Jungheinrich EKS 110, Operating Instructions Manual

Page 1: ...03 09 03 09 51141993 EKS 110 Operating instructions G...

Page 2: ...uarantee of par ticular features of the truck should therefore be assumed from the present operating instructions Safety notices and text mark ups Safety instructions and important explanations are in...

Page 3: ...3 09 EN 2 Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG Jungheinrich Aktiengesellschaft Am Stadtrand 35 22047 Hamburg Germany Tel 49 0 40 6948 0 www jungheinrich com...

Page 4: ...5 Labels and Decals 17 5 1 Truck data plate 18 5 2 Truck load chart capacity 18 C Transport and Commissioning 19 1 Lifting by crane 19 2 Securing the Truck for Transport 20 3 Using the truck for the...

Page 5: ...g and lowering in pedestrian touch mode 50 4 7 Lifting and lowering the operator platform with lift cutout o 53 4 8 Lifting and depositing load units 54 4 9 Adjusting the forks o 55 4 10 Walk on load...

Page 6: ...ce after maintenance and repairs 95 7 Decommissioning the industrial truck 96 7 1 Before taking the truck out of service 97 7 2 Action to be taken during decommissioning 98 7 3 Restoring the truck to...

Page 7: ...03 09 DE 6...

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: ...ns the 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 conside...

Page 11: ...03 09 EN 8...

Page 12: ...item 7 3 2 must be observed There must be a minimum safety distance between the rack and the truck of 100 mm for rail guided trucks and 125 mm for wire guided trucks The ground surface must comply wi...

Page 13: ...ad guard 2 o Duplex mast 3 t Controller 4 t Gate from 1200 mm 5 t Simplex mast 6 t Fork 7 t Operator platform 8 t Electrical system cover 9 o Guide wheels 10 t Front panel 11 t Drive wheel 12 t Batter...

Page 14: ...steer range is 90 in either direction The steering wheel acts electrically on the steering transmission motor The spur gear transfers the steering movement to the drive wheel In rail guidance with ais...

Page 15: ...d capacity 1000 1000 kg Travel speed w w o rated load 9 8 10 1 9 0 9 0 9 0 9 0 km h Lift speed with without rated load Z 0 16 0 20 0 13 0 17 0 13 0 18 m s Lift speed with without rated load L 0 16 0 2...

Page 16: ...ar with battery Z 481 2377 461 2575 461 2611 755 2635 kg Axle load without load front rear with battery Z 1083 775 1105 931 1113 959 1330 1060 kg Axle load with load front rear with battery L 476 2280...

Page 17: ...03 09 EN 14 4 4 Dimensions h4 h4 h1 h1 990 990 217 217 y y l2 l2 l1 l1 h7 h7 s s h13 h13 h3 h3 h12 h12 h9 h9 h6 h6 l l b1 b1 a 2 a 2 Ast Ast e e b5 b5 Wa Wa b11 b11 a 2 a 2 C C Q Q...

Page 18: ...800 mm h12 Overall height raised h3 h7 1200 1800 2100 3000 mm h13 Lowered height 80 80 mm Ast Aisle width for pallets2 800 x 1200 lengthwise 3153 3245 mm Ast Aisle width for pallets2 1000 x 1200 trave...

Page 19: ...ted weighted acceleration in the vertical direction It is calculated when travelling over bumps at constant speed Electromagnetic compatibility EMC The manufacturer confirms that the truck adheres to...

Page 20: ...k data plate 16 Capacity Plate Capacity Load Centre of Gravity Lift Height 17 Test plaque o 18 Danger of trapping warning 19 Do not step under the load handler warning 20 Caution pushbutton operation...

Page 21: ...e with a given load centre of gravity D in mm and the required lift height H in mm Example of how to calculate the maximum capacity For a load centre of gravity D of 600 mm and a max lift height H of...

Page 22: ...aying load XDo not walk into or stand in a hazardous area XOnly use lifting gear with sufficient capacity for truck weight see truck data plate XAttach the crane slings only to the prescribed strap po...

Page 23: ...s adopted XThe truck must be securely fastened when transported on a lorry or a trailer XThe lorry trailer must have fastening rings XUse wedges to prevent the truck from moving XUse only tension belt...

Page 24: ...tall the battery see Battery removal and installation on page 27 Z Only operate the truck with battery current Rectified AC current will damage the electronic components The battery leads tow cable mu...

Page 25: ...ket screws Allen key Procedure Turn the main switch isolator OFF Set the key switch OFF and remove the key Prevents the truck from rolling away Open the front panel 6 and put it aside see Front panel...

Page 26: ...g the battery panel make sure that the battery cable cannot be dam aged There is a risk of short circuits with damaged cables Battery disposal Batteries may only be disposed of in accordance with nati...

Page 27: ...dustrial truck Changing the battery features re quires the manufacturer s approval as compensating weights are required if smaller batteries are fitted When replacing installing the battery make sure...

Page 28: ...aced with the agree ment of the manufacturer 3 Exposing the battery Requirements Load handler lowered Key switch set to OFF Key removed for code lock the O key pressed Emergency Disconnect OFF Procedu...

Page 29: ...ry cover must be open and the battery cell surfaces must be exposed dur ing charging to ensure adequate ventilation X Do not smoke and avoid naked flames when handling batteries X Wherever a truck is...

Page 30: ...ry roller stand replacement trolley etc X Make sure the battery is securely located in the truck s battery compartment Requirements Truck parked Battery exposed see Exposing the battery on page 25 Bat...

Page 31: ...he battery cells Slowly and carefully lower the battery into the truck Installation with a battery replacement trolley Position the battery replacement trolley and battery in front of the battery com...

Page 32: ...issible discharge level the battery symbol 7 is empty Z The standard setting for the battery discharge indicator 8 is based on standard batteries 6 2 Battery discharge monitor If the residual capacity...

Page 33: ...03 09 EN 30...

Page 34: ...pervisor must be immediately informed of any damage or faults to the truck or attachment Trucks which are unsafe for operation e g wheel or brake problems must not be used until they have been rectifi...

Page 35: ...forks 3 Lift button t Lifts the operator platform and forks 4 Aux lift raise button o Raises the forks o 2ndcontrol station 5 Aux lift lower button o Lowers the forks o 2nd control station 6 Warning b...

Page 36: ...Button Two hand operation o Releases lifting and travel when pressed in rail guidance mode with aisle recognition 16 Indicator o End of aisle safety device optional feature Indicates reduced travel s...

Page 37: ...ks 6 Warning button t Activates a warning signal 9 Drive direction pedes trian touch mode o Pedestrian mode optional feature travel is continued as operator walks beside in drive direction slow travel...

Page 38: ...ta tion o Releases lifting and travel when pressed in rail guidance mode with aisle recognition 22 2 Emergency Discon nect 2nd control station o Disconnects the supply current and deacti vates all ele...

Page 39: ...button o Raises the forks o 2nd control station 5 Aux lift lower button o Lowers the forks o 2nd control station 25 Two hand operation FEM fork raise lower button o Raises lowers the forks aux lift Us...

Page 40: ...trian touch mode o Pedestrian mode optional feature travel is continued as operator walks beside in drive direction slow travel 10 Fork direction pedes trian touch mode o Pedestrian mode optional fea...

Page 41: ...200 mm Closed Lifting and travel released 27 Deadman button t Released Travel inhibited or truck deceler ates Applied Travel released 28 2nd control station deadman button o Released Travel inhibited...

Page 42: ...y connector is secure Check the battery retainers are present and test them Make sure the battery cover and side panel if applicable are secure Check the overhead guard for damage Check the load handl...

Page 43: ...ng the control panel make sure no wires or plug connectors are trapped or disconnected XPrevent the control panel from falling down XWhen installing the control panel make sure no wires or plug connec...

Page 44: ...ravelled along in accordance with the truck s technical specifications The truck must always be driven with the load unit facing uphill The industrial truck must not be turned operated at an angle or...

Page 45: ...Emergency Disconnect 19 12 22 must not be affected by any objects placed in its way All electrical functions are deactivated The truck brakes until it comes to a halt 4 2 2 Deadman button Lifting main...

Page 46: ...ocked correctly Procedure Press the deadman button 27 28 Set the controller 13 to the required direction Note the travel direction of the drive wheel on the driver s display 11 Z Always travel outside...

Page 47: ...t of 520 mm and steering angle 10 degrees Travel speed 4 km h slow travel From platform height of 520 mm and steering angle 10 degrees Travel speed 2 5 km h slow travel From platform height of 2000 mm...

Page 48: ...he operator platform Procedure Press the Pedestrian drive direction button 9 The truck travels in the drive di rection at a fixed speed of approximately 2 5 km h slow travel Press the Pedestrian fork...

Page 49: ...rm lifting Procedure Press the lift button 3 until you reach the desired lift height Z On trucks with the pedestrian touch mode option o version L the deadman but ton 27 28 must be applied in addition...

Page 50: ...ged forks the operator platform can only be lowered if the lower button 2 and the two hand operation button 15 are pressed simultaneously Note the order of operation First press and hold down on the l...

Page 51: ...and lowering The auxiliary lift enables the forks to be raised without having to raise the operator platform Auxiliary lift raise Procedure Press the auxiliary lift raise button 4 until you reach the...

Page 52: ...d if the auxiliary lift raise 4 or auxiliary lift lower 5 and the two hand operation 15 21 buttons are pressed simultaneously Note the order of operation First press and hold down on the auxiliary lif...

Page 53: ...ahead XThe operator must always stand beside the truck during pedestrian operation XThere must be no persons standing between the truck and any obstacles XThere must be no persons on the operator pla...

Page 54: ...ing CAUTION Risk of trapping XSteering set straight ahead XThe operator must always stand beside the truck during pedestrian operation XThere must be no persons standing between the truck and any obst...

Page 55: ...ople standing underneath the raised load and driv er s cab XDo not stand on the load handler XDo not lift other people on the load handler XInstruct other people to move out of the hazardous area of t...

Page 56: ...lift height Lifting Procedure Press the lift button 3 until you reach the fixed cutout height To lift beyond the fixed cutout height proceed as follows Press and hold down on the lift button 3 Now pr...

Page 57: ...he fork shank touches the pallet Z The load unit must not extend by more than 50 mm beyond the fork tips Transporting load units Requirements Good ground conditions Procedure Accelerate gradually Trav...

Page 58: ...ift up the locking lever 30 Push the forks 31 into the correct position on the fork carriage 32 Z To lift the load securely the forks 31 must be spread as far apart as possible and positioned centrall...

Page 59: ...sides of the pallet guard centrally with the pallet Slowly insert the forks into the pallet until the fork shank touches the pallet Z The pallet must fully rest on the forks behind the anti slip devic...

Page 60: ...ng the truck securely Parking the truck securely CAUTION An unsecured truck can cause accidents XAlways park the truck on a level surface XAlways lower the forks fully XSelect a place to park where no...

Page 61: ...rendered ineffective misused adjusted or removed XReport any defects to your supervisor immediately XTag out and decommission a faulty lift truck XOnly return the truck to service when you have ident...

Page 62: ...isle Procedure Drive slowly up to the rack aisle until the truck is aligned with the aisle Note the markings attached along the route e g aisle centre line Slowly travel forward while ensuring that th...

Page 63: ...he straight ahead position Entering narrow aisles Procedure Drive slowly up to the rack aisle until the truck is aligned with the aisle Slowly travel forward while ensuring that the guide wheels 39 of...

Page 64: ...is released by the side rails truck with the first guide roller pair outside the side rails the travel speed is automat ically reduced to 2 5 km h slow travel and travel lifting and lowering can resu...

Page 65: ...e end of aisle safety device option the latter is automatically acti vated when the truck is switched on indictor 16 lit In order to travel at normal speed after the truck has been switched on the Res...

Page 66: ...lowering XOnly start the truck when the error has been rectified Requirements Required tools and materials 3 mm diameter pin tool etc Procedure Remove the front panel Using a suitable object pen tool...

Page 67: ...ng display gives information on the travel direction steering angle battery charge condition and other selected truck pa rameters Setting the time Procedure Press the Shift key 58 for 8 secs until men...

Page 68: ...file in bars from 1 to 5 51 No function 52 Profile number travel profile 1 2 or 3 55 Warning and fault indication as text 14 segment display and data registra tion 59 Profile key to select travel mode...

Page 69: ...o factory setting2 5 8 0 is indicated on a removable sticker Change the master and user codes the first time you use the truck Commissioning When the isolator is switched on the LED 65 turns red When...

Page 70: ...ry setting is 7 2 9 5 Change the master code the first time you use the truck Changing the truck settings Procedure Press the63O key Enter master code Enter the three digit parameter number Confirm wi...

Page 71: ...can be entered If the code length is to be changed all opera tor codes must first be deleted 0000 9999 or 00000 99999 or 000000 999999 7295 LED 60 flashes Enter current code Confirm Set 64 LED 61 fla...

Page 72: ...es Enter a new code Confirm Set 64 LED 62 flashes Re enter the code Confirm Set 64 003 0000 9999or00000 99999or00000 0 999999 LED 61 flashes Enter a new code Confirm Set LED 62 flashes repeat code ent...

Page 73: ...09 EN 70 Operator code to be changed does not exist Operator code should be changed to another operating code which already exists Tried to delete an operator code that does not exist Code memory ful...

Page 74: ...th a key switch use the grey service spanner to access the travel param eters Trucks with driver s display and CANCODE o Before entering the SERVICE MENU PARAMETER MENU you will be asked for your pin...

Page 75: ...plug in if neces sary Unlatch main switch Set key switch to I Check battery charge charge battery if neces sary Close gates on either side of the operator plat form Press two hand opera tion button o...

Page 76: ...the fault cannot be rectified after carrying out the above procedures notify the manufacturer s service department as further troubleshooting can only be per formed by specially trained and qualified...

Page 77: ...03 09 EN 74...

Page 78: ...Do not alter the truck s operating speeds under any circum stances Z Only original spare parts have been certified by our quality assurance department To ensure safe and reliable operation of the truc...

Page 79: ...r e g wedges wooden blocks XIn order to raise the truck the lifting gear must only be secured to the points spe cially provided for this purpose see Labels and Decals on page 17 XWhen jacking up the t...

Page 80: ...s Do not clean with pressurised water Z After cleaning carry out the operations detailed in Recommissioning the truck after cleaning or maintenance work see Restoring the truck to service after mainte...

Page 81: ...disconnect the battery before starting cleaning operations WARNING Electric currents can cause accidents Make sure the electrical system is voltage free before starting work on it Before start ing mai...

Page 82: ...the oil contact the manufacturer s cus tomer service department who have been specially trained for this task XNote the safety regulations when handling these materials Welding Remove electrical and...

Page 83: ...rmance of the truck Uneven wear affects the truck s stability and increases the stopping distance XWhen replacing wheels make sure the truck is not skewed XAlways replace wheels in pairs i e left and...

Page 84: ...led fluids must be removed immediately with an appropriate bonding agent The bonding agent consumable mixture must be disposed of in accordance with reg ulations WARNING Hairline cracks in the hydraul...

Page 85: ...ssure cleaners cold or chemical clean ing agents XImmediately after cleaning dry the lift chain with compressed air and apply a chain spray XAlways lubricate a chain when it is discharged XLubricate a...

Page 86: ...on site to work out specific service intervals to prevent damage due to wear The service intervals stated are based on single shift operation under normal operat ing conditions They must be reduced ac...

Page 87: ...n for noise and leakage t 4 2 Replace gear oil if service life exceeded 10000 hours 4 3 Check rail guide roller bedding and attachment t 4 4 Check wheels load wheels drive wheel for wear and damage k...

Page 88: ...ut a test run with rated load t 7 3 Demonstration after servicing t Steering system 8 1 Test the electric steering and its components t 8 2 Check the steering head bearings steering play and steering...

Page 89: ...1 2 Capacity see Consumables on page 88 3 Gear oil values are guidelines only The spur wheel should be dipped approx 2mm g Contact surfaces k Cold Store Application s Grease nipple b Transmission oil...

Page 90: ...rdance with regulations WARNING Oils chain spray hydraulic oil are flammable and poisonous XDispose of used oils in accordance with regulations Store used oil safely until it can be disposed of in acc...

Page 91: ...lines Hydraulic oil capacities Code Purchase Order No Package quantity Description Application 1 29 200 670 5 0 l H LP 46 DIN 51524 Hydraulic system 2 50 380 904 5 0 l Fuchs Titan Gear HSY 75W 90 Tran...

Page 92: ...Press the red button on the ISM access module o Press the Emergency Disconnect Disconnect the battery to prevent the truck from being switched on accidentally When working under a raised lift truck s...

Page 93: ...irs see Preparing the truck for main tenance and repairs on page 89 Tools and Material Required Socket wrench Procedure Position the drive wheel 3 at an angle to the longitudinal axis of the truck Pas...

Page 94: ...til the threads for the retaining bolts are free Screw the retaining blocks 5 onto the mast Lower the mast until the retaining blocks are resting on the mast cross members The mast retainer is now ass...

Page 95: ...panel assembly and disassembly Front panel disassembly Tools and Material Required Allen key size 6 Procedure Remove the screws 7 Lift and remove the front panel 8 Place the front panel 8 safely to on...

Page 96: ...the cover 9 down off the truck until the bottom snap lock connections are disengaged Store the cover in a safe place The electrical system is now exposed and the traction controller and truck fuses ar...

Page 97: ...Close the electrical system The fuses are now checked 11 12 13 14 15 16 17 18 19 20 21 Item Description To protect Rating 11 3F6 Steer motor 30 12 F4 Main contactor control fuse 10 13 3F9 Steering co...

Page 98: ...ecessary Check the hydraulic oil for condensation water and replace if necessary Z The manufacturer s customer service department is specially trained to carry out these operations WARNING Faulty brak...

Page 99: ...follows XJack up the truck only on a level surface and prevent it from moving accidentally XOnly use a jack with sufficient capacity When jacking up the truck take appropriate measures to prevent it f...

Page 100: ...in layer of oil or grease to any non painted mechanical components Lubricate the truck according to the lubrication schedule see Lubrication Sched ule on page 86 Charge the battery see Charging the ba...

Page 101: ...months Procedure Charge the battery see Charging the battery on page 26 CAUTION Risk of battery damage It is important to charge the battery regularly as otherwise automatic discharge will result in...

Page 102: ...ervals and after unusual incidents Z Perform a safety check in accordance with national regulations Jungheinrich rec ommends the truck be checked to FEM guideline 4 004 The Jungheinrich safety departm...

Page 103: ...ning or disposal of the truck in must be performed in accor dance with the regulations of the country of use In particular regulations governing the disposal of batteries fuels and electronic and elec...

Page 104: ...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 105: ...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 106: ...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 107: ...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 108: ...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 109: ...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 110: ...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 111: ...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 112: ...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 113: ...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 114: ...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 115: ...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...

Page 116: ...battery Work on batteries to be carried out by skilled personnel only Use protective glasses and clothes when working on batteries Pay attention to the accident prevention rules as well as DIN EN 5027...

Page 117: ...g plugs must only be made or broken in the open circuit condition To achieve the optimum life for the battery operating discharges of more than 60 of the rated capacity should be avoided deep discharg...

Page 118: ...0 0171 Ex I in areas with a firedamp hazard or Ex II in potentially explosive areas The attention pictograms has to be respected 2 3 Equalising charge Equalising charges are used to safeguard the life...

Page 119: ...1000 4 Care of the battery The battery should always be kept clean and dry to prevent tracking currents Clea ning must be done in accordance with the ZVEI code of practice The Cleaning of Vehicle Trac...

Page 120: ...raction battery CE mark is only for batteries with a nominal voltage greater than 75 volt Item Designation Item Designation 1 Logo 8 Recycling symbol 2 Battery designation 9 Dustbin material 3 Battery...

Page 121: ...0506 GB 18...