Declaration of Conformity
Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg Manufacturer or authorized representative in the Community
Type OptionSerial No.Year of Construction
EKS 513
EKS 515k
EKS 515
EKX 513
EKS 515k
EKS 515
Additional information
Authorised signatory
Date
G EU Declaration of Conformity
1
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.
M
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.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
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 3 2.1Truck functional description ..................B 6 3Standard version specifications .............. ...........B 10 3.1Performance data ............... .........B 11 3.2Dimensions (as per data plate) ...........................................................B 12 3.3Mast version ......... .........B 16 3.4Engine data .............. .........B 18 3.5 Weights ...............................................................................................B 18 3.6Wheels, chassis ....... .........B 21 3.7EN norms ............................................................................................B 22 3.8Conditions of use .......... .........B 23 3.9 Electrical requirements .... .........B 23 4Identification points and data plates ....................................................B 24 4.1Truck data plate ....... .........B 26 4.2Truck capacity plate ........ .........B 27 4.3Attachment capacity plate (o) ................ ...........B 28 5Stability .......... .........B 28 CTransport and Commissioning 1Transport ................ ...........C 1 2Lifting by Crane ............... .........C 2 2.1 Lifting by crane with mast assembled ......... .........C 2 2.2 Crane points / Strap 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 3.3Transport retaining mechanism for trucks with the mast assembled ..................................................................................C 10
Table of contents
I 2 4Using the Truck for the First Time .......................................................C 11 4.1 Moving the industrial truck without a battery .......................................C 11 4.2 Installing and removing the mast ........................................................C 11 5Starting the Truck ................................................................................C 12 5.1Mechanical tilt safety devices (t) .......................................................C 13 5.2Active stabiliser (o) ................ ...........C 14 DBattery - Servicing, Recharging, Replacement 1Safety Regulations Governing the Handling of Lead-Acid Batteries .............. .......D 1 2Battery types ................. .........D 2 2.1Battery compartment dimensions ......... ..................D 3 3Exposing the battery .......... .........D 4 4Charging the Battery ............ .......D 6 5Battery Removal and Installation ............ ...........D 10 5.1Installing and removing a battery with a battery trolley (t) .................D 11 5.2Placing/removing batteries in the battery replacement trolley using a forklift (o) ...............................................................................D 14 5.3Battery lock sensor (t) ................. .........D 18 6On-Board Charger (o) ........................................................................D 19 6.1 Description ........... .........D 19 6.2Different current collectors ..................................................................D 20 6.3Operating modes .................................................................................D 21 6.4Different Operating Modes .. ..................D 22 6.5Symbols and meaning .........................................................................D 24 6.6On board charger maintenance instructions ............. .........D 25 Condition and Acid Level .....................................D 26 8Battery Discharge Indicator "Bar Display" (t) ...................................D 27 8.1Battery discharge monitor with bar display ............. ...........D 28 8.2Battery symbol fluorescent colours .....................................................D 29 9Battery Discharge Indicator "Percentage Display" (o) .......................D 30 9.1 Battery symbol fluorescent colours .....................................................D 30 EOperation 1Safety Regulations for the Operation of Forklift Trucks ......................E 1 2Controls and Displays .......... .......E 3 2.1 Operating and display equipment on control panel ... .........E 3 2.2Display unit controls and displays ........... ...........E 10 2.3Lower range symbols and pushbuttons ........... .......E 16 2.4Truck operational status symbols ................ .........E 22
I 3 3Starting up the truck ............................................................................E 23 3.1 Checks and operations to be performed before starting daily operation ........ ...........E 23 3.2Truck entry and exit ......... .........E 24 .......E 25 3.4 Setting up the operator position .............. ...........E 25 .........E 26 3.6Control panel angle adjustment ...........E 27 3.7Control panel height ad justment ............. ...........E 28 3.8 To prepare the truck for operation (t) ............... ..................E 28 3.9Preparing the truck for operation with an additional access code (o) ..................................................................................E 29 3.10ISM Access Module (o) ......................................................................E 30 3.11 Checks and operations to be carried out when the truck is operational ................... .........E 30 3.12Referencing the main and auxiliary lift ................................................E 32 3.13Setting date and time ...... .........E 35 3.14Operator specific settings (o) ................. ...........E 37 4Industrial Truck Operation .. .........E 40 4.1 Safety regulations for truck operation ......... E 40 4.2Emergency Disconnect, Travel, Steering, Braking ..............................E 44 4.3Negotiating narrow aisles ... .........E 50 4.4Diagonal travel ....... ...........E 57 the rack aisles ........ ...........E 58 4.6 Simultaneous load handler traverse and fork carriage swivel .............E 61 4.7Telescopic table (o) ............... ...........E 64 4.8Symmetrical sideshifter (o) ............... .......E 71 4.9 Fork adjuster (o) ................ .........E 71 4.10Telescopic forks (o) ............... ...........E 72 4.11Symmetrical sideshift with integrated fork adjuster (o) ......................E 74 4.12Asymmetrical sideshifter with integrated fork adjuster (o) .................E 75 4.13 Lifting - Lowering - Traversing - Pivoting inside the rack aisles ..........E 76 4.14Order picking and stacking ................... ..................E 77 4.15Lifting, transporting and depositing loads .............. ..................E 81 4.16Rack Height Select with Zone Entry (o) ............... ..................E 86 4.17Horizontal positioning ( o) ................ .........E 93 4.18Parking the truck securely .........E 107
I 4 5Troubleshooting ..................................................................................E 108 5.1Emergency stop device .......................................................................E 111 ring ........................................E 112 5.3Slack chain safety device override ......................................................E 114 5.4Travel cutout override (o) ...................................................................E 115 5.5Lift cutout override (o) .............. .........E 116 5.6Lower cutout override (o) ...................................................................E 117 5.7Aisle end safety device (o) .................................................................E 118 5.8 ..........E 119 5.9Recovering the truck from a narrow aisle /Moving the truck without a battery ....... .........E 121 6Exiting the driver's cab with the rescue equipment .............................E 131 6.1Rescue equipment storage compartment in the driver's cab ..............E 132 6.2 Rescue equipment testing / servicing ..... ...........E 132 6.3Rescue equipment service life ...........E 133 6.4 Rescue equipment storage and transportation ......... .........E 133 6.5Rescue equipment description / application (- 07.09) .. .........E 134 6.6Rescue equipment description / application (07.09 -) .........................E 149 7Personal Protection System (o) ............. ...........E 165 7.1 Personal Protection System (PPS) ................ .........E 165 7.2 Functional description ........ .........E 165 7.3Cleaning the front panel of the scanners ................ ...........E 167 7.4Daily checks before starting the Personal Protection System .............E 169 7.5Personal Protection System ..................E 170 8EKS 513/515k/515 Stockpicker ............ ..................E 172 8.1 Control panel layout ........ .........E 172 8.2EKS 513/515k/515 with load guard and walk-on pallet (o) ................E 175 8.3Display of stockpicking platform side and / or front gates and load direction gates ......................................................................E 183 8.4Additional symbols in driver's display ..................................................E 185 8.5 Lifting / depositing a load ....................................................................E 185 8.6EKS 513/515k/515 with auxiliary lift (o) .............................................E 193 9Optional equipment .............. .......E 194 9.1 Rear view mirror (o) ...........................................................................E 194 9.2Rider mode (in the driver's cab) (o) ...................................................E 195 9.3Weigher (o) ............. .........E 197 9.4Using a work platform (o) ...................................................................E 198 9.5Fire extinguisher (o) ...........................................................................E 204 9.6Closed driver's cab (o) .......................................................................E 205 9.7Camera system (o) ............................................................................E 213
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
Z
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. The EKS is an electric stockpicker. They are 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 longdistances.
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 / EKS. The safety distances stipulated by Jungheinrich (e.g. EN 1726-2 item 7.3.2) must be observed.
mum safety distance of 100 mm must be maintained between the rack and the truck.
e between the rack and the truck must be no less than 125 mm. 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.
B 1
TypeCapacityLoad centre of gravity EKX 513 / EKS 5131,250 kg600 mm EKX 515k / EKS 515k1,500 kg600 mm EKX 515 / EKS 5151,500 kg600 mm
1.1Travel direction definition
The following determinations have been made for travel direction specification:
EKX 513/515k/515
EKS 513 / 515k / 515
B 2
Drive direction Load direction Right Left Drive direction Load direction Right
Left
B 3 2Assemblies and Functional Description 1 2 3 4 5 6 7 12 16 17 22 23 24 19 20 18 15 11 9,10 8 21 13 14
B 4 1 2 3 4 5 6 7 12 16 17 22 23 24 19 20 18 15 11 9,10 8 21 13 14
B 5
Item Description 1 t Mast 2 t Overhead guard 3 t Auxiliary Lift1) 4 t Control panel 5 t Gates 6 t Lifting driver's cab 7 t Fork 8 t Deadman button 9 o Front sensor for wire guidance system (not shown) 10 o Front scanner for personal safety system (not shown) 11 o Rail guidance rollers in front of the load wheel 12 t Load wheel 13 t Chassis 14 o Rail guidance wheels behind the load wheel 15 t Side panel 16 o Rail guidance wheels on the drive compartment 17 t Tilt safety device o Active stabilisers 18 t Drive wheel 19 o Rear sensor for wire guidance system 20 o Personal protection system rear scanner 21 o Battery cover 22 o Mast braces 23 o Automatic chain lubrication on the free lift cylinders (DZ mast only) 24 o Automatic chain lubrication on the the top mast cross member (ZT / DZ masts)
= Standard equipment o = Optional equipment
1) not applicable on the EKS 513 / 515k / 515
t
2.1Truck functional description
Safety mechanisms:
with rounded edges ensures safe handling of the truck. The overhead guard protects the driver from falling objects.
he load wheels are protected by a solid skirt. A slight danger remains for third parties, even when a drive wheel cover is used.
disconnects all truck movement in hazardous situations.
all truck operations as soon as they are opened.
wering can only be activated when the deadman button ispressed. activated when the deadman button is pressed (EKX only).
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 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 (preventsthe truck from rolling away).
o =
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 ahalt the parking brake applies (prevents the truck from rolling away).
Emergency Stop safety feature
truck automatically brakes to a halt. Control indicators ndicate 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 6
Drive:
vy-duty and maintenance-free threephase motor with no wear parts. The motor is directly attached to the single-wheel driving gear, ensuringrapid and trouble-free maintenance.
Brake system:
nd wear-free electromagnetic multiplate brake acting on the load wheels.
and wear-free by pulling back the travel control button or by changing direction. This feeds energy into the battery (servicebrake).
e acting on the drive motor serves as aparking and handbrake.
acting on the front axle (electro-magneticspring pressure brake) is only activated when the Emergency Disconnect switch is pressed or if the truck is set to emergency stop.
Steering:
with threephase drive system (sturdy and maintenancefree threephase motor with no wear parts).
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 7
Controls and displays:
operation without stressing the wrists; sensitive application of travel and hydraulic movements to spare and position the goods exactly.
lift raise / lower,...) and menus. colour display for all important driver information such as steering wheel position, overall lift, truck status reports (e.g.faults), service hours, battery capacity, time and wire 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.
Ergonomics and Comfort
with extremely low swivel/traverse guides and clearview masts.
folding comfort seat.
Hydraulic system:
a sturdy, maintenance-free AC motor with no wear parts and with a 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.
B 8
• 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
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
