EKS 110 Operating instructions 51539567 02.20 '"s.. 05.16 en-GB EKS 110 ;c~::; P fiUNGHEINRICH
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Foreword
Notes on the operating instructions
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter and the pages are numbered continuously.
The operator manual details different industrial truck models . When operating and servicing the industrial truck , make sure that the particular section applies to your truck model.
Our trucks are subject to ongoing development. We reserve the right to alter the design, equipment and technical features of the system No guarantee of particular 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 indicated by the following graphics :
A DANGER!
Indicates an extremely hazardous situation Failure to comply with this instruction will result in severe irreparable injury and even death
A WARNING!
Indicates an extremely hazardous situation Failure to comply with this instruction may result in severe irreparable injury and even death.
A CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in slight to medium injury.
NOTICE
Indicates a material hazard Failure to comply with this instruction may result in material damage.
[±I Used before notices and explanations.
• Indicates standard equipment
0 Indicates optional equipment
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Contents A Correct Use and Application................................................................................ 11 1 General.................................................................................................................................... 11 2 Correct application 11 3 Approved application conditions.................................................................................. 12 3.1 Internal Operation Combined with Brief External or Cold Store Operation (•) ....................................................................................................................... 14 3.2 Internal Operation in Cold Stores with Cold Store Equipment (0) 14 4 Proprietor responsibilities................................................................................................ 15 5 Adding attachments and/or optional equipment.................................................. 15 B Truck Description.......................................................................................................... 17 1 Application.............................................................................................................................. 17 2 Travel direction definition................................................................................................ 19 3 Assemblies and Functional Description................................................................... 20 3.1 Assembly Overview........................................................................................................... 20 3.2 Functional Description...................................................................................................... 22 4 Technical Specifications................................................................................................... 26 4.1 Performance data .............................................................................................................. 26 4.2 Weights.................................................................................................................................... 27 4.3 Tyre type.................................................................................................................................. 27 4.4 Dimensions............................................................................................................................ 28 4.5 Mast versions........................................................................................................................ 31 4.6 EN norms................................................................................................................................ 31 4.7 Specifications according to RED guideline (Radio Equipment Directive) for radio units................................................................................................... 32 4.8 Conditions of use................................................................................................................ 33 4.9 Electrical Requirements................................................................................................... 33 5 Identification Points and Data Plates........................................................................ 34 5.1 Data plate................................................................................................................................ 35 5.2 Truck capacity plate........................................................................................................... 36 6 Stability 37 C Transport and Commissioning........................................................................... 39 1 Lifting by crane..................................................................................................................... 39 1.1 Lifting the battery by crane............................................................................................. 40 2 Securing the truck during transport............................................................................ 42 3 Using the Truck for the First Time............................................................................... 44 3.1 Tilt safety device.................................................................................................................. 46 3.2 Mast Protection Pane........................................................................................................ 48 4 Moving the industrial truck without a battery......................................................... 49 D Battery - Servicing, Recharging, Replacement.................................... 51 1 Safety instructions for handling lead-acid batteries........................................... 51 cc 1.1 General notes on handling batteries......................................................................... 52 (!) 2 I C Battery types......................................................................................................................... 53 (I) 3 0 Exposing the battery.......................................................................................................... 54 N 4 C'l.i Charging the battery.......................................................................................................... 56 0 7
5 Battery removal and installation................................................................................... 58 E Operation ........................................................................................................................... 61 1 Safety Regulations for the Operation of Forklift Trucks 61 2 Displays and Controls 63 2.1 Control Station in Drive Direction ................................................................................ 63 2.2 Second control station (0) in load direction 66 2.3 Auxiliary lift controls 68 2.4 Pedestrian EKS 110 with gates .................................................................................... 69 2.5 Deadman button and gate 70 2.6 Display unit. ............................................................................................................................ 71 3 Preparing the Truck for Operation 78 3.1 Checks and Operations to Be Performed Before Starting Daily Work .... . 78 3.2 Setting up the operator position ................................................................................... 79 3.3 Entry and exit 80 4 Industrial Truck Operation 82 4.1 Safety regulations for truck operation ....................................................................... 82 4.2 Preparing the truck for operation 90 4.3 Checks and operations to be carried out when the truck is operational .. 92 4.4 Parking the truck securely .............................................................................................. 93 4.5 Emergency Disconnect 95 4.6 Deadman button .................................................................................................................. 97 4.7 Travel ........................................................................................................................................ 98 4.8 Steering 104 4.9 Brakes....................................................................................................................................... 105 4.10 Lifting / lowering - outside and inside narrow aisles 107 5 Order picking and stacking ............................................................................................. 113 5.1 Adjusting the forks (0) ..................................................................................................... 113 5.2 Replacing the fork tines (0) .......................................................................................... 114 5.3 Lifting, transporting and depositing loads 117 6 Troubleshooting 121 6.1 Truck does not start ........................................................................................................... 122 6.2 Emergency lowering 123 6.3 Recovering the truck from a narrow aisle / Moving the truck without a battery 127 7 Optional equipment. 139 7 .1 Keyless Access System ................................................................................................... 139 7.2 General Information about the Use of Keyless Access Systems 139 7.3 Commissioning the Keypad and the Transponder Reader .......................... .. 140 7.4 Using the Display: ............................................................................................................. 143 7.5 Using the Keypad 147 7.6 Using the Transponder Reader 151 7.7 ISM access module (0) ................................................................................................... 155 7.8 Travelling in pedestrian touch mode (0) 156 7.9 Lifting and lowering in pedestrian touch mode 159 7 .10 Lifting and Lowering the Operator's Position with Lift Cutout ( 0) ............ .. 165 7.11 Trucks with Rail Guidance and Aisle Recognition (0) .................................... . 167 7 .12 Negotiating narrow aisles................................................................................................ 172 7.13 Walk-On Load Handler with Pallet Guard (0) 175 aJ 7 .14 JetPilot. 177 (!) I C 7.15 Pre-set Fork Lowering Settings for Stock Picking for L Model 179 CJ) 0 7 .16 USB Charger 179 N c--i 0 8
7.17 Warehouse Management System (WMS).............................................................. 180 7.18 Crawl Speed with Lowered Load Handler.............................................................. 180 7.19 Floor-Spot............................................................................................................................... 181 F Industrial Truck Maintenance.............................................................................. 183 1 Spare Parts............................................................................................................................ 183 2 Operational Safety and Environmental Protection 183 3 Maintenance Safety Regulations................................................................................ 185 3.1 Working on the electrical system ................................................................................ 186 3.2 Consumables and used parts....................................................................................... 186 3.3 Wheels..................................................................................................................................... 187 3.4 Attachment Repairs and Inspection........................................................................... 187 3.5 Lift chain inspection........................................................................................................... 188 3.6 Hydraulic system................................................................................................................. 189 4 Lubricants and Lubrication Schedule........................................................................ 190 4.1 Handling consumables safely....................................................................................... 190 4.2 Lubrication Schedule......................................................................................................... 192 4.3 Consumables........................................................................................................................ 193 5 Maintenance and repairs................................................................................................. 194 5.1 Preparing the truck for maintenance and repairs................................................ 194 5.2 Lifting and jacking up the truck safely....................................................................... 195 5.3 Front panel assembly and disassembly................................................................... 197 5.4 Electrical System................................................................................................................. 198 5.5 Checking electrical fuses................................................................................................ 199 5.6 Replace the Drive and Load Wheels......................................................................... 200 5.7 Tightening the wheel nuts............................................................................................... 200 5.8 Adjusting the battery latch.............................................................................................. 202 5.9 Mast retainer assembly and removal........................................................................ 203 5.10 Cleaning................................................................................................................................... 205 5.11 Lift chain servicing.............................................................................................................. 208 5.12 Lubricate the lift chains, clean and grease the contact surfaces in the mast sections........................................................................................................................ 208 5.13 Checking the hydraulic oil level.................................................................................... 210 6 Restoring the truck to service after maintenance and repairs...................... 212 7 Decommissioning the Industrial Truck...................................................................... 212 7.1 Prior to decommissioning................................................................................................ 213 7.2 During decommissioning................................................................................................. 213 7.3 Restoring the truck to service after decommissioning...................................... 214 8 Safety tests to be performed at intervals and after unusual incidents...... 215 9 Final de-commissioning, disposal............................................................................... 216 10 Human vibration measurement.................................................................................... 216 G Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement............................................................................ 217 1 Maintenance Contents EKS 110.................................................................................. 218 1.1 Owner....................................................................................................................................... 218 1.2 Customer Service............................................................................................................... 222 2 Charging the battery.......................................................................................................... 228 cc (!) 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