EKKO EK25LP Operator's Manual
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EKKO EK25LP Operator's Manual

Counterbalanced type forklift truck with engine
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OPERATOR'S MANUAL
Counterbalanced Type Forklift Truck with Engine
EK25LP/EK25-212LP/EK30LP

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Summary of Contents for EKKO EK25LP

  • Page 1 OPERATOR’S MANUAL Counterbalanced Type Forklift Truck with Engine EK25LP/EK25-212LP/EK30LP...

  • Page 2: Table Of Contents

    CONTENTS .About Safety····························...···········...···········... ···········..···········...···········.. ······· 2 Main Use of Forklift Trucks· ·····························"···········" ············· 2 Working environment Areas of Forklift Trucks·······························. ············2 Safety Problem Before Use··· ············..············. ············ Safety Problem During Operation········..···········..··········..············..············. ····· Safety Problem During Service···············...··········..··········..··········... ··········... ····· Safety Problem of Battery Using • •······ •······ •········· •······ •······ •········· •······ •············.
  • Page 3 VI. Instructions for trucks meeting China IV and EURO V or higher emission limits stage ........................... 1. Introduction on instrument ................• .l 00 2. Introduction on regenerating ····..·..··..·..·..··..·..·..·..·..·..··..·..·..··· 3. Instruction on DPF regeneration ..·106...
  • Page 4 INTRODUCTION This manual should be kept 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.

  • Page 5: About Safety

    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.
  • Page 6 ,A.WARNING ·When crossing the railroad, be sure to once 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.
  • Page 7 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.

  • Page 8: Safety Problem Before Use

    ·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, regions, or at high altitudes. ·In environments with exhaust emission standards.
  • Page 9 ·Do not operate the forklift truck when you are tired, have mix emotional problems, or consumed any drugs or alcohol. 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.
  • Page 10 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.

  • Page 11: Safety Problem During Operation

    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 is in proper shape and securely palletized. ·Prohibition of handling materials without pallets.
  • Page 12 ·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. Safety around the truck CAUTION ·When carrying the large load and visibility is poor, make a drive backward or someone should induce the truck.
  • Page 13 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.
  • Page 14 Prohibition of driving with forks lifted up in the air 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. Prohibition of fork tip working CAUTION ·Do not push a load or lift up by the tip of forks.
  • Page 15 Prohibition of prod goods horizontally with forks ,A.NOTE ·Do not lift goods horizontally with forks or parts, damage may be caused. 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...
  • Page 16 Driving on a slope (10) 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.
  • Page 17 Prohibition of permitting passengers (12) 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.
  • Page 18 Prohibition of lifting when tilting loads forward (14) 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.
  • Page 19 Getting on and off truck (16) 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.
  • Page 20 Adjustment of forks (19) 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.
  • Page 21 Parking of disabled forklift truck (22) (Cenote ·When parki n g t h e f o r k l i f t on the road, warning or "out of order" signs shall be placed on the truck and remove the key. ·When the forks could not be lowered by fault, place a large mark in order not to be hit by other truck or walkers.

  • Page 22: Safety Problem During Service

    ·Parking place should be hard sufficiently and does not disturb a traffic. ·Do not park on or near an inflammable object. ·Do not park trucks on a slope. When park trucks on a slope, the trucks could move inconceivable. When park trucks on a slop by necessity, put wheel drags securely.
  • Page 23 ·Fire extinguishers shall be provided at the servicing facility. Precautions of service ,A.CAUTION ·Smoking shall be prohibited. ·Wear safeguards (helmet, shoes, glasses, gloves and boots) and suitable clothes. ·Wipe off split oil at once. ·On lubricating, lubricate after removing grease and dust off nipples and fittings with a brush or a cloth.
  • Page 24 ·When use a compressed air, wear goggle. ·When dismounting the tire, do not loosen bolts and nuts of joint rim. As inside tire is high pressure, there is a danger of breaking bolts, nuts and rim. Jack up working (exchanging tires) WARNING ·Do not enter under the truck while jacking up the truck.

  • Page 25: Safety Problem Of Battery Using

    ·It is forbidden to damage the piston rod during truck maintenance and commissioning, such as placing hard objects on the piston rod of tilt cylinder or standing on it; ·It is strictly forbidden for the user to adjust the thread distance of the ear ring of the tilt cylinder and then adjust the tilt angle;...
  • Page 26 ,A.CAUTION ·Do not charge the battery which the EB terminal is changed places with the0 terminal. It cause heating, ignition, smoking and an ignite explosion. Prohibition of putting a kind of metallic goods on the battery surface ,A.CAUTION ·Do not make a short circuit between both terminals by bolt or tool. It causes injuries and an ignite explosion.
  • Page 27 be taken care. ·When the electrolyte adheres to eye, skin and clothes, it causes to lose eyesight and a scald. Emergency first aid (cWNOTE When an accident is occurred, take the emergency first aid as following and consult a physician immediately. ·Spilled on the skin: It should be washed off with water for 10-15 minutes.

  • Page 28: Safety Problems During Attachments Installation, Adjustment And Using

    ·The temperature of electrolyte is high. ·The decreasing speed of electrolyte is fast. Prohibition of disassembling (14) .A.CAUTION ·Do not drain the electrolyte from the battery. ·Do not disassemble the battery. ·Do not repair the battery. Storage (15) .A.CAUTION ·When do not use the battery for a long time, store it in a place where is well ventilated and there is no sign of fire.

  • Page 29: Safety Problem During Lpg Truck

    clamp), weld a stopper on both sides of connecting part of fork bracket upper beam and attachment to avoid side shifting during using; for the attachments with lower hook limit, adjust the clearance between lower hook and fork bracket lower cross beam. Hook type is adopted by small and medium attachment.
  • Page 30 charging gas to the cylinder directly. ·charge gas or change cylinder in well-ventilated, safe and local fire protection criteria applied outdoors ·Stop the truck and shut down the engine, then operator shall go away from his seat. ·Be away from the fire, heat source and concave ground. ·Be careful with the cylinder.
  • Page 31 (3) Treatment in case emergency or accident Generally there is odorization agent the LPG so that it easy detect leakage. If there foul smell: ·Drive the truck to outdoors with good ventilation. Stop the engine and make sure there is no fire nearby; ·Turn off the switch on the cylinder manually.

  • Page 32: Decal

    ·Maintain the LPG system regularly; ·If LPG system has fault, contact with changing manufacturer for repair as soon as possible and repair by its specified repair factory. ·The gas is heavier than the air, so the explosive gas and air mixture will be formed in the basement due to insufficient ventilation, which may lead to an explosion hazard.
  • Page 33 Safety decal Position decal not stand under /on forks) Two sides of the outer mast Notes before operation Upper side of the hood Name plate Upper side of the hood or upper side of the dashboard lubrication chart Front side of the dashboard Capacity chart Upper side of the hood Caution before start...
  • Page 34 Decal of notice CAUTON: Name plate(for example) EKKO -31-...
  • Page 35 Decal of lubrication chart Decal of capacity chart(For example) CAUTION The capacity chart represents the relationship between truck load center and allowable load. -32-...
  • Page 36 Decal of caution before start CAUTION CHECK BEFORE START Please fulfill following regular checks before operation Hydraulic oil level. The oil level should be between the upper and lower marks on the dipstick(make sure the mast is lowered). Check all hydraulic pipes and connectors for leakage.
  • Page 37 Decal of tire safety(pneumatic tires) WARNING (1O)Decal of sling CAUTION Safety decal (no entry into the space behind the mast) (11) WARNING -34-...
  • Page 38 Decal of tire's air pressure(For example) (12) AIR PRESSURE FRONT TYRE 970kPa REAR TYRE 790kPa Safety decal (Mind your hand) (13) WARNING Decal of add fuel oil (14) Cieil NOTE FUEL FUEL FUEL (1 S)Decal of add antifreeze liquid Cieil NOTE ANTIFREEZE LIQUID...
  • Page 39 Decal of mind your hands (16) A.WARNING Decal of tie safety belt (17) WARNING Before driving, please tie the safety belt. Decal of noise (For example) (18) [cjjNOTE -36-...
  • Page 40 (19) Plate of protection on corrosion If the users have the requirements on corrosion prevention, the following protection level chosen according particular case. The instructions on the plates of protection on corrosion are following: Protection level and instruction Plates Protection level (protected during transportation ):...
  • Page 41 Protection level IV (Protected on the whole truck): 1) The main structural parts such as frame, mast, backrest, overhead guard and axle and covering parts such as hood and dashboard processed with corrosive prevention layers; 2) Exposed galvanized parts such as joints and bolts and main steel pipelines are coated with paint;...

  • Page 42: Operation Device & Method

    II .Operation Device & Use Method I .Outer mast 2.Inner mast 3.Lift chain 4.Lift cylinder 5.Load backrest 6.Fork stopper 7.Carriage 8.Fork 9.Drive wheel IO.Steer wheel 11.Fuel reservoir cap 12.Hood 13.Tilt cylinder 14.Seat 15.Steering handwheel 16.Head light 17.Front combination lamp 18.Overhead guard 19.Rear combination lamp 20.Balanceweight -39-...
  • Page 43 TORQUE CONVERTER TYPE Hour meter IO.Brake pedal 11.Accelerator pedal Coolant temp. gauge Fuel gauge Tilt lever Parking brake lever Lift lever Forward backward lever Fuse box 15.Ignition switch Steering handwheel Inching pedal Turn signal lever Light switch Horn button -40-...
  • Page 44 FRICTIONAL CLUTCH TYPE I .Hour meter Tilt lever Coolant temp. gauge Lift lever Fuse box Fuel gauge Parking brake lever 15.Ignition switch 5.Forward-backward lever Turn signal lever 6.Steering handwheel Horn button 9.Light switch Clutch pedal IO.Brake pedal Speed select lever 11.Accelerator pedal -41-...

  • Page 45: I.liquid Crystal Displayer

    I.Liquid Crystal Instrument For diesel forklift truck •M:l, WA'ii' _,.,. 'lruY gasoline forklift truck Optional parts -42-...
  • Page 46 Hour meter This meter measures working time of engine. Use meter to schedule lubrication and maintenance periods. Charge indicator This lamp indicates the battery condition of charge. The lamp comes on when the ignition switch is set at "ON" ,but it goes out as the engine starts and accelerator pedal is pressed.

  • Page 47: Switches

    This gauge indicates the temperature of the engine coolant. Under normal conditions, the pointer should be in the natural range(75-110). If the pointer stays in the alarm range(ll0 145), idle the engine until it enters the natural range. CAUTION ·If the pointer enters the alarm range, stop the operation instantly and slow down engine speed to cool the coolant and wait until the pointer goes into the natural range.

  • Page 48: Controls

    Removing hand off key, it is automatically returned to the "ON" position by spring force. ,A.CAUTION ·Do not keep the starter switch in the "ON “position while the engine is shut down. This results in a discharged battery. · With the engine running, do not turn the starter switch into the "START" position, since there is a danger of the starter motor being damaged.
  • Page 49 The steering handwheel is operated in the conventional manner, that when the wheel is turned right, the truck will turn to the right; when the wheel is turned left, the truck will turn to the left. The steer wheels are located at the rear of the truck. These cause the rear of the truck to swing out when a turn is made.
  • Page 50 this lever. The lift speed is controlled by tilt angle of the lever and accelerator pedal effort. The lowering speed can be controlled by tilt angle of the lever. The bigger the angle, the faster the speed. The engine speed, or accelerator pedal does not have to do with the lowering speed of the forks.
  • Page 51 Use this parking brake lever to park the lift truck. The parking brakes are applied on the front two wheels by pulling up on this lever. To release the parking brakes, move the lever forwards. .A.WARNING ·If parking on a grade is unavoidable, be sure to block the wheels. ·When leaving the driver's seat, please apply parking brake.
  • Page 52 TORQUE CONVERTER TYPE TRUCKS Forward-reverse lever® FORWARD NEUTRAL REVERSE The transmission control is a steering column-mounted type and has one speed at forward and reverse respectively. Always brake to a full stop before reversing the direction of travel. Shifting the lever in reverse turns on the back-up lights. CAUTION ·...

  • Page 53: Body & Others

    TORQUE CONVERTER TYPE TRUCKS Inching pedal@ As the inching pedal is pressed, the oil pressure in the hydraulic clutch drops accordingly (the needle of the oil pressure gauge swings to the left)allowing the operator to perform inching operation. Use this pedal to inch the truck while operating the hoist system at a high speed.
  • Page 54 deformed due to chemical reaction and sun light. ·The seat belt must be changed when its metal connecting part is bent, deformed or rusted. ·The seat belt must be changed when its service performance is not so good. 2)If the truck is going to turn over, do not attempt to get out of the truck, because the speed of overturn is much faster than you.
  • Page 55 To swing up the hood ,lift upward on the arrowed hood lock lever and the hood can be lifted up with little effort with an aid of hood damper. To lock the hood, push down on the front of hood until it locks. WARNING ·Use caution not to catch your fingers in the hood when closing it.
  • Page 56 Draw-bar pin The draw-bar pin only used for following situation: ·While the truck can't moving. ·While transporting the truck. .A.CAUTION ·Do not operate the forklift truck as a tow tractor by using a draw-bar pin. Do not tow the forklift truck by other truck. Safety step &...
  • Page 57 The fuse box is located at the right side of the cabinet’s inner surface. (1O)Brake fluid reservoir The brake fluid reservoir is provided at the left inside of the cabinet. This translucent reservoir allows to inspect the fluid level from the outside. (11)Hydraulic fluid reservoir cap The hydraulic fluid reservoir cap is located at the right side in the hood.
  • Page 58 The fuel reservoir cap is located at the rear left side of the truck body. To open it,,turn it counterclockwise. CAUTION ·The fuel reservoir cap has a breather inside it to allow air to enter into the reservoir. If the breather is damaged or clogged, the fuel system will get troubled. Check to see that the breather is good condition every time addition of fuel is made.
  • Page 59 ·Do not wear glove when removing radiator cap. Lamps (15) Two head lamps and combination lamps (turn signal, parking and clearance) are installed at the front side of the truck. The combination lamps at the rear side serve as turn signal, tail lamp, brake lamp, parking lamp, back-up lamp and rear reflector.

  • Page 60: Cab (Optional)

    Cab (optional) 1 Top assembly 2 Front wiper 3 Front glass 4 Rearview 5 Left door 6 Right door 7 Rear window (1) Doors Outside the truck Push the door handle to release the lock and open the door. When closing the door, press until the door lock catches. Both doors can be locked by the key.
  • Page 61 1 Door handle (ie.WNOTICE When opening the engine hood for cabin models, open the right left doors of the cabin first. Inside the truck Shift the inside door lever to release the lock and open the door. Open the door using the door pull handle.
  • Page 62 (3) Switch Press the wiper switch to operate the wiper. Press the heater switch to operate the heater. 1 Wiper switch 2 Heater switch (4) Heater and Defroster The heater is attached to the right side of the instrument panel or attached on the right door, heater switch is attached on the instrument panel .
  • Page 63 (5) Compartment light The compartment light is equipped on the roof of the cabin. Turn on and off the light with the switch. 1 Switch (6) Fan The fan is equipped on the roof of the cabin. Turn on and off the fan with the switch.

  • Page 64: Safety Devices

    6. Safety devices In order to improve the safety of operation, the truck is equipped with multiple safety devices, including: (1) There is a driver controlled horn in the middle of the steering wheel and a reversing buzzer that automatically triggers when reversing. (2) The truck is equipped with reversing mirrors, which are located on the top or both sides of the overhead guard.

  • Page 65: Driving And Operation

    Driving and Operation: To operate the truck safely and get the most out of it, we describe the correct operating procedures on the following pages. I.Notes on New Truck Usage Though the truck has experienced thoroughly adjust and test before delivery, the truck need moderate operation in the first month (200 hours) until all parts of the truck have full running-in time.

  • Page 66: Stability Of Forklift Truck

    of the load. The chart given above shows the relation between the load center and the weight of loads to be allowable for the 2 ton lift truck (Allowable Load). The load Chart will be attached onto the truck. Replace the damaged or missing load chart with new one. ,A.WARNING If a truck is equipped with a load-handling attachment such as a side shifter, load grab or rotating clamp, its allowable load is reduced as compared with that of a...
  • Page 67 can be arranged at the traction pin and overhead guard. ·The truck's length, width, height should be cared when loading it, unloading it or transporting it on the road. And all rules must be complied with. Loading and unloading the truck CAUTION: ·Please use the dockboard with enough length, enough width and enough strength to load and unload the truck.

  • Page 68: Before Starting Engine & After Engine Has Started

    When the engine fault indicator turns on or fault code displays after the electric controlled engine is started, stop to check or contact EKKO’s local dealer. It is suggested not to start the engine until the fault code is removed.
  • Page 69 Basic state for traveling Set the bottom of the fork 15 to 20cm above the ground and fully tilt back the upright. Check the safety around the truck and give a signal when starting the truck. CLUTCH TYPE TRUCKS Depress the clutch pedal and engage the shift levers. Release the parking brake lever.
  • Page 70 Gradually release the clutch pedal while depressing the accelerator pedal to start the truck. .A.CAUTION ·Do not rest your foot on the clutch pedal while you are driving. TORQUE CONVERTER TYPE TRUCKS Depress brake pedal and engage the forward-backward lever. Release the parking brake lever.
  • Page 71 Gear shifting Without loads, the truck can start even with gears in high speed. However, if the truck is underloaded, place the gear in low speed to start the truck. CLUTCH TYPE TRUCKS Always stop the truck before reversing the direction of travel. When gear shifting from high to low speed or vice versa, once increase the engine speed and release accelerator pedal.

  • Page 72: Pick Up

    ·Never stop the truck in ascending on a grade by pressing the accelerator pedal with the clutch in "half-clutch" and torque converter in operation. This will cause undue wear of clutch plates and abnormal rise of torque converter oil temperature, resulting in short life of clutch or torque converter.

  • Page 73: Stacking Operation

    restrict your vision, operate the truck i n reverse except when climbing grads. Stacking Operation CAUTION Check the following items before starting operation of truck. ·Make sure that there is not load's falling and damage of load at loading area. ·Make sure that there is no objects and stacking is carried out safely.

  • Page 74: Picking Operation

    length of the forks. Lift(50-100mm)the forks again and move to forward then lower the load slowly at a proper stacking position. Check clearance backward and move backward avoiding hitching forks to pallets or load. Make sure the tips of forks are off the load or pallet, and lower the forks to the position for running(150-200mm above the floor).

  • Page 75: Notes When The Truck Is Equipped With Solid Tire

    Lower the load up to 150-200mm above the floor. Tilt the mast backward for stabilizing the load. (10) Carry the load to its destination. (11) 11. Notes when the truck is equipped with solid tire When the truck is equipped with solid tires, please pay attention to the following notes: The truck with a solid tire is suitable for intermittent working condition and the working radius shall not exceed 2km.

  • Page 76: .Periodic Inspection & Servicing

    Cover components such as the breather and air cleaner which may be caught with humidity. The machine should be operated at least once a week. Fill with EKKO exclusive coolant (refer to OPERATION & SERVICE MANUAL for operation notes) if the engine coolant is discharged.

  • Page 77: I .General Rules On Inspection

    I. General Rules on Inspection (l)Use authentic parts only. Use authentic or recommended oil only. Clean oil fillers and grease fittings with a brush or waste cloth before adding oil or grease. 0il level check and addition of oil should be made with the truck parked on a level surface.
  • Page 78 Check condition of tires Low air pressure reduces tire service life andincreasese fuel consumption. Unevenness of air pressure between right and left tires or unevenly worn or badly damaged tires will cause uneven steering forces. The standard tire pressures are indicated on the decal at the front left side of the hood.
  • Page 79 CAUTION ·Do not dismantle rim bolt and when detaching hub nut. ·It is very dangerous that the hub nut becomes flexible. In case the hub nut became flexible, the wheel may come off and the vehicle would turn. Overhead guard check The overhead guard is for your protection.
  • Page 80 Check the electrolyte level in the battery. The battery case is given upper and lower level marks to allow the operator to see the electrolyte level. The level should be between the two marks. DANGER ·Never allow flame or sparks near the battery filler holes because explosive hydrogen gas may be present.
  • Page 81 Check hydraulic oil level by means of the oil level dipstick: Remove the oil level dipstick and clean it. Reinsert it and remove it again to see if the oil level is between two slots: High and Low. CAUTION ·The oil level check should be done with the engine shut down, forks on the ground or floor, and the truck itself on a level surface.
  • Page 82 For different lifting system, please refer to the corresponding scale mark. For 5-7t trucks with basic type mast and lifting height lower than 4750 and without attachment, please refer to the oil level gauge face marked with 5-7t, for other 5-7t trucks, refer to the oil level gauge face marked with 8- 1 Ot. H and L are marked on two faces to show the highest level and lowest level.
  • Page 83 Check for loose mounting bolts for the load backrest. Retighten where needed. (15)Fork & fork stoppers Check fork stoppers for correct installation and forks for bending or cracks. ( l 6) Headlamps & front combination lamps Check for dirty or damaged lens. Close the hood, sit on the seat and: Take care not to catch your finger in the hood.
  • Page 84 Fuel level check: (22) The fuel level gauge 1s provided on the indicator panel. Check that fuel level 1s sufficient for the day's work. Lights & lamps (23) Actuate each light or lamp switch to be certain that the respective light or lamp comes on properly.
  • Page 85 Check the tension and abnormality of the lift chains. To check the tension, raise the fork about 5cm above the ground and push the middle of the chain with the thumb. Make certain the tension for the right and left chains is even. If uneven tension is found, loosen the lock nut(A) of anchor pin and adjust the chain, turning the adjusting nut(B)of the chain...

  • Page 86: Maintenance

    Press the clutch pedal to be certain that the clutch is properly disengaged and does not drag. Inching pedal check (TORQUE CONVERTER TYPE TRUCKS ONLY) Press the inching pedal a little (3mm or less) and check that the truck speed decreases. Brake test (33) Run the truck slowly and press the brake pedal to check the braking effect.
  • Page 87 DIESEL When the sedimentor indicator lights up ... Stop the engine, loosen the drain plug by turning 4 to 5 turns(A) and press the priming pump(B) .Continue pressing the priming pump (B)until water is entirely discharged through the sediment. Fasten the drain plug and press the priming pump several times to see that there is no fuel leakage from the plug.
  • Page 88 The fuse protects the electric system against overcurrent. Use the specific ampere rating of fuse. Check to see that the components in each circuit are operating properly. If every component in a circuit is not functioning, it is an indication that the corresponding fuse is blown out.
  • Page 89 This service schedule is worked out on the assumption that the lift truck will be used under typical working conditions. If the lift truck is used under severe working conditions, earlier preventive maintenance services are required. (The black dots in the table mean "Replacement".) G: Gasoline truck D:Diesel truck...
  • Page 90 ENGINE Check and maintenance interval Checking Service Required Tools Item Daily Monthly Quarterly Semiannually Annually (8 hrs) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs) Visually inspect condition of engine rotation. Check for working noise from engine. Check that exhaust gas has proper-color. •...
  • Page 91 ENGINE Check and maintenance interval Checking Service Required Tools Item Daily Monthly Quarterly Semiannually Annually (8 hrs) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs) Visually check for fuel leak from pipe, pump or tank. Check fuel filter for clogging. •...
  • Page 92 POWER TRAIN Check and maintenance interval Checking Service Required Tools Item Daily Monthly Semiannually Annually Quarterly (8 hrs) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs) Check clutch pedal for free travel and clearance Scale between pedal surface and floor when clutch is Frictional unlocked.
  • Page 93 WHEELS Check and maintenance interval Checking Service Required Tools Item Daily Monthly Quarterly Semiannually Annually (8 hrs) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs) Tire gauge Check for inflation pressure. Check for cracks or damage. Depth gauge Tires Check for tread wear.
  • Page 94 STEERING SYSTEM Check and maintenance interval Checking Service Required Tools Item Daily Monthly Quarterly Semiannually Annually (8 hrs) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs) Check king pins for looseness or damage. KnucAklel Check for deflection, deformation, cracks or damage. Check for mounting condition.
  • Page 95 BRAKE SYSTEM Check and maintenance interval Checking Service Required Tools Item Daily Monthly Quarterly Semiannually Annually (8 hrs) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs) Check for fluid leaks. • Check for fluid level.Change brake fluid. Check master cylinder and wheel cylinders for proper Brake Master operation.
  • Page 96 LOADING SYSTEM Check and maintenance interval Checking Service Required Tools Item Daily Monthly Quarterly Semiannually Annually (8 hrs) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs) Check forks for damage,deformation or wear. Check for stopper pins for damage or wear. Fork Check fork base and hook weldings for defective cracks or wear.
  • Page 97 LOADING SYSTEM Check and maintenance interval Checking Service Required Tools Item Daily Monthly Semiannually Quarterly Annually • (8 hrs) (200 hrs) (1200 hrs) (600 hrs) (2400 hrs) Check chains for tension,deformation,damage or rust. (2-4 years) Lubrication of chains. Chains& Check connection of chain anchor pin and chain for Sheave looseness.
  • Page 98 HYDRAULIC SYSTEM Check and maintenance interval Checking Service Required Tools Item Daily Monthly Quarterly Semiannually Annually (8 hrs) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs) (1500hrsfo hefirst time, Check for oil level.Change oil. every2400hrs in the future) Hydraulic C 1 ean Reservoir suction stramer.
  • Page 99 ELECTRICALS Check and maintenance interval Checking Service Required Tools Item Monthly Semiannually Annually Daily Quarterly (8 hrs) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs) Check distributor cap for crack. Check spark plug for bum. Plug gap gauge Adjust spark plug clearance. Ignition Clean spark plug.
  • Page 100 SAFETY APPARATUS & ACCESSORIES Check and maintenance interval Checking Service Required Tools Item Daily Monthly Quarterly Semiannually Annually (8 hrs) (200 hrs) (600 hrs) (1200 hrs) (2400 hrs) k fi O G v u e a r r h d e & ad Test hammer t msta ation.
  • Page 101 CAUTION: · Locally refined oils and cooling water, coolant, or anti-freeze do not allow the same operation period designated in this manual. They must be changed more frequently as half or a quarter of the designated period in this manual. ·Multi-viscosity oils allow a wider temperature range for operation but must be changed more frequently as the addition that provides the multi-viscosity gradually deteriorates lowering the viscosity.

  • Page 102: Preventive Maintenance Service Schedule

    .Others 1. Lubrication chart LUBRICATION CHART Radiator King Pins Axle Shafts Wheel Bearing Center Arm Pump Drive Water Pump Crank Case Tank Distribu Tor Power Steering Tilt Cylinder Tilt Pins Transmission Brake Pedal Wheel Bearing Tilt Cylinder Pins Mast support Free Lift Guide Bars...

  • Page 103: Fuel And Lubricants Used For Forklift Truck

    20W/50 5W/30 degree Engine Applying -30,_+30 -25,_+30 5,_+50 -20~+40 temperature (°C) HLW-40(dedicated for EKKO Hydraulic oil NORMAL TEMPERATURE LOW TEMPERATURE Mobil DTE 25 Mobil DTE Excel 46 Shell Tellus. S2 M46 Shell Tellus.S2 V46 HLT-9(dedicated for EKKO) Hydraulic-power d NORMAL TEMPERATURE...
  • Page 104 ·Oil products of different brands cannot be mixed. ·Engine failure caused by oil quality is not within the scope of warranty. ·Do not mix-use oil of different oil brand. Correction measures: The light diesel oil of different brands should be used for diesel engine according to various atmospheric temperatures and refer to the following table for details: Atmospheric temperature 0- -10...
  • Page 105 VI. Instructions for trucks meeting China IV and EURO V or higher emission limits stage Introduction on the instrument (8) Forklift run-well The display suggests that the truck is normal when the truck gets electricity. (9) Warning of high exhausting temperature When the truck is under regeneration, the instrument will give a warning of high...
  • Page 106 will not be effective. After a period of time, it is easy to cause blockage of post- treatment system. The maintenance cycle shall be shortened. (13) -(16)DPF jammed volume I 00% means the jammed volume to I 00% and it needs cleaning; 75% means the jammed volume is 75% and 50% means the jammed volume is 50%.
  • Page 107 regeneration" figure will be displayed on the instrument at this time. In this process, the whole truck can continue to operate. During the active regeneration process, if the instrument displays the high exhaust temperature warning (as follows), please pay attention to keep the surrounding personnel and inflammable and explosive materials away from the exhaust pipe.
  • Page 108 C-.iiiNOTE ·When truck requests parked regeneration, a n d parked regeneration is not carried out, the truck will limit the truck torque in a short time. When the parked regeneration cann ot be realized, it is necessary to contact the local dealer to clean or change the DPF. ·When the truck is carrying out parked regeneration, the truck cannot be operated, otherwise the parked regeneration will be terminated.
  • Page 109 3. Instruction on DPF regeneration Instruction on DPF regeneration (Kubota engine V2403,KU17 /KU18/ KU19/KU20) 1) When will it regenerate? ·The lamp flashes and active regeneration is required. ·The lamp flashes + fault code 3701-15, stop and regenerate immediately. Sometimes the engine shutdown lamp will turn ·The lamp flashing+...
  • Page 110 Instruction on DPF regeneration (Xinchang 3E22YG51, XC26) I) When will it regenerate? ·The lamp flashes and active regeneration is required. ·The lamp flashes fault code 5270-15, stop and regenerate immediately. Parking regeneration cann ot be carried out in 2 hours. ·The lamp flashes fault code 520261-0, r e g e n e r a t i o n cann ot be...
  • Page 111 "Regeneration reminder/ regeneration status" indicator is and "3251-15" is displayed on the instrument. It is necessary to stop for regeneration. "Regeneration reminder regeneration status" indicator light flashes, the yellow light and "3251-16" is displayed on the instrument LCD. Carry out parked regeneration as soon as possible.
  • Page 112 (-.ijj Note Any fault occurs before regeneration shall be eliminated. · ·Inhibit regeneration: The whole truck will not carry out active regeneration mode, which is easy to cause blockage of post-treatment and shorten maintenance cycle. ·Active regeneration: The whole truck can regenerate automatically during operation, which will produce high exhaust temperature.
  • Page 113 1iiJ ti ii CAPACITY CHART SINGLE TYRE iisft B!' LIFT HEIGHT (mm) 3000 =i'l"ll:AA 4250 5000 l2soo 2-STAGEM 4500 >- 2600 ::- "- " 5000 2400 5500 I""-. 2200 6000 I"-. ":S::- r---... 2000 -:::s I'--. 1soo mlmij ..t---....
  • Page 114 -"STJ 2800 3-SlAGEM -2600 2100 i'.: 4700 2400 1900 2200 1700 .0------ 5400 {31500 U 1600 ,-:- l.111300 '" 1400 r-.:-- "' 1100 6000 1,,; 1200 1400 1200 ttf.'f'P l: LOADCENTER t;l:j':j"9'11L,, LOAD CENTER (mm) {mm) EK25LP EK30LP -111-...
  • Page 115 ll:l3 11:ll CAPACITY CHART CAPACITY CHART SINOI.ETYRE J11.II:; SIJ\IGLETYRE .tiii (rrm) • -ft- {2:LIFT HEIGHT '"' : n• -:f3700-- i3500 J.tTa&,GEM>otl 3000 2500 5000 -- U12000 1500 ====:::Jil::::11:::::111:;::-a--c13i'oooo---'--.;.,. _,IN 1200 1400 □ tlillfltl'l.• LOAD CENTER ITY210<1D>IOII {iffli:p,i.,LOA CENTER (mm) Sl\'20-00-HJ (mm) ll:l3 CAPACITY CHART...
  • Page 116 t'.! f.f aB :f7.l CAPACITY CHART CAPACITY CHART li:7tilfill LIFT HEIGHT (mm) t:ilftJ!ili LIFT HEIGHT (mm) -:,;:sooo-----.,---r---,- ,;;;5000 -- 50CKl 6000 6000 6000 5000 4000 < u 4000 • • • 3000 ll/1 1113000 {ll! • {ll! 2000 2000 1000 1200 1600 1800 ""...
  • Page 117 f;'J.1afrt!J l!I f;' J .1af rt!J CAPACITY CHART CAPACITY CHART r,:=:- :fl- !i (mm) (mm) LIFT HEIGHT RJt-.-!f LIFT HEIGHT ,:cs;sooo -10000 4,.!i9,0 8 5 0 0 <:nnn- § § 5500 7000 6000 8QOO <i <.) 5000 6000 -0' 1 -0' 1 4000\.

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