Operating instructions 51762478 03.20 'rt'" r, 04.19 en-GB EKS 210 EKS 310 EKS 412 fiUNGHEINRICH
EKS 210 - 412
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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
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG .
Cl) (!) I C: Q) 0 N C') 0
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Jungheinrich Aktiengesellschaft
Friedrich-Ebert-Damm 129
22047 Hamburg - Germany
Tel: +49 (0) 40/6948-0
www.jungheinrich.com
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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 Indoor Application outside the Freezer (e)........................................................... 12 3.2 Internal Operation in Cold Stores with Cold Store Equipment (0) 13 4 Proprietor responsibilities................................................................................................ 14 5 Adding attachments and/or optional equipment.................................................. 14 B Truck Description.......................................................................................................... 15 1 Application.............................................................................................................................. 15 2 Travel direction definition................................................................................................ 16 3 Assemblies and Functional Description................................................................... 17 3.1 Functional Description...................................................................................................... 17 3.2 Assembly Overview........................................................................................................... 22 4 Control panel arrangements.......................................................................................... 30 4.1 Version with control panels and driver's display facing the load.................. 30 4.2 Version with control panels and driver's display facing the drive................ 31 4.3 "Control panels arranged on either side" version................................................ 32 4.4 "Control panels and driver's display arranged on drive side with additional control panel for cross position"............................................................. 33 5 Technical Specifications................................................................................................... 34 5.1 Performance data .............................................................................................................. 35 5.2 Dimensions (as per data plate).................................................................................... 38 5.3 Mast versions........................................................................................................................ 50 5.4 Mast bracing.......................................................................................................................... 60 5.5 Weights.................................................................................................................................... 60 5.6 Wheels, chassis................................................................................................................... 64 5.7 Engine Data........................................................................................................................... 66 5.8 EN norms................................................................................................................................ 66 5.9 Conditions of use................................................................................................................ 68 5.10 Electrical requirements..................................................................................................... 69 5.11 Safety of trucks 69 6 Identification Points and Data Plates........................................................................ 70 6.1 Indication Points ................................................................................................................. 70 6.2 Data plate................................................................................................................................ 74 6.3 Truck capacity plate........................................................................................................... 76 6.4 Sign: "Load centre distance on EKS with walk-on platform"......................... 77 6.5 Capacity reduction according to weight (operator, rider or loads) in the operator position.................................................................................................................. 78 6.6 "Medical and technical device operation affected by magnets" warning notice......................................................................................................................................... 80 6.7 Attachment capacity plate............................................................................................... 81 6.8 Jack contact points............................................................................................................. 81 cc 6.9 "Residual capacity" tilt safety device notice (0).................................................. 82 (!) 7 I C Stability ................................................................................................................................... 83 (I) 0 N cvj 0 7
C Transport and Commissioning ........................................................................... 85 1 Transport ................................................................................................................................. 85 2 Lifting by crane 86 2.1 Lifting by crane with mast assembled ....................................................................... 88 2.2 Lifting of the basic truck by crane with a tilted mast (0) 92 2.3 Lifting the basic truck by crane 94 2.4 Loading of the mast with operator position and load handler by crane... . 98 2.5 Lifting the battery by crane ............................................................................................. 102 3 Securing the truck during transport 104 3.1 Transport retainer for basic truck with the mast assembled ......................... . 106 3.2 Basic truck transport retainer with tilted mast (0) .............................................. 108 3.3 Basic truck transport retainer 110 3.4 Mast transport retainer 112 4 Using the Truck for the First Time ............................................................................... 114 4.1 Moving the industrial truck without a battery 115 4.2 Installing and removing the mast 115 4.3 Commissioning ..................................................................................................................... 116 4.4 Tilt safety device 117 D Battery - Servicing, Recharging, Replacement... ................................. 119 1 Safety instructions for handling lead-acid batteries 119 1.1 General notes on handling batteries 121 2 Safety regulations for handling lithium-ion batteries.......................................... 122 2.1 General notes on handling batteries 124 2.2 Battery lifetime and maintenance 125 3 Dimensions of the battery compartment... ............................................................... 126 4 Battery types 126 5 Opening or Closing the Battery Panel 129 5.1 Opening the battery panel 131 5.2 Closing the battery cover 132 6 Charging the battery .......................................................................................................... 133 6.1 Charging lead-acid batteries 133 6.2 Charging the lithium-ion battery 137 7 Battery removal and installation................................................................................... 141 7.1 Removing and installing the lithium-ion battery 141 7.2 Removing and installing the lead-acid battery 141 8 Battery activation with the battery activation button. .......................................... 147 E Operation 149 1 Safety Regulations for the Operation of Forklift Trucks 149 2 Displays and Controls ....................................................................................................... 154 2.1 Controls and displays on the control panel ............................................................ 154 2.2 Load-side controls of the auxiliary lift with drive-side control unit arrangement (variant Z) ................................................................................................... 162 2.3 Driver's display 164 2.4 Symbols in driver's display (truck statuses and input requests) ................. . 166 2.5 Hourmeter............................................................................................................................... 2.6 "Bar display" battery discharge indicator 173 174 aJ (!) I 2.7 Driver's display function symbols ................................................................................ 176 C CJ) 3 Preparing the Truck for Operation .............................................................................. 182 0 N (Y) 0 8
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I C (I) 0 N cvj 0 3.1 Checks and operations to be performed before starting daily operation. 183 3.2 Entry and exit........................................................................................................................ 188 3.3 Setting up the operator position................................................................................... 190 3.4 Backrest/ driver's seat (0)............................................................................................ 190 3.5 Control panel height adjustment.................................................................................. 192 3.6 Safety harness with safety rope (0).......................................................................... 194 4 Industrial Truck Operation.............................................................................................. 213 4.1 Safety regulations for truck operation....................................................................... 213 4.2 Preparing the truck for operation................................................................................. 222 4.3 Switching off the truck...................................................................................................... 224 4.4 Checks and operations to be carried out when the truck is operational.. 226 4.5 Setting the time.................................................................................................................... 227 4.6 Main Lift referencing.......................................................................................................... 228 4.7 Emergency Disconnect.................................................................................................... 230 4.8 Travel........................................................................................................................................ 232 4.9 Brakes....................................................................................................................................... 236 4.10 Lifting and lowering 238 4.11 Diagonal travel 244 4.12 Steering.................................................................................................................................... 245 4.13 Parking the truck securely.............................................................................................. 246 5 Order picking and stacking............................................................................................. 248 5.1 Adjusting the forks (0)..................................................................................................... 248 5.2 Replacing the fork tines (0) .......................................................................................... 252 5.3 Lifting, transporting and depositing loads............................................................... 256 6 Troubleshooting................................................................................................................... 262 6.1 Troubleshooting................................................................................................................... 262 6.2 Emergency stop device.................................................................................................... 268 6.3 Load handler emergency lowering............................................................................. 268 6.4 Cut-offs..................................................................................................................................... 272 6.5 Recovering the truck......................................................................................................... 281 7 Leaving the operator position with the rescue equipment.............................. 294 7.1 Rescue equipment storage compartment in the operator position............. 295 7.2 Rescue equipment testing/ servicing....................................................................... 296 7.3 Seals and rescue equipment bags............................................................................. 297 7.4 Rescue equipment service life..................................................................................... 298 7.5 Rescue equipment storage and transportation.................................................... 299 7.6 Usage and ambient conditions.................................................................................... 299 7.7 Description and use of the rescue equipment...................................................... 300 8 Truck with load guard and walk-on load (e.g. pallet, lattice box)................. 316 8.1 Order-picking platform without load handler option........................................... 318 8.2 Order-picking platform with load handler option.................................................. 320 8.3 Order-picking platform with monitored and secure load handler option.. 324 8.4 Description of the function of the side and load-side safety gates............. 326 8.5 Additional symbols in driver's display....................................................................... 328 8.6 Picking up or setting down the load with the retaining clamp....................... 329 9 Optional equipment............................................................................................................ 340 9.1 Keyless Access System................................................................................................... 340 9.2 General Information about the Use of Keyless Access Systems................ 341 9.3 Keyless access system - commissioning the keypad and the transponder reader............................................................................................................. 341 9.4 Keyless access system - display unit ...................................................................... 344 9.5 Keyless access system - keypad................................................................................ 349 9.6 Keyless access system - transponder reader....................................................... 354 9
9.7 ISM Online "New Generation" (0) 359 9.8 Locking Safety Gates (0) 359 9.9 Rider mode for a second person in the operator position (0) ..................... . 360 9.10 Rear view mirror (0) ......................................................................................................... 364 9.11 Panoramic Mirror (0) ........................................................................................................ 364 9.12 Fire extinguisher (0) 366 9.13 Floor-Spot (0) 368 9.14 "Battery lock" sensors (0) .............................................................................................. 372 9.15 Camera system (0) ........................................................................................................... 374 9.16 Cold-Store Equipment - Important Instructions for Operation within the Cold Store (0) 378 F Industrial Truck Maintenance .............................................................................. 381 1 Spare Parts ............................................................................................................................ 381 2 Operational Safety and Environmental Protection 382 3 Maintenance Safety Regulations 384 3.1 Working on the electrical system ................................................................................ 385 3.2 Consumables and used parts 385 3.3 Hydraulic system ................................................................................................................. 386 3.4 Lift chain inspection 388 3.5 Attachment Repairs and Inspection 389 4 Lubricants and Lubrication Schedule ........................................................................ 390 4.1 Handling consumables safely 390 4.2 Lubrication Schedule 392 4.3 Consumables ........................................................................................................................ 393 5 Maintenance and repairs 394 5.1 Preparing the truck for maintenance and repairs ................................................ 394 5.2 Drive compartment cover disassembly/assembly 396 5.3 Wheels 398 5.4 Fuses ........................................................................................................................................ 400 5.5 Check hydraulic oil, top up 414 5.6 Lifting and jacking up the truck safely 420 5.7 Preventing the operator position from accidentally lowering 421 5.8 Cleaning 426 5.9 Lubricate the lift chains, clean and grease the contact surfaces in the mast sections 430 5.10 Lift chain servicing 432 5.11 Restoring the truck to service after maintenance and repairs ..................... . 434 6 Decommissioning the Industrial Truck 435 6.1 Prior to decommissioning 435 6.2 During decommissioning ................................................................................................. 436 6.3 Restoring the truck to service after decommissioning 436 7 Safety tests to be performed at intervals and after unusual incidents .... .. 437 8 Final de-commissioning, disposal ............................................................................... 438 9 Human vibration measurement. 438 G Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement ............................................................................ 439 1 Maintenance Contents EKS 210-412...................................................................... .. 440 aJ (!) I 1.1 Owner ....................................................................................................................................... 440 C CJ) 1.2 Customer Service ............................................................................................................... 444 0 N (Y) 0 10
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
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