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Jungheinrich EKS 110 Operating Instructions Manual
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Jungheinrich EKS 110 Operating Instructions Manual

Jungheinrich EKS 110 Operating Instructions Manual

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EKS 110
Operating instructions
51586342
01.17
01.17
G
EKS 110

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Summary of Contents for Jungheinrich EKS 110

  • Page 1 EKS 110 01.17 Operating instructions 51586342 01.17 EKS 110...

  • Page 2: Declaration Of Conformity

    Declaration of Conformity Jungheinrich AG, Friedrich-Ebert-Damm 129, 22047 Hamburg, Germany Manufacturer or agent acting in the European Union Model Option Serial no. Year of manufacture EKS 110 Additional information On behalf of Date G EC Declaration of Conformity The undersigned hereby declare that the powered industrial truck described below in...
  • Page 4 Foreword Notes on the operating instructions The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter and the pages are numbered continuously.
  • Page 5 Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG. Jungheinrich Aktiengesellschaft Friedrich-Ebert-Damm 129 22047 Hamburg - Germany Tel: +49 (0) 40/6948-0 www.jungheinrich.com...

  • Page 6: Table Of Contents

    Contents Correct Use and Application ........... General....................Correct application................... Approved application conditions .............. Internal Operation Combined with Brief External or Cold Store Operation (t) ......................Internal Operation in Cold Stores with Cold Store Equipment (o) ..Proprietor responsibilities ................ Adding attachments and/or optional equipment ........Truck Description ..............
  • Page 7 Displays and Controls................Control Station in Drive Direction ............Second control station (o) in load direction ..........Auxiliary lift controls................. Pedestrian EKS 110 with gates ............... Deadman button and gate ............... Display unit ....................Preparing the Truck for Operation ............
  • Page 8 Industrial Truck Maintenance ..........183 Operational Safety and Environmental Protection........183 Maintenance Safety Regulations............. 185 Working on the electrical system............. 186 Consumables and used parts..............186 Wheels..................... 187 Attachment Repairs and Inspection............187 Lift chain inspection ................. 188 Hydraulic system ..................189 Lubricants and Lubrication Schedule ............

  • Page 10: A Correct Use And Application

    A Correct Use and Application General The truck must be used, operated and serviced in accordance with the present instructions. All other types of use are beyond its scope of application and may result in damage to personnel, the industrial truck or property. Correct application NOTE The maximum load and load distance are indicated on the capacity plate and must...

  • Page 11: Approved Application Conditions

    Approved application conditions WARNING! Operation under extreme conditions Operating the industrial truck under extreme conditions can lead to malfunctions and accidents. Special equipment and authorisation are required if the truck is to be constantly used in extreme conditions, especially in dusty or corrosive atmospheres. It is forbidden to operate the truck in areas where there is a risk of explosion.
  • Page 12 Safety distances (interpreted safety distance) The racking systems must be set up for the EKS. The safety distances stipulated by Jungheinrich (interpreted safety distance) must always be observed. – For rail-guided trucks there must be a minimum safety distance on both sides of 100 mm between: –...

  • Page 13: Internal Operation Combined With Brief External Or Cold Store Operation (T)

    Internal Operation Combined with Brief External or Cold Store Operation (t) In addition to the permissible application conditions in industrial and commercial environments, the truck may also be used in outdoor environments, cold stores and fresh food areas. Secure parking is only permissible indoors or in a cold store environment.

  • Page 14: Proprietor Responsibilities

    Proprietor responsibilities For the purposes of the present operating instructions the “operating company” 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.

  • Page 16: B Truck Description

    B Truck Description Application The EKS 110 is an electric powered vertical order picker. The truck is designed to transport and pick goods on level surfaces in accordance with DIN 15185. – The EKS 110 L model includes main lift.
  • Page 17 The EKS is designed to transport and pick loads on level surfaces in accordance with the VDMA guideline. It is designed to lift open bottom, cross-board pallets and roll cages. The truck is not suitable for stacking pallets in racking systems. The operator's position rises together with the load handler to provide excellent visibility and easy access to the various rack heights.

  • Page 18: Travel Direction Definition

    Travel direction definition The following determinations have been made for travel direction specification: Item Travel direction Right Drive direction Load direction Left...

  • Page 19: Assemblies And Functional Description

    Assemblies and Functional Description Assembly Overview...
  • Page 20 Item Description t Overhead guard t Duplex mast (ZZ) t Travel controller t Gate (100E, 160E, 190E, 280ZZ) o Gate (100E) t Simplex mast (E) t Load handler t Operator position t Drive wheel t Driver's display o Guide rollers t Drive panel t Electrical system cover t Battery panel...

  • Page 21: Functional Description

    Retaining bolts prevent the raised operator's position from lowering accidentally during maintenance and repair work (see page 202). The mast protection pane (on the EKS 110 160E, 190E and 280ZZ) prevents people from reaching through the mast during lifting and lowering operations. Deadman switch The deadman switch ensures that the driver's feet do not extend outside the truck during travel.
  • Page 22 Emergency Stop safety feature If a serious error is detected by the controller, the truck automatically brakes to a halt. Control indicators on the driver’s display indicate the emergency stop. Each time the truck is switched on, the system performs a self test which only releases the parking brake (emergency stop) if the functional test is positive.
  • Page 23 Steering The steer range is 90° in either direction. The steering wheel acts electrically on the steering transmission motor. The spur gear transfers the steering movement to the drive wheel. In "rail guidance with aisle recognition" mode (o) the steering is automatically kept in the straight-ahead position.
  • Page 24 Lift mechanism The truck has a welded simplex mast. The load carriage with the operator's position and load handler runs on flanged rollers to limit frictional loss and ensure low energy consumption. Lifting is performed through the hydraulic cylinder extension. In auxiliary lift mode the load handler is raised by a centre-mounted lift cylinder via a pulley chain.
  • Page 25 3.2.1 Hourmeter Prepare the truck for operation, see page 94 or see page 143. Service hours are counted while the truck is operational and the deadman button is pressed. 3.2.2 Hourmeter in Pedestrian Mode Prepare the truck for operation, see page 94 or see page 143. Service hours are counted while the truck is operational and one of the following controls is applied: –...

  • Page 26: Technical Specifications

    Gradeability with/without 5/10 rated load Drive motor, output S2 60 Lift motor, output S3 15% Lift motor, output S3 5% Z auxiliary lift motor, output S3 5%, option 1 For EKS 110 (280 ZZ): Lift motor, output S3 20%...

  • Page 27: Weights

    Weights EKS 110 EKS 110 EKS 110 EKS 110 Description (100 E) (160 E) (190 E) (280 ZZ) Net weight incl. battery, variant L/ 1661/ 1785/ 1813/ 2268/ 1763 1907 1953 2390 Axle load with load at front/rear 491/ 516/...

  • Page 28: Dimensions

    Dimensions...
  • Page 29 EKS 110 - 100E...
  • Page 30 EKS 110 - 280ZZ...
  • Page 31 EKS 110 EKS 110 EKS 110 EKS 110 Description (100 E) (160 E) (190 E) (280 ZZ) Load centre distance 1000 Load distance Wheelbase 1730 1785 Collapsed mast height 1800 2260 2560 2251 Lift 1000 1600 1900 2800 Mast height when extended...

  • Page 32: Mast Versions

    3 Highest point is the overhead guard. EN norms Continuous sound pressure level – EKS 110: 61 dB(A) in accordance with EN 12053 as harmonised with ISO 4871. The continuous sound pressure level is calculated according to standard procedures and takes into account the sound pressure level when travelling, lifting and idling.
  • Page 33 WARNING! Medical equipment can be damaged by non-ionised radiation Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless data transmission) can affect operators' medical equipment (pacemakers, hearing aids etc.) and result in malfunctions. Consult a doctor or the manufacturer of the medical equipment to clarify whether it can be used near the industrial truck.

  • Page 34: Conditions Of Use

    Conditions of use Ambient temperature – without cold store equipment: operating at -10°C to +40°C, see page 14 – with cold store equipment: operating at -28°C to +25°C, see page 14 Special equipment and authorisation are required if the truck is to be used continually in conditions of extreme temperature or condensing air humidity fluctuations.

  • Page 35: Identification Points And Data Plates

    Identification Points and Data Plates Warnings and notices such as load charts, strap points and data plates must be legible at all times. Replace if necessary. Pos. Bezeichnung Warnschild „Scher- / Quetschgefahr“ Verbotsschild „Nicht unter die Lastaufnahme treten“ Verbotsschild „Nicht durch das Hubgerüst greifen“ Prüfplakette (o) Tragfähigkeitsschild Seriennummer...

  • Page 36: Data Plate

    Data plate The illustration shows the standard version for EU member states. The data plate may differ in other countries. Item Description Item Description Type Year of manufacture Serial number Load centre distance (mm) Rated capacity (kg) Nominal power Battery voltage (V) Min./max.

  • Page 37: Truck Capacity Plate

    Truck capacity plate WARNING! Replacing the forks can cause accidents If you replace the forks with ones that differ from the originals, the capacity will change. When adding forks that differ from the ones originally supplied, an additional capacity plate must be attached to the truck. Example: Fitting longer forks to the truck Adding forks that differ from the ones originally supplied requires the manufacturer s approval.

  • Page 38: Stability

    Stability WARNING! Loss of stability can cause accidents The stability as indicated in the capacity plate can only be guaranteed with the components (battery, mast) as shown on the data plate. Always use batteries approved by the manufacturer, see page 55. The truck's stability has been tested according to latest technological standards.

  • Page 40: C Transport And Commissioning

    C Transport and Commissioning Lifting by crane WARNING! All persons involved in loading by crane must be trained Incorrect crane loading procedures due to untrained personnel can cause the truck to fall. There is a risk of injury to personnel and a risk of material damage to the truck. Loading must only be performed by specialist personnel trained for this purpose.

  • Page 41: Lifting The Battery By Crane

    Lifting the truck by crane Requirements – The truck is now parked securely, see page 97. Tools and Material Required – Lifting gear – Crane lifting gear Procedure • Secure the crane lifting gear to the strap points (44). The truck can now be lifted by crane. Lifting the battery by crane WARNING! Improper lifting of the battery by crane can cause accidents...
  • Page 42 WARNING! Batteries can be hazardous Batteries contain an acid solution which is poisonous and corrosive. Avoid contact with battery acid at all times. Dispose of used battery acid in accordance with regulations. Always wear protective clothing and goggles when working with batteries. Do not let battery acid come into contact with skin, clothing or eyes.

  • Page 43: Securing The Truck During Transport

    Securing the truck during transport WARNING! Accidental movement during transport Improper fastening of the truck and mast during transport can result in serious accidents. Loading must only be performed by specialist personnel trained for this purpose. The specialist personnel must be instructed in securing loads on road vehicles and handling load securing devices.
  • Page 44 Securing the industrial truck for transport Tools and Material Required – 3 tensioning belts on truck without overhead guard – 5 tensioning belts on truck with overhead guard Procedure • Drive the truck onto a lorry or trailer. • Park the truck securely, see page 97. •...

  • Page 45: Using The Truck For The First Time

    Using the Truck for the First Time WARNING! The use of unsuitable energy sources can be hazardous Rectified AC current will damage the assemblies (controllers, sensors, motors etc.) of the electronic system. Unsuitable cable connections (too long, insufficient wire cross-section) to the battery (tow cables) can overheat, setting the truck and battery on fire.
  • Page 46 Preparing the Truck for Operation after Delivery or Transport Requirements – Unload the truck from the transport vehicle, lorry or trailer. Procedure • Check the equipment is complete. • Fit the battery if necessary (see page 61). The truck should only be operated with battery current. Rectified AC current will damage the electronic components.

  • Page 47: Tilt Safety Device

    Tilt safety device The EKS is supplied with tilt safety devices (48). The tilt safety devices are fitted on the left and right of the truck chassis in the drive direction. Do not operate the truck without the tilt safety devices fitted.
  • Page 48 The readings from the following table must be maintained. Truck version Distance from tilt safety device to the EKS 110 L 100E 32 ± 1 mm EKS 110 Z 100E 25 ± 1 mm EKS 110 L/Z 160E/190E 14 ±...

  • Page 49: Mast Protection Pane

    Operating the truck with a damaged mast protection pane or none at all can result in injuries and is prohibited. Check the truck's mast protection pane is present and damage-free. The mast protection pane (49) on the EKS 110 160E, 190E and 280ZZ prevents people from reaching through the mast during lifting and lowering operations.

  • Page 50: Moving The Industrial Truck Without A Battery

    Moving the industrial truck without a battery This operation must only be performed by suitably trained maintenance personnel. WARNING! It must not be performed on slopes or inclines (no brakes). Moving the industrial truck without a battery see page 131.

  • Page 52: D Battery - Servicing, Recharging, Replacement

    D Battery - Servicing, Recharging, Replacement Safety Regulations Governing the Handling of Lead-Acid Batteries For use of lithium-ion batteries (o), see the manufacturer's operating instructions. Maintenance personnel Batteries may only be charged, serviced or replaced by trained personnel. These operating instructions and the manufacturer’s instructions concerning batteries and charging stations must be observed when carrying out the work.

  • Page 53: General Notes On Handling Batteries

    The use of unsuitable batteries that have not been approved for the truck by Jungheinrich, can lead to a deterioration of the braking characteristics of the truck during energy recovery, causing considerable damage to the electric controller and resulting in serious danger to the health and safety of individuals.

  • Page 54: Battery Types

    Battery types Depending on the model, the truck will be supplied with different battery types. The following table shows which combinations are included as standard: Battery type (L tray) Voltage Capacity Weight 3 PzV 300 (maintenance-free) 24 V 300 Ah 288 kg 621x281x627 mm 3 PzS 375...
  • Page 55 NOTE Only use a battery whose weight is within the minimum and maximum range stated on the truck’s data plate. Failure to comply with the prescribed battery weight range can render the truck unstable.

  • Page 56: Exposing The Battery

    Exposing the battery WARNING! An unsecured truck can cause accidents It is hazardous and prohibited to park the truck on inclines, with a raised operator's position or load handler. Park the truck on a level surface. In special cases the truck may need to be secured with wedges.
  • Page 57 CAUTION! Short circuits can result in fire Damaged cables can cause short circuits, setting the truck and battery on fire. Before closing the battery cover make sure that the battery cables are not damaged. Report any defects immediately to your supervisor. Mark defective truck and take out of service.

  • Page 58: Charging The Battery

    Charging the battery WARNING! The gases produced during charging can cause explosions The battery produces a mixture of nitrogen and hydrogen (electrolytic gas) during charging. Gassing is a chemical process. This gas mixture is highly explosive and must not be ignited. Switch the charging station and truck off first before connecting/disconnecting the charging cable of the battery charging station to/from the battery connector.
  • Page 59 • Switch on the battery charger. Charge the battery in accordance with the battery and battery charger manufacturers’ instructions. The battery is charging. NOTE If charging has been interrupted, the full battery capacity will not be available. Preparing the battery for operation after charging Requirements –...

  • Page 60: Battery Removal And Installation

    Battery removal and installation WARNING! Accident risk during battery removal and installation Due to the battery weight and acid there is a risk of trapping or scalding when the battery is removed and installed. Note the "Safety regulations for handling acid batteries" section in this chapter. Wear safety shoes when removing and installing the battery.
  • Page 61 Removing the battery Requirements – Truck parked securely, see page 97. – Expose battery, page 57. – Battery disconnected. Tools and Material Required – Crane or forklift truck – Crane lifting gear – Battery replacement trolley (o) Procedure • Pull the clamping lever (55) of the battery lock 180°...
  • Page 62 • Pull the clamping lever (55) of the battery lock 180° clockwise. • Attach the battery connector (52) to the truck. • Check all cables and plug connections for visible signs of damage. • Close the battery cover. When the battery has been installed the truck is ready for operation.

  • Page 64: E Operation

    E Operation Safety Regulations for the Operation of Forklift Trucks Driver authorisation The 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.
  • Page 65 Hazardous area WARNING! Risk of accidents/injury in the hazardous area of the truck A hazardous area is defined as the area in which people are at risk due to travel or lifting operations of the truck, its load handler or the load. This also includes the area within reach of falling loads or lowering/falling operating equipment.

  • Page 66: Displays And Controls

    Displays and Controls Control Station in Drive Direction Item Control/display Function t Controls the travel direction and the speed. Travel controller o 2nd control station Control and display unit t Display for: – Battery charge status – Service hours – Event messages –...
  • Page 67 Item Control/display Function t Issues a warning signal. Warning button o 2nd control station o Pedestrian mode optional feature: Raises the Pedestrian mode lift button operator position and load handler. o Pedestrian mode optional feature: Lowers the Pedestrian mode lower button operator position and load handler.

  • Page 69: Second Control Station (O) In Load Direction

    Second control station (o) in load direction Item Control/display Function Travel controller Controls the travel direction and the speed. Lower button Lowers the operator position and load handler. Lift button Raises the operator position and load handler. Auxiliary lift raise button Raises the load handler. Auxiliary lift lower button Lowers the load handler.
  • Page 70 Item Control/display Function Load direction Pedestrian mode optional feature, travel continues pedestrian touch mode as operator walks beside in load direction (slow travel). Steering wheel Steers the truck. Travel direction arrows The travel direction arrows indicate the travel direction. Emergency disconnect Pedestrian mode optional feature: Disconnects the power supply, deactivates all electrical functions, causing the truck to brake automatically.

  • Page 71: Auxiliary Lift Controls

    Auxiliary lift controls Item Control / Display Function o Raises the load handler Aux. lift “raise” button o 2nd control station o Lowers the load handler Aux. lift “lower” button o 2nd control station o Releases lifting and travel when pressed (in rail “Two hand operation”...

  • Page 72: Pedestrian Eks 110 With Gates

    Pedestrian EKS 110 with gates Item Control/display Function o Pedestrian mode optional feature: Lowers the Pedestrian mode lower button operator position and load handler. o Pedestrian mode optional feature: Raises the Pedestrian mode lift button operator position and load handler.

  • Page 73: Deadman Button And Gate

    Deadman button and gate Item Control/display Function o Open: Lifting and travel inhibited from a lift Gate height of 1200 mm. Closed: Lifting and travel enabled. t Not applied: Travel inhibited, or truck brakes. Deadman switch Applied: Travel enabled. o Not applied: Travel inhibited, or truck brakes. Deadman switch 2nd control station Applied: Travel released, operation changed to...

  • Page 74: Display Unit

    Display unit 2.6.1 Display (4 Inch) Item Control and Function Display 81 Direction presetting Shows the direction selected. 82 Arrow to display the travel Shows the current travel direction of the truck and steering directions and the current wheel position in 15° segments. 83 Information field Displays event messages and optional information such as speed.
  • Page 76 2.6.2 Button allocation of the display Main menu symbols Symbol Meaning Information field toggle: Allows the information displayed in the information field to be changed. Slow travel: Switches slow travel on and off. Travel program down: To switch the travel program down Travel program up: To switch the travel program up Settings:...
  • Page 77 Additional symbols Symbol Meaning Light (o): Switches the lighting on/off. Work lights (o): Switches the work lights on/off. Setting: To change to the menu to administer the codes or transponders Change set-up code: To change the set-up code and to activate the keypad or the transponder reader.
  • Page 78 2.6.3 Symbols in the display Any number of pictograms can be displayed in the pictogram field (86). Which pictograms are shown in the pictogram field depends on the operating and truck status. Symbol Meaning Colour Function Stop notice Functions deactivated due to truck malfunctions Warning Yellow...
  • Page 79 Symbol Meaning Colour Function Lift deactivated Yellow Icon illuminates when lifting functions are cut out due to insufficient battery capacity. Beacon / strobe light Green Beacon / strobe light is switched on. Work lights right Green Right work lights are switched on. Work lights left Green Left work lights are switched on.
  • Page 80 2.6.4 Setting the time Setting the Time Symbol Procedure Press the button under the settings symbol. Press the button under the clock symbol. Use the arrow up key to change the time digit selected. Use the arrow down key to change the time digit selected. Press the confirm key to move to the next digit or to confirm the time.

  • Page 81: Preparing The Truck For Operation

    Preparing the Truck for Operation Checks and Operations to Be Performed Before Starting Daily Work WARNING! Damage and other truck or attachment (optional equipment) defects can result in accidents. If damage or other truck or attachment (optional equipment) defects are discovered during the following checks, the truck must be taken out of service until it has been repaired.

  • Page 82: Setting Up The Operator Position

    Setting up the operator position 3.2.1 Individual assembly of the second control station control panels NOTE Improper assembly of the control panel can cause material damage. When removing the control panel make sure no wires or plug connectors are trapped or disconnected. Prevent the control panel from falling down.

  • Page 83: Entry And Exit

    Entry and exit WARNING! Objects in operator's position leg compartment Objects in the operator's position leg compartment can impede the operation of controls in this area. For example the objects can accidentally start or jam the controls. They also pose a trip hazard. Keep the operator's position leg compartment clear of objects.
  • Page 84 Requirements – Operator's position fully lowered, see page 111. Procedure • If present, lift up the gates (8). • Hold on to the cabin frame (94) when entering and exiting. • If present, close the gates (8). CAUTION! Injuries when leaving the operator's position The operator can be injured when leaving the operator's position raised up to 20 cm.

  • Page 85: Industrial Truck Operation

    Industrial Truck Operation Safety regulations for truck operation Travel routes and work areas Only use lanes and routes specifically designated for truck traffic. Unauthorised third parties must stay away from work areas. Loads must only be stored in places specially designated for this purpose. The truck must only be operated in work areas with sufficient lighting to avoid danger to personnel and materials.
  • Page 86 Ground and ground conditions The ground on which the trucks are used must be level and smooth. There must not be any gaps, drainage systems etc. in this area. The ground must be well maintained to keep it free of contamination, obstacles and liquids that could affect the safe operation of the truck.
  • Page 87 WARNING! What to do if the industrial truck tips over If the truck is in danger of tipping over, the operator should not jump out of the truck. He must keep his whole body inside the operator position. The operator must: Crouch down, Hold onto the operator position with both hands, Lean against the direction of fall.
  • Page 88 Procedure and visibility when operating with a raised operator position or load handler WARNING! Operating the truck with driver's cab and load handler raised can result in accidents Working with a raised operator position or load handler can affect the operator's visibility.
  • Page 89 Work platforms WARNING! The use of working platforms is governed by national law. In some states the use of working platforms is prohibited on industrial trucks. Observe the applicable law. Working platforms can only be used in the country of application if the law permits it. Contact the national authorities before using a working platform.
  • Page 90 WARNING! Suspended and swaying loads can cause accidents and tipovers during transport Transporting suspended and swaying loads can reduce the stability of the truck. In addition, swaying loads can injury or damage people or components in the vicinity of the truck. Do not transport suspended loads.
  • Page 91 Fall protection The operator must not leave the operator's position when it is raised. Do not leave the driver's seat to climb onto parts of the building or onto other trucks. Also, do not climb over or onto safety equipment within the operator's position such as railings and gates.
  • Page 92 WARNING! Falls due to open gates The operator could fall out if the gate is open and the operator's position is raised. Do not open the gate(s) when the operator's position is raised. Seat belt checked and put on (EKS without front railing or guard only). Towing trailers and other vehicles CAUTION! The truck must not be used to tow a trailer or other vehicles.

  • Page 93: Preparing The Truck For Operation

    Preparing the truck for operation Switching on the truck Requirements – Perform visual inspections and operations before starting daily work, see page 82. Procedure • Step onto the operator platform. Take care not to actuate the travel controller or the pedestrian buttons when entering the truck.

  • Page 95: Checks And Operations To Be Carried Out When The Truck Is Operational

    Checks and operations to be carried out when the truck is operational WARNING! Risk of accident due to damage to or other defects in the truck and optional features If damage or other truck or attachment (optional equipment) defects are discovered during the following checks, the truck must be taken out of service until it has been repaired.

  • Page 96: Parking The Truck Securely

    Parking the truck securely WARNING! An unsecured truck can cause accidents Do not park the truck on an incline. Do not park the truck without the brakes engaged. Do not park or leave the truck with a raised operator's position or load handler. Park the truck on a level surface.
  • Page 97 Parking the truck securely Procedure • Park the truck on a level surface. • Fully lower the operator's position and load handler: • Press the "lower" button (57). • Apply the auxiliary lift "lower" button (60) if necessary. • Set the drive wheel to the forward position. •...

  • Page 98: Emergency Disconnect

    Emergency Disconnect CAUTION! Applying maximum braking can result in accidents Applying the Emergency Disconnect switch during travel will cause the truck to decelerate to a halt at maximum force. This may cause the load to slide off the load handler. There is a higher risk of accidents and injury. Do not use the Emergency Disconnect switch as a service brake.
  • Page 99 Applying the Emergency Disconnect Procedure • Press the Emergency Disconnect (73, 66, 76). Do not use the Emergency Disconnect (73, 66, 76) as a service brake. The operation of the Emergency Disconnect (73, 66, 76) must not be affected by any objects placed in its way.

  • Page 100: Deadman Button

    Deadman button Lifting (main lift) and auxiliary lift (o) cannot be applied without pressing the deadman switch (80, 79). If the deadman switch (80, 79) is released during travel, the truck decelerates at the maximum rate until it stops. On trucks with a second control station (o) the deadman switch (80, 79) acts as an interlock.

  • Page 101: Travel

    Travel WARNING! Incorrect travel can cause accidents and injury Incorrect travel can cause accidents and therefore injury to the operator and / or third parties. Always transport a load outside the narrow aisle as low as possible, allowing for ground clearance. Do not lean out of the truck while travelling.
  • Page 103 Travel Requirements – Truck started up, see page 94 or the see page 143. – Beyond a lift height of 1200 mm the gates (8) must be closed to enable travel and lifting (main lift). – Panels closed and locked correctly. Procedure •...
  • Page 104 Travelling into the narrow aisle Requirements – Prepare the truck for operation, see page 94 or see page 143. – Beyond a lift height of 1200 mm the gates (8) must be closed to enable travel and lifting (main lift). –...
  • Page 105 Trucks with main lift (version L) – Maximum speed up to platform height of 1200 mm – From platform height of 1200 mm for steering angle < ± 10 degrees: Travel speed 4 km/h (slow travel) for steering angle > ± 10 degrees: Travel speed 2.5 km/h (slow travel) Trucks with main and auxiliary lift (version Z) for auxiliary lift <...
  • Page 106 4.7.1 Changing direction during travel CAUTION! Danger when changing travel direction during travel When the travel direction is changed, the truck can start travelling at high speed in the opposite travel direction unless the travel control knob is released in time. Changing the travel direction causes the truck to decelerate sharply.

  • Page 107: Steering

    Steering Requirements – Prepare the truck for operation, see page 94 or see page 143. Procedure • Steering outside narrow aisles: • Turn the steering wheel (67) to the left or right, depending on the travel direction. The drive wheel position is indicated on the driver's display (13). •...

  • Page 108: Brakes

    Brakes WARNING! Accident risk while braking The truck’s braking response depends largely on the floor condition and the type of surface. The truck’s braking distance increases when the ground is wet or dirty. The operator must be aware of floor conditions and take them into account when braking.
  • Page 109 Braking with the coasting brake Procedure • While travelling, release the controller (7). The controller reverts to neutral. The truck brakes via the coasting brake. The braking intensity can be set by the manufacturer’s service department. Parking Brake When the truck has come to a halt the parking brake applies automatically. The parking brake is electrically released and actuated through spring pressure.

  • Page 110: Lifting / Lowering - Outside And Inside Narrow Aisles

    4.10 Lifting / lowering – outside and inside narrow aisles WARNING! Risk of accidents during lifting and lowering People can be injured in the hazardous area of the truck. The hazardous area is defined as the area in which people are at risk from the truck movement, the load handler, attachments, etc.
  • Page 111 CAUTION! Placing the load handler or operator's position on the rack support bar The load handler and operator's position can rest on the rack support bar during lowering. This makes the lift chains slack. There is a risk that the load handler and operator's position will drop suddenly when they are clear of the rack support bar.
  • Page 112 Requirements – Prepare the truck for operation, see page 94. – In narrow aisles apply the two-hand operation key (68) with your left hand while simultaneously pressing the (57 or 58) keys with your right hand (two-hand operation). Hydraulic operations can only be activated in the narrow aisle with two- hand operation.
  • Page 114 4.10.2 Auxiliary Lift – raising and lowering When the auxiliary lift is raised or lowered the load handler rises or lowers without the operator's position. The main lift does not change while the auxiliary lift rises or lowers.
  • Page 115 Requirements – Prepare the truck for operation, see page 94. – In narrow aisles apply the two-hand operation button (68) with your left hand while simultaneously pressing the (59 or 60) keys with your right hand (two-hand operation). Travel and hydraulic operations can only be activated in the narrow aisle with two-handed operation.

  • Page 116: Order Picking And Stacking

    Order picking and stacking Adjusting the forks (o) WARNING! Incorrect fork adjustments can cause accidents To lift the load securely, the fork tines should 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.

  • Page 117: Replacing The Fork Tines (O)

    Replacing the fork tines (o) WARNING! Faulty fork tines can cause accidents Faulty fork tines can cause the load to fall. Do not operate the truck with faulty forks. If one fork tine is damaged, both fork tines must be replaced. Report any defects immediately to your supervisor.
  • Page 118 Disassembling the forks Requirements – Park the truck securely, see page 97. – Raise the load handler until the forks are no longer touching the ground. Procedure • Disassemble extension safety mechanism (98). • Lift up the locking lever (95). •...
  • Page 119 Assembling the Forks Requirements – Park the truck securely, see page 97. – Raise the fork carriage so that the forks can be pushed onto the fork carriage. – Disassemble the extension safety mechanism (98). Procedure • Carefully push the fork tines (96) onto the fork carriage (97). •...

  • Page 120: Lifting, Transporting And Depositing Loads

    Lifting, transporting and depositing loads WARNING! Unsecured and incorrectly positioned loads can cause accidents. Before lifting a load the operator must make sure that it has been correctly palletised and does not exceed the truck’s capacity. Instruct other people to move out of the hazardous area of the truck. Stop working with the truck if people do not leave the hazardous area.
  • Page 121 5.3.1 Raising a load Requirements – Prepare the truck for operation, see page 94 or see page 143. – Load correctly palletised. – Fork spread for the pallet checked and adjusted if necessary, see page 117. – Load weight does not exceed the truck's capacity. –...
  • Page 122 5.3.2 Transporting a load WARNING! Ensure there is nobody standing under or on a raised load. Do not stand on the load handler. Do not lift other people on the load handler. Instruct other people to move out of the hazardous area of the industrial truck. Never stand underneath a raised and unsecured load handler.
  • Page 123 5.3.3 Depositing a load WARNING! Depositing loads can be hazardous A storage location that is unsuitable for the load can become damaged when depositing the load. Neighbouring rack components can also be damaged. Deposit the load only in locations that are suitable for storage (in terms of dimensions and capacity).

  • Page 124: Troubleshooting

    Troubleshooting This chapter allows the user to identify and rectify basic faults or the effects of incorrect operation. When trying to locate a fault, proceed in the order shown in the table. If the fault cannot be rectified after carrying out the above procedures, notify the manufacturer’s service department, as further troubleshooting can only be performed by specially trained and qualified service personnel.
  • Page 125 Fault Possible cause Remedy Load cannot be lifted – Truck not operational. – Carry out all measures listed under “Truck does not start”. – Check hydraulic oil level. – Hydraulic oil level too low. – Close the gates on either –...

  • Page 126: Emergency Lowering

    Emergency lowering The operator's position can be lowered by an assistant using the emergency drain valve. This function is important in the following situations: – If the operator is no longer able to operate the truck, e.g. through loss of consciousness.
  • Page 127 WARNING! Risk of accidents / material damage through automatic lowering of the operator position and load handler If the load handler is in the rack, emergency lowering must not be carried out. Due to leakage losses in the hydraulic system, there is also the risk that the rack could be damaged by the load handler lowering.
  • Page 128 Emergency lowering of operator's position (simplex mast) Procedure • Remove the front panel, see page 197. • Loosen the screw (100) by turning it (approx. 3 turns) anti-clockwise. The lowering speed increases the further the screw is turned anti-clockwise. The operator's position lowers. Lowering stops when the screw is turned anti-clockwise as far as the stop.
  • Page 129 Emergency lowering of operator's position (duplex mast) Procedure • Remove the front panel, see page 197. • Turn the screw with the star handle (101) anti-clockwise (approx. 2 turns). The operator's position lowers.

  • Page 130: Recovering The Truck From A Narrow Aisle / Moving The Truck Without A Battery

    Recovering the truck from a narrow aisle / Moving the truck without a battery WARNING! Danger when recovering the truck If the truck is towed away incorrectly, it can collide with persons, warehouse equipment and other trucks. This may result in people being injured, and warehouse equipment and other trucks being damaged.
  • Page 131 6.3.1 Release and activate the drive wheel brake WARNING! Accidental truck movement When the brakes are de-activated the truck must be parked on a level surface, since the brakes are no longer effective. Do not release the brake on slopes or inclines. Do not park the truck with the brake released.
  • Page 132 WARNING! An unsecured truck can cause accidents It is hazardous and prohibited to park the truck on inclines, with a raised operator's position or load handler. Park the truck on a level surface. In special cases the truck may need to be secured with wedges.
  • Page 133 15 17 Activating the brake Requirements – Drive wheel brake wheel. – Truck parked securely. Procedure • Prevent truck from moving accidentally, e.g. by placing wedges underneath the wheels. • Remove the front panel (15), see page 197. • Remove the two M5x42 Allen screws (102) from the drive wheel brake.
  • Page 134 6.3.2 Steering the truck without its own drive system CAUTION! A non-steered truck can cause accidents It may not be possible to steer the truck if the steering system is damaged. The truck can only be steered without its own drive system when it is stationary. Do not adjust the truck's steering angle during a recovery operation.
  • Page 135 Adjusting the steer angle Requirements – Operator's position and load handler fully lowered, see page 111. Procedure • Switch off the truck, to do this: • Turn the key in the key switch (104) to the left as far as the stop and remove the key.
  • Page 136 6.3.3 Recovering the truck from a narrow aisle WARNING! Risk of accidents and trapping during recovery operations Damage to other people and materials can occur if the truck is not towed correctly. There is a risk of accidents and trapping from the towed truck. Towing trucks must have sufficient tow and brake force for the towed truck which does not have any brakes.
  • Page 137 WARNING! An unsecured truck can cause accidents It is hazardous and prohibited to park the truck on inclines, with a raised operator's position or load handler. Park the truck on a level surface. In special cases the truck may need to be secured with wedges.
  • Page 139 Recovering the truck in the drive direction with or without a load Requirements – Operator position and load handler fully lowered, see page 111. – Truck switched off, see page 97. – Battery disconnected. – Drive wheel brake released, see page 132. Tools and Material Required –...
  • Page 140 Route the tow ropes at the front so as to avoid damaging the hydraulic hoses, the electric cables, the mast and the operator position during recovery. • EKS 110 L model with simplex mast: • Sling the tow rope (105) around the mast below the control panel (108) (see illustration).
  • Page 141 • Route 2 tow ropes (105) past the outside of the masts (6) and around the mast cross member (107) in the load direction (see illustration). • Recover the truck carefully and slowly in the load direction. • If the steer angle has to be changed during a recovery operation, brake until the truck comes to a halt: •...

  • Page 142: Optional Equipment

    Optional equipment Keyless Access System The keyless access system allows an individual code to be allocated to each operator or group of operators. I D E N T ? mode Item Description Display unit (EasyAccess Softkey): – Description, see page 75 –...

  • Page 143: General Information About The Use Of Keyless Access Systems

    General Information about the Use of Keyless Access Systems The default code is to be found on a sticker. When using for the first time, change the set-up code and remove the sticker! – Default code: 1-2-3-4 – Factory set-up code: #VAR:2ZOLL_MASTERCODE_VARJH# When allocating the codes, ensure the rider trucks are given a different code than pedestrian trucks.
  • Page 144 7.3.1 Activating the keypad Procedure • Release the emergency disconnect switch, see page 99. • Enter the default code 1-2-3-4 using the keys below the display unit (109). The truck is switched on. • Press the key below the "Settings" symbol (113).
  • Page 145 7.3.2 Activating the transponder reader Procedure • Release the emergency disconnect switch, see page 99. • Enter the default code 1-2-3-4 using the keys below the display unit (109). The truck is switched on. • Press the key below the "Settings" symbol (113).

  • Page 146: Using The Display

    Using the Display: 7.4.1 Switch on the truck with the access code. Procedure • Release the emergency disconnect switch, see page 99. • Enter the access code with the buttons below the display (109). The truck is switched on. 7.4.2 Switching off the truck Procedure •...
  • Page 147 7.4.3 Changing the Set-up Code Requirements – The truck is switched on, see page 151. Procedure • Press the key below the "Settings" symbol (113). • Press the key below the "Change set- up code" symbol (114). • Enter the set-up code using the keys below the display unit (109).
  • Page 148 7.4.4 Adding a new access code Requirements – The truck switched page 151. Procedure • Press the key below the "Settings" symbol (113). • Press the key below the "Edit access code" symbol (119). The set-up code is requested. • Enter the set-up code using the keys below the display unit (109).
  • Page 149 7.4.5 Deleting an access code Requirements – The truck switched page 151. Procedure • Press the key below the "Settings" symbol (113). • Press the key below the "Edit access code" symbol (119). The set-up code is requested. • Enter the set-up code using the keys below the display unit (109).

  • Page 150: Using The Keypad

    Using the Keypad 7.5.1 Switch on the truck with the access code. Procedure • Release the emergency disconnect switch, see page 99. • Enter the access code with the keypad (110). The truck is switched on. 7.5.2 Switching off the truck Procedure •...
  • Page 151 7.5.3 Changing the Set-up Code Requirements – The truck is switched on, see page 151. Procedure • Press the key below the "Settings" symbol (113). • Press the key below the "Change set-up code" symbol (114). • Enter the set-up code using the keypad (110).
  • Page 152 7.5.4 Adding a new access code Requirements – The truck switched page 151. Procedure • Press the key below the "Settings" symbol (113). • Press the key below the "Edit access code" symbol (119). The set-up code is requested. • Enter the set-up code using the keypad (110).
  • Page 153 7.5.5 Deleting an access code Requirements – The truck is switched on, see page 151. Procedure • Press the key below the "Settings" symbol (113). • Press the key below the "Edit access code" symbol (119). The set-up code is requested. •...

  • Page 154: Using The Transponder Reader

    Using the Transponder Reader NOTE Take care not to damage the transponder. If the transponder is damaged, the truck cannot be switched on. 7.6.1 Switching on the truck with the transponder Procedure • Release the Emergency Disconnect switch, see page 99. •...
  • Page 155 7.6.3 Changing the Set-up Transponder Requirements – The truck is switched on, see page 155. Procedure • Press the key below the "Settings" symbol (113). • Press the key below the "Change set-up code" symbol (114). • Place the set-up transponder on the transponder reader (111).
  • Page 156 7.6.4 Adding a new transponder Requirements – The truck is switched on, see page 155. Procedure • Press the key below the "Settings" symbol (113). • Press below "Edit transponder" symbol (119). The set-up transponder is requested. • Place the set-up transponder on the transponder reader (111).
  • Page 157 7.6.5 Deleting transponders Requirements – The truck is switched on, see page 155. Procedure • Press the key below the "Settings" symbol (113). • Press the key below the "Edit transponder" symbol (119). set-up transponder requested. • Place the set-up transponder on the transponder reader (111).

  • Page 158: Ism Access Module (O)

    ISM access module (o) If the truck is equipped with an ISM access module refer to the “ISM Access Module” operator manual.

  • Page 159: Travelling In Pedestrian Touch Mode (O)

    Travelling in pedestrian touch mode (o) There are 2 versions for pedestrian touch mode: – Touch mode version with gate – Touch mode version without gate Touch mode version with gate...
  • Page 160 Touch mode version without gate...
  • Page 161 CAUTION! Trapping hazard from the truck during pedestrian mode In pedestrian mode the truck can pose a trapping hazard for the operator and other people. Wear personal protective equipment (e.g. safety shoes, ...). The operator must always stand beside the truck during pedestrian operation. The truck must be operated with particular care and attention in pedestrian mode.

  • Page 162: Lifting And Lowering In Pedestrian Touch Mode

    Lifting and lowering in pedestrian touch mode In pedestrian touch mode lifting and lowering can be operated from either side of the truck as an optional feature. On trucks with main lift (version L) the entire operator's position and load handler rise or lower with the forks in pedestrian touch mode lifting or lowering.
  • Page 164 7.9.2 Lowering the Operator's Position (Version L) WARNING! Ensure there are no other people standing underneath the raised load and driver's cab. Do not stand on the load handler. Do not lift other people on the load handler. Instruct other people to move out of the hazardous area of the truck. The operator must stand outside the geometry of the truck and the load.
  • Page 166 7.9.3 Raising the Auxiliary Lift (Version Z) CAUTION! Trapping hazard from the truck during pedestrian mode In pedestrian mode the truck can pose a trapping hazard for the operator and other people. Wear personal protective equipment (e.g. safety shoes, ...). The operator must always stand beside the truck during pedestrian operation.
  • Page 167 7.9.4 Lowering the Auxiliary Lift (Version Z) WARNING! Ensure there are no other people standing underneath the raised load and driver's cab. Do not stand on the load handler. Do not lift other people on the load handler. Instruct other people to move out of the hazardous area of the truck. The operator must stand outside the geometry of the truck and the load.

  • Page 168: Lifting And Lowering The Operator's Position With Lift Cutout (O)

    7.10 Lifting and Lowering the Operator's Position with Lift Cutout (o)
  • Page 169 On trucks with the lift cutout option (o) the operator's position rises to a fixed cutout height which is less than the maximum lift height. Lifting Procedure • Press the deadman switch (80). • Press the lift button (58) until you reach the fixed cutout height. •...

  • Page 170: Trucks With Rail Guidance And Aisle Recognition (O)

    7.11 Trucks with Rail Guidance and Aisle Recognition (o) Notes on rail-guided operation The "aisle recognition via light button" option enables the truck to travel at maximum speed in the aisle. In rail-guided mode with aisle recognition, the two-hand operation button (68) must also be pressed in order to travel, lift and lower.
  • Page 171 The lift (58) or lower (57) buttons and the two-hand operation button (68) must be pressed and held down switch for lifting and lowering operations. Exiting narrow aisles As soon as the first light button in the travel direction is released by the side rails (truck with the first guide roller pair outside the side rails), the travel speed is automatically reduced to 2.5 km/h (slow travel) and travel, lifting and lowering can resume again without having to press the two-hand operation button (68).
  • Page 172 7.11.1 End of aisle safety device (o) Trucks with the end of aisle 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 can be adjusted by the manufacturer's customer service department.
  • Page 173 2. Braking up to 2,5 km/h When crossing over the end of aisle safety device (magnets in the ground) travelling towards the aisle end, the truck brakes to 2,5 km/h and the end of aisle safety device indicator lamp (69) lights up. The truck can be driven out of the narrow aisle at this speed.

  • Page 174: Negotiating Narrow Aisles

    7.12 Negotiating narrow aisles 7.12.1 Safety notices for travelling in narrow aisles WARNING! Unauthorised entry of narrow aisles by other trucks or people can cause accidents Unauthorised personnel must not enter narrow aisles (truck lanes in racking systems with safety distances < 500 mm), nor must any personnel cross through them. These work areas must be marked and identified accordingly.
  • Page 175 WARNING! Objects protruding out of the racks can be hazardous The operator of the truck in a narrow aisle can be injured by objects protruding from the racks (e. g. pallets, loads etc.). A collision between the truck and the protruding objects could also cause material damage to the truck and the rack construction.
  • Page 176 Travelling in narrow aisles with rail-guided trucks Requirements – Narrow aisles must be equipped with guide rails (125). – Prepare the truck for operation, see page 94 or see page 143. Procedure • Press the deadman switch. • Approach the aisle at reduced speed so that the truck (126) is aligned with the narrow aisle and is within the demarcations.

  • Page 177: Walk-On Load Handler With Pallet Guard (O)

    7.13 Walk-On Load Handler with Pallet Guard (o) CAUTION! Risk of crashing with walk-on pallets Only walk on a pallet if it has a pallet guard (o). Beyond lift heights > 1200 mm the gates must be closed to enable travel, lifting and lowering (Main Lift).

  • Page 178: Jetpilot

    Lifting pallets Procedure • Fully lower the operator's position (main lift). • Drive the truck carefully up to the pallet. • Align the sides of the pallet guard centrally with the pallet. • Slowly insert the load handler into the pallet until the fork face touches the pallet. The pallet must fully rest on the load handler behind the anti-slip device (131) and the pallet must be below the tilt safety device (128) on the fork shank.
  • Page 179 Item Control/display Function Lift button Raises the operator position and load handler. Auxiliary lift raise button Raises the load handler. Auxiliary lift lower button Lowers the load handler. Warning button Issues a warning signal. Clip pad For holding A4 paper 132 JetPilot travel switch Controls the travel direction and the speed.

  • Page 180: Pre-Set Fork Lowering Settings For Stock Picking For L Model

    7.15 Pre-set Fork Lowering Settings for Stock Picking for L Model On trucks equipped with the pre-set fork lowering settings for stock picking option (o), the operator position lowers when the lower button is pressed down to a defined cut-off height such that the load handler is lowered to just above the ground. If the pallet is to be set down, the lower button must be pressed again.

  • Page 181: Warehouse Management System (Wms)

    7.17 Warehouse Management System (WMS) Control station without and with controls in the load direction Item Control/display Function 138 WMS additional display Truck terminal for working at the control station in the load direction. 137 Push button Push button for acknowledging the raised load. 7.18 Crawl Speed with Lowered Load Handler The crawl speed function (o) reduces the truck speed when the operator position and...

  • Page 182: F Industrial Truck Maintenance

    F Industrial Truck Maintenance Operational Safety and Environmental Protection The checks and servicing operations contained in this chapter must be performed in accordance with the maintenance checklist service intervals. WARNING! Risk of accidents and component damage Any modification to the truck, in particular the safety mechanisms, is prohibited. Exception: Operating companies should only make changes or have changes made to powered industrial trucks if the manufacturer is no longer operating in the field and there is no successor to the business;...
  • Page 183 NOTE Only original spare parts are subject to the manufacturer's quality control. To ensure safe and reliable operation, use only the manufacturer's spare parts. For safety reasons, only components which have been specially agreed by the manufacturer for this truck may be installed near the computer, controllers and wire guidance sensors (antennae).

  • Page 184: Maintenance Safety Regulations

    Maintenance Safety Regulations Maintenance and repair personnel The manufacturer has a service department specially trained for these tasks. A maintenance contract with the manufacturer will ensure trouble-free operation. Truck maintenance and repair work must only be carried out by specially trained personnel.

  • Page 185: Working On The Electrical System

    Working on the electrical system WARNING! Electrical current can cause accidents Ensure the electrical system is de-energised before starting work. The capacitors in the control must be completely discharged. The capacitors are fully discharged approx. 10 minutes after disconnecting the electrical system from the battery. Before starting maintenance on the electrical system: Only suitably trained electricians may work on the truck's electrical system.

  • Page 186: Wheels

    Wheels WARNING! The use of wheels that do not comply with the manufacturer's specifications can result in accidents The quality of wheels affects the stability and driving characteristics of the truck. Uneven wear affects the truck's stability and increases the stopping distance. After replacing wheels, make sure the truck is not skewed.

  • Page 187: Lift Chain Inspection

    Lift chain inspection Unauthorised wear and external damage: NOTE In accordance with official regulations, a lift chain is considered to be worn if its length has increased by 2,9 % in the section which runs over the pulley. WARNING! Accident risk from damaged lift chains Replace a chain immediately if it shows external signs of damage.

  • Page 188: Hydraulic System

    Hydraulic system NOTE Testing and replacing hydraulic hoses Hydraulic hoses can become brittle through age and must be checked at regular intervals. The application conditions of the industrial truck have a considerable impact on the ageing of the hydraulic hoses. Check the hydraulic hoses at least annually and replace if necessary.

  • Page 189: Lubricants And Lubrication Schedule

    Lubricants and Lubrication Schedule Handling consumables safely Handling consumables Consumables must always be handled correctly. Follow the manufacturer’s instructions. WARNING! Improper handling is hazardous to health, life and the environment Consumables can be flammable. Keep consumables away from hot components and naked flames. Always keep consumables in prescribed containers.
  • Page 190 WARNING! Improper handling of oils can be hazardous Oils (chain spray / hydraulic oil) are flammable and poisonous. Dispose of used oils in accordance with regulations. Store used oil safely until it can be disposed of in accordance with regulations. Do not spill oil.

  • Page 191: Lubrication Schedule

    Lubrication Schedule B 1,05 l g Contact surfaces Cold-store application Hydraulic-oil filler neck a Transmission oil drain plug 1 Mixture ratio for cold-store usage 1:1 2 Transmission oil is a guideline. The spur wheel should be dipped approx. 2 mm into the transmission oil.

  • Page 192: Consumables

    The Jungheinrich hydraulic oil can only be obtained from the Jungheinrich service department. The use of named alternative hydraulic oils is not prohibited but may lead to a decline in functionality. The Jungheinrich hydraulic oil may be mixed with one of the named alternative hydraulic oils.

  • Page 193: Maintenance And Repairs

    Maintenance and repairs Preparing the truck for maintenance and repairs All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made: Procedure • Park the truck securely, see page 97. •...

  • Page 194: Lifting And Jacking Up The Truck Safely

    Lifting and jacking up the truck safely Lifting and jacking up WARNING! Lifting and jacking up the truck safely In order to raise the truck, the lifting gear must only be secured to the points specially provided for this purpose. You may only work under a raised load handler / raised cab if they have been secured with a sufficiently strong chain or the fastening bolt.
  • Page 195 Raising and jacking up the truck securely Requirements – Prepare the truck for maintenance and repairs (see page 194). Tools and Material Required – Jack – Hard wooden blocks Procedure • Place the jack against the contact point. Jack contact point, see page 36. •...

  • Page 196: Front Panel Assembly And Disassembly

    Front panel assembly and disassembly Front cover disassembly Requirements – Prepare truck maintenance and repairs (see page 194). Tools and Material Required – Allen key, size 6 Procedure • Remove the screws (139). • Lift and remove the front panel (15).

  • Page 197: Electrical System

    Electrical System Exposing the electrical system Procedure • Open the battery panel, see page 57. • Hold the top of the electrical system cover (17) and pull it away from the truck until the top two snap lock connections are disengaged. •...

  • Page 198: Checking Electrical Fuses

    Checking electrical fuses Checking fuses Requirements – Truck prepared maintenance repairs. – Electrical system exposed. Procedure • Check fuse ratings and check for damage. • Replace any damaged fuses in accordance with the table. • Close electrical system. fuses checked. Item Component To protect Value...

  • Page 199: Replace The Drive And Load Wheels

    Replace the Drive and Load Wheels The load and drive wheels must only be replaced by the manufacturer's customer service department which has been specially trained for these tasks. Tightening the wheel nuts...
  • Page 200 The wheel nuts on the drive wheel must be retightened in accordance with the maintenance intervals indicated in the maintenance checklist, see page 217. Tightening the wheel nuts Requirements – Prepare the truck for maintenance and repairs, see page 194. Tools and Material Required –...

  • Page 201: Mast Retainer Assembly And Removal

    Mast retainer assembly and removal EKS 110 100E, 160 E, 190E mast retainers EKS 110 280ZZ mast retainers...
  • Page 202 The truck has four (for simplex mast 2) retaining blocks to secure the mast. Mast retainer assembly Requirements – Prepare the truck for maintenance and repairs (see page 194). Tools and Material Required – Allen key, size 10 Procedure • Open the front panel. •...

  • Page 203: Cleaning

    Cleaning 4.9.1 Cleaning the truck CAUTION! Fire hazard Do not use flammable liquids to clean the industrial truck. Disconnect the battery before starting cleaning work. Carry out all necessary safety measures to prevent sparking before cleaning (e.g. by short-circuiting). CAUTION! Risk of component damage when cleaning the truck Cleaning with a pressure washer can result in malfunctions due to humidity.
  • Page 204 Cleaning the truck Requirements – Prepare the truck for maintenance and repairs (see page 194). Tools and Material Required – Water-based solvents – Sponge or cloth Procedure • Clean the surface of the truck with water-based solvents and water. Use a sponge or cloth to clean.
  • Page 205 4.9.2 Cleaning the electrical system assemblies CAUTION! Risk of electrical system damage Cleaning the assemblies (controllers, sensors, motors etc.) of the electronic system with water can damage the electrical system. Do not clean the electrical system with water. Clean the electrical system with weak suction or compressed air (use a compressor with a water trap) and not a conductive, anti-static brush.

  • Page 206: Lift Chain Servicing

    4.10 Lift chain servicing WARNING! Non-lubricated and incorrectly cleaned lift chains can cause accidents Lift chains are safety-critical parts. They must not contain any serious contamination. Lift chains and pivot pins must always be clean and well lubricated. Lift chains should only be cleaned with paraffin derivatives e.g. petroleum or diesel fuels.
  • Page 207 Procedure WARNING! An extended mast can cause accidents Be aware of the ceiling height when raising the operator's position and load handler. • Fully raise the operator's position and load handler. • Switch off the truck and remove the key if applicable. •...

  • Page 208: Checking The Hydraulic Oil Level

    4.12 Checking the hydraulic oil level CAUTION! The hydraulic oil is pressurised during operation and is a hazard to health and to the environment. Do not touch pressurised hydraulic lines. Dispose of used oil in accordance with regulations. Store used oil safely until it can be disposed of in accordance with regulations.
  • Page 209 CAUTION! Consumables and used parts are an environmental hazard Used parts and consumables must be disposed of in accordance with the applicable environmental-protection regulations. Oil changes should be carried out by the manufacturer's customer service department, whose staff are specially trained for this task.

  • Page 210: Restoring The Truck To Service After Maintenance And Repairs

    Restoring the truck to service after maintenance and repairs The truck can only be restored to service after cleaning or maintenance after the following procedures have been carried out: Procedure • Connect the battery connector to the truck, siehe "Battery removal and installation" in Kapitel 5.

  • Page 211: Prior To Decommissioning

    Prior to decommissioning Procedure • Thoroughly clean the truck, see page 204. • Prevent the truck from rolling away accidentally. • Check the hydraulic oil level and replenish if necessary, see page 209. • Apply a thin layer of oil or grease to any non-painted mechanical components. •...

  • Page 212: Restoring The Truck To Service After Decommissioning

    Restoring the truck to service after decommissioning Procedure • Thoroughly clean the truck, see page 204. • Lubricate the truck according to the lubrication schedule, see page 192. • Clean the battery, grease the terminal screws and connect the battery. •...

  • Page 213: Safety Tests To Be Performed At Intervals And After Unusual Incidents

    Safety tests to be performed at intervals and after unusual incidents The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector. The manufacturer offers a safety inspection service which is performed by personnel specifically trained for this purpose.

  • Page 214: Final De-Commissioning, Disposal

    Final de-commissioning, disposal Final de-commissioning or disposal of the truck in must be performed in accordance with the regulations of the country of use. In particular, regulations governing the disposal of batteries, consumables and electronic and electrical systems must be observed. The truck must only be disassembled by trained personnel in accordance with the procedures as specified by the manufacturer.

  • Page 216: G Maintenance And Inspection

    G Maintenance and Inspection WARNING! Lack of maintenance can result in accidents Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment. Thorough and expert servicing is one of the most important requirements for the safe operation of the industrial truck.

  • Page 217: Maintenance Checklist

    Maintenance checklist Owner 1.1.1 Standard equipment Brakes W A B C Test the brakes. Electrics W A B C Test warning and safety devices in accordance with operating instructions. Test the emergency disconnect switch. Power supply W A B C Check battery and battery components.
  • Page 218 1.1.2 Optional equipment Rail guidance Driving W A B C Check rail guide rollers for wear and damage. Work lights Electrics W A B C Test the lighting. Strobe light / beacon Electrics W A B C Test the strobe light/beacon and check for damage. Overhead guard Chassis and superstructure W A B C...

  • Page 219: Customer Service

    Customer Service 1.2.1 Standard equipment Brakes W A B C Test the brakes. Check the magnetic brake air gap, adjust if necessary. Electrics W A B C Check the cables and motor mounting are secure. Test warning and safety devices in accordance with operating instructions.
  • Page 220 Chassis and superstructure W A B C Check chassis connections and screw connections for damage. Check doors and/or covers. Check labels are legible, complete and plausible. Test the adjustable floor plate and make sure it is secure. Test the operator platform and check for damage. Check mast mounting/bearings.
  • Page 221 Steering W A B C Test the electric steering and its components. Check the steering bearings, steering play and steering toothing or steering chain. Lubricate the steering toothing or steering chain. 1.2.2 Optional equipment Electrolyte circulation Power supply W A B C Check hose connections and test the pump.
  • Page 222 Aisle recognition System components W A B C Test aisle recognition magnetic switch and/or light button, check for contamination and damage. Lift cutout Hydr. movements W A B C Test the lift-limit cut-off/lift cut-off, check for damage and make sure it is secure.
  • Page 223 Strobe light / beacon Electrics W A B C Test the strobe light/beacon and check for damage. Audible warning devices Electrics W A B C Test the buzzer/warning alarm, check for damage and make sure it is secure. Discharge strap Electrics W A B C Check anti-static discharge strap/chain is present and not damaged.
  • Page 224 Hydr. movements W A B C Note: In cold-store applications, we recommend replacing the hydraulic oil every 1000 service hours or once a year. Pallet clamp Hydr. movements W A B C Test the pallet clamp and check for wear and damage. Issued on: 08.11.2016 10:07:28...