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EKKO EK20TLP Instruction Manual
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EKKO EK20TLP Instruction Manual

Internal combustion engine powered
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Internal combustion engine powered
FORKLIFT
EK20TLP/ EK20D
EK25TLP/ EK25D
EK30TLP/ EK30D
EK35TLP/ EK35D
EK40TLP/ EK40D

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Summary of Contents for EKKO EK20TLP

  • Page 1 Internal combustion engine powered FORKLIFT EK20TLP/ EK20D EK25TLP/ EK25D EK30TLP/ EK30D EK35TLP/ EK35D EK40TLP/ EK40D...
  • Page 2 Thanks for your purchase of EKKO product This Operation & Maintenance Manual was written to provide the owner/ operator with information about the safe operation and maintenance of the forklifttruck. Read this manual thoroughly and become completely familiar with the lift truck before using it. If you have any questions, see your dealer.
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  • Page 4 The following symbols, found throughout this manual, alert you to potentially dangerous conditions to the owner and the operator. Become completely familiar with the truck before proceeding with operating, checking and servicing the truck. This manual and the decals affixed to the truck use the following safety alert indications.

  • Page 5: Improper Use

    PROPER USE OF THE LIFT TRUCK IMPROPER USE The proper use of a lift truck is to transport a load which is Transporting a person, elevating a person, and towing another placed on the pallet and stacked within the prescribed vehicle are examples of the improper use of a lift truck.
  • Page 6 INSTALL CURBS OR RAILINGS MAKE AN OPERATING PLAN AND DISCUSS IT If the truck is to be used on a loading dock, shore wall or Before using the lift truck, plan out the travel routes and op- other raised surface, install curbs or railings. erating procedures, and thoroughly discuss the details with all involved personnel.
  • Page 7 KEEP PEOPLE OUT OF THE OPERATING AREA KEEP THE GROUND LEVEL AND DRY No other personnel should be allowed in areas where the lift truck is used. Be sure that all areas where the lift truck travels are level and Where other people must be present, post a guide whose job regular.
  • Page 8 ASSIGN TRAFFIC GUIDES TO CONGESTED AREAS PROVIDE AND MAINTAIN EMERGENCY EQUIPMENT Post a traffic guide in confined or congested areas where other Fire extinguishers and first aid kits should be provided and main- people or vehicles may pass. All personnel must obey the guide's tained for use in case of a fire or accident.
  • Page 9 GOT A LICENSE? NO LOAD, NO TOWING It is usually illegal to carry a load on a public road. It is also not Before traveling on a public road, be sure that the truck has allowed to make a sideways travel or tow another vehicle on a been licensed and inspected as required by local laws.
  • Page 10 WEAR PROTECTIVE GEAR PERSONNEL WITHOUT LICENSE IS NOT ALLOWED TO DO THE OPERATION. The operator must take good training and instruction. Always wear proper work clothes for driving. Work clothes should be designed to prevent any part from accidentally catch- ng on knobs or other parts of the truck or equipment. For example, shirts and trousers should have tight cuffs.
  • Page 11 TRAIN YOUR STAFF TO STACK SAFELY TIMELY TRAINING AND INSTRUCTION IS NECESSONY FON THOSE EXPERT OPENATON. Each 5 years : technical improvment will cause the change of fabrication of lift trucks. The laws will be changed too. Significant modification to lift trucks: make sure the new training and equipment is proceeded through according to the modifciation.
  • Page 12 USE THE RIGHT TRUCK FOR THE JOB USE THE PROPER ATTACHMENT Be sure the type and capacity of the lift truck is suitable for the Popular Attachment Examples work environment. Capacity Power Source Gasoline, natural gas, diesel, and battery-powered models are available. Fuel costs and exhaust composition will vary.
  • Page 13 NO OPERATION WITHOUT LIGHTS, OVERHEAD KEEP DECALS LEGIBLE GUARD, OR BACKREST The decals on the truck describe safety precautions and operating instructions. Replace any damaged or missing decals. Check that the decals are legible during regular inspections. The lift truck cannot be used if the headlights, taillights, overhead guard, backrest, horn or turn signals have been removed.
  • Page 14 HAVE A GOOD VENTILATION STACK LOADS SECURELY When the engine is run indoors such as in an enclosed When stacking loads, place them in stable manner that they will warehouse, have a fresh-air ventilation. Exhaust fumes can not easily come apart, and be sure the weight is evenly cause chemical poisoning, and in the worst case exhaust fumes distributed.
  • Page 15 ALWAYS INSPECT BEFORE OPERATING REPLACE SAFETY PARTS REGULARLY Recommended Replace- ment Interval (year) Master cylinder and wheel cylinder cups and dust seals Power steering hose Reserve tank tubing Fuel hose Torque converter rubber hose Rubber parts inside power steering unit Lift chain Load handling means hoses The operator should always inspect the truck before each use...
  • Page 16 DESIGNATE A REPAIR AND ASSEMBLY TRANSPORTING THE LIFT TRUCK SUPERVISOR Use a level, hard road surface when loading the truck onto or unloading from a trailer and when unloading it. Be certain that Repairs and the mounting and dismounting of attachments the ramps have sufficient length and width as well as strength.
  • Page 17 Use optional "Lifting Eyes"for lifting your lift truck 1-15...
  • Page 18 KEEPING THE TRUCK BALANCED HOW THE CENTER OF GRAVITY SHIFTS Lift trucks are equipped with load handling means including a mast and forks at its front part. The front wheels of the truck work as a fulcrum to balance the center of gravity of the truck and the center of gravity of the load.
  • Page 19 OUTSIDE THE TRIANGLE OF BALANCE, THE RATED LOAD (LOAD WEIGHT AND TRUCK TIPS LOAD CENTER) For a lift truck to remain stable, the overall center of gravity The load center is the distance from the front face of the forks to must be inside the triangle formed by the contact points of the center of gravity of the load.
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  • Page 36 The caution plates attached to the lift truck explain cautions to be taken when using the truck, and procedures for operating the truck. Read messages on the caution plates as well as the description in this manual. Damaged or missing decals must be replaced with new ones.
  • Page 37 B.Warning decal for handling C.Warning decal for mast inflated tires connecting member YOU MUST FOLLOW THESE RULES TO AVOID SEVERE INJURY OR DEATH TO YOURSELF AND OTHERS. 1.Operate truck only if trained and authorized by your employer. Know Operation & Maintenance Manual and all work rules.
  • Page 38 P.Load chart: Decal for overloading K.Name plate P.Warning decal for front guardO.Decal for tire inflation pressure 1 - 3 6...
  • Page 39 Caution plate for handling batteries If the battery is used or charged when the electrolyte level Hydrogen gas produced by a battery can explode. Keep is below the LOWER LEVEL mark, the battery may be all open flames and sparks away from the battery. To damaged.

  • Page 41: Operating Controls

    2. OPERATING CONTROLS The following symbols, found throughout this manual, alert you to potentially hazardous conditions to the owner and the operator. Become completely familiar with the truck before CONTENTS proceeding with operating, checking and servicing. PICTORIAL NOMENCLATURE........2- 2 This manual and decals affixed to the truck use the following safety INSTRUMENTS AND CONTROLS........2- 4 alert indications.
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  • Page 44 NOTE...

  • Page 45: Horn Button

    HORN BUTTON COMBINATION SWITCH (LIGHTING) (TURN SIGNAL) This light switch can be pulled out in 2 steps. Use the turn signals (front and rear) to in- Press the horn button at the center of the dicate the traveling direction of the truck. steering wheel to sound the horn.
  • Page 46 METERS AND WARNING LIGHTS NOTE When checking the fuel level, park NOTE the truck on a level surface; oth- erwise you cannot get the correct fuel level. Add fuel before the fuel level drops to the minimum, to avoid the entrance of air into the fuel system.
  • Page 47 CAUTION If the truck is used neglecting the warning light, the fuel injection pump might be seized. For the procedure for draining water from the sedimenter, see page 2 - 7...
  • Page 48 NOTE If the pointer enters the red range, stop the truck and check the torque converter oil level and piping for leaks. If the oil level is proper and no oil leaks are found, consult your local dealer.
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  • Page 53 NOTE CAUTION 2-13...

  • Page 54: Lift Lever

    LIFT LEVER TILT LEVER NOTE...

  • Page 55: Steering Wheel

    STEERING WHEEL STEERING COLUMN TILT LEVER PARKING BRAKE LEVER 2-15...
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  • Page 62: Sideview Mirrors

    LIGHTS AND LAMPS SIDEVIEW MIRRORS Rear side CAUTION Check that lights and lamps come on and off properly. If any light bulb is blown out, replace with a new one.If the lens is contaminated or damaged, clean or repair. 2 - 2 2...
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  • Page 88: Items To Be Checked

    ITEMS TO BE CHECKED CAUTION Never try to operateafaulty truck. Check to see if any defect found on the previous inspection has been repaired properly. The standard tire pressure is indicated on the decal at the left side of the front guard. Turn the tire valve cap counterclockwise and remove it.
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  • Page 90 CAUTION Pull the hood opening lever and open the hood fully. Make sure the hood is locked securely and remove your hand. CAUTION Do not use or charge the battery with the electrolyte level below the "LOWER LEVEL" otherwise the inside of the battery deteriorates to cause a short battery life and in the worst case it might cause an explosion.
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  • Page 92 The engine oil level dipstick is located at the left side of the engine. Remove the dipstick, clean the rod and reinstall. Pull it out again and check the oil level. The level should be within the range between the High and Low marks on the dipstick.
  • Page 93 Check the fan belt for proper tension and cracks or damage. 4 - 9...
  • Page 94 Check the rear combination lamps (turn signals tail Visually check the hydraulic oil piping and lift and tilt cylinders for lamps back-up lamp oil leaks. brake lamp and rear reflector) for a damagedorcontaminated lens. Check the hydraulic oil level in the tank using the oil level dipstick. Remove the dipstick, clean the rod with a clean cloth and reinsert it.
  • Page 95 Check for dirty or damaged lens of the head lamps. Check also the CAUTION combination lamps (clearance lamps and turn signals) for a dirty or Do not modify or remove the load backrest. damaged lens. The operator might get injured by a falling load. The forks might come off the carriage.
  • Page 96 Check the direction and speed range shift levers (C type) and Check the fuel level using the fuel level gauge on the meter panel. shift lever (T type) for looseness and smooth operation. Make sure the fuel level is sufficient for the day's work or for each shift.
  • Page 97 CAUTION If the pedal returns poorly or the pedal height is not as specified, check the return spring and take necessary measures. If neglected, the pedal might become locked, making it difficult to press. Press the clutch pedal to check if it operates smoothly. Release the pedal to check if it returns securely.
  • Page 98 Press the brake pedal and inching pedal (T type) to check if the pedal can be pressed smoothly and returns securely. Check the brake pedal and inching pedal for play (see the sketches). Operate each of the lift and tilt levers to check if the forks and mast operate smoothly without squeaking.
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  • Page 100 Run the truck slowly and press the clutch pedal for proper operation. Run the truck slowly and press the inching pedal (T type) a little to check if the truck slows down. Run the truck slowly and press the brake pedal to check if the truck is braked properly without being pulled to one side.
  • Page 101 Run the truck at a low speed and turn the steering wheel a little to the right and left to check if the truck is steered properly. Pull the parking brake lever to check if the truck is properly braked. Also make sure the truck does not move and keeps its stopping position.
  • Page 102 1) Loosen the air bleeding plug (overflow valve) of the injection pump. CAUTION 2) Loosen the priming pump of the sedimenter and pump the priming pump until the fuel coming from the plug hole is free Make sure there is not any fuel leak from the air bleed- from bubbles.

  • Page 103: Replacing Fuses

    REPLACING FUSES Check to see that the components in each As the main fuse for the entire truck, a fusible circuit are operating properly. If every com- link wire (red cable) is provided at the positive ponent in a circuit is not functioning, it in- (+) side of the battery.
  • Page 104 REPLACING TIRES AND REPAIRING FLAT TIRE "A". "B"...
  • Page 105 REPLACING LAMP BULBS If any light bulb burns out, replace it with a new one of the same capacity, referring to the following table: Lampcapacity 4-21...
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  • Page 108 Just as your body needs to undergo physical examinations, your truck needs periodical checks and maintenance. When the truck appears to be in good condition, checks and main- tenance are likely to be neglected. But early discovery of trouble which may decrease truck efficiency and immediate correction, will greatly increase the working capacity of the truck, bring about greater productivity, prolong its life span and make it more economical.
  • Page 109 In order to perform safe operation, the importance of preventive maintenance of the truck cannot be overemphasized. Especially, the parts listed in the table below must be replaced periodically since they are the most important parts for safety of the truck and operator.
  • Page 110 MONTHLY (200 OPERATING HOURS) CHECKS Perform preoperational checks in addition to the following. The adjustment and replacement of components and parts listed as monthly check items are difficult and need a sufficient tech- nical knowledge and special tools. 4 - 2 6...
  • Page 111 Apply engine oil to the lift chains using an oiler or brush. To allow oil to enter between each pin and link plate of the lift chain, ob- serve the following conditions: 1) Loosen the chain sufficiently. 2) After applying engine oil, move the mast up and down at least 10 times.
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  • Page 113 CAUTION Do not climb the mast. Do not pour your hand or foot on the connecting members or into the mast assembly. You might get injured if the mast moves accidentally. Apply grease on the U-shape guides shown in the sketch (for masts with free lift mechanism) 4-29...

  • Page 114: Checking Air Cleaner Element

    Removing the element CHECKING AIR CLEANER ELEMENT Remove the two (or three) clips of the case and remove the wing nut securing the element. Then you can take the element out. Open the engine hood and disengage the air cleaner case clip and remove the element.

  • Page 115: Changing Engine Oil

    CHANGING ENGINE OIL CAUTION Do not drain waste oil into a waterway nor throw it away on the ground. Disposal of waste oil should be left to a specialist, dealers will undertake oil change job, if required. Change the engine oil once a month (200 hours of operation). However, for new trucks, the engine oil should be changed at the first 50 hours or after one week.
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  • Page 117: Changing Fuel Filter

    CHANGING FUEL FILTER Using a filter wrench, remove the filter case from the cover. Re- move the sedimenter sensor from the bottom of the filter case. Attach the sedimenter sensor to a new filter case and install the filter case into the cover. Sedimenter sensor tightening torque: 12-14 N-m (120 - 140 kg- Filter case mounting torque: 12 - 14 N - m (120 - 140 kg-m) 4-33...

  • Page 118: Changing Engine Oil Filter

    CHANGING ENGINE OIL FILTER 6)Make sure there is no oil leak from the filter mounting area. (Add engine oil to the specified level, start the engine and run it at idle rpm for a while.) Change the engine oil filter in the following manner: 1)Using a filter wrench, loosen the filter cartridge and remove.
  • Page 119 Items to be checked Driver's 4-35...
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  • Page 131 Driver's 4 - 4 7...
  • Page 133 The following symbols, found throughout this manual, alert you to potentially hazardous conditions to the owner and the operator. Become completely familiar with the truck before proceeding with operating, checking and servicing. This manual and decals affixed to the truck use the following safety alert indications.
  • Page 134 5 - 2...
  • Page 135 EK40D EK30/35D EK20D EK20TLP EK25D EK25TLP EK40TLP EK30/35TLP...
  • Page 136 5 - 4...
  • Page 137 EK40D/TLP EK20D/TLP EK30D/TLP EK25D/TLP EK35D/TLP 5 - 5...
  • Page 138 5 - 6...
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  • Page 140 REFILL CAPACITY 32L / 8.45gal 0.2L / 0.05gal 11L / 2.9gal 7.5L / 1.98gal 3T / 6000lb 7L / 1.85gal 10.7L / 2.82gal 70L / 18.5gal Notes: 1. Use light oil for diesel engine trucks. 2. For more information about lubricants to be used, contact your local dealer. 5 - 8...
  • Page 141 SERIAL NUMBERS OF MAJOR COMPONENTS In addition to the truck serial number, the se- rial numbers (unit numbers) of the major com- ponents are imprinted on the truck or indicated on name plates. The above sketch shows the serial number plate of the mast. These decals should be replaced immediately if missing or defaced (damaged or illegible).
  • Page 142 GENUINE EKKO PARTS 5 - 1 0...

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