EKKO EK25LP User manual

OPERATOR’S MANUAL
Counterbalanced Type Forklift Truck with Engine
EK25LP/EK25-212LP/EK30LP

CONTENTS
I .About Safety····························...···········...···········... ···········..···········...···········.. ·······2
I. Main Use of Forklift Trucks· ·····························"···········"·············2
2. Working environment and Areas of Forklift Trucks·······························.············2
3. Safety Problem Before Use··· ············..············. ············ 5
4. Safety Problem During Operation········..···········....··········..············..············. ····· 8
5. Safety Problem During Service···············...··········....··········....··········... ··········... ·····19
6. Safety Problem of Battery Using • •······•······•·········•······•······•·········•······•············. ·····22
7. Safety problems during attachments installation, adjustment and using ................... 25
8. Safety problem during LPG truck ................................................................................... 26
9. Decal ............................................
II . Operation Device & Use Method
I.Liquid Crystal Displayer················
........ 29
..... 39
. ...........................................42
2. Switches············· ·················...... ·······..................................·······...... ······· ....... ..·· 44
3. Controls ············· ....................... ········.............................................. ········ .............45
4. Body & Others ··· · ···· ··· ······ · ·· · · ... ·· · ······ · · ... ·· · ·· · ···· ··.. ····· · ···· ··· ·· · ······ · · ... ·· · ······ · · ... • •••• ••• 50
5. Cab (optional) ···········....·········....··········....··········....··········....·········....··········... · 57
6. Safety devices
60
III .Driving and Operation· .................................................................................................... 62
I.Notes on New Truck Usage ............................................................................................... 62
2. Relationship Between Load and Stability of Truck····....·.·······....··········...············62
3. Load Center and Rated Load ............................................................................................. 62
4. Stability of Forklift Truck·····························............................................................. 63
5. Transporting and Loading the Truck • • 63
6. Before starting Engine & After Engine Has Started ········....··········..···········... ··
64
7. Traveling·················· ·················· ·······································.. ···········.. ············..·
... 65
8. Pick up ·········..············..············..···········..············..············..··········· ...69
9. Stacking Operation
10. Picking Operation ············
11. Notes when the truck isequipped with solid tire
12. Storing ...
N .Periodic Inspection & Servicing··
I .General Rules On Inspection
2.Inspection Contents ··
3.Maintenance ·················
4. Preventive Maintenance Service Schedule··
V .Others················· ············· ·············
..... 70
. ..................................................... 71
72
. 72
73
_74
. 74
83
85
99
I. Lubrication
chart · ············· ····························..··· ········..··· ·······. ···············99
2.Fuel and lubricants used for forklift truck ··· ·..·· · ·· ·· ·· · ··..·· · ·· · ·····....···· · ·· · ··.. • •••• • • •• • · · • •
1OO

VI. Instructions for trucks meeting China IV and EURO V or higher emission limits
stage .. .................................................................................................................................100
1. Introduction on instrument
................................................................................ • .. l 00
2. Introduction on regenerating
3. Instruction on DPF regeneration ····......·..··..·......·..··..·......·..·..·......·..··..·......·..···
101
...... ·106

- 1-
INTRODUCTION
This manual should bekept by the operator and read it repeatedly.
·This operator’s manual provides the proper operation, easy maintenance, and
routine inspection.
·Prior to operation, read this carefully to secure safe and efficient materials
handling by proper driving and maintenance.
·This manual content might not correspond with the actual condition because of the
improvement of our products.
·When lending transferring for the forklift truck, this manual should be attached to
the forklift truck.
·If you have any questions, please consult with the sale apartment of our company.
A and marked instruction is very important to you and others for safety.
You shall keep to the instruction.
A DANGER
Indicates an imminently hazardous situation that, if not avoided,
will result in death or serious injury. You must observe this
instruction.
A WARNING
Indicates a potentially hazardous situation that, if not avoided,
could result in death or serious injury. You must observe this
instruction.
A CAUTION
Indicates a potentially hazardous situation that, if not avoided,
may result in minor or moderate injury. You must observe this
instruction.
NOTE
Indicates a statement directly or indirectly related to the safety of
personnel and maintenance of the truck.

- 2-
I . About Safety
Safety is your business and your responsibility. The "ABOUT SAFETY" covers basic
safety procedures and warnings of general application to the typical forklift truck.
However, safety precautions given on the following pages are also applicable to lift trucks
that have special specifications or attachments.
I. Main Use ofForklift Trucks
(1) Main use of forklift trucks
The main use of forklift trucks is to handle and stack the load on the pallets. When
they are assembled with proper attachments, they also can handle and stack the loads that
not on the pallets.
(2) Prohibitive use
The following prohibitive uses are not allowed.
·Stand on the forks or pallets and rise
·Stand on the pallets to press the loads.
·Hoist the loads with the steel wire rope and hang on the forks directly.
·Tow other trucks.
·Push the loads or other trucks with forks.
·Open or close the doors of other trucks with forks.
2.Working Environment and Areas of Forklift Trucks
(1) Ground condition
Keep good condition of flat road surface and ventilation.
Lift truck performance depends on the ground or floor conditions and travel speed
should be adjusted properly. Use extreme care when operating on a ramp or rough ground
or floor.

- 3-
,A.WARNING
·When crossing the railroad, besure toonce stop and make sure to be safe.
·Go around rocks and stumps. If unavoided, reduce speed and go slowly and
carefully. Use caution not to damage the bottom of the truck.
When traveling on grounds covered with snow or ice, use tire chains. On such ground
conditions, avoid sudden accelerations, stops, or turns. It is good practice to control the
travel speed by accelerator pedal effort.
,A.WARNING
·When equipped with tire chains, the truck get a larger driving power. However,
sideway anti-slip performance is almost reduced so extreme care should be used.
(2) Weather condition
The following requirements apply in these climatic conditions:
-Average ambient temperature for continuous duty:+25°C;
-Maximum ambient temperature, short term (up to 1 h):+40°C;
-Lowest ambient temperature for trucks intended for use in normal indoor conditions:
+5°C;
-Lowest ambient temperature for trucks intended for use in normal outdoor conditions:
-20°C;
-Altitude:up to 2000m.
,A.CAUTION
· Do not rise the mast too high in the air when it's windy, this will lead to a
dangerous condition unexpectedly.
(3) Measures against cold and hot
weathers a)Oil
Use the oil suitable for ambient temperature.
Always fill the tank up to the top in cold weather. This minimizes the air within the
tank and thus reduces possible freezing from moisture condensation, rust in the fuel system
and hard starting.
b) Battery
·In cold weather
Under normal charged conditions, the freezing point of electrolyte is about -35.
Always keep the battery in a well-charged condition since there is danger of damaging
the battery jar if the electrolyte freezes. To prevent the freezing, charge at least 75% of the
whole capacity.

- 4-
Also, it is effective to keep the specified gravity up to 1.260, but not higher than this
value.
·In hot weather
As the water of electrolytes is especially likely to evaporate in hot weather, replenish
distilled water from time to time. Check the battery once a week, and supply distilled water.
In a region where the ambient temperature is intensely hot, it is practicable to lower
the specified gravity of a completely charged battery down to 1.220±0.01.
Since the battery is better inefficient under hot temperatures, no other care is needed.
.A,DANGER
·Gases produced by the battery can be explosive. Do not smoke, use an open
flame, or create an arc or sparks in the vicinity of the battery. Ventilate well when in an
enclosed space and when charging. The battery contains SUI PHURIC ACID which
causes severe burns. Do not get in eyes, on skin, or clothing. In case of contact, flush
immediately and thoroughly with clean water. Obtain medical attention when eyes are
affected.
c) Cooling system
Your lift truck is generally shipped with the cooling system filled with Long Life
Coolant (LLC)of 50% volumetric mixture. The freezing point of the coolant of such a
mixing ratio is -35?.
In hot weather, to maintain a good cooling effect, special care should be paid the
radiator and cooling system. Parking in the shade is recommended.
Clogged radiator fins can cause overheating. Clean them out regularly with a blast of
compressed air. Also, check for water leakage at the same time.
Check the fan belt tension and adjust it to the specified tension.
Even if the engine overheats and the coolant boils over, let the engine idle awhile until
the temperature falls, before shutting it off. Long Life Coolant is mixed in with the coolant,
so do not run tap water into it right away. Raise the engine hood and allow it to cool down
by itself.
(4) Work environment
In special work environments, it may not be possible to use this forklift under its
standard specifications. Consult with us if this forklift will be used in any of the following
environments:
·In harbors or waterfronts where there is the risk of salt corrosion.

- 5-
·In chemical plants where the forklift may be affected by acids or other chemicals.
·In environments where there is a risk of explosions due to suspended particulate
matter or explosive gases, etc.
·In cold regions, hot regions, or at high altitudes.
·In environments with exhaust emission standards.
For engine-powered forklifts
·Do not use the forklift in bad weather conditions such as thunderstorms or high
winds. Similarly, when dense fog arises, wait until visibility is good before using the
forklift.
·When working indoors, exhaust gas(carbon monoxide) can be hazardous. Where
work must be done indoors, ensure that windows or doors are open to allow adequate
ventilation.
3. Safety Problem Before Use
(1) Get permission from a supervisor
A.CAUTION
·Onlytrained and authorized operators shall be permitted to operate the truck.
·The characteristics of brake, accelerator and hydraulic control levers are
different every truck which has same specifications. After getting accustomed to
operating, operate the forklift truck.
(2) Clothing of forklift truck working
A.CAUTION
· Wear a helmet, safety shoes and working clothes.
· For security, do not wear loose clothes, which have a fear to be hooked or caught
in. If hooking on the clothes, this will lead to a dangerous condition unexpectedly.
(3) Do not operate after drinking
A.CAUTION

- 6-
·Do not operate the forklift truck when you are tired, have mix emotional
problems, or consumed any drugs or alcohol.
(4) Safety for your place of work
_A.CAUTION
·Ensure that any water, oil, sand, ice or snow is removed from the road surface
before work begins as these may cause the operator to lose control of the forklift.
·Never operate on rough or potholed roads, or roads with sharp objects on them,
as any one of them could damage the forklift or cause it to tip over. Always ensure that
the forklift will travel on a smooth surface free of hazards.
·Excessive peripheral noise can distract the operator and cause fatigue. There is
also the risk that warnings to pedestrians and will go unnoticed. Operators must take
particular care when using the forklift in noisy environments.
·Lighting for the operating area is needed for safety working operation.
·Operating on a platform and dock boards is in danger of turnover, provide wheel
stops or other positive protection to prevent a turnover.
(5) Keep clean condition of operator's compartment.
_A.CAUTION
·Operator's compartment shall bekept in a clean condition at all times.
· When having slippery oily hands or muddy hands, this condition will lead a
dangerous operation.
·Tools and other metallic objects shall be kept away from the operator's
compartment. These obstruct the movements of the lever or pedal.
(6) Truck complete
Only in the event that the truck manufacturer is no longer in business and there is no
successor in the interest to the business, the user may arrange for a modification or
alteration to a powered industrial truck, provided, however, that the user shall:
·Arrange for the modification or alteration to be designed, tested and implemented by
an engineer(s) expert in industrial trucks and their safety.
·Maintain a permanent record of the design, test(s) and implementation of the
modification or alteration.
·Approve and make appropriate changes to the capacity plated(s), decals, tags and
instruction handbook.
·Affix a permanent and readily visible label to the truck stating the manner in which
the truck has been modified or altered together with the date of the modification or

- 7-
alteration, and the name and address of the organization that accomplished the tasks.
CAUTION:
·Truck should be equipped with an overhead guard and a load backrest.
(ciiNOTE
The overhead guard shall be used as protection against falling objects. It
should be noted that an overhead guard is intended to offer protection from the
impact of small packages, boxes, etc., representative of job application, but not to
withstand the impact of falling capacity load. Precaution shall be taken to falling
objects.
WARNING:
· It is not allowed to modify or add any working device on the truck without
written authorization from our company or such behavior will badly affect rated
capacity or safety operation.
·Do not install any parts that maybadly affect the operator's view.
· Forks with pairing marks shall be installed in a paired way. It is strictly
forbidden to install in a mixed way.
·All parts of the fork are not allowed to be welded. If welding is required, it must
be carried out according to the specified welding process.
(7) Periodic servicing
CAUTION:
·Carry out daily servicing and periodic servicing.
WARNING:
·When find a damage or a fault at the truck, stop operating the truck and inform
an employee about the truck condition immediately. Do not operate the truck until the
truck has been repaired completely.
(8) Avoid fire hazards.
CAUTION:
·Setting a fire extinguisher to avoid fire hazards, accident. Use the fire
extinguisher according to it’s operating rules.
(9) Prohibition of overload
CAUTION:
·It is prohibited to overload and observe the allowable load and the capacity
chart on the truck. Make sure the weight of load and the center of gravity are the load
position.

- 8-
Gi,WNOTE
capacity means what the maximum load can be put on the forks in
accordance with a load center.
(1O)Using a proper pallet
CAUTION
·Use a pallet which is suitable size and strength for a load.
·Make sure palletized load isin proper shape and securely palletized.
·Prohibition of handling materials without pallets.
4. Safety Problem During Operation
(1)Cautionary proceeding for start
C
AUTION
·The parking brake lever is applied securely.
·The directional switch lever is in "N".

- 9-
·Depress the clutch pedal or the
brake pedal.
·Adjust the seat so you can get easy
access to all hand and foot controls.
·Make sure no one is under, on and
close to the truck.
(2) Safety around the truck
,A CAUTION
·When carrying the large load and
visibility is poor, make a drive backward
or someone should induce the truck.
·When driving to backward, make
sure no person is around the truck. Make
sure to use the rearview mirror provided.
·Someone should induces the truck
at narrow aisle.
·The driver shall be required to stop
at cross aisles and other location where
vision is obstructed and make sure
security at right and left of the truck.
·Make sure the safety distance from
sideways or platform's edges. Working
on the sideways or platform may cause
the truck dropping, put stopper and so
on.
·A forklift truck is a rear wheel
steering which is different from a car,
slow down the traveling speed and
approach to a turning corner then operate
steering wheel with taking care of a turn
at the truck back.

- 10-
(3) Prohibition of rough driving
CAUTION
·Do not turn on the key switch with
depressing the accelerator pedal.
·Do not make a sudden start, braking
or turn. A sudden start and braking can
cause a falling of load. A sharp turn on
traveling can cause a overturn of truck and
may relate to a serious accident.
·Operate hydraulic control levers slowly when loading and unloading. There is a
danger of falling load or overturning the truck when operating the levers suddenly at
high height position of forks.
ij..$jNOTE
·Do not run over bumps and obstacles scattered on the road.
·When passing by the other truck, slow down tie traveling speed and sound the
horn.
·Do not drive into a weak floor or ground.
·Slow down the traveling speed on a wet, slippery, uneven and inclined place,etc.
·Make sure that there issufficient clearance between mast and ceiling or entrance
of a structure.

- 11-
(4) Prohibition of driving with forks lifted up in the air
,A CAUTION
·Do not drive with forks lifted up. When traveling with lifted forks, this could
cause an unstable condition and a turn over of the truck.
(5) Prohibition of fork tip working
,A CAUTION
·Do not push a load or lift up by the tip of forks. When catch a load by the tip of
forks, it can cause jumping up the truck or a load and permanent deformation of
forks.
(6)
Prohibition of pushing and pulling working
,A CAUTION
·Do not push or pull a load. The load would be damaged or dropped and damage
of trucks' parts will be caused.

- 12-
(7) Prohibition of prod goods horizontally
with forks
,A.NOTE
·Do not lift goods horizontally with forks
or parts, damage may be caused.
(8)Prohibitions of carry goods with a single
fork
,A.NOTE
·When loading, two forks shall be loaded
at the same time. When using a single fork to
pick up goods, the goods will fall off and the
parts of will be damaged.
(9) Prohibition of carrying goods with arc-
shaped bottom
,A.NOTE
When the forklift truck is loaded, the
load shall be evenly distributed on the upper
surface of the horizontal section of the two
forks, and the direction of force should be
vertical downward, so that no force of other
direction can be generated; it is forbidden to
carry the goods with arc-shaped bottom.

- 13-
(10) Driving on a slope
CAUTION
·Drive the truck on a slop as
following.
LOADED: Drive the truck forward to
ascend and backward to descend.
UNLOADED: Drive the truck
backward to ascend and forward to
descend.
·When the truck goes down on a slope,
drive slowly with the brakes on. Make sure
that the forks should not touch the ground.
·Driving, turning, and loading shall not be taken on a slope. It could cause turning
sideways of the truck, it is very dangerous.
(11) Prohibition of off-center loads
C AUTION
·Make sure if loads are arranged stable and safely, insert the forks to the pallet
correctly and care must be taken not to handle off-center loads.
·To handle off-center loads could lead to overturn the truck and falling loads.

- 14-
(12) Prohibition of permitting passengers
to ride
WARNING:
·Do not permit passenger to ride on
the forks or a pallet.
·Do not ride people on the truck
except driver.
·Do not ride people on the truck as a
counterbalance.
·Do not stand on the load or pass
under forks.
(13) Prohibition of putting into mast structure
A WARNING
·Never put any part of the body into the mast structure or between the mast and
truck.
A CAUTION
·Keep hands and feet inside the operator's compartment. Do not put any part of
the body outside the operator compartment of the truck.

- 15-
(14) Prohibition of lifting when tilting loads forward
A.CAUTION
·Do not lift up a load and drive a truck when tilting the mast forward. When lifting
loads or diving the truck, tilt the mast backward enough and stabilize the load. When
traveling with or without load, raise the forks for 150-200mm from the floor.
·Do not tilt the mast forward with the load.
·When lifting or lowering the load, be sure to stop the truck.
·Do not load and unload the load at the condition in which the truck isleaning.
(15) Driving into trailer
A.CAUTION
·Operate the truck at the place where has holding means of a trailer at the docks.
·Before starting the operation of truck, fix a dock board and inspect it's strength.
·When getting into or off the trailer, drive carefully and slowly across the dock
board or bridge plate.

- 16-
(16) Getting on and off truck
CAUTION:
·Do not jump on and off the truck.
·When getting on and off the truck, grasp a grip, put on your foot at step and
supporting your body.
·When getting on the truck, do not grasp a steering wheel or hydraulic control
levers.
· Prohibition of loading high stacked loads
CAUTION:
·Loaded load should be contacting with a load
backrest. Do not handle the load which a exceeded
height of a backrest. When loads go over a load
backrest, there is a danger of loads 's falling against
operator.
·When making a double stack loading, fasten
the loads with rope to protect falling of loads.
(18) Loosen chains
CAUTION:
·Do not draw out the forks from a pallet when
chains are loosen. When chains are loosen, there is
a danger of catching loads and rack by forks or
falling of loads and overturning of the truck.
E-,$jNOTE
·When chains are loosen, pull the lift lever a
little and lift the forks, the loosen chains could be
corrected. After correcting the loosen chains, draw
out the forks from a pallet.

- 17-
(19) Adjustment of forks
CAUTION:
·Adjust the spreading of forks in accordance with a pallet size. Care must be
taken not to pinch fingers when adjusting a spreading of forks.
·When adjusting the width of forks, make sure that the setting pin of the forks are
fixed. If the forks are not fixed, the forks could move and there is a danger of the
load's crumbling and falling.
·For the forks with hydraulic fork positioning function, the adjustment of fork
width shall be carried out without load. It is prohibited to adjust with load.
(20) Handling of wide loads
CAUTION
·Careful driving should be taken when handling long or wide loads.
·Be careful of around security when turning, and turn slowly in order not to move
loads.
·Be careful of balancing of loads, and handle the loads at low height position.
·Lifting and lowering loads should be slowly, and be earful of around security.
(21) Prohibition of holding down loads by hands
CAUTION:
·Do not hold down the loads by hands. There is a danger of load's falling.