Jungheinrich Forklift EKS 210a Operating instructions Manual 51269254 – PDF DOWNLOAD by www.heydownloads.com

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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 :

,& DANGER!

Indicates an extremely hazardous situation Failure to comply with this instruction will result in severe irreparable injury and even death.

WARNING!

Indicates an extremely hazardous situation. Failure to comply with this instruction may result in severe irreparable injury and even death.

,& CAUTION!

Indicates a hazardous situation. Failure to comply with this instruction may result in slight to medium injury .

NOTE

Indicates a material hazard. Failure to comply with this instruction may result in material damage.

Used before notices and explanations.

Indicates standard equipment

Indicates optional equipment

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Contents A Correct Use and Application .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. ... .. .. ... .. .. .. .. 11 1 General.................................................................................................... 11 2 Correct application................................................................................... 12 3 Approved application conditions.............................................................. 13 4 Proprietor responsibilities........................................................................ 14 5 Adding attachments and/or accessories.................................................. 14 B Truck Description.................................................................... 15 1 Application 15 2 Travel direction definition......................................................................... 16 3 Assemblies and Functional Description................................................... 16 3.1 Functional Description 16 3.2 Assembly Overview................................................................................. 22 4 Technical Specifications.......................................................................... 26 4.1 Performance data 26 4.2 Dimensions (as per data plate)................................................................ 28 4.3 Mast versions 30 4.4 Weights.................................................................................................... 32 4.5 Wheels, chassis....................................................................................... 32 4.6 Engine Data............................................................................................. 33 4.7 EN norms................................................................................................. 34 4.8 Conditions of use..................................................................................... 36 4.9 Electrical Requirements........................................................................... 37 5 Identification points and data plates .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 38 5.1 Data plate 40 5.2 Truck capacity plate................................................................................. 41 5.3 Attachment capacity plate .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 42 5.4 "Medical and technical device operation affected by magnets" warning notice....................................................................................................... 42 5.5 Jack contact points.................................................................................. 42 6 Stability.................................................................................................... 43 C Transport and Commissioning .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. ... .. .. .. . .. .. . 45 1 Transport 45 1.1 Securing the truck during transport......................................................... 45 2 Lifting by crane........................................................................................ 48 2.1 Loading with another industrial truck....................................................... 48 2.2 Moving the truck manually on and off the transporting truck................... 50 2.3 Lifting the battery by crane...................................................................... 52 3 Using the Truck for the First Time 54 3.1 Moving the industrial truck without a battery........................................... 55 3.2 Commissioning ................. ...... ........ ....... ................... ............... ................ 56 3.3 Tilt safety device...................................................................................... 57 D z Battery - Servicing, Recharging, Replacement....................... 59 UJ Cl0 1 .... Safety Regulations Governing the Handling of Lead-Acid Batteries 59 r....: 0 7

o o t o o o o 1.1 General notes on handling batteries 61 2 Battery types 62 2.1 Dimensions of the battery compartment.. ............................................... . 63 3 Exposing the battery 64 4 Charging the battery 68 5 Battery removal and installation ............................................................. . 72 6 "Battery lock" sensors ( ) 76 E Operation ............................................................................... . 79 1 Safety Regulations for the Operation of Forklift Trucks .......................... . 79 2 Displays and Controls 82 2.1 Controls and displays on the control panel. 82 2.2 Driver display luminous buttons 88 2.3 Driver's display 90 2.4 Hourmeter ............................................................................................... . 91 2.5 "Bar display" battery discharge indicator 92 2.6 "Percentage display" battery discharge indicator ( ) 94 2.7 Driver's display function symbols ............................................................ . 96 2.8 Displays, sensors and controls for automatic mode 100 3 Preparing the Truck for Operation 106 3.1 Checks and operations to be performed before starting daily operation 106 3.2 Entry and exit. 110 3.3 Control panel height adjustment ............................................................. . 112 4 Industrial Truck Operation 114 4.1 Safety regulations for truck operation 114 4.2 Preparing the truck for operation ............................................................ . 129 4.3 Switching off the truck 130 4.4 Checks and operations to be carried out when the truck is operational 131 4.5 Personal protection system test ............................................................. . 132 4.6 Load handler referencing 133 4.7 Changing between manual and automatic modes ................................. . 136 4.8 Date and time setting 140 4.9 Emergency Disconnect. 143 4.10 Travelling in manual mode ..................................................................... . 145 4.11 Manual steering 149 4.12 Manual braking 149 4.13 Manual lifting and lowering of the load handler ...................................... . 151 4.14 Aligning the truck for automatic mode 155 4.15 Parking the truck securely ...................................................................... . 159 5 Order picking and stacking 161 5.1 Adjusting the Forks ( ) 161 5.2 Automatic mode procedures ................................................................... . 163 5.3 Raising, Transporting and Depositing Loads Manually 173 6 Troubleshooting 180 6.1 Troubleshooting ...................................................................................... . 180 6.2 Emergency stop device 185 6.3 Load handler emergency lowering 185 6.4 Lift cutout override ( ) ........................................................................... . 189 6.5 Lower cutout override ( ) 191 6.6 Travel cutout override ( ) ...................................................................... . 193 6.7 6.8 External control panel ( ) ...................................................................... . Recovering the truck / moving the truck without a battery 195 z 202 w CIC) 7 Personal protection system .................................................................... . 215 ..... r-..: 0 8

o o o o o o o z UJ Cl0 .... 0 7 .1 Personal Protection System (PPS).......................................................... 215 7.2 Functional description.............................................................................. 215 7.3 Environmental awareness....................................................................... 217 7.4 Cleaning the laser scanner front screen.................................................. 218 7.5 Displays on the seven segment display and indicator light (LED)........... 219 7.6 Daily checks before starting the Personal Protection System................. 221 7. 7 Personal safety system 221 8 Optional equipment 223 8.1 ISM access module ( )....... ..... ... ............. .. ..................... .............. .......... 223 8.2 Full pallet stacking ( ) .... 223 8.3 Empty pallet stacking ( ) ............. .. ............ .............. ................. ........... ... 225 8.4 Orthogonal sensors ( )....... ..... ... ............. .. ..................... .............. .......... 227 8.5 Broken pallet sensors ( ) ....................................................................... 227 8.6 Obstacle detection for travelling in the drive direction in automatic mode (laser scanner) ( ) .................................................................................. 229 8.7 Weighing system ( )............................................................................... 231 F Industrial Truck Maintenance .................................................. 233 1 Operational Safety and Environmental Protection................................... 233 2 Maintenance Safety Regulations............................................................. 235 2.1 Wheels 236 2.2 Lift chain inspection................................................................................. 237 2.3 Hydraulic system .......... .. .................... ............. ........... ... ............. ... .......... 238 2.4 Consumables and used parts.................................................................. 239 2.5 Working on the electrical system............................................................. 240 2.6 Attachment Repairs and Inspection......................................................... 241 3 Lubricants and Lubrication Schedule 242 3.1 Handling consumables safely.................................................................. 242 3.2 Lubrication Schedule............................................................................... 244 3.3 Consumables........................................................................................... 245 4 Maintenance and repairs......................................................................... 246 4.1 Preparing the truck for maintenance and repairs 246 4.2 Drive compartment cover disassembly/assembly 248 4.3 Checking electrical fuses......................................................................... 250 4.4 Checking the hydraulic oil level 254 4.5 Lifting and jacking up the truck safely...................................................... 258 4.6 Cleaning ............... .............. ...... ... ................... ................ ........... .. ............ 260 4.7 Lift chain servicing................................................................................... 266 4.8 Lubricate the lift chains, clean and grease the contact surfaces in the mast sections........................................................................................... 266 4.9 Restoring the truck to service after maintenance and repairs 267 5 Decommissioning the industrial truck...................................................... 268 5.1 Prior to decommissioning 268 5.2 During decommissioning 269 5.3 Restoring the truck to service after decommissioning ................ ............. 269 6 Safety tests to be performed at intervals and after unusual incidents 270 7 Final de-commissioning, disposal............................................................ 271 9

8 Human vibration measurement............................................................... 271 G Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement........................................................... 273 1 Maintenance Contents EKS 210a 274 1.1 Owner ... .. .. ........... .. ............ .. .. ........... .. ............ .. ............ .. ............ .. .... ....... 27 4 1.2 Customer Service 277 10 z w CIC) ..... r-0