Jungheinrich EKS 410 Operating Instructions Manual Download Page 13

Page: 13 / 99

708

.GB

B 2

Assemblies and Functional Description

Item

Description

Mast

Aux. lift

Control panel

Height-adjustable driver’s position

Chassis

= Standard equipment

= Optional Equipment

EKS 513 / 515k / 515

EKS 410

708

.GB

B 2

Assemblies and Functional Description

Item

Description

Mast

Aux. lift

Control panel

Height-adjustable driver’s position

Chassis

= Standard equipment

= Optional Equipment

EKS 513 / 515k / 515

EKS 410

Summary of Contents for EKS 410

Page 1: ...EKS 513 515 EKS 410 Operating instructions 52025221 EKS 410 513 515k 515 G 12 03 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: ...ting by crane C 1 2 1 Crane points C 2 2 2 Lifting the battery by crane C 2 3 Securing the truck during transport C 2 3 1 Basic truck transport safety C 3 3 2 Mast transport safety C 4 3 3 Mast assemb...

Page 5: ...4 2 Travelling Steering Braking E 11 4 3 Lifting lowering outside narrow aisles E 16 4 4 Lifting lowering within narrow aisles E 16 4 5 Order picking and stacking E 17 4 6 Parking the truck securely E...

Page 6: ...carriage F 11 5 3 Lift Chain Servicing F 12 5 4 Inspecting the lift chains F 12 5 5 Hydraulic oil F 13 5 6 Hydraulic hoses F 14 5 7 Check brake fluid EKS 513 515 F 14 5 8 Checking electrical fuses EKS...

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: ...the industrial truck himself or on whose behalf it is used In special cases e g leasing or renting the proprietor is considered the person who in accordance with existing contractual agreements betwe...

Page 11: ...1004 GB A 2...

Page 12: ...ust be observed The ground surface must comply with DIN 15185 Guide rails must be provided in the narrow aisles for the rail guidance system Vulkollan guide rollers attached to the truck chassis guide...

Page 13: ...and Functional Description Item Description 1 t Mast 2 t Aux lift 3 t Control panel 4 t Height adjustable driver s position 5 t Chassis t Standard equipment o Optional Equipment 2 2 1 1 3 3 4 4 5 5 E...

Page 14: ...wheel brake acting on the front axle hydraulic brake is only activated when the EMERGENCY DISCONNECT switch is pressed or if the truck is set to EMERGENCY STOP Steering Particularly smooth steering wi...

Page 15: ...ally measuring sensor system The controller provide smooth start up and braking of the load in all limit positions through limit position and intermediate cushioning Highly efficient threephase techno...

Page 16: ...B 5 0708 GB Ast Wa h15 h10 h3 h9 h7 h6 h1 h4 b2 l1 l2 m2 R b5 l...

Page 17: ...10 Overall lift 48401 43402 43402 58403 mm h15 Stockpicking height 59951 55702 55702 70703 mm Ast Working aisle width for pallets 1000 x 1200 traverse 1640 1640 1640 1640 mm b2 Overall width 1440 1450...

Page 18: ...705 6405 mm h1 Retracted height DZ 2595 3895 2595 4695 2595 5795 mm h3 Lift ZT 3000 7500 3000 9500 3000 10000 mm h3 Lift DZ 4250 7500 4250 9500 4250 12500 mm h4 Extended height ZT 5550 10050 5550 1205...

Page 19: ...when travelling over bumps at constant speed Electromagnetic compatibility EMC The manufacturer confirms that equipment complies with tolerance levels for electromagnetic emissions and resistance as w...

Page 20: ...ta plate 8 Capacity plate 9 Decal Abseil device 10 Decal No passengers 11 Test sticker o 12 Decal Do not step onto or beneath the load risk of trapping 13 Jack contact points 14 Serial number engraved...

Page 21: ...Do not step onto or beneath the load risk of trapping 13 Jack contact points 14 Serial number engraved in chassis underneath the battery cover 15 Add hydraulic oil notice 16 Emergency drain decal 17...

Page 22: ...e load centre of gravity distance D in mm and lift height H in mm in tabular form Item Description Item Description 20 Type 26 Manufacturer 21 Serial no 27 Min max battery weight kg 22 Rated capacity...

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

Page 24: ...EKS 513 515 only vertically with the mast folded M Only personnel trained by the manufacturer may assemble the truck on site commission it and instruct the driver 2 Lifting by crane M Only use liftin...

Page 25: ...eight see data plate Crane points for the basic truck items 2 and 3 weight 2000 kg EKS 410 3000 kg EKS 513 515 Mast crane points including driver s cab and load handler items 1 and 3 weight 2 600 kg E...

Page 26: ...e 13 M If the truck s battery is supplied in the chassis disconnect the battery Fastening belts should be attached to at least 4 different lorry eyes 12 Belts placed over sharp edges must be protected...

Page 27: ...he mast 18 Use the attachment latch 19 as the mast bottom strap point for securing to the lorry eyes 17 Route the belt over the lift cylinder chains to act as the mast top strap point M Protect the be...

Page 28: ...st be attached to the mast 3 4 Safely transporting the truck with the mast folded EKS 513 515 M If the truck s battery is supplied in the chassis disconnect the battery Z Only use belts with a rated c...

Page 29: ...Rectified AC current will damage the electronic components The battery leads tow cable must be less than 6m long To prepare the truck after delivery or after transport proceed as follows Install and...

Page 30: ...e 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 or dispos...

Page 31: ...tery If necessary remove the insulating mat from the battery F When charging the tops of the battery cells must be exposed to provide sufficient ventilation Do not place any metal objects on the batte...

Page 32: ...ls 4 Undo the battery retainer 5 by moving the lever 6 down and remove the retainer Pull the battery 7 onto the side of the prepared battery trolley F Make sure the battery trolley is properly secured...

Page 33: ...attery make sure that the battery is well secured in the battery compartment Z The battery retainers 13 17 can swap positions This means that they can both be fitted in either the left or right side o...

Page 34: ...handler into the fork shoes 25 of the battery replacement carriage Assembly is the reverse order M When fitting the batteries 24 in the battery replacement carriage make sure that the load handler of...

Page 35: ...1004 GB D 6 21 23 22 25 24 19 18 20 20 24 22...

Page 36: ...acid level should be at least 10 15 mm above the top of the plates If necessary re charge the battery 6 Battery discharge indicator When you turn the EMERGENCY DISCONNECT switch and turn the key in th...

Page 37: ...1004 GB D 8...

Page 38: ...diately informed of any damage or faults to the forklift truck Trucks not safe for operation e g wheel or brake problems must not be used until they have been rectified Repairs The driver must not car...

Page 39: ...0206 GB E 2 2 Operating and Display Equipment 2 1 Operating and display equipment on control panel 1 22 21 9 8 13 14 7 7 15 16 17 10 11 12 20 19 18 3 4 6 5 2...

Page 40: ...Display unit t Operating information and warning message display 10 Parking brake on display t Lit when the parking brake is applied 11 EMERGENCY STOP display t Lit when the EMERGENCY STOP device is a...

Page 41: ...g in progress Automatically guided Deviation from guidance wire t R G IG IG IG IG Indicates the current steering angle with reference to the centre position Centre position is permanently displayed on...

Page 42: ...ay t Displayed when lift cutout is actvated due to low battery capacity and only forward or reverse travel is possible Acknowledge lift cutout due to battery discharge switch Confirms lift cutout due...

Page 43: ...on display not active Guidance on display active t R G W G Displays automatic guidance in the aisle Rail guidance display drive wheel set to forward position Indicates that inductive guidance is acti...

Page 44: ...open Foot switch not pressed When the following symbols are displayed you must carry out a reference movement in accordance with the display i e the Primary raise must be raised approx 10 cm and then...

Page 45: ...re than one person to enter the driver s cab at a time Adjusting the driver s seat Pull up the adjusting lever and add or remove weight to obtain the correct height Control panel angle adjustment Z Th...

Page 46: ...the time Simultaneously press switches 32 and 33 to set the time forward by an hour and 34 to set the time back by an hour and 35 to set the time forward by a minute and 36 to set the time back by a...

Page 47: ...of travel and must always have a clear view of the route ahead When carrying loads which affect visibility these must be stored at the rear of the truck If this is not possible a second person must wa...

Page 48: ...oot switch must be kept depressed for travel Travelling in apron field Close the safety gates Turn the EMERGENCY DISCONNECT switch 18 to undo it Put the key in the key switch and turn it clockwise App...

Page 49: ...he EMERGENCY DISCONNECT switch Braking with the operating brake While travelling set the travel direction switch to the zero position or the opposite travel direction the traction current controller w...

Page 50: ...switched off the truck may only be removed from the narrow aisle at crawl speed Rail guidance truck Rail guidance trucks are equipped with sensors which activate aisle recognition when they enter nar...

Page 51: ...n it reaches the guidance wire Approach the guidance wire 40 at an angle at reduced speed When aligning the truck should not be parallel to the guidance wire The optimum approachment angle is between...

Page 52: ...ion controller and hydraulic controller handle 7 two handed operation Turn the travel selection switch 13 to change travel speed and direction Press the push button 34 to quit the guidance wire The di...

Page 53: ...ressure switch 15 Turn the hydraulic control switch 8 simultaneously Left turn Lift Right turn Lower The lift and lower speeds are proportional to the amount of turn Lowering Primary raise and Aux Lif...

Page 54: ...pallet and adjust if necessary Adjusting the forks To pick up the load securely the forks must be as far apart as possible and centrally positioned with respect to the fork carriage The load centre of...

Page 55: ...y accelerate Drive at constant speed Always be prepared to brake Only stop suddenly in dangerous situations Reduce speed accordingly at narrow bends Depositing a load Drive the truck carefully up to t...

Page 56: ...ave it for a short time F Do not park the truck on an incline In special cases the truck may need to be secured with wedges Z Select a parking place where nobody will collide with the forks Always par...

Page 57: ...d via aisle end safety device Set foot switch or travel button to neutral and press it again Chains slack See Slack Chain Safety Device Override section in Chapter E Load cannot be lifted Truck not op...

Page 58: ...ption Current location of truck Error 144 Truck has quit guidance wire Restore wire guidance Error 330 Travel control button pressed during power up test Do not press travel control button switch truc...

Page 59: ...x Lift emergency lowering F When using emergency 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 thi...

Page 60: ...instructed in how to use the emergency abseil device To exit the cabin with the emergency abseil device proceed as follows Turn the key switch 2 to 0 Press the EMERGENCY DISCONNECT switch 18 Remove th...

Page 61: ...lift the primary raise if the override switch 56 is depressed and held down while the hydraulic control button is pressed Lowering is now disabled Before starting again rectify the damage Travel is i...

Page 62: ...or in the transfer aisle There are two basic versions for this 1 Braking to a halt 2 Braking to 2 5 km h Other variants affecting the subsequent travel speed lift height etc are available 1 Braking to...

Page 63: ...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 E 144 is displayed...

Page 64: ...ground as the brakes are no longer effective Fully lower the mast Z Seek assistance from another person The other person must be trained and familiar with recovery operations To recover the truck from...

Page 65: ...e fluid retainer 65 above it F The brake fluid retainer is pressurised Risk of scalding Open the bleed valve 67 and drain the excess brake fluid into the brake fluid retainer 65 Close the bleed valve...

Page 66: ...counterweight 70 by the left or right sides of the antenna 71 M Note the wire routing in the drive compartment and the antenna 72 Carefully and slowly pull the truck out of the narrow aisle Emergency...

Page 67: ...0206 GB E 30...

Page 68: ...hnicians 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 th...

Page 69: ...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 70: ...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 redu...

Page 71: ...ive motor and transmission t 2 2 Check transmission for noise and leakage t 2 3 Change transmission oil t Wheels 3 1 Check wheels for wear and damage t 3 2 Check bearings and attachment t Steering 4 1...

Page 72: ...for damage 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...

Page 73: ...11 2 Check attachment on truck and load bearing components t Lubrication 12 1 Lubricate the truck according to the lubrication schedule t General Measure ments 13 1 Check electrical system for frame l...

Page 74: ...F 7 0708 GB 4 1 Lubrication Schedule Grease nipple consumable E Inner mast 513 515 Driver s position 513 515 Fork carriage 513 515 Outer mast 513 515 Centre mast 513 515...

Page 75: ...0708 GB F 8 g Contact surfaces a Transmission oil drain plug s Grease nipple Hydraulic oil filler neck c Hydraulic oil drain plug G E H E B G E E EKS 410 EKS 513 515 A A D...

Page 76: ...lations EKS 410 fuels and lubricants 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 addit...

Page 77: ...hydraulic oilt Plantohyd 22 S BIO hydraulic oil Code Order no Quantity supplied Capacity Description Used for A 51037497 51037494 5 l 1 l approx 110 l HLP D22 including 2 share additive 68 ID Hydraul...

Page 78: ...a raised industrial truck secure them to prevent them from lowering tipping or sliding away When raising the industrial truck also refer to the instructions in the Transport and Commissioning section...

Page 79: ...4 Inspecting the lift chains Unauthorised wear and external damage In accordance with official regulations a chain is considered to be worn if it has extended in length by 3 in the section which pass...

Page 80: ...rew the discharge filter backon F Check which hydraulic oil is being added If Plantohyd 22 S BIO hydraulic oil is being used the warning Only add BIO hydraulic oil 8b will be on the hydraulic reservoi...

Page 81: ...d also be noted that brake fluid corrodes the truck paint M Brake fluid is added in the factory and must be replaced after 12 months at the latest as it changes over time and loses its original qualit...

Page 82: ...must not be used for UL standardised fuses The opposite also applies Item Description To protect Rating 12 1F11 Travel 160 A DIN EN 250 A UL 13 3F10 Steering 35 A DIN EN 35 A UL 14 2F15 Hydraulics 250...

Page 83: ...ler DIN and EN standardised fuses must not be used for UL standardised fuses The opposite also applies Item Description To protect Rating 21 1F11 Travel 250 A 22 3F10 Steering 35 A 23 2F15 Hydraulics...

Page 84: ...e clear of the ground This is the only way of ensuring that the wheels are not damaged If the truck is to be out of service for more than 6 months further measures must be taken in consultation with t...

Page 85: ...brication schedule see Chapter F Clean the battery grease the terminals and connect the battery Charge the battery see Chapter D Check transmission oil for condensed water and replace if necessary Che...

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 20...

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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