Jungheinrich Forklift EKX 410/513/515k/515 Operating instructions Manual 52017697

EKX 410/513/515k/515

11.03 -

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Operating instructions 52017697 07.08

EKX 410

EKX 513 - 515

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

M Z

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

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

Table of Contents A

Correct use and application of the truck

B

Truck Description

1 2 2.1 3 3.1 3.2 3.3 3.5 3.6 4 4.1 4.2

Application ........................................................................................... B 1 Assemblies and Operational Description ............................................ B 2 Truck ................................................................................................... B 3 Standard Version Specifications ......................................................... B 4 Performance data ................................................................................ B 4 Dimensions (as per data plate) ........................................................... B 6 EKX 410 mast version ......................................................................... B 7 on ............................................................... B 7 EN norms ............................................................................................ B 8 Conditions of use ................................................................................ B 8 Identification points and data plates .................................................... B 9 Truck data plate .................................................................................. B 11 Capacity .............................................................................................. B 11

C

Transport and Commissioning

1 2 2.1 2.2 3 3.1 3.2 3.3 3.4 4 4.1 4.2 5

Transport ............................................................................................. C 1 Lifting by crane .................................................................................... C 1 Crane points ........................................................................................ C 2 Lifting the battery by crane .................................................................. C 2 Securing the Truck for Transport. ....................................................... C 2 Basic truck transport safety ................................................................. C 3 Mast transport safety ........................................................................... C 4 Mast assembled .................................................................................. C 5 Transport retaining device: truck with folded mast (EKX 513 - 515) ... C 5 Commissioning .................................................................................... C 6 Moving the truck without a battery ...................................................... C 6 Installing and removing the mast ........................................................ C 6 Commissioning .................................................................................... C 7

D

Battery Maintenance, Charging & Replacement

1 2 3 4

Safety Regulations for handling acid batteries .................................... D 1 Battery types ....................................................................................... D 2 Charging the battery ............................................................................ D 2 Battery removal and installation .......................................................... D 3 and acid level ........................................ D 6 Battery discharge indicator .................................................................. D 6

6

I1

E

Operation

1 2 2.1 2.2 2.3 2.4 3 4 4.1 4.2

Safety Regulations for the Operation of Forklift Trucks ...................... E 1 Operating and Display Equipment ...................................................... E 2 Operating and display equipment on control panel ............................. E 2 Display unit controls and displays ....................................................... E 4 Lower range symbols and keys ........................................................... E 6 Truck operational status symbols ........................................................ E 10 Starting up the truck ............................................................................ E 11 Lift truck operation ............................................................................... E 13 Safety regulations for truck operation ................................................. E 13 Travelling, Steering, Braking ............................................................... E 14 ersing outside the rack aisles ... E 19 ersing inside the rack aisles ..... E 22 Order picking and stacking .................................................................. E 22 Park the truck securely ........................................................................ E 25 Troubleshooting .................................................................................. E 26 Emergency stop device ....................................................................... E 28 emergency lowering ........................................ E 28 Exiting the driver's cab with the emergency abseil device .................. E 29 Bypassing the chain slack safety device ............................................. E 30 Bypassing the travel cutout (o) .......................................................... E 30 Lift cutout (o) ...................................................................................... E 30 Aisle end safety device (o) ................................................................. E 31 WG emergency operation ................................................................... E 31 Recovering the truck from a narrow aisle / Moving the truck without a battery ......................................................................... E 33

4.5 4.6 5 5.1 5.3 5.4 5.5 5.6 5.7 5.8 5.9

I2

F

Maintenance of the forklift truck

1 2 3 4 4.1 4.2 5 5.1

Operational safety and environmental protection ................................ F 1 Maintenance Safety Regulations ........................................................ F 1 Servicing and inspection ..................................................................... F 3 EKX maintenance checklist ................................................................. F 4 Lubrication Schedule ........................................................................... F 7 Fuels, coolants and lubricants ............................................................. F 9 Maintenance and Repairs ................................................................... F 11 Preparing the truck for maintenance and repairs ................................ F 11 tion carriage ................................................ F 12 5.3 Maintaining the lift chains .................................................................... F 12 5.4 Inspecting the lift chains ...................................................................... F 12 5.5 Hydraulic oil ......................................................................................... F 13 5.6 Hydraulic hoses ................................................................................... F 14 5.7 Checking the brake fluid (EKX 513 - 515) ........................................... F 14 5.8 Checking electrical fuses (EKX 410) ................................................... F 15 5.9 Checking electrical fuses (EKX 513 - 515) .......................................... F 16 5.10 Recommissioning ................................................................................ F 17 6 Decommissioning the forklift truck ...................................................... F 17 6.1 Prior to decommissioning: ................................................................... F 17 6.2 During decommissioning: .................................................................... F 18 6.3 Recommissioning ................................................................................ F 18 7 Safety checks to be performed at regular intervals and following any unusual incidents .......................................................................... F 19 8 Final de-commissioning, disposal ....................................................... F 19

I3

A Correct use and application of the truck Z

supplied with the truck. The guidelines form part of these operating instructions and must be observed. National regulations apply in full.

The truck described in the present operator manual is an industrial truck designed for lifting 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. In particular, avoid overloading the truck with loads which are too heavy or placed on one side. The data plate attached to the truck or the load diagram are binding for the maximum load capacity. The industrial truck must not be used in fire or explosion endangered areas or in places which can result in corrosion or produce dust.

Proprietor responsibilities: the meaning of this operator manual is defined as 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 the owner 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 truck users have read and understood this operator manual.

M

Failure to comply with the operator manual shall invalidate the warranty. The same applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufact service department.

Mounting attachments: The mounting or installation of additional equipment which affects or supplements the performance of the industrial truck requires the written permission of the manufacturer. In some cases, local authority approval shall be required.

Approval of the local authorities however does not cons approval.

A1

B Truck Description 1

Application The EKX is an electric three-way stockpicker. It is designed to be used on level surfaces in accordance with DIN 15185 to transport and pick goods. Open or cross board pallets can be lifted outside the contour of the load wheels or trolley.

Loads can be stacked and unstacked and transported over long distances.

The driver's cab is raised together with the load lifting device to provide excellent visibility and easy access to the rack levels.

The racks must be suitable for the EKX. The safety distances stipulated by the manufacturer (e. g. EN 1726-2 item 7.3.2) must be observed. The ground surface must comply with DIN 15185. Guide rails must be installed in the narrow aisles for the rail guidance system.

Vulkollan guide rollers attached to the truck chassis guide the truck between the guide rails.

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

The capacity is shown on the data plate.

Type EKX 410 EKX 513 EKX 515k/515

Capacity 1000 kg 1250 kg 1500 kg

Load centre of gravity 600 mm 600 mm 600 mm

Travel direction definition The following determinations have been made for travel direction specification.

Left

Load direction

Drive direction

Right

B1

2

Assemblies and Operational Description

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EKX 513 / 515k / 515 ï

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î

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EKX 410

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Item 1 2 3 4 5

Description t t t

Mast Aux. lift Control panel

t t

Chassis

t = Series Equipment

B2

o = Optional Equipment

2.1

Truck Safety devices: An enclosed truck contour with rounded edges ensures safe handling of the truck. The overhead guard protects the driver from falling objects.

The Emergency Disconnect switch immediately cuts out all truck movements in hazardous situations. Safety gates on either side of the cab interrupt all truck movements as soon as they are opened.

Travelling, lifting/lowering and reach/traversing can only be activated when the foot switch is pressed.

Drive: Vertically mounted, heavy duty AC motor (asynchronous). The motor is directly attached to the single-wheel driving gear, ensuring rapid and trouble-free maintenance.

Brake system: t inducing wear by pushing back the travel selection switch or steering in the opposite direction. This feeds energy into the battery (operating brake). pressure brake acting on the drive motor serves as a parking and handbrake.

Depending on the lift height, the load wheel brake acting on the front axle (hydraulic brake) is only activated when the EMERGENCY DISCONNECT switch is pressed or if the truck is set to EMERGENCY STOP. Steering: Especially smooth steering with threephase drive system. The practical steering wheel 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.

With the mechanical rail guidance system the drive wheel is set to the forward position at the press of a button.

In wire guidance mode, steering is automatically assumed by the truck controller when it detects the guidance wire, and manual steering is deactivated.

Controls and display units: The functions are activated via ergonomic thumb movements to ensure fatigue-free operation without straining the wrists; sensitive application of travel and hydraulic movements to spare and position the goods exactly.

Integrated information display unit 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.

B3

Hydraulic system: All hydraulic movements are controlled by a maintenance-free AC motor with a flanged low emission gear pump. Oil is distributed via magnetic switch valves. The varying oil requirements are controlled by the speed of the motor. When the truck performs a lowering operation, 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: Service laptop connection interface: damping, lift cutout, retardation and acceleration patterns, reach speeds, cut-outs etc.) rapidly and reliably. analyse fault causes. program operations. by releasing code numbers.

The controller is fitted with a CAN Bus and a constantly measuring sensor system.

The controller provide smooth starting and braking of the load in all limit positions through lift limit and intermediate dampers.

Highly efficient threephase technology with energy retention for the traction and lift motors provides high travel and lift speeds and better use of energy.

The MOSFET threephase controller provides smooth starting for all movements.

For drive battery options see chapter D. 3

Standard Version Specifications

Z

Technical data specified in accordance with VDI 2198.

Technical modifications and additions reserved.

3.1

Performance data Description Q Capacity (where C = 600 mm) c Load centre of gravity distance Travel speed without load (RG) Travel speed with load (RG) Travel speed without load (IG) Travel speed with load (IG) Lift speed without load Lift speed with load Lowering speed w / w.o. load Reach speed w / w.o. load

B4

EKX 410 1000 600 9 9 7 7 0,40 0,36 0,40 0,25

EKX 513

EKX 515k/515

1250 600 10,5 10,5 9 9 0,45 0,40 0,40 0,2

1500 600 10,5 10,5 9 9 0,47 0,42 0,40 0,2

kg mm km/h km/h km/h km/h m/s m/s m/s m/s

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B5

3.2

Dimensions (as per data plate) Description h1 h3

Mast height retracted Lift

EKX 410 31001) 40001)

h4

Mast height extended

65501)

60502)

60502)

75503)

mm

h7 h9

Seat height / standing height Aux. lift

395 1750

470 1750

470 1750

470 1750

mm mm

h10 Overall lift h12 Stockpicking height Ast Working aisle width for pallets 1000 x 1200 traverse b2 Overall width

57501) 59951)

52502) 55702)

52502) 55702)

67503) 70703)

1640

1640

1640

1640

mm mm mm

1440

1450

1500

1500

793

535

535

535

1620

1540

1540

1540

3577

3340

3440

3736

3273

3200

3300

3596

1200 2035

1200 2101

1200 2201

1200 2497

80

85

85

85

5218

6499

6926

8083

b5

Width across forks (PAL width 1200) b6 Width across guide rollers L1 Overall length w.o. load (PAL width 1200) L2 Length incl. fork back (PAL width 1200) l Fork length Wa Turning radius m2 Ground clearance centre wheelbase Net weight incl. battery, w.o. load

EKX 513 29552) 35002)

EKX 515k 29552) 35002)

EKX 515 37053) 50003)

mm mm

1) ZT mast performance data measured for 400 ZT. 2) ZT mast performance data measured for 350 ZT. 3)

B6

ZT mast performance data measured for 500 ZT.

mm mm mm mm mm mm mm mm kg

3.3

EKX 410 mast version Description Retracted height (ZT)

EKX 410 2550 - 4100 mm

h3 Lift h4 Extended height h6 Height above overhead guard h9 Aux. lift

2500 - 6000 mm 5050 - 8550 mm 2550 mm

h10 Overall lift height h15 Stockpicking height

4250 - 7750 mm 4495 - 7995 mm

Bezeichnung h1 Retracted height (ZT) h1 Retracted height (DZ) h3 Lift (ZT)

EKX 513 2705 - 5055 2595 - 3895 3000 - 7500

h1

1750

mm

EKX 515k EKX 515 2705 - 6155 2705 - 6405 mm 2595 - 4695 2595 - 5795 mm 3000 - 9500 3000 - 10000 mm

h3 Lift (DZ) 4250 - 7500 4250 - 9500 4250 - 12500 h4 Extended height (ZT) 5550 - 10050 5550 - 12050 5550 - 12550 h4 Extended height (DZ) 6800 - 10050 6800 - 12050 6800 - 15050 h6 Height above overhead guard 2550 2550 2550 h9 Aux. lift 1750 1750 1750 h10 Overall lift height (ZT) 4750 - 9250 4750 - 11250 4750 - 11750 h10 Overall lift height (DZ) 6000 - 9250 6000 - 11250 6000 - 14250 h15 Picking height (ZT) 5070 - 9570 5070 - 11570 5070 - 12070 h15 Picking height (DZ) 6320 - 9570 6320 - 11570 6320 - 14570

mm mm mm mm mm mm mm mm mm

B7

3.5

EN norms

Noise emission:

EKX 410

EKX 513 - 515

61 dB(A)

68 dB(A)

in accordance with EN 12053 as harmonised with ISO 4871.

Z

Z

The noise emission level is calculated in accordance with standard procedures and takes into account the noise level when travelling, lifting and when idle. The noise EKX 410

EKX 513 - 515

Vibration:

0.79 m/s2 in accordance with EN 13059

0.79 m/s2 in accordance with EN 13059

Seat vibration:

0.56 m/s2

0,64 m/s2

The vibration acceleration acting on the body in the operating position is, in accordance with standard procedures, the linearly integrated, weighted acceleration in the vertical direction. It is calculated during travel over bumps at constant speed.

Electromagnetic compatibility (EMC) The manufacturer confirms that equipment complies with tolerance levels for electromagnetic emissions and resistance as well as static electricity discharge testing in accordance with EN 12895 including the normative procedures contained therein.

Z

No changes to electrical or electronic components or their assembly may be made without the written agreement of the manufacturer.

3.6

Conditions of use Ambient temperature operating at 5pC to 40 pC

Z

Special equipment and authorisation are required if the truck is to be constantly used in conditions of extreme temperature or air humidity fluctuations.

The truck is not authorised for use in cold stores.

The truck may only be used in closed areas. The following applies: e over 24 hours: max. 25 °C ty (inside) 70%, non-condensing.

B8

4

Identification points and data plates

and information labels, such as capacity diagrams, attachment points and F Warning identification plates, must be readable at all times or be replaced, if necessary.

EKX 410

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Item 6 7 8

Description Strapping points for lifting by crane Truck data plate Decal: Capacity

11 12 13 14

Test sticker (o) Decal: Do not step onto or beneath the load, risk of trapping Jack contact point Serial number (engraved in chassis underneath the battery cover)

B9

EKX 513 - 515

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Ï øµ¹÷

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ïôë Ê

B 10

Item 6 7 8

Description Strap points for crane lifting Truck data plate Capacity plate

11 12 13 14

Test sticker (o) Decal: Do not step onto or beneath the load, risk of trapping Jack contact points Serial number (engraved in chassis underneath the battery cover)

4.1

Truck data plate 20

31

21

30

22

29

23

28

24

27

26 25

Item Description

Item Description

20 21 22 23 24

26 27 28 29 30

Type Serial no.

Rated capacity (kg) Battery voltage (V) Net weight w.o. battery (kg)

Manufacturer Min./Max. battery weight (kg) Drive output (kw) Load centre of gravity (mm) Year of manufacture

For queries regarding the truck or spare part orders, please quote the serial number (21).

4.2

Capacity The plate (8) gives the capacity (Q in kg) of the truck as a function of the load centre of gravity distance (D in mm) and lift height (H in mm) in tabular form.

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B 11

C Transport and Commissioning 1

Transport The truck can be transported in two different ways, depending on the height of the mast and the local conditions. and load lifting device assembled (for low heights) load lifting device disassembled (for large heights) al, with the mast folded.

M

Only personnel trained by the manufacturer may assemble the truck on site, commission it and instruct the driver.

2

Lifting by crane

M

Only use lifting gear with sufficient capacity (for truck weight see truck data plate. See Chapter B).

M

The truck must only be lifted by crane with the battery removed.

(See Chapter E).

M

Attach the crane slings to the strap points (1-3) so that the truck cannot slip.

ï ï

EKX 410

î

î í

ê

ë

ì

é í

è

EKX 513 - 515

C1

2.1

Crane points EKX 410: The crane points (1) are the eyes in the mast.

To access the crane points (2), remove the battery panels (4) and the drive panel (8).

The side panels (6) must also be removed. The side panels (6) must also be removed. To do this, remove the 2 screws at the top (5) and on the inside (7).

The crane points (3) are the mast's lower strap points connecting it to the chassis.

EKX 513 - 515: The crane points (1) are the eyes in the mast.

The crane points (2) are the eyes on the drive compartment.

The crane points (3) are the mast's lower strap points connecting it to the chassis.

When lifting by crane, use the following crane points: points (1) and (2) (for weight see data plate) Items (2) and (3) (weight 2000 kg (EKX 410), 3000 kg (EKX 513-515) ab and load handler: Items (1) and (3) (weight 2,600 kg (EKX 410), 6,500 kg (EKX 513-515)

2.2

Lifting the battery by crane When lifting the battery with a crane attach suitable lifting gear to the four eyes of the battery container (for weight see battery data plate).

For battery removal see Chapter D, Section 4.

3

Securing the Truck for Transport.

transported on a lorry or a trailer the truck must be securely fastened down.

F When The lorry or trailer must have fastening rings.

M

C2

Loading shall be carried out by staff especially trained for that purpose in accordance with recommendations contained in Guidelines VDI 2700 and VDI 2703. In each case correct measurements shall be determined and appropriate safety measures adopted.

3.1

Basic truck transport safety

M

The mast must only be disassembled by department.

thorised service

To ensure secure transport of a disassembled EKX, use the prescribed attachment points for fastening/quick release belts.

Z M M

With the EKX 410 only use straps with a rated capacity of > 5 tonnes and with the EKX 513-515 only straps with a rated capacity of > 9 tonnes.

When transporting, always relieve the drive wheel by placing the entire surface of a wooden beam (11) underneath the counterweight (minimum chassis width). In addition, secure the load wheels with a wedge (13).

If the truck battery is supplied in the chassis, disconnect the battery.

Fastening belts should be attached to at least 4 different lorry eyes (12).

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ïð

ïí

ïï ïî otected by a suitable support material,

e. g. foam.

The top holes of the counterweight attachment (10) can be used as attachment points for the rear end of the truck chassis.

The tensioning belts should be tightened over both outriggers at the front end of the truck chassis.

M

Note the cable routing and cover sharp edges with a suitable material.

The tensioning belt above the upper chassis section is routed behind the two mast attachment bars (9).

To do this remove the side panels and open the battery panel. After tensioning the belt, fit the side panels back again and close the battery panel.

C3

3.2

Mast transport safety

M

Use a transport retaining device (20) to prevent the operator compartment carriage (21) from sliding.

M

Secure the fork carriage (14) to prevent it from slipping.

If the mast is stored on a pallet(s), fasten them securely to the mast (18).

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ïë

îð

ïé

ïç

ïé

ïè

ïé

Use the attachment latch (19) as the "mast bottom" strap point for securing to the lorry eyes(17).

Route the belt over the lift cylinder/chains to act

M

Protect the belt placed over the lift chains with a suitable material (15).

Any supplied parts (forks (16), guide rollers etc.) can be attached to a pallet, which can then be fastened to the mast.

C4

3.3

Mast assembled Safely transporting the truck with the mast assembled

M M

Z

If the truck battery is supplied in the chassis, disconnect the battery îî îí

When transporting, always relieve the drive wheel by placing the entire surface of a wooden beam (25) underneath the counterweight (minimum chassis width). In addition, secure the load wheels with a wedge (26).

îì

Only use belts with a rated capacity of EKX 410 EKX 513 - 515

> 5 tonnes > 9 tonnes

At least 4 belts, 2 on the left and 2 on the right (23, 24) must be attached to the mast.

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îê

Ensure a positive fit from the LAM to the front of the transporter using wooden planks, a pallet or a rubber mat (22).

3.4

Transport retaining device: truck with folded mast (EKX 513 - 515)

M

chassis, disconnect the battery.

Z

Only use belts with a rated capacity of > 9 tonnes.

The fastening belts (27) should be attached to at least 4 different lorry / truck eyes.

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îç îè

Risk of tipover through high F Attention centre of gravity.

The tensioning belts are tensioned on the mast.

Using wooden beams (29), make sure the system is a positive fit from the load wheels to the front of the transporter.

Z

Place the entire surface area of a wooden beam (28) underneath the counterweight, the chassis width as minimum, to discharge the drive wheel.

C5

4

Commissioning

4.1

Moving the truck without a battery

M M

This operation must only be performed by suitably trained maintenance personnel.

This operation is forbidden on slopes and inclines (no brakes).

See also Chapter E, Section 5.9

4.2

Installing and removing the mast

M

This operation must only be performed by the manufacturer or a customer service team authorised by the manufacturer.

M

There is an additional risk of trapping when reaching and traversing in the traverse/ reach section of the attachment.

C6

5

Commissioning

M

Operate the truck only with battery current. Rectified AC current will damage the electronic components. The battery leads (tow cable) must be less than 6m in length.

To prepare the truck after delivery or after transport, proceed as follows: harge the battery (see Chapter D, Sections 4 and 3). ions (See Chapter E, Section 3).

Z

With the EKX 410/513/515k/515 a tipover retaining device (31) is fitted, depending on the tipover test. When a tipover retaining device is used, an X (30) is engraved on the truck chassis on the right hand side of the battery compartment, after the serial number.

M

Before commissioning, check the trucks to ensure the tilt safety devices (31) are present.

M

Check that all safety devices are present and operational.

30

31

C7

D Battery Maintenance, Replacement 1

Charging

&

Safety Regulations for handling acid batteries Park the industrial truck securely before carrying out any work on the batteries (see Chapter E).

Maintenance personnel: Batteries may only be charged, serviced or replaced by trained personnel. Observe the operator manual and the manufactu concerning batteries and charging stations when carrying out this work.

Fire protection: Do not smoke and avoid naked flames when working with batteries Wherever an industrial truck is parked for charging there shall be no inflammable material or operating fluids capable of creating sparks within 2 metres around the truck. The area must be well ventilated. Fire protection equipment must be provided.

Battery maintenance: The battery cell covers must be kept dry and clean. The terminals and cable shoes must be clean, secure and have a light coating of dielectric grease. Batteries with non insulated terminals must be covered with a non slip insulation mat.

Battery Disposal: Batteries may only be disposed of in accordance with national Environmental Protection Regulations disposal instructions must be followed.

M

Before closing the battery cover make sure that the battery lead cannot be damaged.

contain an acid solution which is poisonous and corrosive Therefore, always F Batteries wear protective clothing and eye protection when carrying out work on batteries.

Above all avoid all contact with battery acid.

Nevertheless, should clothing, skin or eyes come in contact with acid the affected parts should be rinsed with plenty of clean water - if the skin or eyes are affected call a doctor immediately. Immediately neutralise any spilled battery acid.

M

Only batteries with a sealed battery container may be used.

weight and dimensions of the battery have a considerable effect on the F The operational safety of the industrial truck. Battery equipment changes may only be made with the agreement of the manufacturer.

D1

2

Battery types The EKX can be fitted with a range of battery types. All the batteries correspond to DIN 43531-A. The following table indicates the capacities to show which combinations can be used as standard: Battery type 48V 4EPzS460 48V 4EPzS575 48V 4EPzS690 80V 3EPzS420 80V 4EPzS560 80V 5EPzS700 80V 6EPzS840

Battery type Single part Single part Single part Single part / two part Single part / two part Single part / two part Single part / two part

Industrial truck type EKX 410 EKX 410 EKX 410 EKX 513 / EKX 515k EKX 515k EKX 515 EKX 515

The battery weights can be taken from the battery data plate. weight and dimensions of the battery have a considerable effect on the F The operational safety of the industrial truck. Battery equipment changes may only be made with the agreement of the manufacturer.

3

Charging the battery

F Park the industrial truck securely (see Chapter E).

and press the EMERGENCY DISCONNECT

switch. he battery panels. connect and disconnect the battery connector and the socket when the mains F Only and charger are switched off. lating mat from the battery. charging, the top surfaces of the battery cells must be exposed to provide F When sufficient ventilation. Do not place any metal objects on the battery. Before charging, check all cables and plug connections for visible signs of damage. harger station with the battery connector. ccordance with the battery and charger station is essential to follow the safety regulations of the battery and charger station F Itmanufacturers.

D2

4

Battery removal and installation

batteries with insulated cells and terminal connectors may be used. When F Only replacing the battery always use the same battery type. Extra weights must not be removed and must remain in the same position. truck must be horizontral to prevent the battery from falling out when the battery F The retainer is removed. connect and disconnect the battery connector and the socket when the mains F Only and charger are switched off. replacing/fitting the battery, make sure that the battery is well secured in the batF After tery compartment. t EKX 410 (installing/removing a battery with a battery trolley): to "O" (Zero) and press the EMERGENCY DISCONNECT switch (1). and disconnect the battery (3). retainer (5) by moving the lever (6) down and remove the retainer. of the prepared battery trolley.

F Make sure the battery trolley is properly secured.

Z

The battery retainers (5, 8) can swap positions. This means that they can both be fitted in either the left or ri Assembly is the reverse order.

M

To avoid pushing the battery (7) through on assembly, the battery retainer (8) must first be plugged in on the opposite side.

installing again, check all cables and connectors for signs of visible damage and F After before using the truck again check that: tted and secured by the lever (6), (4) are properly closed.

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D3

t

g/removing a battery with a battery trolley): o) and press the EMERGENCY DISCONNECT switch (10). ery panel (11).

12) up and lift them off.

13) by moving the lever (14) down and remove the retainer. of the prepared battery trolley.

F Make sure the battery trolley is properly secured.

Z

The battery retainers (13, 17) can swap positions. This means that they can both be fitted in either the left or right side of Assembly is the reverse order.

M

To avoid pushing the battery (16) through on assembly, the battery retainer (17) must first be plugged in on the opposite side.

installing again, check all cables and connectors for signs of visible damage and F After before using the truck again check that: (13) is fitted and secured by the lever (14), 12) are properly closed. ïì ïí ç ïð ïë

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D4

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o riage with a forklift):

eries in the battery replacement carero) and press the EMERGENCY DISCONNECT

switch (19). ery panel (20).

21) up and lift them off. e left and right-hand side of the battery compartment.

(22) from the left and right-hand side of the battery compartment. es (24) from the left or right hand side using a forklift truck. To do this, enter th battery replacement carriage.

Assembly is the reverse order.

M

When fitting the batteries (24) in the battery replacement carriage, make sure that the load handler of the forklift truck used for assembly is located in the fork shoes (25) of the battery frame. In addition, the fork tips of the load handler must not project beyond the battery replacement carriage.

installing again, check all cables and connectors for signs of visible damage and F After before using the truck again check that: are inserted and are secure, 21) are properly closed.

D5

ondition and acid level intenance instructions apply. cracks and any spilled acid. from the battery terminals and apply an acid-free grease to the battery terminals. check the acid level.

The acid level should be at least 10-15 mm above the top of the plates. harge the battery.

6

Battery discharge indicator When you pull the EMERGENCY DISCONNECT switch and turn the key in the key switch clockwise, the battery discharge indicator will show the residual capacity available. The display starts to flash when the battery has reached a residual capacity of 30%. Lift cut-out occurs at a 20% capacity display.

For maintenance-free and special batteries the display and cutout points can be adjusted by authorised personnel by assigning parameters.

D6

E Operation 1

Safety Regulations for the Operation of Forklift Trucks Driver authorisation: The forklift truck may only be used by suitably trained personnel, who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to operate the truck by the proprietor or his representative. ons and responsibilities: The driver must be informed of his duties and responsibilities and be instructed in the operation of the truck and shall be familiar with the operator manual. The driver shall be afforded all due rights.

Unauthorised Use of Truck: The driver is responsible for the truck during the time it is in use. He shall prevent unauthorised persons from driving or operating the truck.

It is forbidden to carry passengers or lift personnel.

Damage and Faults: Report any damage or faults concerning the forklift truck or its attachments to a supervisor immediately. Trucks not safe for operation (e.g. wheel or brake problems) shall not be used until they have been rectified.

Repairs: The driver must not carry out any repairs or alterations to the forklift truck without the necessary training and authoristion to do so. On no account may the driver disable or adjust safety mechanisms or switches.

Danger area: A danger area is defined as the area in which a person is at risk due to truck movement, lifting operations, the load lifting device (e.g. forks or attachments) or the load itself. This also includes areas which can be reached by falling loads or lowering operating equipment.

persons must be kept away from the danger area. Where there is F Unauthorised danger to personnel, a warning must be sounded in good time. If unauthorised personnel are still within the danger area the truck shall be brought to rest immediately.

Safety Devices and Warning Signs: Safety devices, warning signs and warning instructions in the present operating instructions shall be strictly observed.

E1

2

Operating and Display Equipment

2.1

Operating and display equipment on control panel

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E2

Item Operating / Display unit Function 1 Control panel t All displays and functions 2 Keyswitch t Switches control voltage on and off. Removing the key prevents the truck from being switched on by unauthorised personnel.

3 Control panel t Sets the height and distance of the control stop panel.

4 Cabin safety gate t Prevents operator from falling out 5 Seat height adjustment t be vertically adjusted.

6 Deadman switch t Release the parking brake. When activated, (foot switch) releases the spring pressure brake and travel.

Releasing the deadman switch causes the truck to brake immediately until it comes to a halt.

7 Hand rest and t Two-hand operation contact point 8 Hydraulic control switch t Raising and lowering of Main and Aux. lift, reach and swivel of load forks 9 Display unit t Operating information and warning message display t Lit when the parking brake is applied t Lit when the EMERGENCY STOP device is display automatically activated t Lit when a fault occurs 13 Travel selection switch t Controls the travel direction and speed of the truck t Enables simultaneous lowering of Main and switch Aux. Lift. t Switches the hydraulic control switch to lift and lower the fork carriage wi t Switches the hydraulic control switch to the switch t Changes the hydraulic control switch to the switch 18 EMERGENCY t Interrupts the main supply, all truck DISCONNECT switch movements are disabled 19 Switch t Activates or confirms the function related to the symbol displayed above it t Sets the menu to standard display 21 Steering wheel t Steers the truck in the required direction. t Activates a warning t = Standard equipment

o = Optional Equipment

E3

2.2

Display unit controls and displays 25

26 27

28

29

24 23

30

19

Upper range symbols Item Symbol Operating / Display Equipment 23 Displays possible travel speeds: Turtle Rabbit

Function t Creep mode Max. travel speed

WG Sensors which have detected the guidance wire have a dark background 25

Steering angle display t Indicates the current steering angle with reference to the centre position RG Centre position is permanently displayed once the truck is in the track WG The steering angle display fades and is replaced by guidance wire symbols changes with display WG WG WG

E4

guidance wire (inductive guidance) guided by the guidance wire iates without guidance from the guidance wire and automatic guidance

Item Symbol Operating / Display Equipment 26 Display

t Displays the lift height of the forks

Main lift - lift

Requests Main Lift to lift

Main lift - lower

Requests Main Lift to lower

Aux. lift - lift

Requests Aux. Lift to lift

Aux. lift - lower

29

Function

display Battery discharge indicator

Requests Aux. Lift to lower t Shows the time t Displays the number of operating hours since the truck was commissioned t Displays the battery charge condition (residual capacity as a percentage)

E5

2.3

Lower range symbols and keys Activates switch (19) under the respective symbols (30) displayed or confirms the related function. The symbol will be given a dark background.

Symbol Operating / display unit Warnings

display ft cutout switch

switch

switch display (option)

switch (PSA)

Function t Displayed when the chain slack safety device engages Bypasses the chain slack safety device to lift the driver's position freely t Displayed when the lift cutout device is actvated due to low battery capacity and only forward or reverse travel is possible.

Confirms the lift cutout due to low battery capacity and releases travel (the Fwd./Rev. travel only display has a dark background) o Displayed when the height dependent lift cutout is activated Bypasses the height dependent lift cutout (display has a dark background). Observe the maximum passage heights o Indicates that the automatic lowering limit has been activated.

Bypasses the lowering limit, controlled by hydraulic control switch o Indicates that automatic, height dependent travel cutout has been activated Bypasses the automatic, height dependent travel cutout o Indicates that the aisle end safety device has been activated. The truck brakes. o Indicates that the personal safety system has identified persons or objects in the aisle.

The truck brakes.

Bypasses the protective function and enables creep mode if there is sufficient distance from the obstacle.

If a personal safety system is fitted, read the accompanying operator manual. o Indicates that several warnings (e.g. chain slack safety device height dependent lift cutout) have been issued.

Displays individual warnings

menu. o Indicates that the sub-menu can be quit. menu. sub-menu to the standard menu

E6

Symbol Operating / display unit Guidance systems

Function

not active

active

t Displays automatic guidance in the aisle: RG Rail guidance display (drive wheel set straight ahead) WG Indicates that wire guidance is activated Sets the drive wheel to straight ahead position WG

other frequencies)

Activates the aligning process (and frequency selection for multi-frequencies) o Indicates that guidance is possible through Frequency 1 WG

menu) switch (similar to other frequencies) Attachment fork operation

Activates guidance through Frequency 1 (sub-menu is quit automatically after 1 sec. duration) t Changes the display unit menu to Activates synchronous swivel menu change t Indicates that the fork synchronous left Activates fork left swivel, simultaneous control of boom right reach via the hydraulic control switch o Indicates that automatic fork synchronous reach is possible

display Activates fork left swivel with simultaneous boom right reach switch t Indicates that the fork synchronous right ach is possible Activates fork right swivel, simultaneous control of boom left reach via the hydraulic control switch

E7

Symbol Operating / display unit synchronous right

Function o Indicates that automatic fork synchronous reach is possible

synchronous right

Activates fork right swivel with simultaneous automatic boom left reach

synchronous swivel to

synchronous swivel to

display switch

display switch

E8

o Indicates that the forks can be automatically set to the centre position (forks facing forwards) Activates traversing with automatic fork stop in centre position, simultaneous automatic boom reach with stop at centre position o Indicates that the KOOI forks can be operated OI forks, controlled via the hydraulic control switch o Indicates that the telescopic forks can be operated he telescopic forks, controlled via the hydraulic control switch o Indicates that the 2nd stacking depth is possible Activates the 2nd stacking depth, controlled via the hydraulic control switch o Indicates that fork tilt is possible fork tilt, controlled via the hydraulic control switch o Indicates that the special attachment can be controlled Activates control of the special attachment, controlled via the hydraulic control switch

Symbol Operating / display unit Attachment fork adjustment

Function o Indicates that fork adjustment can be operated Activates fork adjustment with simultaneous operation of hydraulic control switch, Right turn = forks turn in; Left turn = forks turn out o Indicates that it is possible to change to the

adjustment menu Changes the display unit menu to adjustment menu o Indicates that left only fork adjustment is possible Activates left only fork adjustment, controlled via the hydraulic control switch o Indicates that right only fork adjustment is possible Activates right only fork adjustment, controlled via the hydraulic control switch t = Standard equipment RG = Rail guidance

o = Optional Equipment IG = Wire guidance

E9

2.4

Truck operational status symbols The operational status of the truck when it has been switched on is indicated by symbols in the display unit.

Safety gates open

Foot switch not pressed

Attachment in home position (see page E25)

When the following symbols are displayed you must carry out a reference/test run in accordance with the display, i.e. primary lift and aux. lift must be raised approx. 10 cm and then lowered again. This is the only way for the controller to release all the truck movements at full speed.

Referencing: Main lift - lift

Referencing: Main lift - lower

Referencing: Aux. lift - lift

Referencing: Aux. lift - lower

E 10

3

Starting up the truck

the truck can be put into operation, operated or a load unit lifted, the driver F Before must ensure that there is nobody within the danger area.

Checks and operations to be performed before starting daily work on the outside for signs of visible damage and leaks. connections for damage, make sure they are secure. onnector is fixed. d guard for damage. damage such as cracks, bent or severely worn load forks. heels for damage. ns are evenly tensioned. sms are correct and functional. check the guidance rollers are smooth and check for damage.

F It is forbidden for more than one person to enter the d add or remove weight to obtain the correct height.

Control panel angle adjustment

Z

The control panel can be tilted to one of five settings.

1

) to the right and adjust the angle until the pin engages again.

Control panel height adjustment

18

2

(upwards or downwards) Preparing the truck for operation curely on both sides.

SCONNECT switch (18) to undo it. clockwise.

18 run on the lift mast to adjust the height display (see page E 10)

F

3 Press the EMERGENCY DISCONNECT switch immediately if the truck starts to move or lift when it is switched on.

E 11

Setting the time

Press switch 31, the display changes to the sub menu.

Z

Truck movements are inhibited in this sub-menu Now press switch 32 twice; appears in the display unit.

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Setting the time: Simultaneously press switch 32 me forward by an hour. time back by an hour. forward by a minute. me back by a minute.

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Press switch 31, the display changes to the sub menu.

Now press switch 36, the

E 12

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4

Lift truck operation

4.1

Safety regulations for truck operation Travel routes and work areas: Only use lanes and routes specifically dedicated to truck traffic. Unauthorised persons must stay away from work areas. Loads must only be stored in places specially designated for this purpose.

Driving conduct: The driver must adapt the travel speed to local conditions. The truck must be driven at slow speed when negotiating bends or narrow passageways, when passing through swing doors and at blind spots. The driver must always observe an adequate braking distance between the forklift truck and the vehicle in front and must be in control of the truck at all times. Sudden stopping (except in emergencies), rapid U turns and overtaking at dangerous or blind spots is not permitted. It is forbidden to lean out of or reach beyond the working and operating area.

Visibility when travelling outside the narrow aisle: The driver must look in the direction of travel and must always have a clear view of the route ahead. When carrying loads which affect visibility, these must be stored at the rear of the truck. If this is not possible, a second person must walk in front of the truck as a lookout.

M M

Negotiating slopes and inclines: It is forbidden to negotiate slopes and inclines.

Negotiating docks: It is forbidden to negotiate docks.

Negotiating lifts: Lifts may only be negotiated if they have sufficient capacity, are suitable for driving on and authorised for truck traffic by the owner. The driver must satisfy himself of the above before entering these areas. The truck must enter lifts with the load in front and must take up a position which does not allow it to come into contact with the walls of the lift shaft.

People travelling in the lift with the forklift truck must only enter the lift after the truck has come to a halt and must exit the lift before the truck.

Type of loads to be carried: The operator must make sure that the load is in a satisfactory condition. Do not carry loads unless they are positioned safely and carefully. Use suitable precautions to prevent parts of the load from tipping or falling down.

E 13

4.2

Travelling, Steering, Braking EMERGENCY DISCONNECT DISCONNECT switch (18) down.

All truck movements are inhibited.

The switch operation must not be affected by any objects placed in its way.

ïè Travelling The truck can be driven in 3 modes: Free travel, with wire or rail guidance.

The operating mode used depends on the guidance system of the racking system operated.

M

Do not drive the truck unless the panels are closed and properly locked.

The foot switch must be kept depressed for travel.

Travelling in apron field ê DISCONNECT switch (18) to undo it. it clockwise;

lift and raise the Main lift with the hydraulic control switch (8) until the forks are clear of the ground. el selection switch (13) with the right thumb.

Right turn = Forward travel Left turn = Reverse travel continuing to turn or retracting the travel selection switch. the truck in the required direction.

E 14

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Steering Use the steering wheel to steer the truck outside narrow aisles.

The position of the drive wheel is shown in the display unit (9).

9

Braking

Z

The braking pattern of the truck depends largely on the ground conditions. The driver must take this into consideration when handling the truck. in three different ways: - with the operating brake - with foot switch - with EMERGENCY DISCONNECT switch.

Braking with the operating brake While driving set the travel direction switch to the zero position or the opposite travel direction; the traction current controller will cause the truck to brake.

Braking with the foot switch Releasing the foot switch causes the truck to brake.

Z

This type of braking can only be used as a parking brake and not as an operating brake.

Braking with the EMERGENCY DISCONNECT switch Applying the EMERGENCY DISCONNECT switch will cause the truck to brake to a halt.

M

The EMERGENCY DISCONNECT switch must only be used in dangerous situations.

E 15

Negotiating narrow aisles

M

M Z Z

It is forbidden for unauthorised personnel to enter narrow aisles (truck lanes in racking systems with safety distances < 500 mm) or for personnel to cross through them. These work areas must be marked and identified accordingly. Carry out a daily inspection of the safety devices on the truck or the racking sysem to avoid hazards and protect personnel. These must not be made ineffective, misused, adjusted or removed. Immediately report and rectify any missing safety devices.

Observe the instructions of DIN 15185 Part 2.

Before entering a narrow aisle, the driver must look for people or other trucks in the aisle. Never enter an aisle where there are people or other trucks. If there are people in the aisle, stop the truck immediately.

Only enter narrow aisles in trucks which are designated for such use. If a narrow aisle is equipped with a guidance wire for wire guidance and the system is faulty or switched off, the truck may only be removed from the narrow aisle at crawl speed.

Rail guidance truck Rail guidance trucks are equipped with sensors which activate aisle recognition when they enter the racking lanes.

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so that the truck is aligned with the narrow aisle and is within the demarcation.

Z

Observe the notices attached along the route.

Z

Travel and hydraulic operations can only be activated in the narrow aisle with twohanded operation.

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Ensure that the truck guide rollers enter the narrow aisle guidance rails. lay light (38) changes to active mode. d. The steering angle display (25) shows the steering angle permanently in the centre position after alignment. Manual steering is disabled. ller and hydraulic controller handle (7) (twohanded operation). itch (13) to change travel speed and direction. Right turn =Forward travel; Left turn = Reverse travel ong the narrow aisle at your required speed.

E 16

Wire guidance trucks starting or continuing the truck after the wire guidance has been deactivated, F When note the position of the drive wheel as manual steering is now activated again. an automatically guided truck is switched off, the wire guidance is no longer active F Ifwhen it is switched on again. Risk of accidents! When you continue to travel a warning is sounded and the speed is reduced. Use push button (34) to re-activate the wire 38) goes on in active mode) and re-align the truck.

F During alignment, the rear part may veer out when it reaches the guidance wire. up to the guidance wire (40) at reduced speed and at an angle

When aligning, the truck should not be parallel to the guidance wire. The optimum approachment angle is between 10° and 50°.

The attachment should be in the home position (see page E25), otherwise it will be outside of t The travel speed would be restricted to the reduced speed.

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Tracking should preferably be forward, as this involves less time and distance. guidance wire, switch on the wire guidance with pressure switch (34).

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display light (38) changes to active mode.

When the guidance wire is reached the truck is automatically guided.

When the guidance wire is reached tracking automtically ensues at reduced speed. The steering angle display (25) . The audible tracking signal is sounded.

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E 17

Inductive automatic steering takes over the steering and applies it to the guidance wire.

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Tracking is completed once the truck has been set to the guidance wire. . The tracking signal is no longer sounded. The track is now automatically guided. íì

Z

Travel and hydraulic operations can only be activated in the narrow aisle with two-handed operation.

Grab the hand rest in the traction controller and hydraulic controller handle (7) (two-handed operation). Turn the travel selection switch (13) to change travel speed and direction.

Press the push button (34) to quit the guidance wire. The display (38) changes to non-active mode. In (42) display changes to the steering angle display (25).

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íì Diagonal travel

Z

Diagonal travel is only possible if the truck is wire or rail guided.

Diagonal travel is possible (simultaneous travelling and lifting / lowering) when both control switches (8 and 13) are pressed simultaneously).

can only change from automatic to manual steering once the truck has fully left F You the rack lane.

E 18

Traversing outside the rack aisles of trapping when traversing or reaching with the forks.

F Risk There must be nobody in the danger zone when carrying out traverse, reach or synchronous turn movements of the load lifting device.

Risk of injury when the fting device are lowered.

There must be nobody in the danger zone.

control switch (8) Right = Lower Left = Lift

Z

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The lift and lower speeds are proportional to the amount of turn of the hydraulic control switch.

Max. lift speed if the attachment home position (see page E25) is shown in the display unit

Z

If the wire break safety device has applied during a non-permissible lowering speed (E 287), raise and slowly lower the primary raise.

E 19

pressure switch

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(15). control switch (8) simultaneously Left turn = Lift Right turn = Lower The lift and lower speeds proportional to the amount of turn.

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Reach (attachment boom) (16) (= attachment reach) switch (8) simultaneously.

Right turn = Right reach Left turn = Left reach The reach speed is proportional to the amount of turn.

Traverse (fork carriage) (= fork carriage traverse) switch (8) simultaneously.

Right turn = Right traverse Left turn = Left traverse The traverse speed is proportional to the amount of turn of the hydraulic control switch.

Lowering Main Lift and Aux. Lift simultaneously erneath the traction controller handle (= primary and aux. raise lower). the hydraulic control switch (8) to the right.

The lower speed is proportional to the amount of turn.

E 20

Simultaneous boom reach and fork carriage traverse of trapping when traversing or reaching with the forks.

F Risk Make sure there is nobody present in the danger zone when carrying out traverse, reach or synchronous turn movements of the load lifting device.

Z

If you move the attachment the fork carriage will traverse simultaneously.

The speed of turn cannot be changed.

The reach speed is proportional to the amount of turn of the hydraulic control switch. play in the display unit menu changes ed traverse menu

switch (8) to the left = Traverse fork carriage to the right and boom reach to the left.

switch (8) to the right = Traverse fork carriage to the left and boom reach to the right.

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Attachment telescopic fork reach rk push button (16). switch (8) simultaneously: Right turn = Right reach Left turn = Left reach

Z

The reach speed is proportional to the amount of turn of the hydraulic control switch.

The telescopic fork automatically stops in the centre position. If you release the hydraulic control switch (8) and press it again, the telescopic fork can then be moved either left or right.

E 21

Traversing inside the rack aisles

Z

The driver must not leave the operator position w onto objects or other trucks.

forbidden to climb

Lifting and lowering inside the rack aisles requires two-handed operation. Otherwise, operation is the same as for outside the rack aisles.

4.5

Order picking and stacking Picking up, transporting and placing load units

M

Before picking up a load unit the driver must make sure that it has been correctly s capacity. Observe the load diagram. he pallet and adjust if necessary.

Adjusting the forks To pick up the load securely, the forks must be as far apart as possible and centrally positioned with respect to the fork carriage. The load centre of gravity must be centrally aligned between the forks.

position on the fork carriage (46). move the forks until the locking pin engages in a notch.

E 22

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Picking up a load from the side. storage location

until the fork back touches the load or the pallet.

E 23

Picking up a load from the front.

until the fork back touches the load or the pallet. ly and slowly reverse the truck.

M

The ground surface must be in good condition to ensure this works correctly.

Transporting loads rack aisle as low as possible, allowing for ground clearance.

When transporting heavy loads always ensure that both forks carry the same weight.

e. Only stop suddenly in dangerous situations. ingly on narrow bends.

Placing loads y up to the storage location

M

Before a load can be placed, the driver must ensure that the storage location is suitable for storing the load (size and capacity). load can be taken to the storage location without striking any objects. load into its storage location. he load lifting device so that the forks are clear of the load.

M

E 24

Avoid placing the load down suddenly to avoid damaging the load and the load lifting device.

4.6

Park the truck securely When you leave the truck it must be securely parked even if you only intend to leave it for a short time.

not park the truck on an incline. In special cases the truck may need to be secured F Do with wedges.

Z

Select a parking place where nobody will collide with the forks. he mast completely lowered. the home (standard) position. and remove the safety key.

Attachment in standard position the right or left hand limit position of the sideshift frame (51). parallel to the sideshift frame (51).

48 49

50

51

E 25

5

Troubleshooting This chapter enables the user to identify and rectify basic faults and the effects of incorrect operation. When trying to locate a fault, proceed in the order shown in the table.

Fault Truck does not start.

Possible cause

DISCONNECT switch pressed

Action battery plug and plug in if necessary. the safety gates DISCONNECT switch

position battery if necessary pressed travel cutout override switch via aisle end safety device

neutral and press it again.

Load cannot be lifted

all measures listed under

lift cutout

battery if necessary

oil

necessary replenish on in Chapter E

Rapid travel disabled

in home position

position

raised above 0.5m

0.5m

activated Truck cannot be steered

all measures listed under

switch pressed

E 26

function

Fault

Possible cause

Action

guidance wire pressed during powerup test

switch truck off and on again

button pressed during power-up test

button, switch truck off and on again

test a key was pressed below the display unit

and on again

test a function preselect key (aux. lift, rotate, traverse) was pressed

(aux. lift, rotate, traverse), switch truck off and on again

during power-up test

truck off and on again aminated, clean

system

Z

If, after carrying out the remedial action, the truck cannot be restored to operation or if a fault in the electronics system is displayed with a corresponding error code, contact the manufacture Additional troubleshooting must only be performed by service engineers. The manufacturer has a customer service department specially trained for these tasks.

To provide targeted and rapid response to faults, the following details are useful and important to provide for the customer service department: - Truck serial number - Display unit error number (if present) - Error description - Current location of truck.

E 27

5.1

Emergency stop device When the automatic emergency stop mechanism applies (e.g. if the wire guidance is lost, electric steering fails) the truck brakes to a halt. Before starting again, the cause of the error must be identified and corrected. Start the truck again in accordance with ontained in these oper

using emergency lowering, make sure that nobody is present in the danger F When zone. If a second person is used to lower the load lifting device via the emergency lowering device, this person must consult with the driver. Both people must be in a safe area to avoid danger.

The truck may only be started again once the error has been localised and rectified.

If necessary, a second person can be deployed to lower the cabin from the ground.

Z

The attachment must be in the standard position. the bracket above the beacon. into the hole (53).

(52) using the Allen key.

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E 28

5.3

Exiting the driver's cab with the emergency abseil device Industrial trucks with a height-adjustable operator position which can exceed 3m from the ground, have an emergency lowering mechanism and an emergency abseil device for the driver which he can use if the operator position ever becomes stuck.

Z

a fault, not even with the emergency must exit the driver's cab via the emergency abseil device.

The driver must be instructed in how to use the emergency abseil device. To exit the cabin with the emergency abseil device, proceed as follows: ONNECT switch (18). the abseil device (55) from the compartment under the seat.

For the EKX 513-515 remove it from the compartment in the overhead guard. of the abseil device (left or right) to the eye (54) of the overhead guard. knots, the rope must pass over fixed objects. Do not pass the rope over sharp edges. slings in accordance with the accompanying operating instructions or as instructed. belt to the karabiner hook (59) of the abseil device (55).

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E 29

Abseiling

F Do not drop into loose rope. Watch out for obstacles when abseiling. towards the truck.

56) on the abseil device down. e the brake lever (56).

5.4

Bypassing the chain slack safety device If the slack chain safety device has applied, e.g. if the lift chain has loosened or broken, it is possible to "lift" the primary raise when the fork carriage is in the standard position (standard position = attachment pivoted in and retracted), if the override switch is held down and the hydraulic control button simultaneously pressed.

Before starting again, rectify the damage.

If the fork carriage is not in the home position when the chain slack safety device engages, e.g. is inserted in a rack, Main Lift "lowering" is the primary raise by pressing the override switch and at the same time applying the hydraulic control button. After raising, bring the forks out of the rack. Travel is inhibited whatever the position of the fork carriage.

M

The truck may only be started again once the damage has been removed.

5.5

Bypassing the travel cutout (o) If travel is inhibited from a certain lift height, but the position of the truck relative to the rack must be adjusted to load or unload goods, press the apply the travel lever as descri ws you to travel in creep mode.

5.6

Lift cutout (o) If local conditions require, an automatic lift cutout to apply from a given lift height can be fitted for safety reasons.

M

Lift cutout only becomes effective after a test run has been carried out. You can tell when this is the case, because the actual height is shown in the display unit.

disabling the lift cutout the driver must look out for obstacles when the mast is F When extended. lift cutout mechanism.

Z

Lift cutout is re-activated each time the mast falls below the lift limit height.

The respective travel and lift limit keys are located in the control panel.

E 30

5.7

Aisle end safety device (o) Trucks with the aisle end safety device brake before the aisle exit or in the transfer aisle. There are two basic versions for this: 1. Braking to a halt 2. Braking to 2.5 km/h Other variants (affecting the subsequent travel speed, lift height etc.) are available.

1. Braking to a halt: When the truck passes over the aisle end safety magnets heading for the aisle end, it comes to a halt.

To continue traveling: switch and then apply it again The truck can be driven out of the narrow aisle at max. 2.5 km/h.

2. Braking to 2.5 km/h When the truck passes over the aisle end safety magnets heading for the aisle end, it brakes to 2.5 km/h and can be driven out of the narrow aisle at this speed.

M

In both cases the braking distance depends on the travel speed.

end safety braking is an additional function designed to support the operator, F Aisle but which does not release him from any responsiblity, e.g. to monitor braking at the aisle end and if necessary to apply the brakes.

5.8

WG emergency operation If in a wire guidance system the guiding antenna extends beyond the pre-determined range of the guidance wire, the truck automatically undergoes an emergency stop.

If the truck is travelling directly parallel to the guidance wire, travel is not disabled. The ng signal however remain permanently on and hence warn the driver.

Automatic EMERGENCY STOP If during operation one of the monitors for steering control, steering system, wire guidance or the safety cutout for the traction electronics or power electronics applies, the truck safety devices will cause the truck to stop.

E 31

To enable the truck to travel again after an EMERGENCY STOP, carry out the following: e of the EMERGENCY STOP. and turn it again to release it.

y align the truck with the guidance wire.

F If the truck now starts, check that it is operating correctly.

Automatic and manual EMERGENCY STOP

If, after an automatic or manual EMERGENCY STOP and having rectified the problem, you cannot start the truck again, turn the key switch off and on again.

Now carry out a test run as follows: Lift and lower the primary and aux. raise in accordance with the symbol display about 10 cm until the respective display goes out.

Carry out a test run: - REF-Test run: Raise Main Lift

- REF-Test run: Lower Main Lift

- REF-Test run: Raise Main Lift

- REF-Test run: Lower Aux. Lift

The truck is now operational.

E 32

5.9

Recovering the truck from a narrow aisle / Moving the truck without a battery

F Before recovering the truck from a narrow aisle, disconnect the battery.

M

This operation can only be performed by a specialist service engineer specially trained in operating the truck.

When the brakes are de-activated the truck must be parked on an even ground as the brakes are no longer effective.

Z

Obtain the help of another person. The other person must be trained and familiar with recovery operations.

To recover the truck from the aisle, release the brakes.

Release the magnetic brake partment cover at the back. on the magnetic brake above the drive motor to release it. the lamp bracket (60).

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M

When using the truck again, check the braking deceleration.

E 33

Releasing the load wheel brake (hydraulic brake) partment cover at the back. from the bleed valve 66). e brake fluid retainer (64). vent connection (67) of the bleed valve (66) and attach the other end of the hose to the brake fluid retainer (64) above it.

F The brake fluid retainer is pressurised. Risk of scalding.

drain the excess brake fluid into the brake fluid re-

tainer (64).

(65) from the vent connection (67) and cover the vent connection with the protective cap. ner (64) with the lid (63).

Z

The brake system is restored to operation by powering down the truck and activating the foot switch several times.

65

63

64

66

67

M

E 34

When using the truck again, check the braking deceleration.

Adjust the steering angle battery must be disconnected when F The adjusting the steering angle.

Using an Allen key set the steered wheel to the required direction via the screw in the steering motor (68).

Z

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It is advisable to discharge the wheel if setting an angle greater than 4 degrees.

Emergency recovery in drive direction: tment cover at the back. w force > 5 tonnes, around the counterweight (70) by the left or right sides of the antenna (71).

M

Note the wire routing in the drive compartment and the antenna (71)! truck out of the narrow aisle.

Emergency recovery in load direction: tow force > 5 tonnes, around the aux. raise (72). truck out of the narrow aisle.

72 69

70

Load direction 69

71

Drive direction recovery, prevent the truck from accidentally moving.

F After To do this, unscrew the setscrews on the magnetic brake above the drive motor. If the brake is not functional, prevent the truck from moving by placing wedges underneath the wheels.

E 35

F Maintenance of the forklift truck 1

Operational safety and environmental protection The checks and servicing operations contained in this chapter must be performed in accordance with the intervals as indicated in the servicing checklists.

to the forklift truck, especially to the safety devices, are not permitted.

F Modifications The operational speeds of the truck must not be changed under any circumstances.

M

Only original spare parts come under the remit of our quality assurance service. To ensure safe and reliable operation of the forklift truck, only us spare parts. Used parts, oils and fuels must be disposed of in accordance with the applicable environmental protection regulations. For oil changes, contact the service department.

Upon completion of inspection and servicing, carry out the tasks contained in the F).

2

Maintenance Safety Regulations Maintenance personnel: The forklift truck must only be serviced and maintained by trained personnel provided by the manufacturer. T department has specially trained field engineers for this work. We therefore recommend a maintenance contract with the manufacture Lifting and jacking up: When a forklift truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When the truck is to be jacked up, take appropriate measures to prevent the truck from slipping or tipping over (e.g. wedges, wooden blocks). Only work under a raised load handler and cab if they are secured by a chain of sufficient capacity curing the Driver's Position

Z

Jacking point see chapter B. Cleaning: No inflammable liquids may be used to clean the forklift truck. Prior to cleaning, all safety measures required to prevent sparking (e.g. through short circuits) must be taken. For battery-operated trucks, the battery connector must be removed.

Only weak suction or compressed air and non-conductive antistatic brushes may be used for cleaning electrical or electronic assemblies.

M

If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical and electronic components must be carefully covered beforehand as moisture can cause malfuntions.

Do not clean with steam jets.

After cleaning, carry out the tasks detailed in the

F1

Electrical System: Work on the electrical system may only be performed by trained personnel. Before commencing work on the electrical system, take all precautionary measures to avoid electric shocks. For battery-operated trucks, also de-energise the truck by removing the battery connector.

Welding: To avoid damaging electrical or electronic components, remove them from the truck before performing welding operations.

Settings: When repairing or replacing hydraulic, electric or electronic components or assemblies, always keep the truck-specific settings.

Wheels: The quality of wheels affects the stability and performance of the truck.

When replacing wheels fitted at the factory, only use manuf parts. Otherwise the truck's rated performance cannot be ensured.

When replacing wheels, ensure that the truck does not slew (e.g. always replace left and right wheels at the same time) Lift chains: Lift chains wear rapidly if not properly lubricated. The intervals given in the service checklist apply to normal duty. More demanding conditions (dust, temperature) require more regular lubrication. The prescribed chain spray must be used in accordance with the instructions. Applying grease externally will not provide sufficient lubrication.

Hydraulic hoses: The hoses must be replaced every six years

F2

3

Servicing and inspection Thorough and expert servicing is one of the most important preconditions for safe operation of the forklift truck. Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment.

M

The application conditions of an industrial truck considerably affect the wear levels of the service components.

We recommend an application analysis carried out on site by a Jungheinrich customer adviser to establish specific maintenance intervals in order to restrict damage caused by wear.

The service intervals listed are based on single shift operation under normal operating conditions. They must be reduced accordingly if the truck is to be used in conditions of heavy dust, temperature fluctuations or multiple shifts.

The following service checklist indicates the tasks to be performed and the respective intervals to be observed. The service intervals are defined as follows: W A B C

Z

= Every 50 = Every 500 = Every 1000 = Every 2000

service hours, at least weekly operating hours operating hours, or at least annually operating hours, or at least annually

W service intervals are to be performed by the customer.

F3

4

EKX maintenance checklist

Maintenance intervals Standard = t W A B C Chassis/ Superstructure:

Drive:

Wheels: Steering:

Brake system:

1.1 Check all load bearing items for damage 1.2 Check screw connections atform and check for damage 1.4 Check that identification points, data plates and t warnings are legible and replace if necessary 1.5 Check battery panel and sides are secure t 1.6 Test gas pressure damper and check for damage b) t 2.1 Lubricate the bearing between traction motor and transmission 2.2 Check transmission for noise and leakage 2.3 Change transmission oil 3.1 Check wheels for wear and damage t 3.2 Check bearings and attachment 4.1 Test operation and setting of wheel setting display 4.2 Check the distance between the guide rollers and the rail guidance over the entire length of the rails. The play between the two guide rollers and the rails (measured over the axle) should be 0-5 mm. The rollers should not jam.

5.1 Test operation and settings 5.2 Check the brake lining wear 5.3 Check brake mechanism, adjust and lubricate if necessary b) 5.4 Check brake lines, connections and brake fluid level b) t 5.5 Check brake fluid b) 5.6 Replace brake fluid b)

b) applies only to the EKX 513-515

F4

t t t

t t t t t t

t t t

t t

Maintenance intervals Standard = t W A B C Hydraulic System:

Electrical System:

Electric motors: Battery:

6.1 Test operation 6.2 Check connections and ports for leaks and damage 6.3 Check hydraulic cylinder for leaks and damage and make sure it is secure 6.4 Check oil level 6.5 Test the hoses and check for damage 6.6 Check ventilation and discharge filter on hydraulic reservoir 6.7 Replace ventilation and discharge filter on hydraulic reservoir 6.8 Replace hydraulic oil and filter cartridge 6.9 Test pressure relief valves 6.10 Make sure hydraulic hoses are sealed and check for damage. p) 6.11 Test line brake safety device 7.1 Test static charge eliminator t 7.2 Test operation 7.3 Make sure wire connections are secure and check for wire damage 7.4 Test cable guide operation and check for damage 7.5 Test operation of warning devices and safety switches.

7.6 Make sure sensors are fixed, not damaged, clean and operational 7.7 Test operation of controls and displays.

7.8 Check contactors and relays; if necessary replace worn parts 7.9 Check fuse rating 8.2 Check motor attachment

t t t

9.1 Check acid density, acid level and cell voltage 9.2 Check terminals are securely attached, and apply grease 9.3 Clean battery plug connections, make sure they are firmly secured 9.4 Check battery cables for damage, replace if necessary.

t t

t t t t t t t t t t t t t t t t t

t t

p) Replace hydraulic hoses after 6 years' operation

F5

Maintenance intervals Standard = t W A B C Lift mechanism

10.1 Clean rollers, guide rollers and contact surfaces in the mast sections and apply grease.

M

t

Warning: Danger of crashing!

10.2 Check mast attachments (bearings and retaining screws) 10.3 Check lift chains and chain guide for wear, adjust and lubricate 10.4 Lubricate lift chains t 10.5 Visually inspect rollers, slide pieces and stops 10.6 Check forks and fork carriage for wear and damage Attachments 11.1 Test operation and settings 11.2 Check attachment on truck and load bearing items 11.3 Check bearings, guides and stops for wear and damage, clean and lubricate; also clean and lubricate toothed racks 11.4 Check eccentric bolts and sliding strip adjustment on the traverse/reach frame, adjust if necessary.

11.5 Lubricate rollers, guide rollers and traverse bearings on the traverse reach fork.

Lubrication: 12.1 Lubricate the truck according to the lubrication schedule General mea- 13.1 Check electrical system for accidental earth surements: 13.2 Check travel speed and braking distance 13.3 Check lift and lowering speeds 13.4 Check safety devices and cutouts 13.5 IG: Measure the current in the guidance wire, adjust if necessary e) 13.6 Check travel on the IG wire, check maximum deviation and adjust if necessary e) 13.7 Check tracking mode on the IG wire for aisle tracking. e) 13.8 Check IG EMERGENCY STOP operation e) Demons14.1 Test run with rated load tration: 14.2 When maintenance is completed, present the truck to the responsible person.

e) IG: inductive guidance trucks

F6

t t

t t t t t t t t t t t t t t t t t t

4.1

Lubrication Schedule Grease nipple consumable E

Outer mast (513 - 515)

Centre mast (513 - 515)

Boom (410 - 515)

Inner mast (513 - 515)

Fork carriage (513 - 515)

F7

G

G

G

E

E

H E B

E

D A A

EKX 513-515

g

Slide surfaces s Grease nipple Hydraulic oil filler neck

c Hydraulic oil drain plug

F8

EKX 410

a Transmission oil drain plug

4.2

Fuels, coolants and lubricants Handling consumables: Consumables must always be handled correctly. Follow s instructions.

handling is hazardous to health, life and the environment. Consumables F Improper must only be stored in appropriate containers. They may be flammable and must therefore not come into contact with hot components or naked flames.

Consumables must always be stored in clean containers only. The mixing of different grade consumables is forbidden. The only exception to this is when mixing is expressly stipulated in the operator manual.

Avoid spillage. Spilled liquids must be removed immediately with suitable bonding agents and the bonding agent / consumable mixture must be dispoed of according to regulations.

EKX 410 fuels and lubricants Code

A

B

Order no.

Quantity

51037497 51037494

5l 1l

51085361*

5l

50022968

5l

Volume approx.

30 l approx.

3.6 l

29201430

400 g (cartridge) 1 kg

-

G

29201280

400 ml

-

H

50157382

1 kg

400 g

E

14038650

Description HLP D22 + 2% share of additive 68 ID Plantohyd 22 S (BIO hydraulic oil)

Used for

Hydraulic System

SAE80EPAPI GL4

Transmission

Grease Lithium KP2K-30 (DIN 51825)

general Toothed racks

Chain spray Tunfluid LT 220 Grease Lithium K3K-20 (DIN 51825)

Mast track Lift chains Front wheel bearings

* Plus 2% additive 68 ID (order no. 50307735)

F The trucks are supplied from oil + 2 % 68 ID additive.

You cannot change from the Plantohyd 22 S BIO hydraulic oil to HLP D22. The same applies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIOhydraulic oil.

Furthermore, you cannot mix HLP D22 hydraulic oilt Plantohyd 22 S BIO hydraulic oil.

F9

EKX 513/515k/515 fuels and lubricants Code

Order no.

Quantity

51037497 51037494

5l 1l

51085361*

5l

B

50022968

5l

D

29201580

5l

A

Volume approx.

110 l approx.

5,8 l approx.

0,18 l

29201430

400 g (cartridge) 1 kg

---

G

29201280

400 ml

---

H

50157382

1 kg

400 g

E

14038650

Description HLP D22 + 2% share of additive 68 ID Plantohyd 22 S (BIO hydraulic oil) SAE 80 EP API GL4 SAE DOT 4 brake fluid

Used for

Hydraulic System

Transmission Hydraulic brake system

Lithium KP2K-30 General toothed racks grease (DIN 51825) Tunfluid LT 220 chain spray

Mast Track Lift chains

Lithium K3K-20 Front wheel bearings grease (DIN 51825)

* Plus 2% additive 68 ID (order no. 50307735)

F The trucks are supplied from oil + 2 % 68 ID additive.

You cannot change from the Plantohyd 22 S BIO hydraulic oil to HLP D22. The same applies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIOhydraulic oil.

Furthermore, you cannot mix HLP D22 hydraulic oilt Plantohyd 22 S BIO hydraulic oil.

F 10

5

Maintenance and Repairs

M

Load bearing parts of the truck, e. g. chassis and mast, may only be welded after consultation with the manufacturer.

5.1

Preparing the truck for maintenance and repairs All necessary safety measures must be taken to avoid accidents during maintenance and repair work. The following preparations must be made: ly (See Chapter E). uck from being switched on accidentally truck, secure it to prevent it from lowering, tipping or sliding away.

working under a raised load fork or a raised industrial truck, secure them to preF When vent them from lowering, tipping or sliding away. When raising the industrial truck also ransport and Commi When working on the parking brake, prevent the industrial truck from rolling away.

F 11

carriage

secured in the raised position. position carriage until the inner mast (1) is above the carriage (2) of the load lifting safety device. and remove the retaining bolt (3) from the carriage (2) on the mast.

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vertical hole of the carriage (2) and secure them. carriage until the inner mast (1) is positioned on the retaining bolt.

5.3

M

5.4

Maintaining the lift chains It is important that all lift chains and pivots are at all times kept clean and well lubricated. Only lubricate discharged chains. A chain must be lubricated with particular care at the points where it passes over a pulley. Lift chains are safety-critical parts.

Chains should not have any major contamination. They should only be cleaned with parafin derivatives e. g. petroleum or diesel fuels. Never clean chains with steam jet high pressure cleaners, cold or chemical cleaning agents.

ì

Inspecting the lift chains Unauthorised wear and external damage: In accordance with official regualtions, a chain is considered to be worn if it has extended in length by 3% in the section which passes over the deflection pulley. For safety reasons, we advise replacing chains when they elongate by 2%.

Chains should also be replaced immediately when visible damage is noted, as such damage leads to permanent breakage after a certain time.

M

F 12

If the truck is fitted with two lift chains, both chains must always be replaced. This is the only way to ensure even load distribution over the two chains. When replacing chains the connecting bolts between the chain anchor and the chain must be replaced. Only new original parts may be used.

5.5

Hydraulic oil r maintenance and repairs

M

Oil must never be allowed to enter the drainage system or the soil. Used oil must be preserved until it can be disposed of in the correct manner.

Draining oil: Suction off the hydraulic oil with the discharge filter removed (5). If this is not possible, the hydraulic oil can be drained from the bottom of the hydraulic reservoir after the oil drain screw (8a) has been unscrewed.

Adding oil:

é

Screw in the oil drain screw (8a).

Replenish with new hydraulic oil up to the Max. mark on the dipstick (7). Screw the discharge filter backon.

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which hydraulic oil is being added. If Plantohyd 22 S F Check 8b BIO hydraulic oil is being used, hydraulic reservoir. In this case you may only use Hydrauliköl oil to fill the hydraulic reservoir. cannot change from the Plantohyd 22 S BIO hydraulic oil to HLP D22. The same F You applies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIO hydraulic oil.

Furthermore, you cannot mix HLP D22 hydraulic oilt Plantohyd 22 S BIO hydraulic oil.

Checking the hydraulic oil level When the mast is fully lowered, check that the hydraulic oil level is between the min. and max. markings on the dipstick (7).

If this is not the case, add new hydraulic oil.

F 13

5.6

Hydraulic hoses Hose lines must be replaced every six years, see Safety Regulations for Hydraulic Hose Lines ZH 1/74.

5.7

Checking the brake fluid (EKX 513 - 515)

fluid is poisonous and should therefore F Brake only be stored in sealed, original containers. It should also be noted that brake fluid corrodes the truck paint.

M

Brake fluid is added in the factory and must be replaced after 12 months at the latest, as it changes over time and loses its original qualities.

The brake fluid container (11) is located at the rear of the truck and can be accessed by removing the panel. The container should always be filled to 2cm below the container lid.

Only use the prescribed brake fluid.

The entire brake system must be checked for leaks.

F 14

11

5.8

Checking electrical fuses (EKX 410)

F Electric fuses must only be checked and replaced by authorized personnel. intenance and repairs

(see Chapter F). accordance with the table; replace if necessary. use the rating indicated on the controller. DIN and EN standardised fuses must F Only not be used for UL standardised fuses. The opposite also applies.

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ITEM 12 13 14 15 16 17 18 19 20

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Description 1F11 3F10 2F15 F2.1 5F1 F3.1 F1.2 5F2 1F3

To protect: Travel Steering Hydraulics DC/DC converter U1 input 48 V Lighting and special equipment 48 V DC/DC converter U1 output 24 V DC/DC converter U16 input 48 V DC/DC converter U16 output 24 V Drive controller

Rating 160 A (DIN, EN) 250 A (UL) 35 A (DIN, EN) 35 A (UL) 250 A (DIN, EN) 400 A (UL) 48 V / 10 A (UL) 48 V / 10 A (UL) 24 V / 10 A (UL) 48 V / 4 A (UL) 24 V / 6,3 A (UL) 1 A (UL)

F 15

5.9

Checking electrical fuses (EKX 513 - 515)

F Electric fuses must only be checked and replaced by authorized personnel. intenance and repairs

(see Chapter F). accordance with the table; replace if necessary. use the rating indicated on the controller. DIN and EN standardised fuses must F Only not be used for UL standardised fuses. The opposite also applies.

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îç îè îé îê

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ITEM 21 22 23 24 25 26 27 28 29

F 16

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Description 1F11 3F10 2F15 F2.1 5F1 F3.1 F1.2 5F2 1F3

To protect: Travel Steering Hydraulics DC/DC converter U1 input 80V Lighting and special equipment 80V DC/DC converter U1 output 24V DC/DC converter U16 input 80V DC/DC converter U16 output 24V Drive controller

Rating 250 A 35 A 325 A 80 V / 10 A 80 V / 10 A 24 V / 10 A 80 V / 4 A 24 V / 6,3 A 1A

5.10

Recommissioning Recommissioning after cleaning or repair work is permitted only after the following operations have been performed.

6

Decommissioning the forklift truck If the forklift truck is to be decommissioned for more than one month, e.g. for operational reasons, it must be parked in a frost-free and dry location and all necessary measures must be taken before, during and after decommissioning as described.

M

On decommissioning the truck must be jacked up so that all the wheels are clear of the ground. This is the only way of ensuring that the wheels are not damaged.

If the truck is to be out of service for more than 6 months, further measures must be taken in consultation with the manufacturer.

6.1

Prior to decommissioning:

level and replenish as necessary (see Chapter F). grease to all parts not protected by a coating of paint. the lubrication schedule (see Chapter F). (see Chapter D). and apply grease to the terminals.

Z

In addition, observe the battery manufactu t spray to all exposed electrical contacts.

F 17

6.2

During decommissioning: Every 2 months: (see Chapter D).

M 6.3

Battery powered trucks: The battery must be charged at regular intervals to avoid depletion of the battery through self-discharge. The sulfatisation would destroy the battery.

Recommissioning

the lubrication schedule (see Chapter F). ease the terminals and connect the battery. (see Chapter D). water and replace if necessary. water and replace if necessary.

Z

Battery powered trucks: If there are switching problems in the electrical system, apply contact spray to the exposed contacts and remove any oxide layers on the contacts of the operating controls by applying them repeatedly.

F Perform several brake tests immediately after starting the truck again.

F 18

7

Z

Safety checks to be performed at regular intervals and following any unusual incidents Carry out a safety check in accordance with national regulations. Junheinrich recommends checks in accordance with FEM Guideline 4.004. Jungheinrich has a special safety department with trained personnel to carry out such checks.

The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector. The inspector shall assess the condition of the truck from purely a safety viewpoint, without regard to operational or economic circumstances. The inspector shall be sufficiently instructed and experienced to be able to assess the condition of the truck and the effectiveness of the safety mechanisms based on the technical regulations and principles governing the inspection of forklift trucks.

A thorough test of the truck must be undertaken with regard to its technical condition from a safety aspect. The truck must also be examined for damage caused by possible improper use. A test report shall be provided. The test results must be kept for at least the next 2 inspections.

The owner is responsible for ensuring that faults are immediately rectified.

Z

A test plate is attached to the truck as proof that it has passed the safety inspection.

This plate indicates the due date for the next inspection.

8

Final de-commissioning, disposal

Z

Final, proper decommissioning or disposal of the truck must be performed in accordance with the regulations of the country of application. In particular, regulations governing the disposal of batteries, fuels and electronic and electrical systems must be observed.

F 19