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

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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.

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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.

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,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.

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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.

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·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

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·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

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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.