EKS 310s - 414s
Instructions 51762456 01.20 ~ 1~: :: 04.19 en-US EKS 310s EKS 412s EKS 414s fiUNGHEINRICH
Operating
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Foreword
References to the Operating Instructions
All operators of industrial trucks should be familiar with applicable local, regional and national regulations. Operators in the United States should be familiar with the standards and regulations of the Occupational Safety and Health Administration (OSHA) and ANSI/ITSDF B56.1, the safety standard of the Industrial Truck Standards Development Foundation (ITSDF) for low lift and high lift trucks.
Safe operation of the industrial truck requires special knowledge, which is acquired from these operating instructions, from the training required by OSHA under 29 CFR 1910.178 and by training operators in factory installations and their functions. Safe operation of the industrial truck also requires knowledge that can be acquired from these ORIGINAL OPERATING INSTRUCTIONS. Information is set out concisely and in a clear format. The chapters are arranged by letter and the pages are numbered sequentially.
Various types of trucks are described in these Operating Instructions. When operating the truck and carrying out maintenance work, make certain you use the description corresponding to the relevant truck type.
The Internet site www.osha.gov offers further information about requirements for powered industrial trucks according to OSHA (Regulations (Standards - 29 CFR) Powered industrial trucks - 1910.178). The Internet page www.itsdf.org offers further information about safety standards according to ITSDF for low lift and high lift trucks (B56.1 Safety Standards for Low Lift and High Lift Trucks).
Safety instructions and other important instructions together with their relative importance are indicated by the following safety warning symbols and indicator words:
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Table of contents A Compliance with regulations - Legal requirements and common sense................................................................................................................ 13 B Recognition and avoidance of risks............................................................... 15 C Proper use.......................................................................................................................... 17 1 General.................................................................................................................................... 17 2 Proper use.............................................................................................................................. 18 3 Permissible usage conditions....................................................................................... 19 4 Duties of the operator....................................................................................................... 20 5 Installing attachments and/or attaching accessory parts................................ 22 6 General instructions for operating personnel and the owner........................ 23 7 Nameplate.............................................................................................................................. 25 D Description of vehicle................................................................................................ 27 1 Description of use............................................................................................................... 27 2 Defining the direction of travel...................................................................................... 31 3 Description of components and functions............................................................... 32 3.1 Functional description....................................................................................................... 32 3.2 Overview of components................................................................................................. 38 3.3 Overview of modules for optional equipment "Lithium-ion battery"............ 44 4 Control console arrangements..................................................................................... 49 4.1 Version with control consoles and driver's display facing the load............. 49 4.2 Version with control consoles and driver's display facing the drive........... 49 4.3 Version with "Control consoles arranged on both sides"................................. 50 4.4 Version with " Control consoles and operator display arranged on drive side with additional control console for side stance"............................. 51 5 Technical data....................................................................................................................... 52 5.1 Performance data .............................................................................................................. 52 5.2 Dimensions (as per specification sheet).................................................................. 58 5.3 Mast models.......................................................................................................................... 70 5.4 Mast braces........................................................................................................................... 79 5.5 Weights.................................................................................................................................... 80 5.6 Wheels, chassis................................................................................................................... 84 5.7 Motor data............................................................................................................................... 85 5.8 US standards........................................................................................................................ 86 5.9 Electromagnetic Compatibility (EMC)....................................................................... 88 5.10 Usage conditions................................................................................................................. 89 5.11 Electrical requirements..................................................................................................... 89 6 Position of signs and nameplates............................................................................... 90 6.1 Positions of signs 90 6.2 Nameplate.............................................................................................................................. 94 6.3 Load capacity of the industrial truck.......................................................................... 96 6.4 Label "Load center distance for the EKS with walk-on platform"................ 98 6.5 Warning Label "Influencing of the Function of Medical Devices Due to en => Magnets''................................................................................................................................. 98 I 6.6 C (I) Jack attachment points.................................................................................................... 98 0 6.7 C'! 6.8 .... 0 Attachment load capacity plate.................................................................................... 99 Sign - tipping safety device "Residual load capacity" (0) 99 7
6.9 Load capacity display in the operator display ....................................................... 100 6.10 Reduced load capacity depending on the weight (operator, passenger or loads) within the driver's cab 102 7 Stability..................................................................................................................................... 104 E Operation 105 1 Important general issues affecting safe operation and use of the industrial truck....................................................................................................................... 105 1.1 Training, certification, and permission to operate the industrial truck 105 1.2 Damage and repairs to the industrial truck 110 1.3 Issues related to the load ................................................................................................ 110 1.4 Operating environment. 112 1.5 Safety devices, warning labels and warning systems 118 1.6 Lifting persons ...................................................................................................................... 120 2 Description of indicators and controls 122 2.1 Controls and displays on the control console 122 2.2 Load-side auxiliary lift control elements with drive-side arrangement of control console (version 2) 132 2.3 Driver's display 134 2.4 Icons on the Operator Display (Vehicle States and Input Commands) 136 2.5 Operating hours counter 145 2.6 Additional Icons for Vehicle Guidance in the Narrow Aisle ........................... . 146 2.7 "Bar display" battery discharge indicator 148 2.8 Driver's display function symbols 150 3 Preparing the industrial truck for operation ............................................................ 158 3.1 Safety Regulations for Industrial Truck Operators 158 3.2 General operation of the industrial truck 158 3.3 Ensuring that the industrial truck is properly equipped 160 3.4 Daily visual inspections and actions before startup 161 3.5 Entry and exit ........................................................................................................................ 166 3.6 Setting up the operator's compartment... 168 3.7 Backrest/ driver's seat (0) 168 3.8 Control console height adjustment. ............................................................................ 170 3.9 Safety belt with self-retracting lanyard (0) ............................................................ 172 4 Operation of the industrial truck 195 4.1 General .................................................................................................................................... 195 4.2 Travel routes and work areas 197 4.3 Driving conduct 199 4.4 Safe loading and transporting ....................................................................................... 205 4.5 Preventing overturning and tipping 207 4.6 Supervising and securing the industrial truck 209 4. 7 Lifting persons ...................................................................................................................... 209 4.8 Preparing for operation 211 4.9 Turning off the industrial truck. 212 4.10 Checks and operations to be carried out when the truck is ready for operation 213 4.11 Setting the time 215 4.12 Referencing the main lift 217 4.13 EMERGENCY STOP 219 4.14 Single-handed operation ................................................................................................. 4.15 Driving 221 en => 223 I C CJ) 4.16 Braking 227 0 C'! ..... 0 8
4.17 Driving in narrow aisles.................................................................................................... 229 4.18 Lifting / lowering - outside and inside narrow aisles ........................................ 238 4.19 Diagonal travel 245 4.20 Steering.................................................................................................................................... 246 4.21 Switching off and securing the industrial truck..................................................... 247 5 Picking and stacking.......................................................................................................... 249 5.1 Adjusting the fork arms (0) 249 5.2 Replacing the fork arms (0).......................................................................................... 253 5.3 Lifting, transporting and depositing loads............................................................... 257 6 Troubleshooting................................................................................................................... 263 6.1 Emergency Stop equipment.......................................................................................... 263 6.2 Emergency lowering of load lifting tackle................................................................ 263 6.3 Shutdowns.............................................................................................................................. 267 6.4 Aisle end safety device (0) ........................................................................................... 277 6.5 WG emergency operation (event messages 3670 / 3752)............................. 279 6.6 Recovering the industrial truck from a narrow aisle / moving the truck without a battery.................................................................................................................. 280 7 Exiting the Operator Position with the Rescue Equipment............................. 293 7.1 Rescue Equipment Storage Compartment in the Operator P....................... 294 7.2 Test/ maintenance of the rescue equipment........................................................ 295 7.3 Seal and equipment bag................................................................................................. 296 7.4 Usage duration of rescue equipment........................................................................ 297 7.5 Storage and transport of the emergency equipment......................................... 298 7.6 Usage conditions and ambient conditions............................................................. 298 7.7 Description and application of the rescue equipment....................................... 299 8 Personal Protection System ( 0) 315 8.1 Function of the Personal Protection System (PPS) 315 8.2 Description of functions.................................................................................................... 316 8.3 Environmental awareness.............................................................................................. 317 8.4 Cleaning the laser scanner front screen.................................................................. 318 8.5 Displays on the seven segment display and indicator light (LED).............. 319 8.6 Daily checks before starting the Personal Protection System...................... 321 8.7 Function of the Personal Protection System......................................................... 322 9 Collision Protection with the Personal Protection System (0)..................... 325 9.1 Positions and Number of Reflectors on the Industrial Truck......................... 327 9.2 Description of Collision Protection with the Personal Protection System..................................................................................................................................... 329 9.3 Daily Visual Inspections and Checks before Startup........................................ 329 9.4 Description of Various Operating Situations.......................................................... 331 10 Industrial truck with load guard and walk-on load (pallet, mesh box, etc.)............................................................................................................................................ 337 10.1 Order picking platform without load lifting option................................................ 339 10.2 Order picking platform with load lifting option....................................................... 341 10.3 Order picking platform with monitored and secured load lifting option..... 345 10.4 Description of the function of the side and load-side safety gates............. 347 10.5 Additional symbols in driver's display....................................................................... 349 10.6 Lifting or setting down loads depending on load locking................................. 350 11 Optional equipment............................................................................................................ 361 11.1 Keyless access systems................................................................................................. 361 en 11.2 => 11.3 I C (I) 0 General information about operation with keyless access systems.......... 361 Keyless Access System - Starting up the Keypad and Transponder Reader...................................................................................................................................... 362 C'! 11.4 .... 0 Keyless access system - display unit ...................................................................... 365 9
11.5 Keyless access system - keypad ................................................................................ 370 11.6 Keyless access system - transponder reader ....................................................... 375 11. 7 ISM Online "New Generation" ( 0) 380 11.8 Lockable safety gates (0) 380 11.9 Single telescopic forks (0) 381 11.10 Fork arms side shift (0) 383 11.11 Weighing system (0) ........................................................................................................ 385 11.12 Lift height selection (0) 387 11.13 Horizontal positioning (0) 393 11.14 Ride-on mode for a second person in the operator position (0) .............. .. 408 11.15 Rear view mirror (0) 412 11.16 Panorama Mirror (0) 413 11.17 Fire extinguisher (0) ......................................................................................................... 414 11.18 Floor-Spot (0) ...................................................................................................................... 416 11.19 "Battery lock" sensors (0) 422 11.20 Camera System (0) 424 11.21 Working platform (0) 426 F Battery - maintenance, charging, and changing ................................ . 429 1 Safety instructions for handling lead-acid batteries 429 1.1 General information for handling batteries 431 2 Safety provisions for the handling of lithium ion batteries.............................. . 432 2.1 General information for handling batteries 434 2.2 Service life and maintenance of the battery........................................................... 435 3 Dimensions of the battery compartment... ............................................................... 436 4 Battery types 437 5 Opening the battery cover .............................................................................................. 440 6 Closing the battery cover ................................................................................................ 442 7 Charging the battery 444 7.1 Charging a lead battery.................................................................................................... 444 7.2 Charging the lithium-ion battery 448 8 Removing and installing the battery 454 8.1 Removing and Installing the Lithium-Ion Battery................................................. 454 8.2 Removing and installing the lead battery 455 9 Battery activation with the battery activation button. ........................................ .. 460 G Industrial truck maintenance and troubleshooting 461 1 Spare Parts 461 2 Operating safety and environmental protection ................................................... 462 3 Safety regulations for maintenance ........................................................................... 464 3.1 Working on the electrical system 468 3.2 Consumables and used parts ....................................................................................... 468 3.3 Wire Cables ........................................................................................................................... 469 3.4 Lift chain inspection 470 3.5 Hydraulic system ................................................................................................................. 472 3.6 Repairs and inspection of attachments: 474 3.7 Inspection and Repair of Fork Arms 474 4 Consumables and lubrication chart ........................................................................... 478 en 4.1 Handling consumables safely 478 => I C 4.2 Lubrication chart 480 CJ) 0 4.3 Consumables ........................................................................................................................ 481 C'! ..... 0 10
5 Description of maintenance and servicing jobs.................................................... 482 5.1 Preparing the industrial truck for maintenance and servicing....................... 482 5.2 Drive compartment cover disassembly/assembly............................................... 484 5.3 Wheels..................................................................................................................................... 486 5.4 Fuses........................................................................................................................................ 488 5.5 Check hydraulic oil level and refill if necessary.................................................... 500 5.6 Safely lifting and jacking the industrial truck.......................................................... 506 5.7 Preventing the Operator Position from Accidentally Lowering..................... 507 5.8 Cleaning................................................................................................................................... 512 5.9 Lubricate the lift chains, clean and grease the contact surfaces in the mast sections........................................................................................................................ 516 5.10 Lift chain servicing.............................................................................................................. 518 5.11 Restarting the industrial truck after maintenance and servicing work...... 520 6 Longterm storage of the industrial truck.................................................................. 521 6.1 Actions to be taken before shutting down the vehicle...................................... 521 6.2 Actions to be taken during shutdown........................................................................ 522 6.3 Restarting the industrial truck after shutdown....................................................... 522 7 Safety check after time and unusual events.......................................................... 523 8 Permanent decommissioning and disposal........................................................... 524 9 Measuring human vibration............................................................................................ 524 10 Troubleshooting................................................................................................................... 525 10.1 Fault - industrial truck not ready for operation...................................................... 526 10.2 Fault - industrial truck does not start......................................................................... 527 10.3 Fault - load lifting device cannot be raised............................................................. 528 10.4 Fault - industrial truck cannot be steered................................................................ 529 10.5 Fault - fast travel disabled............................................................................................... 529 10.6 Event and information messages................................................................................ 530 10.7 Additional information or event messages when equipped with lithiumion battery (0) ...................................................................................................................... 533 H Transport and initial startup.................................................................................. 535 1 Transport................................................................................................................................. 535 2 Handling by crane............................................................................................................... 536 2.1 Handling by crane with mast assembled................................................................. 538 2.2 Handling of the basic truck by crane with mast tilted (0)............................... 542 2.3 Handling the basic truck by crane............................................................................... 544 2.4 Handling by Crane of Mast Including Operator Position and Load Lifting Device......................................................................................................................... 548 2.5 Handling the battery by crane....................................................................................... 552 3 Securing the industrial truck during transport....................................................... 554 3.1 Transport locking device for basic truck with the mast assembled............ 556 3.2 Transport locking device for basic truck with the mast tilted (0) ................ 558 3.3 Basic truck transport locking device.......................................................................... 560 3.4 Mast transport locking device....................................................................................... 562 4 Initial startup.......................................................................................................................... 564 4.1 Moving the industrial truck without a battery......................................................... 565 4.2 Installing and removing the mast................................................................................ 565 4.3 Startup...................................................................................................................................... 566 4.4 en Tipping safety device......................................................................................................... 567 => I C (I) 0 C'! .... 0 11
Maintenance, inspection, and change of parts to be changed ................................................................................................................................ 569 1 Contents of the Maintenance EKS 310s-414s..................................................... 570 1.1 Operator................................................................................................................................... 570 1.2 Customer service................................................................................................................ 575 12 en :) I C CJ) 0 C'! ..... 0
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