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Operating instructions

51009741

EKS 308

G

03.06 -

07.08

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Содержание EKS 308

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

Страница 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...

Страница 3: ...0108 GB...

Страница 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...

Страница 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...

Страница 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...

Страница 7: ...0708 GB I 4...

Страница 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...

Страница 9: ...0506 GB 2...

Страница 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...

Страница 11: ...0306 GB A 2...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 17: ...0708 GB B 6...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 23: ...0708 GB B 12...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 31: ...0306 GB C 8...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 87: ...0708 GB F 16...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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