Jungheinrich EKS 308 Operating Instructions Manual Download

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Operating instructions

51009741

EKS 308

03.06 -

07.08

Summary of Contents for EKS 308

Page 1: ...Operating instructions 51009741 EKS 308 G 03 06 07 08...

Page 2: ...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 materi...

Page 3: ...0108 GB...

Page 4: ...y crane C 1 2 1 Crane points Strap points C 3 2 2 Lifting the battery by crane C 3 3 Securing the truck during transport C 3 3 1 Basic truck transport safety C 4 3 2 Mast transport safety C 5 3 3 Mast...

Page 5: ...perator specific settings E 13 4 Industrial truck operation E 14 4 1 Safety regulations for truck operation E 14 4 2 Travelling Steering Braking E 15 4 3 Negotiating narrow aisles E 17 4 4 Lifting Low...

Page 6: ...riage and mast F 10 6 3 Lift Chain Servicing F 10 6 4 Inspecting the lift chains F 10 6 5 Hydraulic oil F 11 6 6 Hydraulic hoses F 11 6 7 Checking electrical fuses F 12 6 8 Recommissioning the truck a...

Page 7: ...0708 GB I 4...

Page 8: ...06 GB Appendix JH Traction Battery Operating Instructions Z These operating instructions apply only to Jungheinrich battery models If using another brand refer to the manufacturer s operating instruct...

Page 9: ...0506 GB 2...

Page 10: ...proprietor is defined as any natural or legal person who either uses the industrial truck himself or on whose behalf it is used In special cases e g leasing or renting the proprietor is considered the...

Page 11: ...0306 GB A 2...

Page 12: ...cks guided in the aisle rail guidance a minimum safety distance of 100 mm must be maintained between the rack and the truck For wire guidance trucks a minimum safety distance of 125 mm is recommended...

Page 13: ...oad direction 4 t Side safety gates 5 o Handle for two hand operation in narrow aisles 6 t Control panel 7 t Safety belt 8 t Height adjustable driver s position 9 t Chassis 10 t Foot button deadman bu...

Page 14: ...operating outside narrow aisles the driver s platform 8 on trucks without safety gates 3 in the load direction can only be raised to a height of 1 2 m Drive Vertical heavy duty threephase motor asynch...

Page 15: ...r which then acts as a generator regenerative lowering The energy produced is then fed back to the battery Electrical System Service laptop connection interface To configure all the key truck data lim...

Page 16: ...308 Q Capacity where D 600 mm 1 360 kg D Load centre of gravity 600 mm Travel speed without load RG 10 5 km h Travel speed with load RG 10 5 km h Travel speed without load WG 7 5 km h Travel speed wi...

Page 17: ...0708 GB B 6...

Page 18: ...pprox 750 mm Width across guide wheels before load wheels Width across guide wheels behind load wheels min 1310 min 1320 l1 Overall length 4 030 mm l2 Length incl fork shank 2015 mm s e l Fork dimensi...

Page 19: ...eed Electromagnetic Compatibility The manufacturer confirms that equipment complies with tolerance levels for electromagnetic emissions and resistance as well as static electricity discharge testing i...

Page 20: ...Item Description 15 Read operating instructions notice 16 Truck data plate 17 Capacity plate 18 Wear safety belt decal option 19 Abseil device decal 20 No passengers decal 21 Test sticker o 22 Do not...

Page 21: ...d hydraulic oil notice 27 Emergency drain decal 28 Caution Low voltage electronics system decal 29 Emergency drain key decal 30 Do not step onto or beneath the load risk of trapping decal 25 mV 1 5 V...

Page 22: ...f the load centre of gravity distance D in mm and lift height H in mm in tabular form Item Description Item Description 35 Type 41 Manufacturer 36 Serial no 42 Min max battery weight kg 37 Rated capac...

Page 23: ...0708 GB B 12...

Page 24: ...manufacturer may assemble the truck on site commission it and instruct the driver 2 Lifting by crane M Only use lifting gear with sufficient capacity for truck weight see Truck data plate chapter B F...

Page 25: ...k with a folded mast by crane always attach the transportation components M Attach the crane slings to the strap points 3 so that the truck cannot slip Loading by crane with the mast disassembled With...

Page 26: ...the lift height the weight with the DZ mast is between 2200 kg and 2625 kg ZT mast between 2100 kg and 2400 kg 2 2 Lifting the battery by crane When lifting the battery with a crane attach suitable li...

Page 27: ...uck s battery is supplied in the chassis disconnect the battery Fastening quick release belts 9 11 should be attached to at least 4 different lorry truck eyes 7 Fastening quick release belts placed ov...

Page 28: ...material 14 Any supplied parts forks 15 guide rollers etc can be attached to a pallet which can then be fastened to the mast 3 3 Mast assembled Safely transporting the truck with the mast assembled M...

Page 29: ...ake sure the system is a positive fit from the load wheels to the front of the transporter Z Place the entire surface area of a wooden beam 26 underneath the counterweight the chassis width as minimum...

Page 30: ...l and installation and Charging the battery Commission the truck as per instructions See chapter E Starting up the truck F Before commissioning check the truck to ensure the tilt safety device 27 is p...

Page 31: ...0306 GB C 8...

Page 32: ...and cable shoes must be clean secure and have a light coating of dielectric grease Battery Disposal Batteries may only be disposed of in accordance with national environmental protection regulations o...

Page 33: ...e weight and dimensions of the battery have a considerable affect on the operational safety of the truck Changing the battery features requires the manufacturer s approval as compensating weights are...

Page 34: ...e tops of the battery cells must be exposed to provide sufficient ventilation Do not place any metal objects on the battery Before charging check all cables and plug connections for visible signs of d...

Page 35: ...removed and must remain in the same position F The truck must be horizontal in order to prevent the battery from falling out when the battery retainer is removed F Only connect and disconnect the batt...

Page 36: ...ositions This means that they can both be fitted in either the left or right side of the truck s chassis Installation is the reverse order of removal M To avoid pushing the battery 6 through on assemb...

Page 37: ...level should be at least 10 15 mm above the top of the plates Now close the stops If necessary re charge the battery 6 Battery discharge indicator When you turn the EMERGENCY DISCONNECT to activate it...

Page 38: ...Trucks which are unsafe for operation e g wheel or brake problems must not be used until they have been rectified Repairs The driver must not carry out any repairs or alterations to the forklift truc...

Page 39: ...nel 4 Warning button t Activates a warning 5 EMERGENCY DISCONNECT t Interrupts the main supply all truck movement is disabled 6 Keys F1 F5 t Activate or confirm the function related to the symbol disp...

Page 40: ...gress Automatically guided Deviation from guidance wire t RG WG WG WG WG Indicates the current steering angle with reference to the middle position When Rail guidance is selected the steering angle is...

Page 41: ...eferencing required display Main lift raise Main lift lower t Displays the height of the forks Raise request Lower request 19 Foot switch not pressed Gates open EMERGENCY DISCONNECT pressed t Requests...

Page 42: ...o Displayed when the lift limit is activated Lift limit override switch Overrides the lift limit display has a dark background Observe the maximum passage heights Lower limit display o Indicates that...

Page 43: ...es Displays Select Frequency 1 similar to other frequencies Guidance on sub menu o W G Indicates that guidance is possible via frequency 1 Select Frequency 1 switch similar to other frequencies Activa...

Page 44: ...reference movement in accordance with the display i e the Main Lift must be raised approx 10 cm and then lowered again This is the only way for the controller to release all the truck movements at ful...

Page 45: ...guard for damage Check the load handler for visible damage such as cracks bent or severely worn load forks Test pallet clamp operation option Check the load wheels for damage Make sure the load chain...

Page 46: ...ediately replaced after an accident catching a person or if it becomes damaged or worn Any damage must be reported to a supervisor All warnings on the safety restraint harness must be read and observe...

Page 47: ...SCONNECT 5 by turning it Put the key in the key switch 3 and turn it clockwise Test the warning device horn 4 Test the operating and parking brakes Carry out a test run of the mast to adjust the heigh...

Page 48: ...five function keys 6 the digits 0 4 or 5 9 for entering the code pin Z Unless the correct code pin is entered none of the truck s functions will operate Z A maximum of 10 different code pins can be s...

Page 49: ...are inhibited in this truck menu Simultaneously press key 35 and 36 to set the time forward by an hour and 37 to set the time back by an hour and 38 to set the time forward by a minute and 39 to set t...

Page 50: ...truck menu The operator can adjust the settings in Acceleration Travel Apron speed Aisle Speed Steering Wheel Transmission between 1 weak and 8 strong Key 36 weakens the chosen function and key 38 in...

Page 51: ...in front of the truck as a lookout Operating with a walk on pallet If the truck is equipped for operation with a walk on pallet without side gates or railing the opeator must wear a restraint belt in...

Page 52: ...ressed for travel Travelling in apron field Close the safety gates Turn the EMERGENCY DISCONNECT 5 to undo it Put the key in the key switch 3 and turn it anti clockwise the operational display lamp wi...

Page 53: ...three ways with the service brake with the foot switch with the EMERGENCY DISCONNECT Braking with the service brake While travelling set the travel direction switch to the zero position or the opposit...

Page 54: ...red ineffective misused adjusted or removed Immediately report and rectify any faulty safety devices M Observe the instructions of DIN 15185 Part 2 Z Before entering a narrow aisle the driver must loo...

Page 55: ...n display light 46 changes to active mode The drive wheel is automatically set forward The steering angle display 14 shows the steering angle permanently in the centre position after alignment Manual...

Page 56: ...ngle is between 10 and 50 Tracking should preferably be in the load direction as this involves less time and distance When the truck is close to the guidance wire switch on the wire guidance with push...

Page 57: ...direction Continue to travel along the narrow aisle at your required speed M Press the push button 37 to quit the guidance wire The display 46 changes to non active mode In addition the guidance wire...

Page 58: ...same time turn the hydraulic control knob 2 down in drive direction R Lift in load direction L Lower Z The lift and lower speeds are proportional to the degree of turn of the hydraulic control knob Z...

Page 59: ...ity Observe the load chart Check the fork distance for the pallet and adjust if necessary o Adjusting the forks To lift the load securely the forks must be as far apart as possible and centrally posit...

Page 60: ...the display 7 in the control panel that the pallet clamp is closed option Slowly reverse the truck M The ground surface must be in good condition to ensure this works correctly 4 6 2 Transporting a lo...

Page 61: ...nel that the pallet clamp is open option Carefully lower the load handler so that the forks are clear of the load M Avoid placing the load down suddenly to avoid damaging the load and the load handler...

Page 62: ...tout activated via aisle end safety device Set foot switch or travel control knob to neutral and press it again Chains slack See Slack Chain Safety Device Override section in Chapter E Load cannot be...

Page 63: ...vide for the customer service department Truck serial number Display unit error number if present Error description Current location of truck Error 144 Truck has quit guidance wire Restore wire guidan...

Page 64: ...rgency lowering make sure that nobody is present in the danger zone If a second person is used to lower the load handler via the emergency lowering device this person must consult with the driver Both...

Page 65: ...tch 3 to 0 Press the EMERGENCY DISCONNECT switch 5 Take the abseil device 58 out of its compartment below the control panel Insert the karabiner hook 61 of the safety rope 60 into the attachment rail...

Page 66: ...truck relative to the rack must be adjusted to load or unload goods press the unlock travel switch 39 and apply the travel control knob as described in Travelling This allows you to travel at crawl sp...

Page 67: ...halt To continue traveling Briefly release the foot switch and then apply it again The truck can be driven out of the narrow aisle at max 2 5 km h 2 Braking to 2 5 km h When the truck passes over the...

Page 68: ...travel again after an EMERGENCY STOP carry out the following Determine the possible cause of the EMERGENCY STOP Press the EMERGENCY STOP switch and turn it again to release it Error E144 is displayed...

Page 69: ...as the brakes are no longer effective Fully lower the mast Z Obtain assistance from another person The other person must be trained and familiar with recovery operations To recover the truck from the...

Page 70: ...ive direction Remove the electronic compartment cover at the back Lower the operator position carriage and release the magnetic brake Guide the tow rope 75 tow force 5 tonnes around the counterweight...

Page 71: ...76 77 Guide the tow rope 78 around the side of the driver s position carriage above the safety gates at the front in the load direction Carefully and slowly pull the truck out of the narrow aisle F A...

Page 72: ...echnicians specially trained for these tasks We therefore recommend a maintenance contract with the manufacturer s local service centre Lifting and jacking up When an industrial truck is to be lifted...

Page 73: ...ttings Wheels The quality of wheels affects the stability and performance of the truck When replacing factory fitted wheels only use manufacturer s original spare parts Otherwise the truck s rated per...

Page 74: ...o establish specific maintenance intervals in order to restrict damage caused by wear The service intervals stated are based on single shift operation under normal operating conditions They must be re...

Page 75: ...the battery panel attachment and check for damage t Drive 2 1 Lubricate the bearing point between the drive motor and transmission t 2 2 Check transmission for noise and leakage t 2 3 Change transmis...

Page 76: ...age p t 6 11 Test line brake safety device t Electrical System 7 1 Test static charge eliminator t 7 2 Test operation t 7 3 Make sure wire connections are secure and check for damage t 7 4 Test the op...

Page 77: ...12 2 Check receptacle eye on overhead guard for damage and wear and test operation t 12 3 Check legibility of notices on safety restraint belt t Lubrication 13 1 Lubricate the truck according to the l...

Page 78: ...F 7 0708 GB 5 Lubrication Schedule g Contact surfaces a Transmission oil drain plug s Grease nipple c Hydraulic oil drain plug Hydraulic oil filler neck G E B E G H A E G...

Page 79: ...ulations Plus 2 additive 68 ID order no 50307735 F The trucks are supplied from the factory with HLP D22 hydraulic oil or the Plantohyd 22 S BIO hydraulic oil 2 68 ID additive You cannot change from t...

Page 80: ...pter E Disconnect the battery to prevent the truck from being switched on accidentally When working under a raised lift truck secure it to prevent it from lowering tipping or sliding away Remove the e...

Page 81: ...pulley Lift chains are safety critical components Chains should not have any significant contamination They should only be cleaned with paraffin derivatives e g petroleum or diesel fuels Never clean...

Page 82: ...dipstick 7 Screw the discharge filter backon F Check which hydraulic oil is being added If Plantohyd 22 SBIOhydraulic oil is being used the warning Only add BIO hydraulic oil 8 will be on the hydrauli...

Page 83: ...circuit Rating type 10 1F11 Travel threephase controller AC 3 Power Control U8 250 A 11 3F10 Steering threephase controller AC 3 Power Control U8 35 A 12 2F15 Hydraulic threephase controller AC 3 Powe...

Page 84: ...be jacked up so that all the wheels are clear of the ground This is the only way of preventing damage to the wheels and wheel bearings If the truck is to be out of service for more than 6 months deter...

Page 85: ...Section F Clean the battery Grease the terminal screws with delectric grease and re connect the battery Charge up the battery see Charging the Battery in chapter D Check if the transmission oil conta...

Page 86: ...veness of the safety mechanisms based on the technical regulations and principles governing the inspection of forklift trucks A thorough test of the truck must be undertaken with regard to its technic...

Page 87: ...0708 GB F 16...

Page 88: ...tive tubular plates type EPzS and EPzB 2 6 Type plate Jungheinrich traction battery 7 Instruction for use Aquamatic BFS III water refilling system 8 12 2 Jungheinrich traction battery Maintenance free...

Page 89: ...d clothes when working on batteries Pay attention to the accident prevention rules as well as DIN EN 50272 3 DIN 50110 1 No smoking Do not expose batteries to naked flames glowing embers or sparks as...

Page 90: ...ucks is the standard which ap plies to the operation traction batteries in industrial trucks 2 1 Discharging Be sure that all breather holes are not sealed or covered Electrical connections e g plugs...

Page 91: ...The containers for batteries with plate protection packs must not be closed until at least half an hour after charging has past 2 3 Equalising charge Equalising charges are used to safeguard the life...

Page 92: ...ound further testing and maintenance by the service department should be requested 3 4 Annually In accordance with DIN VDE 0117 at least once per year the insulation resistance of the truck and the ba...

Page 93: ...be taken into account when considering the life of the battery 6 Malfunctions If malfunctions are found on the battery or the charger our service department should be called in without delay The meas...

Page 94: ...l battery capacity 5 Battery tray number 12 Number of battery cells 6 Delivery date 13 Battery weight 7 Battery manufacturer s logo 14 Safety instructions and warnings Typ 1 T ype Nennspannung 5 Nomin...

Page 95: ...sing batteries which comply with I and II it is important to follow the in structions on maintaining the respective protection class during operation see asso ciated certification Cell series Aquamati...

Page 96: ...d by means of a central sealing coupler through the hose connections in the individual Aquamatic BFS plugs 2 Application The Aquamatic BFS battery water refilling system is used in traction batteries...

Page 97: ...surface 5 2 Pressurised water The pressure reducing valve in the Aquamatic System is set from 0 2 bars to 0 6 bars and from 0 3 bars to 1 8 bars in the BFS system 5 3 Water Refill Trolley serviceMobi...

Page 98: ...ve a diagnostics hole with a 6 5 mm diameter Aquamatic plugs or a 7 5 mm diameter BFS plugs 9 2 Float Different floats are used depending on the cell design and type 9 3 Cleaning The plug systems may...

Page 99: ...en tral supply pipe This is connected to the water supply system at the battery charging station by means of a sealing coupler system On the battery side a closing nipple ident no 50219538 is mounted...

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