EKS 514 - 516 / EKX 410 - 516 Operating instructions 51710474 06.19 10.15 en-GB EKS 514 EKS 516k EKS 516 EKX 410 EKX 412 EKX 514 EKX 516k EKX 516 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
Cl) (!) I C: Q) 0) .,... (0 0
5
Contents A Correct Use and Application................................................................................ 13 1 General.................................................................................................................................... 13 2 Correct application 13 3 Approved application conditions.................................................................................. 14 4 Proprietor responsibilities................................................................................................ 16 5 Adding attachments and/or optional equipment.................................................. 16 B Truck Description.......................................................................................................... 17 1 Application.............................................................................................................................. 17 2 Travel direction definition................................................................................................ 20 3 Assemblies and Functional Description................................................................... 21 3.1 Functional Description...................................................................................................... 21 3.2 Assembly Overview........................................................................................................... 30 4 Technical Specifications................................................................................................... 32 4.1 Performance data 32 4.2 Dimensions (as per data plate).................................................................................... 42 4.3 Mast versions........................................................................................................................ 70 4.4 Weights.................................................................................................................................... 78 4.5 Wheels, chassis................................................................................................................... 82 4.6 Engine Data........................................................................................................................... 84 4.7 EN norms................................................................................................................................ 86 4.8 Conditions of use................................................................................................................ 88 4.9 Electrical Requirements................................................................................................... 89 5 Identification Points and Data Plates........................................................................ 90 5.1 Data plate................................................................................................................................ 94 5.2 Truck capacity plate........................................................................................................... 96 5.3 Capacity indicator on the driver's display................................................................ 98 5.4 Capacity reduction according to weight (operator, rider or loads) in the operator position.................................................................................................................. 100 5.5 "Medical and technical device operation affected by magnets" warning notice......................................................................................................................................... 102 5.6 Attachment capacity plate............................................................................................... 102 5.7 Jack contact points............................................................................................................. 102 5.8 Sign: "Load centre distance on EKS with walk-on platform"......................... 103 5.9 "Residual capacity" tilt safety device notice (0).................................................. 104 6 Stability 105 C Transport and Commissioning........................................................................... 107 1 Transport................................................................................................................................. 107 2 Lifting by crane..................................................................................................................... 108 2.1 Lifting by crane with mast assembled....................................................................... 109 2.2 Lifting the basic truck by crane..................................................................................... 111 2.3 Loading of the mast with operator position and load handler by crane.... 113 2.4 Lifting the battery by crane............................................................................................. 115 cc 3 (!) I 3.1 C (I) 3.2 O') ,Securing the truck during transport............................................................................ 117 Transport retainer for basic truck with the mast assembled.......................... 119 Basic truck transport retainer........................................................................................ 121 3.3 (0 0 Mast transport retainer..................................................................................................... 123 7
4 Using the Truck for the First Time ............................................................................... 125 4.1 Moving the industrial truck without a battery ......................................................... 125 4.2 Installing and removing the mast 125 4.3 Commissioning ..................................................................................................................... 127 4.4 Tilt safety device .................................................................................................................. 131 D Battery - Servicing, Recharging, Replacement.. ................................ .. 133 1 Safety Regulations Governing the Handling of Lead-Acid Batteries ........ . 133 1.1 General notes on handling batteries ......................................................................... 135 2 Battery types 136 2.1 Dimensions of the battery compartment.. ................................................................ 141 3 Exposing the battery 142 4 Charging the battery 146 5 Battery removal and installation. .................................................................................. 150 5.1 Removing and installing the battery with a battery roller stand (single part batteries) ........................................................................................................................ 150 5.2 Battery assembly/ removal using a fork lift truck (two part batteries) 154 E Operation ........................................................................................................................... 159 1 Safety Regulations for the Operation of Forklift Trucks .................................. . 159 2 Displays and Controls ....................................................................................................... 162 2.1 Controls and displays on the control panel 162 2.2 Driver's display ..................................................................................................................... 170 2.3 Symbols in driver's display (truck statuses and input requests) 172 2.4 Hourmeter 181 2.5 Truck guidance symbols in narrow aisle .................................................................. 182 2.6 "Bar display" battery discharge indicator 184 2.7 Driver's display function symbols 186 3 Preparing the Truck for Operation .............................................................................. 198 3.1 Checks and operations to be performed before starting daily operation. 198 3.2 Entry and exit ........................................................................................................................ 202 3.3 Driver's seat removal and assembly 204 3.4 Setting up the operator position 206 3.5 Safety harness with safety rope (0) 214 4 Industrial Truck Operation .............................................................................................. 233 4.1 Safety regulations for truck operation 233 4.2 Preparing the truck for operation 239 4.3 Switching off the truck. 239 4.4 Checks and operations to be carried out when the truck is operational .. 241 4.5 Setting the time .................................................................................................................... 243 4.6 Referencing the main and auxiliary lift ..................................................................... 245 4.7 Re-referencing the load handler (traverse/rotate) 247 4.8 Emergency Disconnect .................................................................................................... 249 4.9 Travel 251 4.10 Steering 255 4.11 Brakes....................................................................................................................................... 255 4.12 Negotiating narrow aisles 257 4.13 Diagonal travel 265 4.14 Lifting/ lowering - outside and inside narrow aisles 4.15 Traversing / rotating outside and inside narrow aisles 266 aJ 272 (!) I C 4.16 Parking the truck securely .............................................................................................. 284 CJ) O') 5 Order picking and stacking 288 ,(0 0 8
5.1 5.2 5.3 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 7 7.1 7.2 7.3 7.4 7.5 7.6 7.7 8 8.1 8.2 8.3 8.4 8.5 8.6 8.7 9 9.1 9.2 9.3 9.4 10 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 11 11.1 11.2 11.3 cc 11.4 (!) 11.5 I C (I) 11.6 O') ,- 11.7 (0 0 Adjusting the forks.............................................................................................................. 288 Replacing the forks............................................................................................................ 290 Lifting, transporting and depositing loads............................................................... 294 Troubleshooting................................................................................................................... 305 Troubleshooting................................................................................................................... 305 Emergency stop device.................................................................................................... 310 Load handler emergency lowering............................................................................. 310 Cut-offs..................................................................................................................................... 314 End of aisle safety device ( 0) 326 WG emergency operation (event messages 3670 / 3752)............................. 328 Recovering the truck from a narrow aisle / Moving the truck without a battery....................................................................................................................................... 329 Leaving the operator position with the rescue equipment.............................. 352 Rescue equipment storage compartment in the operator position............. 353 Rescue equipment testing I servicing....................................................................... 354 Seals and rescue equipment bags............................................................................. 355 Rescue equipment service life..................................................................................... 356 Rescue equipment storage and transportation.................................................... 357 Usage and ambient conditions 357 Description and use of the rescue equipment...................................................... 358 Personal safety system (0)........................................................................................... 374 Personal Protection System (PPS) ........................................................................... 37 4 Functional description....................................................................................................... 375 Environmental awareness.............................................................................................. 376 Cleaning the laser scanner front screen.................................................................. 377 Displays on the seven segment display and indicator light (LED).............. 378 Daily checks before starting the Personal Protection System...................... 380 Personal safety system.................................................................................................... 381 Collision protection with the Personal Protection System (0)...................... 384 Description of collision protection with the Personal Protection System. 386 Positions and Number of Items of Reflectors on Truck.................................... 387 Additional Checks and Operations to be performed before starting Daily Operation.................................................................................................................... 388 Description of various operational situations......................................................... 390 Order picker - EKS ............................................................................................................. 396 Truck with load guard and walk-on pallet (0)....................................................... 396 Truck equipment - stockpicking platform without pallet lift option............... 398 Stockpicking platform with pallet lift option (not monitored, not locked).. 400 Stockpicking platform with pallet lift option including pallet monitoring and fixing................................................................................................................................. 404 Displays the side or front gates of the picking platform................................... 406 Additional symbols in driver's display....................................................................... 407 Lifting / depositing a load with a load lock (with / without load sensing).. 408 Auxiliary Lift raise/lower (0).......................................................................................... 417 Optional equipment............................................................................................................ 419 Keyless Access System................................................................................................... 419 General Information about the Use of Keyless Access Systems................ 419 Keyless access system - commissioning the keypad and the transponder reader............................................................................................................. 420 Keyless access system - display unit 423 Keyless access system - keypad................................................................................ 428 Keyless access system - transponder reader....................................................... 433 ISM access module (0)................................................................................................... 438 9
11.8 Telescopic table (0) 439 11.9 Sideshifter / Fork positioner (0) 455 11.10 Telescopic forks (0) .......................................................................................................... 463 11.11 Weighing system (0) ........................................................................................................ 467 11.12 Rack Height Select (0) .................................................................................................... 469 11.13 Horizontal positioning (0) 485 11.14 Fire extinguisher (0) 505 11.15 Rider mode in the operator position (0) .................................................................. 506 11.16 Working platform ( 0) ........................................................................................................ 509 11.17 Closed driver's cab (0) .................................................................................................... 521 11.18 On-board charger (0) ....................................................................................................... 530 11.19 Rear view mirror (0) 549 11.20 Panoramic Mirror (0) 551 11.21 Floorspot (0) 553 11.22 Emergency console (0) .................................................................................................. 559 11.23 Camera system (0) ........................................................................................................... 569 11.24 Heater (0) .............................................................................................................................. 571 11.25 Sideshift Plus (0) 575 11.26 Floor Pro (0) 577 F Industrial Truck Maintenance .............................................................................. 579 1 Spare Parts ............................................................................................................................ 579 2 Operational Safety and Environmental Protection 580 3 Maintenance Safety Regulations 582 3.1 Working on the electrical system 583 3.2 Consumables and used parts 583 3.3 Hydraulic system ................................................................................................................. 584 3.4 Lift chain inspection 586 3.5 Attachment Repairs and Inspection 587 4 Lubricants and Lubrication Schedule ........................................................................ 588 4.1 Handling consumables safely 588 4.2 Lubrication Schedule 590 4.3 Consumables ........................................................................................................................ 591 5 Maintenance and repairs 592 5.1 Preparing the truck for maintenance and repairs .............................................. .. 592 5.2 Drive compartment cover disassembly/assembly 594 5.3 Wheels 598 5.4 Fuses ........................................................................................................................................ 600 5.5 Check hydraulic oil, top up 614 5.6 Lifting and jacking up the truck safely 620 5.7 Preventing the operator position from accidentally lowering 621 5.8 Cleaning 630 5.9 Lubricate the lift chains, clean and grease the contact surfaces in the mast sections ........................................................................................................................ 634 5.1 0 Lift chain servicing 636 5.11 Restoring the truck to service after maintenance and repairs 638 6 Decommissioning the Industrial Truck 639 6.1 Prior to decommissioning 639 aJ 6.2 During decommissioning ................................................................................................. 640 (!) I 6.3 Restoring the truck to service after decommissioning 7 Safety tests to be performed at intervals and after unusual incidents .... .. 640 C CJ) 641 O') ,(0 0 10
cc (!) I C (I) O') ,(0 0 8 Final de-commissioning, disposal............................................................................... 642 9 Human vibration measurement.................................................................................... 642 G Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement............................................................................ 643 1 Maintenance Contents EKX 514-516 & EKS 514-516..................................... 644 1.1 Owner....................................................................................................................................... 644 1.2 Customer Service............................................................................................................... 649 2 Maintenance Contents EKX 410-412........................................................................ 663 2.1 Owner....................................................................................................................................... 663 2.2 Customer Service............................................................................................................... 668 11
• 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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