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Operating Instructions 51166874 EKX 410 G 01.1003.10 ÖËÒÙØÛ×ÒÎ×ÝØ

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Declaration of Conformity

Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg Manufacturer or authorized representative in the Community

Type OptionSerial No.Year of Construction

EKX 410

Additional information

Authorised signatory

Date

G EU Declaration of Conformity

Foreword

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. Each chapter starts with page 1. The page identification consists of a chapter letter and a page number.

For example: Page B 2 is the second page in chapter B.

The operating instructions detail different truck models. When operating and servicing the truck, make sure that the instructions apply to your truck model.

Safety instructions and important explanations are indicated by the following graphics:

F Used before safety instructions which must be observed to avoid danger to personnel.

Used before notices which must be observed to avoid material damage.

Z Used before notices and explanations.

t Used to indicate standard equipment.

o Used to indicate optional equipment.

Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. No guarantee of particular features of the truck should therefore be inferred from the present operating instructions.

Jungheinrich Aktiengesellschaft

Am Stadtrand 35

22047 Hamburg - GERMANY

Telephone: +49 (0) 40/6948-0

www.jungheinrich.com

I 1

ACorrect Use and Application 1General ...............................................................................................A 1 2Correct application ..............................................................................A 1 3Approved application conditions .........................................................A 1 4Proprietor responsibilities ....................................................................A 2 5Adding attachments and/or accessories .............................................A 2 BTruck Description 1Application .............. ...........B 1 1.1Travel direction definition ....................................................................B 2 2Assemblies and Functional Description ..............................................B 2 2.1Truck functional description ..................B 4 3Standard version specifications .............. ...........B 7 3.1 Performance data ............ .........B 7 3.2 Dimensions (as per data plate) ..........................................................B 9 3.3Mast version ......... .........B 12 3.4 Standard mast version with telescopic mast (ZT) ..............................B 12 3.5 Engine data .........................................................................................B 12 3.6Weights ................ .........B 13 3.7Wheels, chassis ..................................................................................B 16 3.8 EN norms ............. .........B 16 3.9 Conditions of use .......... .........B 17 3.10 Electrical requirements ........................................................................B 17 4Identification points and data plates ............... .........B 18 4.1Truck data plate ....... .........B 20 4.2Truck capacity plate ........ .........B 21 4.3Attachment capacity plate (o) ................ ...........B 22 5 Stability .......... .........B 22 CTransport and Commissioning 1Transport ................ ...........C 1 2Lifting by Crane ............... .........C 2 2.1 Loading by crane with mast assembled ......... .........C 2 2.2 Crane points ........... ...........C 3 2.3Lifting the battery by crane .. ..................C 4 3Securing the Truck during Transport ......... .........C 5 3.1Basic truck transport safety .......C 6 3.2Mast transport retainer ....... .........C 8 3.3Safely transporting the truck with the mast assembled .......................C 10

Table of contents

I 2 4Using the Truck for the First Time .......................................................C 11 4.1 Moving the truck without a battery ......................................................C 11 4.2 Installing and removing the mast ........................................................C 11 5Starting the Truck ................................................................................C 12 DBattery - Servicing, Recharging, Replacement 1Safety Regulations Governing the Handling of Lead-Acid Batteries ........ .........D 1 2Battery types ................. .........D 2 2.1 Battery compartment dimensions ......... ..................D 3 3Exposing the battery .......... .........D 4 4Charging the Battery ............ .......D 5 5Battery Removal and Installation ............ ...........D 8 Condition and Acid Level ....... ..................D 12 7Battery Discharge Indicator .. .......D 12 EOperation 1Safety Regulations for the Operation of Forklift Trucks ......................E 1 2Controls and Displays .......... .......E 3 2.1 Controls and displays on the control panel ............. ...........E 3 2.2Lower range symbols and buttons ............ .........E 10 2.3Truck operational status symbols ................ .........E 14 3Starting up the Truck .......... .........E 15 3.1Truck entry and exit ......... .........E 16 3.2Setting up the operator position .............. ...........E 17 .........E 17 3.4 Control panel angle adjustment ...........E 17 3.5 Control panel height adjustment .......... ..................E 17 3.6Preparing the truck for operation ................. .........E 18 3.7 Preparing the truck for operation with an additional access code (o) .............. .........E 18 3.8ISM Access Module (o) .............. .........E 20 3.9 Checks and operations to be carried out when the truck is operational .......................................................................................E 20 3.10Referencing the main and auxiliary lift ................................................E 22 3.11Setting the time ...................................................................................E 24 4Industrial Truck Operation ...................................................................E 25 4.1 Safety regulations for truck operation .................................................E 25 4.2Emergency Disconnect, Travel, Steering, Braking ..............................E 29 4.3Negotiating narrow aisles ....................................................................E 32 4.4Diagonal travel ....................................................................................E 36 the rack aisles ........ ...........E 37 4.6 Lifting - Lowering - Traversing - Pivoting inside the rack aisles ........ ...........E 44

I 3 4.7Stockpicking and stacking ...................................................................E 45 4.8Lifting, transporting and depositing loads ............................................E 48 4.9Parking the truck securely ...................................................................E 53 5Troubleshooting ..................................................................................E 54 5.1Emergency stop device .......................................................................E 56 emergency lowering ............ ...........E 56 5.3Bypassing the chain slack safety device .............................................E 58 5.4Bypassing the travel cutout (o) ..........................................................E 59 5.5Lift cutout override (o) ........................................................................E 60 5.6Lower cutout override (o) ...................................................................E 62 5.7Aisle end safety device (o) ................ .......E 64 5.8Wire guidance emergency mode (E144) .............................................E 66 5.9 Recovering the truck from a narrow aisle /Moving the truck without a battery ....... .........E 67 6Exiting the driver's cab with the rescue equipment .............................E 72 6.1Rescue equipment storage compartment in the driver's cab ..............E 73 6.2 Rescue equipment testing / servicing ..... ...........E 73 6.3Rescue equipment service life ...........E 74 6.4Rescue equipment storage and transportation ......... .........E 75 6.5Rescue equipment description / application (- 07.09) .. .........E 76 6.6Rescue equipment description / application (07.09 -) .........................E 91 7Optional equipment .............. .......E 107 7.1 Rear view mirror (o) .............. ...........E 107 7.2Fire extinguisher (o) .............. ...........E 108 7.3Rider mode (in the driver's cab) (o) .............. .........E 109 7.4Using a work platform (o) ................ .........E 111 7.5Weigher (o) ............. .........E 115 FIndustrial Truck Maintenance 1Operational Safety and Environmental Protection .... .........F 1 2Maintenance safety regulations .............. ...........F 1 3Servicing and Inspection .... .........F 7 4EKX Maintenance Checklist .. .......F 8 4.1 Lubrication Schedule .......... .........F 11 5Lubricants and Lubrication Schedule .......... .........F 12 5.1 Handling consumables safely ...........F 12 5.2Consumables ........... .........F 15 6Maintenance and Repairs ......... .........F 16 6.1 Preparing the truck for maintenance and repairs ...... .........F 16 6.2 Securing the operator position carriage ......... .........F 17 6.3Lift chain servicing ......... .........F 19 6.4Lubricating the lift chains, cleaning and greasing the contact surfaces in the mast sections ..................F 20 6.5Lift chain inspection ......... .........F 22

I 4 6.6Hydraulic hose lines ............................................................................F 23 6.7Drive panel disassembly / assembly ...................................................F 24 6.8Checking the hydraulic oil level ...........................................................F 25 6.9Checking electrical fuses ....................................................................F 28 6.10Recommissioning the truck after cleaning or maintenance work ........F 30 7Decommissioning the industrial truck ............. .........F 32 7.1Prior to decommissioning ....................................................................F 33 7.2 During decommissioning .....................................................................F 33 7.3Returning the truck to operation after decommissioning .....................F 34 8Safety tests to be performed at intervals and after unusual incidents ................. ...........F 35 9Final de-commissioning, disposal ........... ...........F 35 10Human vibration measurement ...........F 35

ACorrect Use and Application

1General

The industrial truck described in the present operating instructions is designed for lifting, lowering and transporting load units.

It must be used, operated and serviced in accordance with the present instructions. Any other type of use is beyond the scope of application and can result in damage to personnel, the industrial truck or property.

2Correct application

The maximum load and load distance are indicated on the load chart and must not be exceeded.

The load must rest on the load handler or be lifted by an attachment approved by the manufacturer.

The load must rest on the back of the fork carriage and centrally between the forks. and picking loads.

the narrow aisle as low as possible, allowing for ground clearance.

l load units.

3Approved application conditions

F Do not exceed the permissible surface and spot load limits on the travel routes. At blind spots get a second person to assist. Z

The industrial truck must not be used in fire or explosion endangered areas, or areas threatened by corrosion or excessive dust. Furthermore, the truck must not be operated in the vicinity of unprotected active components of electrical systems. and commercial environments. range +5°C to +40°C.

surfaces in accordance with DIN15185 part 1.

een the truck and rack to EN 1726-2 item 7.3.2.

e between rail guided truck and rack. between wire guided truck and rack.

Z Special equipment and authorisation are required if the truck is to be constantly used in extreme conditions or areas at risk from explosion.

A 1

4Proprietor responsibilities

For the purposes of the present operating 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 considered the person who, in accordance with existing contractual agreements between theowner and user of the industrial truck, is charged with operational duties. The proprietor must ensure that the industrial truck is used only for the purpose it is intended for and that danger to life and limb of the user and third parties are excluded. Furthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The proprietor must ensure that all users have read and understood these operating instructions.

ZFailure to comply with the operating instructions shall invalidate the warranty. Thesame applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufacturer.

5Adding attachments and/or accessories

The mounting or installation of additional equipment which affects or enhances theperformance of the forklift truck requires the written permission of themanufacturer. Local authority approval may also need to be obtained. Approval of the local authorities however does not cons approval.

A 2

BTruck Description

1Application

The EKX is an electric three-way stockpicker. It is designed to transport and pick goods on level surfaces in accordance with DIN15185 Part 1.

It can lift open bottom or diagonal board pallets as well as roll cages beyond the area of the load wheels. Loads can be stacked, unstacked and transported over long distances.

The driver's cab rises together with the load handler to provide excellent visibility and easy access to the various rack heights.

The racks must be set up for the EKX. The safety distances stipulated by Jungheinrich (e.g. EN 1726-2 item 7.3.2) must be observed.

distance of 100mm must be maintained between the rack and the truck.

e between the rack and the truck must be no less than 125mm. The safety distance may however be increased if special attachments are fitted.

ZThe ground must comply with DIN 15185 Part 1.

Guide rails must be provided in the narrow aisles for the rail guidance system. Vulkollan guide wheels attached to the truck chassis guide the truck between the guide rails.

A guide wire must be routed in the ground for the wire guidance system. The signals from the wire are received by sensors on the chassis and processed by the on-board computer.

The capacity is shown on the data plate.

TypeCapacityLoad centre of gravity

EKX 4101,000 kg600 mm

B 1

1.1Travel direction definition

The following determinations have been made for travel direction specification:

B 2

2Assemblies and Functional Description Left Drive direction Load direction Right î ï ì ê é è ë ïï ïî ïí ïëïì ïéïê ïè í ç ïð

B 3

1 t Mast 2 t Aux. lift 3 t Overhead guard 4 t Control panel 5 t Gates 6 t Lifting operator position 7 t Deadman button 8 t Fork 9 o Front sensor for wire guidance system (not shown) 10 t Load wheel 11 o Rail guidance wheels behind the load wheel 12 t Chassis 13 t Battery cover 14 o Rail guidance wheels on the drive compartment 15 t Tilt safety devices 16 t Drive panel 17 t Drive wheel 18 t Rear sensor for wire guidance system

= Standard equipment o = Optional equipment

Item Description

2.1Truck functional description

Safety mechanisms:

ensures safe handling of the truck. iver from falling objects.

disconnects all truck movement in hazardous situations.

all truck operations as soon as they are opened.

only be activated when the deadman button is pressed.

activated when the deadman button is pressed.

Deadman button

After preparing the truck to operation ("Preparing the truck for operation" and "Preparing the truck for operation with an additional access code (o)" in chapter E) and closing the gates, the deadman button in the leg well:

t =

be pressed and held down to allow the drive to operate the truck. Lifting and travel are inhibited if the driver takes his foot off the foot switch. Steering and braking remain enabled. When the deadman button is released and the truck comes to a halt the parking brake applies (prevents the truck from rolling away).

o =

be pressed once to allow the drive to operate the truck. When the travel control button is released and the truck comes to a halt the parking brake applies (prevents the truck from rolling away).

Emergency Stop safety feature

uck automatically brakes to a halt. Control indicators on te the emergency stop. Every time the truck is switched on, the system performs a self test which only releases the parking brake (emergency stop) if the functional test is positive.

B 4

Drive:

y AC motor (asynchronous). The motor is directly attached to the single-wheel driving gear, ensuring rapid and trouble-free maintenance.

Brake system:

ly and wear-free by pulling back the travel control button? Or steering in the opposite direction. This feeds energy into the battery (service brake).

pressure brake acting on the drive motor serves as a parking and handbrake.

Steering:

ng with threephase drive system. is integrated within the control panel. The position of the steered drive wheel is shown in the control panel display unit. The steering angle is +/- 90°, offering maximum manoeuvrability in narrow aisles. can be set to the forward position at the press of a button (optional).

ing is automatically assumed by the truck controller when it detects the guidance wire, and manual steering is deactivated (optional).

B 5

Controls and displays:

operation without stressing the wrists; sensitive application of travel and hydraulic movements to spare and position the goods exactly.

l important driver information such as steering wheel position, overall lift, truck status reports (e.g.faults), service hours, battery capacity, time and inductive guidance status etc. ing principle for maximum safety and operating comfort. Sensors record any contact made by the operator and feed this information to the on-board computer.

Hydraulic system:

flanged low emission gear pump. etic switch valves. The varying oil requirements are controlled by the speed of the motor.

the hydraulic pump drives the motor which then acts as a generator (regenerative lowering). The energy produced is then fed back to the battery.

Electrical system:

ction interface:

To configure all the key truck data (end position damping, lift cutout, retardation and acceleration patterns, reach speeds, cut-outs etc.) rapidly and reliably. To read off the error log to analyse fault causes. To simulate and analyse program operations. Simple function extension by releasing code numbers.

h a CAN Bus and a constantly recording sensor system. All operations can be set using parameters. The controller provide smooth start-up and braking of the load in all limit positions through end position and intermediate dampers. The MOSFET threephase controller provides smooth starting for all movements.

energy retention for the traction and lift motors provides high travel and lift speeds and better use of energy.

For drive battery options see chapter D.

B 6

3Standard version specifications

ZTechnical data specified in accordance with VDI 2198. Technical modifications and additions reserved.

3.1Performance data

DescriptionEKX 410

Q (t)Capacity (where C = 600 mm)1,000kg

c / D*Load centre distance600 mm

Travel speed without load (RG)9km/h

Travel speed with load (RG)9km/h

Travel speed without load (WG)7km/h

Travel speed with load (WG)7km/h

Travel speed without load (free ranging)8km/h

Travel speed with load (free ranging)8km/h

Lift speed without load0.40m/s

Lift speed with load0.36m/s

Lowering speed with / without load0.40m/s

Aux. lift speed without load0.37m/s

Aux. lift speed with load0.32m/s

Aux. lift lower speed without load0.29m/s

Aux. lift lower speed with load0.31m/s

Reach speed w / w.o. load0.25m/s

Rotate without load15s/180°

Rotate with load15s/180°

Service brakeInversion / regenerative

Parking brakeElectric spring brake

Type of traction controllerAC drive control

RG:Rail guidance

WG:Wire guidance

FR:free ranging

B 7

B 8 ¸ïð ¸í ¸ç ¸é ¸ê ¸ïî ¸ïë ¸ï ¸ì ´ï ´î ³î ¦ § ¨ ¨ ¾ë ¾í ¾ïî ß¬ ¾ê ¾î ¾ï ¾é ´ ´ ê ¾ è ® ½ ³ï ¾ïì ¾ ç ´è ×ïð»

3.2Dimensions (as per data plate)

DescriptionEKX

DLoad

yWheelbase

/ counterweight (truck

B 9

ZThe data listed in the table (performance data, dimensions and weights) are based on a truck with a 400 ZT mast (*). The data (performance data, dimensions and weights) on the particular truck supplied can be found on the data plate. 410

600mm

c /

centre of gravity

distance 428mm

1,780mm

xLoad

drive wheel

geometry)255mm h1 Mast height retracted 3,100*) mm h3 Lift 4,000*) mm h4 Mast height extended 6,550*) mm h6 Overhead guard height 2,550mm h7 Seat height / standing height 395mm h9 Aux. lift 1,750mm h10 Overall lift (h3 + h9)5,750*) mm h12 Truck height raised 4,395mm h15 Picking height (h12+1,600) 5,995*) mm

aisle width for pallets 1200x1,200 traverse1,640mm b1/ b2 Overall width 1,210/1,450mm

Fork carriage width880mm

Width across forks (PAL width 1,200) 793mm b6 Width across guide wheels 1,620mm b7 Traverse, sideways 1,295mm

Traverse, to the side of truck centre490mm b9 Outer operator position width1,440mm b12 Pallet width 1,200mm b14 Swivel/traverse frame width1,440mm

zCentre

AstWorking

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