the body can be achieved by rotating the steering wheel:
When the whole vehicle is driving forward, rotate the steering wheel in the S
direction, and the whole vehicle rotation direction is S; if the steering wheel is
rotated in the N direction, the whole vehicle rotation direction is N.
When the whole vehicle is traveling backwards, turn the steering wheel in the S
direction, and the whole vehicle will rotate in the N direction; if the steering
wheel is rotated in the N direction, the whole vehicle will rotate in the S
direction.

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5.7 Emergency situations
During operation, if the forklift has an abnormal failure, the power supply needs
to be cut off quickly, please press the red emergency stop switch.
5.8 The use of Horn and reversing Horn
For the safety of driving, the truck equipped with Horn .To remind others
when driving, Press the horn button on the joystick and the horn will ring to
warn pedestrians.
5.9 Monitor
Curtis instruments are used to realize auxiliary control functions and
provide a display interface for the driver's truck operating conditions. It is
composed of control circuit, accumulated time counter (liquid crystal display),
battery fuel gauge, fault code display and other display circuits. According to the
current demand of electric trucks, this instrument has a brand new design in the
control circuit and display form, which can provide the driver with intuitive
truck status information, compact structure, beautiful appearance, high degree of
automation, and reliable quality.
Curtis instruments provide operators with some simple information about
the operating conditions of the vehicle mechanism. As shown as below
Parameter adjustment key (turn left)
1. Speed mode switch key/parameter adjustment key (upward)
3.Parameter adjustment key (turn right)
4. Parameter adjustment key (turn down)

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5.Parameter adjustment key (Enter)
6.Turtle speed indicator 7.Parking indicator light
8. Fault indicator 9. Lifting lock indicator
10.foot switch indicator light 11.Battery warning light
5.10Operation
（1）How to move heavy objects on a cargo pile
Slowly drive the forklift to the object to be moved, make the fork parallel to
the ground, lift the fork to a height where it can be inserted into the cargo, insert
the fork and move it forward slowly, when the fork is fully inserted into the
cargo Stop the car and manipulate the lifting handle to lift the heavy object to a
certain height, tilt the mast backwards, and slowly reverse the vehicle. Do not
touch the adjacent goods. When the heavy object completely leaves the pile of
goods, lower the goods to the correct position. Running position, and then for
traveling and transport.
（2）Put heavy objects on the cargo pile
Place the heavy object in a low position, tilt the mast backward, and slow
down when driving toward the stack of goods. When it is determined that the
forklift is in a straight line with the stacked goods, the joystick lever slowly
adjusts the inclination of the mast to the vertical state to lift the weight. The
object slightly exceeds the height of the stack, and then the forklift is slowly
driven forward to stop above the stack. Slowly pull the joystick lever. Once the
heavy objects being transported and stacked are dragged, lower the fork to the
hollow position. When pulling the fork out of the heavy objects, first confirm that
the back position is unobstructed before going backwards. After the forks are
completely removed from the heavy objects, lower the forks and tilt the mast
backwards before performing another round of handling operation.

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6.Electrical Schematic diagram

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7. Hydraulic Schematic diagram

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8.Maintenance and care instructions
The spare parts of the truck ,especially the safety devices are not allowed to
change without permission. The driving speed of the truck must never be
changed. All parts supplied by the original manufacturer are subject to strict
quality inspection. To ensure the safety and reliability of the vehicle, please use
the original parts. Replacement parts, including all oils, must be collected and
processed in accordance with local environmental and health laws and
regulations.
8.1 Repair and Maintenance
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.
Lifting of the Truck: When a truck needs to be lifted for maintenance, the lifting
device must be safe and secure and strictly attached to the lifting point. When the
truck is lifted, appropriate measures must be taken to prevent the truck from
slipping or tipping over (wedges, blocks can be used).
Cleaning Operation: Flammable liquid cannot be used for cleaning the stacker.
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.
Welding operations: To prevent damage to electrical or electronic components,
these electrical components must be removed from the vehicle before any
welding operations are taken.
Installation: When repairing or replacing hydraulic components, electric and
electronic components, make sure to install them back to their original positions.
Wheels: Quality of the wheels has significant effect on stability and driving
performance of the truck. Modification on wheels can be performed only with