EKKO EP15JLi User manual

Specification
Electric Pallet Jack
EP15JLi/EP18JLi/EP20JLi
Warning: PLEASE RED THIS MANUAL BEFORE USING!
Warning: PLEASE DON’T USE IT BEFORE COMPLETING THE
INSTALLATION!

1
Introduction
To meet the needs of the national environmental protection cause, reduce industrial
pollution, and improve the quality of life of the public, based on absorbing the
advantages of domestic and foreign battery trucks, we have specially developed,
developed, and produced the EP15JLi/EP18JLi/EP20JLi electric pallet jack. It is
especially suitable for cargo loading, unloading, handling, and other operations in
enterprises and institutions such as food, banks, textiles, stations, ports, and
warehouses.
This manual introduces the technical parameters, working principles, operation and
maintenance, maintenance, and other aspects of the battery forklift. It can help the
operator to use the forklift rationally and maximize its performance.
It is hoped that the operator will strictly abide by the regulations and precautions in this
manual during the use of the battery forklift produced by our company and use it carefully
so that your forklift will be in the best working condition for a long time, exert the greatest
efficiency, and serve your Units create better economic benefits.

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The Statement
Our company production model EPJ type 3300lbs-4400lbsWalking Electric Pallet jack is
a special motor vehicle used in factories, tourist attractions, amusement places which
are specified by “special equipment safety supervision regulations”.

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Table of Content
1. The General Introduction.......................................................................................... 5
2. Proper usage ............................................................................................................. 6
3. Introduction of the product ...................................................................................... 7
3.1 Model overview.........................................................................................................................7
3.2 Model parameters....................................................................................................................7
4. Control Mechanism diagram.................................................................................. 10
5. Operating principle ................................................................................................. 11
5.1 Running system......................................................................................................................11
5.2 Steering system......................................................................................................................11
5.3 Brake structure and brake schematic diagram................................................................11
5.4 Operating System..................................................................................................................13
5.5 Electric System.......................................................................................................................13
5.6 Hydraulic principle..................................................................................................................13
6. Electrical schematic diagram................................................................................. 14
7. Hydraulic schematic diagram ................................................................................ 16
8. Operating Instruction.............................................................................................. 17
8.1 Operation.................................................................................................................................17
8.2 Emergency reverse function................................................................................................19
8.3 The use of the horn and the reversing horn.....................................................................19
8.4 Battery capacity display........................................................................................................19
8.5 Handling and stacking operations......................................................................................19
9. Safety operating and matters needing attention ................................................ 21
9.1 Repair and maintenance......................................................................................................21
9.2 Routine Maintenance............................................................................................................22
9.3 Professional Maintenance Manual.....................................................................................23
9.4 Battery maintenance, charging and maintenance..........................................................23

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10. Safety Caution......................................................................................................29
10.1 General rule......................................................................................................................... 29
10.2 Storage and transportation.............................................................................................. 29
10.3 Check before using............................................................................................................ 31
10.4 Safety operation regulation.............................................................................................. 31
11. Service Manual.....................................................................................................35
11.1 Troubleshooting.................................................................................................................. 35
11.2 Preparation before repair................................................................................................. 36
11.3 Check the amount of hydraulic oil.................................................................................. 36
11.4 Complete repair,the preparation before using............................................................. 36
12. After Sales Service...............................................................................................37

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1. The General Introduction
EP15JLi/EP18JLi/EP20JLi is an electric pallet jack. It adopts the advanced structure
such as ring rod lifting system and new ac controller, at same time it is equipped with
high quality motor, lithium battery and pump station motor. It has the characteristics of
superior performance, convenient operation, flexible steering, reliable braking, good
dynamic performance, less noise, less pollution, and beautiful appearance.
This series truck is suitable for working on the smooth ground in warehouse, if not,
please don’t use it.
The service environment：
a. The altitude does not exceed 1200 meters.
b. Indoors at room temperature from +5°C to +40°C.
c. When environment temperature at +40℃, the relative humidity can’t over 50%，At
low temperature，allow big relative humidity.
d. Ground need hard and flat.
e. It is forbidden to use this truck in corrosive environment such as flammable and
explosive or acid base.

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2. Proper usage
Please using the electric pallet truck accord to this specification.
This is a tramp type electric pallet truck with autonomous control, lifting and lowering is
controlled by the handle button. 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-10°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.
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
Pallet Jack damage caused by not following Instruction will lose its warranty.

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3. Introduction of the product
3.1Model overview
This specification is for EPJ series 3300lbs-4400lbs type electric pallet jack.
The type is “EP15JLi/EP18JLi/EP20JLi load capacity is 3300/4000/4400lbs” to meet the
requirement of JB/T8452-1996《Battery forklift model establishment method》, "S" is the
product code, "6" is the model code.
3.2Model parameters

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Mode
EP15JLi
EP18JLi
EP20JLi
Drive type
Electrical
Electrical
Electrical
Manner of operation
Walking
Walking
Walking
Load Capacity
Q (lb)
3300
4000
4400
Load Centre
c (in)
23.6
23.6
23.6
Distance between fork backrest and front
wheel
x (in)
37.2
37.2
37.2
Wheel Base
y (in)
47.6
47.6
47.6
Service Weight（with battery）
lbs
308
319
326
Tire material
PU
PU
PU
Driving wheel size
Φ×w(in)
Φ8.27×2.76
Φ8.27×2.76
Φ8.27×2.76
Balance wheel size
Φ×w(in)
Φ3.15×3.35
Φ3.15×3.35
Φ3.15×3.35
Qty of wheel，Front/Rear（x=driving wheel
）
1x/2
1x/2
1x/2
Tread
b11 (in)
15.75/21
15.75/21
15.75/21
Lifting Height
h3 (in)
7.87
7.87
7.87
The height of handle in the operation
position
h14 (in)
30.5/43.9
29/45.7
29/45.7
Lowered fork height
h13 (in)
3.35
3.35
3.35
Overall Length
l1 (in)
61.8
61.8
61.8
Body Length
l2 (in)
20.5
20.5
20.5
Overall Width
b1/ b2 (in)
27
27
27
Fork Size
s/e/l (in)
1.97/5.9/48
1.97/5.9/48
1.97/5.9/48
Fork Width
b5 (in)
27
27
27
Ground clearance under mast
m2 (in)
1.38
1.38
1.38
Aisle width for pallets 39.4*47.2’
crossways
Ast (in)
69.7
69.7
69.7
Aisle width for pallets 39.4*47.2’
lengthways
Ast (in)
71.6
71.6
71.6
Turing Radius
Wa (in)
53.7
53.7
53.7
Driving Speed，load/unload
(km/h)
4.2/4.5
4.2/4.5
4.2/4.5
Maximum gradeability load/unload
(%)
5/10
5/10
5/10
Brake Type
Electromagnetic
Electromagnetic
Electromagnetic
Drive Motor
(kW)
0.75
0.75
0.75
Lift Motor
(kW)
0.8
0.8
0.8

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Battery，according to DIN 43531/35/36
A,B,C,no
no
no
no
Lithium Battery voltage/rate capacity
(V/Ah)
24/30
24/40
48/20
Battery Weight（±5%）
(lb)
21.1
26.4
27.8
Type of drive control
DC
DC
DC
Noise level
(dB(A))
≤70
≤70
≤70
Steering type
Mechanical
Mechanical
Mechanical

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4. Control Mechanism diagram
With the battery as a power producer and controlled by electrical and hydraulic, trucks can do
some actions like walking, turning, pallet forklift, etc.
Operating mechanism diagram:
1.Horn 2. Emergency reverse switch 3. Accelerator 4. Lifting button
5. Lowering button 6. Turtle speed switch 7. Key switch 8. Coulombmeter

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5. Operating principle
5.1 Running system
The Pallet Jack is powered by a battery, which is realized by controlling the DC motor on
the drive wheel. The speed of walking is realized by frequency conversion control motor
speed, which is controlled by the accelerator.
5.2 Steering system
The steering of the truck is driven by the handle lever, through the handle lever to drive
the drive motor to realize the steering.
5.3 Brake structure and brake schematic diagram
Braking performance depends on road conditions and vehicle load conditions.
5.3.1The brake function can be activated by the following ways：
⚫Turn the travel switch (2) to "0" position or release the switch to make truck brake
until it stops.
⚫With the driving switch (2) moving directly from one driving direction to the opposite
direction, the vehicle regenerates the brake until it begins to move in the opposite
direction.
⚫The handle moves up and down to the braking area (' B ') and the vehicle brakes. If
the handle is released, the handle automatically moves to the upper braking area (' B
') and the vehicle stops until it stops.
⚫Belly switch (4) can prevent the operator will be squeezed, when vehicles are driven
towards (' Fw) encounters an obstacle, body touch belly to slow down or start to
switch vehicles (' Bw) driven a short distance, then stop. If the handle is in the
operating area and the vehicle is not moving, please consider that this is still working.

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5.3.2 Braking operation principle：
As follow picture：The brake constitutes by 1、bolt 2、magnetic yoke 3、spring 4、
hollow bolt 5、flange 6、guide pillar 7、mounting screw 8、O-rings 9、magnet exciting coil
and so on. The brake is mounted on the drive rack and adjusts the mounting screw to the
specified air gap value.
When magnet exciting coil 9 for brake on power，the coil generates a magnetic field
to draw the hollow bolt 4 to the magnetic yoke 2, hollow bolt 4 is separated from the
brake disc (release). Magnet exciting coil generates a magnetic field to absorb the
magnetic yoke 2, which separates the hollow bolt 4 from the brake disc. At this moment,
the motor will start and operate normally with the brake disc. When the magnet exciting
coil 9 is off, the flux disappears and the hollow bolt 4 is released, Spring 3 puts pressure
on hollow bolt 4, The friction plate of the brake disc on the hub motor is pressed tightly
and the friction force is produced to achieve the braking purpose.
Brake schematic diagram

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5.4 Operating System
The main working body of a moving truck is a cargo fork, which relies on a fork to carry the pallet
or cargo for transport and short distance transportation. The expansion of the cylinder is realized
by the control of the operating handle, and the pressure oil is provided by the pumping station.
5.5 Electric System
The electrical system includes walking and operation control. The Pallet Jack use DC electric
control assembly.
The meter has a battery indicator. When the battery power is too low, the electric meter will cut
off the starting control line of the oil pump motor. The moving truck can only walk without lifting
the fork, and the prompt should be charged immediately.
The motor of the oil pump is the dc motor for 5 minutes, so the pump motor is not suitable for
long-running. That is, the lifting movement should have time interval, cannot continuously carry
on, otherwise would make the motor heating, even burn.
Special note: when the truck is used for a long time, the starter of the oil pump motor may fail,
and it can't be broken after being sucked or closed. The latter is not thrown control handle, the oil
pump motor is kept in the rotation, should immediately stop at this moment, to cut off the power
supply, make the oil pump motor stop running, and promptly replace the starter.
5.6 Hydraulic principle
The oil pump motor drives the gear pump to provide hydraulic power, lifting oil cylinder is
responsible of fork’s lifting and lowering, the control of the lift oil road is controlled by the buttons
on the operating handle, The lifting action is controlled by a single action oil circuit on the valve
block. This model of the hydraulic system pressure can only be adjusted on the valve block, has
been debugging good, before they go out after they leave our company after-sales personnel or
professional maintenance personnel are strictly forbidden to adjust themselves, to avoid safety
accident.

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6. Electrical schematic diagram
(24V)

15
(48V)

16
7. Hydraulic schematic diagram

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8. Operating Instruction
Before operation, please familiarize yourself with the functions of the switches and
buttons on the dashboard.
8.1 Operation
①、Turn on the emergency stop switch.
②、Turn on the key switch.
③、Forklifting and lowering：
Lifting：Control the lifting button on the handle.
Lowering：Hold the lowering button.
Turn on the emergency stop
switch.
Lowering button
Turn on the key switch.

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④、Driving:
Rotate the handle to the driving range.
A and C is brake range.
B is driving range.
Slowly rotate the accelerator to start the truck. (In order to be safe, fast acceleration is
prohibited.)
⑤、Brake
When the accelerator is released normally, the truck will stop until the brake is held in the
truck through the regenerative braking of the motor.
When emergency braking, the operating handle is quickly turned to zone A or area C,
and the brake is carried to the death to realize the emergency braking function.
Forward
direction

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⑥、Parking
Release the acceleration button to stop the moving truck and slow down the truck until
the brakes are on.
Lower the fork to the lowest position.
Turn off the electric lock.
Park for a long time, then the battery power cord is pulled out.
8.2 Emergency reverse function
The red button at the end of the handle is the emergency reverse button. When the
body is in contact with the emergency reverse button, the vehicle will stop immediately
and drive backward for a distance. This is a safety switch designed to prevent the vehicle
from being crushed when the operator encounters an obstacle.
8.3 The use of the horn and the reversing horn
In order to drive safely, the truck is equipped with a driving horn. To remind others
when driving, press the horn button in the middle of the handle, and the horn will ring to
warn pedestrians.
8.4 Battery capacity display
The battery capacity of the forklift truck on the dashboard has capacity display function.
8.5 Handling and stacking operations
（1）How to carry goods
Slowly drive the truck to the items to be transported, insert the pallet fork and move
forward slowly, when the goods are completely inserted into the goods after parking,
Emergency reverse button