Jungheinrich EKE 20 b Operating Instructions Manual Download Page 1

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Operating instructions

50261576

EKE 20 b

04.02-

04.02

Summary of Contents for EKE 20 b

Page 1: ...Operating instructions 50261576 EKE 20 b G 04 02 04 02 ...

Page 2: ...t explanations are indicated by the following graphics f Used before safety instructions which must be observed to avoid danger to personnel m Used before notices which must be observed to avoid material damage A Used before notices and explanations t Used to indicate standard equipment o Used to indicate optional equipment Our trucks are subject to ongoing development Jungheinrich reserves the ri...

Page 3: ...0108 GB ...

Page 4: ...ls and identification labels B 6 3 1 Truck identification plate B 7 C Transportation and commissioning 1 Transportation by crane C 1 2 Commissioning C 1 3 Moving the truck with the drive unit inoperative C 2 D Battery Servicing recharging replacement 1 Safety regulations governing the handling of lead acid batteries D 1 2 Battery types D 2 3 Exposing the battery D 2 4 Charging the battery D 3 5 Re...

Page 5: ... Safety regulations applicable to truck maintenance F 1 3 Servicing and inspection F 3 4 Maintenance checklist F 4 5 Lubrication schedule F 6 5 1 Fuels coolants and lubricants F 7 6 Instructions for the servicing operations F 8 6 1 Preparing the truck for servicing and maintenance operations F 8 6 2 Tilting up the armrest F 8 6 3 Opening the battery hood F 9 6 4 Opening the seat hood F 9 6 5 Openi...

Page 6: ...elf or on whose behalf it is used In special cases e g leasing or renting the user is consid ered the person who in accordance with existing contractual agreements between the owner and the user of the fork lift truck is charged with the observance of the op erating duties The user must ensure that the truck is not abused and only used within its design lim its and that all danger to life and limb...

Page 7: ...0600 GB A 2 ...

Page 8: ... with electric steering wheel control The EKE 20 b is designed for transport and order picking operations on level ground Pallets with open ground support or pallets fitted with lateral boards provided that the boards are outside the range of the load bearing wheels can be picked up The rated capacity of the truck is shown on the identification plate or on the capacity label Qmax ...

Page 9: ...e indicator 7 t Battery door 2 t Control lever 8 t Seat hood 3 t Master switch emerg stop 9 t Drive wheel 4 t Armrest 10 t Supporting wheel 5 t Battery hood 11 t Dead man s switch 6 t Lifting device 12 t Parking brake t Standard equipment o Optional equipment 1 2 3 4 6 7 8 9 10 11 12 5 ...

Page 10: ...nation Standard t Rapid drive o Q Rated capacity 2 000 2 000 kg c Load centre distance 600 600 mm Travelling speed with without rated load 7 7 10 0 9 5 12 5 km h Lifting speed with without rated load 8 0 12 0 8 0 12 0 cm s Lowering speed with without rated load 6 5 4 0 6 5 4 0 cm s Max climbing capacity 5 min with without rated load 6 13 7 14 70 l2 l l1 l6 b 12 b 11 b 5 b 3 e x Ast3 h 13 h 3 h 7 b...

Page 11: ... width 950 b5 Distance between forks outside 510 540 670 b11 Track 340 370 500 b3 Distance between forks inside 170 200 330 e Fork width 170 a Safety distance 200 Dead weight Refer to truck identifi cation label l l1 y1 x1 l6 b12 Wa 1 Ast3 1 150 2 030 1 689 964 1 200 800 1 844 2 280 1 600 2 480 2 139 1 414 1 600 1 200 2 294 2 680 2 400 3 280 2 565 1 840 2 400 1 200 2 720 3 480 70 l2 l l1 l6 b 12 b...

Page 12: ...ned by driving over bumps with a constant speed Electromagnetic compatibility EMC The manufacturer confirms compliance with the limit val ues for electromagnetic emission and interference immu nity as well as testing of static electricity discharge ac cording to prEN 12895 and the references to other standards contained therein A Electrical or electronic components and their arrangement may only b...

Page 13: ...corresponding hood The battery identification plate 18 is visible after opening the battery hood and door refer to chapter D Item Designation 13 Label CAUTION Low voltage electronics 14 Capacity Qmax 15 Control lever 16 Floor load 17 Attachment point of hooks for transportation by crane 18 Battery identification plate 19 Accident prevention inspection label D only 20 Truck identification plate mV ...

Page 14: ... 24 Battery Voltage V 31 Empty weight without battery in kg 25 Manufacturer 32 Year of manufacture 26 Order no 33 Manufacturer logo 27 Load centre distance in mm kg kg mm kg Xxx Xxxx Xxxxxxx Xxxxxxxxx Xxxxxxxxx Xxxxxxxxxx Xxxxx Xxxx Xxxxxxx Xxxxxx Xxxxxx Xxxxxx Xxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxx V kW Xxxxxxxxx Xxxxxxxxxx xxxxxxxxxx xxxxxxxx Xxxxxxxxxxxxxxx...

Page 15: ...0402 GB B 8 ...

Page 16: ...s lifted 2 Commissioning m The truck must only be operated on battery current Rectified alternate current will damage the electronics Cables connected to the battery trailing cables must be less than 6 meters in length In order to prepare the truck for work following delivery or transportation the following operations must be performed Check the truck for completeness and satisfactory condition of...

Page 17: ...nd remove the key Ensure that the truck cannot accidentally move Open the seat hood refer to chapter F Slacken the lock nuts 4 and tighten the screws 3 The brake has now been released and the truck can be moved f After arriving at the repair bay ensure that the brake is put back to its initial state The truck must on no account be parked with the brake in the released condition Loosen the screws 3...

Page 18: ...d cable shoes must be clean lightly greased with pole grease and must be securely tightened Batteries with bare terminal posts must be covered using a non skid insulating mat Disposal of the battery Batteries must only be disposed of as stipulated in the na tional environmental protection regulations or waste disposal provisions The manu facturer s specifications for the disposal must be heeded m ...

Page 19: ... the battery is correctly secured in the battery compartment of the truck 3 Exposing the battery f Park the truck and render it safe refer to chapter E Use the hex key located beneath the armrest 2 see chapter F to open the battery door 5 take out the door and put it aside Pull the unlocking lever 1 for the bat tery hood 3 Swing up the battery hood 3 and en gage it f Open and close the battery hoo...

Page 20: ... the battery cells must be exposed to en sure adequate ventilation No metal objects must be placed on the battery Prior to starting the recharging operation check all cable connections and plugged connec tions for visible damage All safety instructions as provided by the battery supplier and battery charger supplier must be strictly observed Withdraw the battery connector 6 Remove any insulating m...

Page 21: ...h a way that the lifting gear when slack cannot collapse on the battery cells Expose the battery refer section 3 Withdraw the battery connector 6 Open the battery door 5 with the hex key A The square key is located under the armrest refer to chapter F Remove the red battery lock 8 Pull the battery 7 laterally onto the battery change station f Heed the operating instructions of the manufacturer of ...

Page 22: ...ttery may be damaged due to a complete discharge Contact the customer service for setting the instrument If the remaining battery capacity falls be low 30 it is required to recharge the battery Battery discharge monitor If the residual capacity falls below the specified mini mum value the lifting function is switched off A corresponding message is displayed in the information and service indicator...

Page 23: ...0402 GB D 6 ...

Page 24: ...ruck or on the attach ments must immediately be brought to the notice of the person in charge Fork lift trucks that cannot be safely operated e g due to worn tyres or defective brakes must not be used until they have been properly repaired Repairs Without specific training and express authorisation the driver is not allowed to perform any repairs or modifications on the fork lift truck Under no ci...

Page 25: ...ON and OFF 9 Master switch emergency stop t The circuit is interrupted all electrical func tions are switched off and the truck is auto matically braked 10 Deadman key t released Driving function blocked or truck is slowing down operated Driving function released 11 Brake pedal t Braking of the truck 12 Adjusting wheel for seat damping t Sets the driver weight for optimum damping effect The set we...

Page 26: ...E 3 0402 GB 1 2 3 4 11 10 14 5 6 7 9 13 12 17 16 15 8 ...

Page 27: ...arting daily work Visually check the entire truck especially the wheels and the lifting device for vis ible damage Visually check the battery attachment and the cable connections f Do not actuate the control lever when entering the truck Adjusting the driver seat f Do not reach into the rear wall of the truck when adjusting the driver s seat Sit down on the seat Release the driver seat locking mec...

Page 28: ...t functioning Check whether the deadman key 10 brake pedal 11 Parking brake switch 15 and control lever 7 are properly functioning refer section 4 2 The truck is now ready for operation A The information and service indicator 17 briefly displays the vehicle code followed by the current steering position of the drive wheel the available battery capacity and the hours of operation 17 1 4 9 11 15 7 1...

Page 29: ...t always be carried at that end of the truck facing uphill U turns cutting obliquely over slopes or inclines and parking of the fork lift truck on slopes or inclines is not permitted Inclines must only be negotiated at slow speed with the driv er ready to brake at any moment Use of lifts and driving on loading platforms Lifts and loading platforms must only be used if they are of adequate load bea...

Page 30: ...em is a safety relevant component the fault must be eliminated by trained service personnel Emergency stop Depress the master switch 9 This will switch off all electric functions Deadman key The deadman key 10 must be operated for all operating functions If it is not applied all functions exception the information and service indicator 17 are deactivated and the brake is operated Driving f Do not ...

Page 31: ...ects the truck s rolling down on an incline The control lever 7 is used to release the service brake the speed and driving direction are set as desired m When the service personnel has switched off the coast down brake only the service and or the counter current brake can be used Steering Turn the steering wheel to the left or to the right A The position of the steered wheel is displayed on the in...

Page 32: ... coasting by counter current braking control lever 7 f In case of emergencies the truck must only be braked using the service brake break pedal 11 A During normal operation the generator brake and counter current braking should be applied These methods of braking reduce wear and require less energy energy re covery Braking by means of the service brake Depress the brake pedal 11 The truck is brake...

Page 33: ...ction A The braking effect depends on the setting of the control lever 4 3 Picking up and setting down loads m Before picking up a load the driver has to make sure that it is correctly palletised and that the capacity of the truck is not exceeded Pass the lifting device as far as possible under the load Picking up long loads crosswise is not permitted m Pick up the load ensuring that it does not p...

Page 34: ...wered Operate the parking brake switch 15 Lower the lifting device Set the drive wheel to the straight ahead position Turn the steering wheel until the drive wheel is set to its straight ahead position A Control the displayed steering angle on the information and service indicator 17 Switch the key switch 1 to position OFF 0 and remove the key Depress the master switch emergency cut out 9 to the O...

Page 35: ...o lit LED indicators show the following states 5 2 Keyboard assignment Item Function 22 Driving direction forward direction of the drive green LED 23 Driving direction backwards direction of the load green LED Item Function 24 Double function increase of the selected parameter in steps Selection of the individual menu items in upward direction 25 Double function decrease of the selected parameter ...

Page 36: ... FORW L CUT BACK FORW L MAX REVERS SPEED L BUZZER ON OFF O F F L RELOAD L Issues an audible alarm in case of an operating fault This setting has no function This driving parameter may only be adjusted by the cus tom service This driving parameter has no function This driving parameter may only be adjusted by the cus tom service This driving parameter has no function This driving parameter may only...

Page 37: ...want to check or modify any truck parameters Use the following keys to change between the adjustment parameters 30 and 24 and 25 Acceleration L1 Setting the time XX XX L1 Buzzer on off OFF L1 Low speed ride Load direction L1 Speed Load direction L1 Low speed ride Direction of the driveL1 Speed Direction of the driveL1 Reverse brake L3 Coasting brake L1 Acceleration S2 Setting the time XX XX S2 Buz...

Page 38: ...r switch emergency stop depressed Key switch in position 0 Battery exhausted The deadman s key has not been pressed Fuse defective Check the battery connector and connect if necessary Release the master switch Set the key switch to position I Check the charging condition of the battery and recharge if necessary Press the deadman s key Check fuses F1 1F1 and 3F9 Load cannot be lifted Truck not oper...

Page 39: ...0402 GB E 16 ...

Page 40: ...cians trained especially for these assignments We thus recommend signing a maintenance contract with the relevant service location of the manufacturer Lifting and jacking up When a fork lift truck is to be lifted the lifting gear must only be secured to the points specially provided for this purpose When the truck is to be jacked up suitable measures must be taken to prevent the truck from slippin...

Page 41: ...The quality of the tyres greatly affects the stability and the driving behaviour of the fork lift truck The factory mounted tyres must only be replaced by original spare parts of the manufacturer since otherwise the specification of the data sheet cannot be met When replacing wheels or tyres it must be ensured that the fork lift truck remains level tyres and wheels must always be replaced in pairs...

Page 42: ...g hours but at least once per week M3 every 500 operating hours but at least every 3 months M6 every 1000 operating hours but at least every 6 months M12 every 2000 operating hours but at least every 12 months A The W1 maintenance intervals must be carried out by the operator customer In the running in phase of the truck the following additional operations have to be car ried out After the first 5...

Page 43: ...t for wear adjust and grease c k t 4 3 Replace actual value steering angle potentiometer on the steering motor t k t Brake system 5 1 Performance and adjustment check t 5 2 Check the brake linings for wear t 5 3 Check reset function of the brake pedal k t 5 4 Check the brake linkage adjust if necessary t Lifting de vice 7 1 Check performance wear and adjustment t 7 2 Perform a visual check of roll...

Page 44: ...eck contactors replace wearing parts if necessary t Electric mo tors 10 1 Check the carbon brushes for wear t 10 2 Check the motor for secure attachment t 10 3 Clean motor housing by means of a vacuum cleaner and check the commutator for wear k t 10 4 Check whether the cover of the steering engine potenti ometer is present Battery 11 1 Check acid density acid level and cell voltage k t 11 2 Check ...

Page 45: ...Filler plug for hydraulic oil b Filler plug for gear oil a Drain plug for gear oil Cold store usage 1 Compound for cold store usage 1 1 2 1 25l 1 3l depending on the drive type always up to the lower edge of the filler neck s s E a B 1 25 1 3 l B C b 1 g A C A 0 7 l 1 F G ...

Page 46: ...des or qualities except if mixing is expressively prescribed in these operating instructions Avoid spilling Spilt liquid must be removed immediately using a suitable binding agent and the mixture of consumption type material and binding agent is to be dis posed of according to the regulations Grease data Code Order No Supply Qty Designation Used for A 29 200 670 5 0 l H LP 46 DIN 51524 Hydraulic s...

Page 47: ...ck and render it safe refer to chapter E Disconnect the battery plug to prevent accidental starting of the truck refer to chapter D f When work has to be performed under the jacked up truck suitable measures must be taken to prevent any dropping tilting or slipping of the truck When lifting the truck the instructions contained in the chapter Transportation and commissioning have to be observed 6 2...

Page 48: ... battery hood 4 upward and lock it 6 4 Opening the seat hood Use the hex key located beneath the armrest 2 to open the seat hood 5 Swing the seat hood 6 to the outside A Drive unit steering motor steering control and the hydraulic installation can be easily accessed for maintenance works 3 4 8 7 6 5 ...

Page 49: ...ey located beneath the armrest 2 Take out the control flap 10 and put it aside A The drive current control system and the truck fuses are readily accessible for serv icing purposes f Do not drive the truck unless the hoods are closed and locked in the stipulated man ner 9 10 ...

Page 50: ...d in the servicing checklist Position the drive wheel 12 at right angles to the longitudinal axis of the truck Tighten all wheel fixing bolts 10 using a wrench which is to be inserted through the opening 13 of the collision guard A Tightening torque 1st step MA 10 Nm 2nd step MA 105 Nm m Remove the wrench after tightening the wheel fixing bolts 11 13 12 ...

Page 51: ...ing to the table check all fuses for correct rating and damage replace fuses where required Reclose the hoods refer to chapter F section 6 3 and 6 4 Item Designation Protection of Value 14 3F9 Steering motor 30 A 15 1F1 Pump motor 150 A 16 2F1 Drive motor 150 A 17 1F10 Field Driving 40 A 18 6F2 Battery discharge indicator operating hour meter 10 A 19 F1 Entire control circuit 10 A 15 14 17 16 18 1...

Page 52: ...r more than 6 months additional meas ures must be discussed with the Service Department of the manufacturer 7 1 Operations to be performed prior to decommissioning Thoroughly clean the fork lift truck Check the brakes for correct function Check the hydraulic oil level and top up if required refer to chapter F Apply a thin film of oil or grease to all parts not protected by a paint coating Grease t...

Page 53: ...ecked by a qualified inspector The inspector must assess the condition of the truck from a standpoint purely concerned with safety aspects uninfluenced by any compa ny or economic circumstances The inspector must be adequately informed and ex perienced to be able to assess the condition of the fork lift truck and the effectiveness of the safety installations based on the technical rules and princi...

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