EKKO EG30 Series User manual

The Specification
EG30 Series Electric Tow Tractor

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 Electric Tractor on the basis of
absorption of the advantages of domestic & overseas battery towing tractor,they are especially
suitable for cargo loading and unloading, handling, stacking, etc for food, bank, light textile, station,
port, logistics and other enterprises.
This Tractor adopts the advanced structure of the electronic power steering system and new AC
controller, and also has high quality motor, traction accumulator . It has advantages of superior
performance, easy operation, flexible steering, braking reliable, dynamic enough, low noise, no
pollution, beautiful appearance and so on.
This manual describes the technical parameters of the tow Tractor, working principle and operation,
maintenance, and other aspects. It can help operators use the tow tractor more reasonable, make its
maximum effect.
It is hoped that Operator strictly abide the regulations and the precautions in this manual when using
the tractor. Carefully use them so that your tow tractor can be in the best working condition for long
period of time to maximize its effectiveness. And create better economic benefits.
Our company production model EG30 Electric Tow Tractor is a special motor vehicle used in
factory ,tourist attractions ,amusement places which is specified by “special equipment safety
supervision regulations”
Due to the need of continuous improvement for the products, the manufacturer reserves the right to
change the design and specifications of our products, without further notice. If you want to know
the latest product parameters, please contact us. Note: all parameters here are subject to the date of
publication.
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Contents
一、The Introduction of product
1.1Model overview .......................................................................................................................1
1.2Model Parameter......................................................................................................................1
二、Basic structure and principle
2.1 Basic Structure........................................................................................................................3
2.2 Operating Principle ...............................................................................................................4
2.3 Electrical Principle..................................................................................................................5
三、 Safety Operating and Cautions
3.1 General Rule ...........................................................................................................................7
3.2 Transportation & Storage........................................................................................................7
3.3 Check before using ...............................................................................................................7
3.4 Operating Specification ..........................................................................................................8
3.5 Safety Operation Rules ...........................................................................................................8
四、Maintenance & Service Manual
4.1 Repair & Maintenance Safety procedure ............................................................................11
4.2 Routine Maintenance ............................................................................................................11
4.3 Professional Maintenance manual ........................................................................................12
4.4 Maintenance ,Recharging and replacement of the Accumulator...........................................14
五、Repair Manual
5.1 Troubleshooting ..................................................................................................................18
5.2 Preparation before Repair .....................................................................................................18
5.4 Preparation after Maintenance or Repairing .........................................................................18

1
一、The Introduction of product
1.1Model Overview
This manual collects EG30 series,10000LBS of all electric tow tractor（Hereinafter referred to as
"tractor" ）。
The truck models “EG30 rated load 10000LBS” meet the requirement of JB/T8452-1996
《Battery forklift model establishment method》，“T” is the product code，
1.2Model Parameter

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Model
EG30
Power type
Battery
Operation type
Stand-on
Rated Capacity
Q (lbs)
10000
Wheel base
y (Inc)
41
Weight (With battery)
lbs
1694
Wheel type
PU
Driving wheel size
(Inc)
Ф9.8x2.9
Bearing wheel size
(Inc)
Φ7×3
Wheel number ,Front/Rear (X=Driven)
2/1x
Track width Loading size
b11 (Inc)
24.3
Coupler height range
h10 (Inc)
9.2/13/13.6/17.2
Overall Length
l1 (Inc)
55
Overall Width
b1/ b2 (Inc)
31.8
Ground clearance ,Center of Wheelbase
m2 (Inc)
2.6
Turning Radius
Wa (Inc)
49
Travel spped Laden/unladen
M/ H
3.8/5
Rated Traction
N
600
Max Traction
N
2600
Gradeability Laden/Unladen
%
3/15
Service Brake Type
Electromagnetic
Driving motor rating
KW
3
Battery ,According to DIN 43531/35/36
A,B,C,no
(Inc)
no
Battery Voltage/ Capacity
V/ Ah
24/210
Battery weight
lbs
462
Type of Drive unit
AC
Type of Steering
Electronic
Noise level at the driver’s ear
dB (A)
70
Traction Coupling ，According to DIN15170
Pin type

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二、Basic structure and principle
2.1 Basic structure
With battery as power producer and controlled by electrical , tractor can do some actions like
walking, turning, pallet fork lift, ect.
1. Lazyback 2.Rear Cowl 3Emergency reversing button 4.Operating
handlebar 5.Key Switch 6.Emergency stop switch 7.Coulombermeter
8.Cover 9.Main frame 10.Side sliding door 11.The cover for Battery
12.Hand lever 13.Traction pin 14.Traction base

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2.2Operating principle
2.2.1 Running system
It is battery provides energy storage and the frequency conversion system converts direct current
to alternating current that make the truck walk. Ac motor transforms high speed low torque into
low speed high torque through the gear reducer，and finally by the driving wheel to perform
actions. Walking speed is achieved by variable frequency control of motor speed and controlled
by the accelerator.
Gear box has been posited enough gear lubricating oil in the factory . And please change the gear
lubricating oil every 1000 hours under normal circumstances.
If you hear abnormal sound from gear box when using, please stop and check immediately. If
there are bearing failure or some problem in gear, please replace and repair them.
2.2.2 Steering system
The operating handle drives the rotation direction sensor which can send out the turn signals that
makes the tractor turn around.
2.2.3Operating system
1.Travel Switch 2.Emergency reversing button
3.Horn button
2.2.4 Braking system
Braking performance depends on road conditions and vehicle load conditions.
The 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

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stops.
⚫Move driving switch (2) directly from a driving directions to the opposite direction, truck
regenerative braking until it began in the opposite direction.
⚫Move the handle up and down to the braking area（‘B’），truck braking. If the handle
is released, it will automatically move to the braking area (" B ") ,and the truck brakes
until it stops.
⚫Belly switch (3) is set for preventing the operator squeezed. When the truck is driven
towards (' Fw) and encounters an obstacle, and driver's body touches belly switch ,the
truck will CBDow down or drive to （‘Bw’） for a distance and then stop. If the handle
is in operation area but the truck is not driving, please consider if it still work.
2.3 Electrical principle
2.3.1 Electric System
Tractor electrical system includes walking and job control, etc. Truck uses American CURTIS1232E
electronic assembly.
Instruments can display electric power, working time and have low voltage protection function.

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Electrical schematic diagram

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三Safety operation and matters needing attention
3.1 General rule
3.1.1 The operator must have a forklift operation qualification which proved by the relevant
departments of the training before driving Tractor.
3.1.2 The operator must read the instructions before use all of the content, after fully understand
operation method can drive Tractor.
3.1.3 Tractor must not carry passengers.
3.1.4 Operators should pay special attention to when homework operating environment, including
other people nearby and fixed object.
3.1.5 Without the manufacturer's approval, shall not modify, add or remove tractor parts, lest affect
performance of tractor.
3.2 Storage and transportation
3.2.1 Use container or car should pay attention to at the time of shipment:
○
1 Front and rear wheels with wedge, begin to pull up the parking system, prevent CBDiding in the
process of transportation;
○
2 Using the lasso, not placed in the weak structure of the tractor;
○
3 During Transportation, Remove the Trailer and fix the tractor with a dedicated strap for lifting
according to the figure below:
3.2.2 When Tractor doesn't work, should be parked in a dry ventilated cleaning warehouse, prevent
weathered. And:
○
1 Close electric lock, make the safety switch power, unplug the power plug;
○
2 Begin to pull up the parking system, front and rear wheels with block mat;
○
3 Such as discontinued for a long time, battery should be added once every 15 day electricity.
3.3 Check before using
3.3.1 New car if there is any damage in transportation, please don't be put into use, and promptly
get in touch with the supplier, do proper processing.
3.3.2 New cars in the factory run parts has been filling lubricating oil,
3.3.3 Tractor equipped with battery. The battery is charged before leaving factory. If leaving the
factory for a long time, may the battery is low. Before use should pay attention to electricity meter

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shows that when the electricity meter display to the last two warning, must charge at once. Every
day before using, or before charging, should open the battery blocks, check the liquid level height,
such as liquid level is too low to add distilled water in charge.
3.4 Operation specification
Before operating the forklift, please be familiar with the dashboard function of each switch/button.
3.4.1 Start, run and parking:
○
1 Insert the key into the key switch, turn to the right, the emergency power safety switch
clockwise reset, gently open the control circuit.
○
2 egin to loosen parking system.
○
3 According to the requirements in the direction of the forward or backward direction of
switches.
○
4 When forklift driving turn, should reduce speed, where possible, try not to turn suddenly.
○
5 Forklift truck carrying gradeability is 6%, so the uphill CB Dope need to understand the
situation, when climbing the forklift must accelerator pedal pressed down as far as possible, the
maximum climbing force can be achieved.。
3.4.2 The using of emergency power safety switch
When vehicles out of control on the moving or having smoking and anxious burnt flavor in the using,
please pressed emergency switch on the dashboard shut off. Find out the reason and clear fault than
to open. The method of the opening: turn the red button as clockwise, pop-up button up, open end.
Emergency power switch button for plastic parts, press down or clockwise not too hard, so as not to
damage the switch.
3.4.3 The use of speakers and reversing speakers
For the safety of driving, vehicle equipped with speakers and reversing speakers. To remind others
when driving, the steering wheel in the middle of the horn button, when walking vehicle reversing,
reversing the horn alarm sound will start automatically alert pedestrians.
3.4.4 Battery capacity indicator
The dashboard for tractor battery capacity has capacity display function, can also use electricity
time statistics (cumulative hour).

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3.4.5 Traction Operation
（一）How to traction goods
First slowly move the tractor to the cargo which needs to be towed ,Pull puller pin with Pull
rod ,Put the connecting frame under the traction pin ,Then put down the traction pin ,And make sure
that the traction pin has fixed the connecting frame on the traction seat before driving .
（二）How to leave the goods
When The hauling operation finished .Just pull the pull bar on the car and the pull pin will detach
from the cargo automatically
3.5 Safety operation regulation
3.5.1.Requirement for operator: The Tractor must be operated by a trained operator, He can
perform and operation demonstration on the user to move and manipulate the cargo, and can clearly
guide the user how to operate the forklift.
3.5.2 Operator’s rights, obligations and responsibilities：Has been trained by the operation of
the vehicle, the driver must be clear of his rights and obligations; and he is familiar with the contents
of the relevant operating instructions. If the vehicle is pedestrian type, the driver must also wear
safety boots.
3.5.3 Prohibit unauthorized person to operate：The operator is responsible for the vehicle, he
need to prohibit unauthorized person to operate. Transport or lift person is also forbidden.
3.5.4 Malfunctions and defects：If the vehicle has any malfunctions or defects, need to inform
administrator, If the vehicle cannot be safely operated (e.g.: wheel wear or brake failure), then it
must stop using until it is fully repaired.
3.5.5 Safe operation and environmental protection ：inspection and maintenance must be
performed in accordance with the time intervals on the maintenance list.
Parts of the vehicle cannot be changed without any permission, especially safety devices. The
operating speed of the vehicle is not allowed to change.
All original spare parts have been verified by quality assurance department. To ensure the safety
and reliability of the operation of the vehicle must use only the manufacturer's spare parts. The old

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parts, such as oils and fuels must be handled in accordance with the relevant environmental
protection rules.
3.5.6 Hazardous area: Hazardous area usually refers to the following range: vehicle or its load
lifting devices (e.g. fork or accessories) is dangerous for personnel when running or lifting
movements, or the ongoing regional transport loads. Typically, this range extends to the load or
vehicle accessories landing area.
Unauthorized personnel must be asked to leave the dangerous zone. As long as the situation might
cause some kind of damage, the driver must give a warning, if the driver asked the person to leave
but did not leave the hazardous zone, the driver must immediately stop the vehicle.
3.5.7 High-risk environment：Working in high-risk environment, operator must have a special
design to be protected
The vehicle was not specially designed for the high-risk environment.
3.5.8 Safety devices and warning signs: Safety devices, warning signs and warning notes
described in the previous operating instructions must be taken seriously enough.
3.5.9 Driving in public places: the vehicle is forbidden to drive in public places expect in specified
special areas.
3.5.10 Distance between vehicles: keep an appropriate distance, avoid the front vehicle suddenly
stop.
3.5.11 headroom: When the headroom is below the cargo or mast, it is forbidden to use the vehicle.
3.5.12 Using in the elevator and loading platform maneuvering: if there is sufficient loading
capacity, won’t affect the operation of the vehicle, and being agreed by the operator of the vehicle,
then the elevator and loading platform can be used for vehicle transport. Before entering the elevator
or loading station, operator must personally identify. The goods must be placed in front and occupy
an appropriate place, to avoid touching the wall of the elevate when the vehicle enters the elevator.
When personnel and vehicles take the elevator together, person can enter only after the vehicle has
safely entered, and person must leave before the vehicle.
3.5.13. Driving aisle and working area: The vehicle must be operated on the specified aisle, all
non-related person must leave the work area, and cargo should be stacked in designated places.
3.5.14 Operation Management：Driving speed must be adapted to local conditions. When through
the corners, narrow passage, swing doors and closed place, speed must be slowed down. Drivers

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must be able to visually an adequate braking distance between vehicle and the front vehicle, and he
must remain in control of his vehicle. Sudden stop (unless urgent needs), rapid U-turn, chased each
other in the Aisle is not allowed.
3.5.15 Visibility: The driver must look attentively at the direction of driving, to ensure the front
situation is clearly visible. When the vehicle is backing off, if the carriage of goods block the line
of sight, a second person walk in front of the vehicle to give appropriate guidance and warnings is
necessary.
3.5.16 Pass through the ramp: Only a known ramp which should be clean, non-slip, and with the
vehicle technical availability was allowed to go through. The goods on the forks must face uphill.
It is forbidden to turn back, move diagonally or park on the ramp. The operator must slow down
when going through the ramp, and prepare to brake at any time.
3.5.17 Load capability on ground: when the vehicle is in operation, make sure the load pressure
of the body weight or wheels on the ground does not exceed the load capacity of the ground .
3.5.18 Vehicle Change: Any possible changes or modifications for rated load, stability or safe
operation of the vehicle, must obtain prior written approval from origin manufacturers or its
successor. After vehicle manufacturer check and approve the changes, nameplates, labels and
markings of Operation and Maintenance Manual must be modified as well.
4.Maintenance
4.1 Maintenance procedures
Maintenance technician: The maintenance and service should only be performed by special

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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 vehicle: when a Vehicle needs to be raised and maintained, The lifing device muse
be safe and securely attached to the lifting point. when the Vehicle is lifted. Appropriate measures
must be taken to prevent the vehicle 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.
If spray water or high-pressure cleaners are used to clean the vehicle. All electrical and electronic
components must be carefully Covered beforehand, because moisture can cause malfunctions .Do
not use steam nozzles for cleaning
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 operation :In order to prevent damage to electrical or electronic components. This
electrical component must be removed from the vehicle before any welding operation is performed
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
stacker. Modification on wheels can be performed only with the approval from the manufacturer.
When replacing wheels, ensure that the stacker is levelled as delivery state(wheels must be replaced
in pairs, i.e. replace right wheel together with left one).
4.2 Daily Maintenance
4.2.1 Check the electrolyte level of the battery .
The liquid level will be higher when it is charging.
4.2.2 Check every pole, every cable and their covers.

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4.2.3 Check if the accumulator box is secured.
4.2.4 Check the horn.
4.2.5 Check the brake.
4.2.6 Check the wear and tear of drive wheels and loading wheels.
4.3 Maintenance Manual
It is very important for safe operation of the device to perform overall professional maintenance.
Failure in performing maintenance according to specified interval may cause malfunction of the
device, and potential risk to human and equipment.
Maintenance periods listed in this manual apply to single shift a day under normal operation
conditions. If using in dusty environment, the ambient temperature varies remarkably or in multi-
shift situation, the maintenance period has to be shortened.
Maintain the device according to following maintenance list. Maintenance periods are as follows:
W = Every 50 work hours, but at least once a week.
A = Every 250 work hours, but at least once every three months
B= Every 500 work hours, but at least once every six months
C = Every 2000 work hours, but at least once every 12 months
Additional operations should be performed in trial run period:
(In initial 50 – 100 working hours or after two months)
— Check the nuts on the wheels, and tighten them if necessary.
— Check the nuts on traction seat, and tighten them if necessary.
List of maintenance
W
A
B
C
Braking
1.1
Check the air gap of electromagnetic brake
●
Electric
System
2.1
Check switch operation, display the function of the equipment and
components
●
2.2
Check the alarm system and safety device
●
2.3
Check whether there is any damage on the cable and terminal is rigid
●
2.4
Check the function of the micro switch Settings
●
2.5
Check the controller
●

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Maintenance, Recharging and Replacement of the
Accumulator(Battery)
The device must be parked in a safe location before any operation on the accumulator.
4.4.1 Maintenance Technician
Only qualified technician can perform operations on the accumulator such as recharging,
2.6
Fixed cable and motor
●
Energy Supply
3.1
By observing the battery
●
3.2
Visual inspection battery charging plugs
●
3.3
Check whether the battery cable connection fastening, if necessary,
with oil daub electrode
●
Traveling
System
4.1
Check if have gearbox abnormal sound
●
4.2
Check the travel agency, and the oil, check the reset function of
operating handles
●
4.3
Check the drive wheels and bearing wheel for wear and damage
●
4.4
Check the wheel bearing and fixed
●
Massive
Structure
5.1
Check whether the framework has damaged
●
5.2
Check whether the sign is complete
●

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maintenance and replacing. Before operation carefully read instruction manuals including operation
manual, replenishment preparation and recharging requirements.
4.4.2 Fire Prevention Measures
Never smoke or use open fire when perform operations on the accumulator. The accumulator should
be away from flammable material at least two meters when storage or recharging. The location for
accumulator storage should be well ventilated and equipped with firefighting devices.
4.4.3Maintenance of the Accumulator
1) Keep the nuts on every battery cell dry and clean. Tighten every terminal and cable end, and
brush them with grease to prevent corrosion. Naked cable ends and terminal posts should be covered
with a skid-proof insulating cover.
2) Every two cells should be well-connected. Check the nuts on each pole, if loose, tighten the nuts.
3) Keep the surfaces of accumulator clean and dry. After the completion of recharging, clean spilled
acid with cotton yarns or brush. And clean with wet towel if necessary.
4) Over recharging and over discharging should be avoided, and fast charging and insufficient
recharging are also not allowed. Otherwise life span of the accumulator may be affected.
5) Do not put conductive objects including metal tools on the accumulator, or short circuit or even
explosion may be caused.
6) Never spill any hazardous liquid or solid material on surfaces of the accumulator. When using a
densimeter or a thermometer, make sure the surface is clean and clear.
7) Recharge the discharged accumulator in time. Delayed recharging may damage the accumulator.
Do not delay recharging more than 24 hours. Recharging of the accumulator may not work outdoors
in cold weather. In this case, move it indoors to perform recharging.
8) If the accumulator will not be in use for a long time, it should be recharged and discharged once
every month and it should be fully recharged every time.
9) During recharging or using, the liquid level of electrolyte lowers because of water evaporation,
so pure water should be added.
10) If individual cell fails, identify the cause and repair the cell immediately. Replace the cell when
it cannot be repaired.
11) The site for recharging should be well ventilated. It is prohibited to smoke or use open fire,
avoiding the risk of hydrogen explosion.

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12) The electrolyte in accumulator is toxic and corrosive. For this reason, always wear working suit
and protection glasses to protect your body from contacting the electrolyte in accumulator.
13) If your clothes, skin or eyes are spilled with acid liquid in accumulator, flush with large amount
of clean water. For skin and eyes, flush with large amount of clean water and also seek doctor’s
treatment immediately. Acid spillage must be neutralized and treated immediately.
14) The weight and dimensions of the accumulator have remarkable effect on stability of the device .
Therefore do not modify the type of accumulator without approval from the manufacturer.
15) Never discharge in large current, for example, performs travelling and lifting simultaneously.
4.4.4 Dispose worn-out accumulators
Worn-out accumulators should be recycled according to local regulations, and stored in specified
zone or cast-off treatment zone. These works should be done by qualified specialized companies.
4.4.5 Specification of the accumulator
Battery
Charger
Rated power：24V
Rated capacity：
210/210Ah
Input：195/265VAC
50/60Hz
Output：24V30A
Uninsulated terminal poles on the accumulator should be protected with an insulated cover. When
connecting the accumulator and socket, make sure to stop the device and put the switch at position
“0”.When replace or install the accumulator, make sure the accumulator is fixed securely in battery
box.
4.4.6 Storage, transportation and installation of the accumulator
The device must be parked on the level ground steadily. To prevent short circuit, naked cable ends
and the terminal posts should be covered with insulated covers. When pulling out the accumulator,
properly arrange removed accumulator's connectors and cables without blocking access of the
accumulator.
When using the lifting equipment to load or unload the battery. Make sure that the lifting equipment
has sufficient load capacity(the weight of the battery is marked on the nameplate of the battery and
the vehicle. The lifting device must be pulled in the vertical direction to avoid damage battery

17
box .The hook of the lifting device must be safe and reliable. And the hook must never fall on a
single battery within the battery pack.
— Press the emergency stop witch and the power key witch to the OFF position so that it is in
the cutoff position
— Disconnect the battery cable connector.
— Connect the lifting device to the lifting hole
— Remove the battery from the top and remove it with the handling equipment .
The installation process is in the reverse procedure.it is importance that the battery must place in
correct place and the wiring is reliable .After re-installing the battery. All cable connections and
connectors must be inspected for obvious damage.
4.4.7 Battery power indicator
Battery power display table: ten article showing represent 100% of the battery.
With the consumption of battery capacity, the glowing article shows will be from top to down.
The color of LED show the different states ：
Name
LED Color
Parameter value
The standard battery remaining
power
Green
70-100%
Orange
30-60%
Red blinking
0-20%
Battery discharge on 70%,red lamp will blinking“Energy storage”.
Battery discharge on 80%,two lamp will blinking “run out of battery”,Need to charge the
accumulator.
full Need to recharge Low battery