Jungheinrich EKE 30-2 ac Operating Instructions Manual

Operating instructions
50272276
EKE 30-2 ac
G
08.02-
09.03
0108.GB
Foreword
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter. Each chapter starts with page 1. The page identification consists of a chapter letter and a page number. For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following graphics:
f
Used before safety instructions which must be observed to avoid danger to personnel.
m
Used before notices which must be observed to avoid material damage.
A
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
0108.GB
I 1
0903.GB
Table of contents
A Correct use and application of the truck
B Truck description
1 Application description ........................................................................ B 1
2 Description of assembly groups and functions .................................... B 2
2.1 Truck ................................................................................................... B 3
3 Technical data - standard version ....................................................... B 4
3.1 Performance data ................................................................................ B 4
3.2 Dimensions ......................................................................................... B 5
3.3 EN standards ...................................................................................... B 6
3.4 Conditions for application .................................................................... B 6
3.5 Technical description – load lifting devicet .......................................... B 7
4 Label positions and identification plates .............................................. B 7
4.1 Truck identification plate ..................................................................... B 8
C Transportation and commissioning
1 Transportation by crane ...................................................................... C 1
2 Commissioning .................................................................................... C 2
3 Parking brake shipping restraint .......................................................... C 2
D Battery - Servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ........ D 1
2 Battery types ....................................................................................... D 2
3 Exposing the battery ........................................................................... D 2
4 Charging the battery ............................................................................ D 3
5 Removing and installing the battery .................................................... D 4
6 Information and service display (LISA) ............................................... D 5
0903.GB
I 2
E Operation
1 Safety regulations governing the operation of the fork lift truck .......... E 1
2 Description of operating and display elements ................................... E 2
3 Starting up the truck ............................................................................ E 4
3.1 Emergency stop facility ....................................................................... E 6
4 Operation of the fork lift truck .............................................................. E 7
4.1 Safety regulations applicable when operating the truck ...................... E 7
4.2 Driving, steering, braking .................................................................... E 8
4.3 Picking up and putting down load units ............................................... E 10
4.4 Safe parking of the truck ..................................................................... E 10
5 Troubleshooting .................................................................................. E 11
6 Emergency steering ............................................................................ E 12
6.1 Mechanical auxiliary steering .............................................................. E 12
6.2 Electric emergency steering mode ...................................................... E 13
F Maintenance of the fork lift truck
1 Operational safety and environmental protection ................................ F 1
2 Safety regulations applicable to truck maintenance ............................ F 1
3 Servicing and inspection ..................................................................... F 3
4 EKE 30-2 ac maintenance checklist ................................................... F 4
5 EKE 30-2 ac lubrication schedule ....................................................... F 6
5.1 Fuels, coolants and lubricants ............................................................. F 7
6 Notes on maintenance ........................................................................ F 8
6.1 Preparing the truck for servicing and maintenance operations ........... F 8
6.2 Opening the driver door ...................................................................... F 8
6.3 Swinging up the balcony ..................................................................... F 8
6.4 Opening the steering controller ........................................................... F 9
6.5 Checking electric fuses ....................................................................... F 10
6.6 Recommissioning the truck ................................................................. F 11
7 Decommissioning the fork lift truck ..................................................... F 11
7.1 Operations to be performed prior to decommissioning ....................... F 11
7.2 Measures to be taken during decommissioning .................................. F 11
7.3 Recommissioning the truck ................................................................. F 12
8 Safety checks to be performed at regular intervals and following any
untoward incidents (D: Accident prevention check
according to BGV D27) ....................................................................... F 12
A 1
0600.GB
A Correct use and application of the truck
A
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are included in the scope of delivery for this truck. The guidelines are part of these ope- rating instructions and must always be heeded. National regulations are fully applica- ble.
The fork-lift truck described in these operating instructions is a truck that is suitable for lifting and transporting loads. It must be used, operated and maintained according to the information in these ope- rating instructions. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. admis- sible load to be picked up is indicated on the identification plate or load diagram label shown on the truck. The fork-lift truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres pre- vail.
Duties of the user: A “user” within the meaning of these operating instructions is de- fined as any natural or legal person who either uses the fork-lift truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is conside- red the person, who, in accordance with existing contractual agreements between the owner and the user of the fork-lift truck, is charged with the observance of the opera- ting duties. The user must ensure that the truck is not abused and only used within its design li- mits and that all danger to life and limb of the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety-related provisions, as well as the operating, servicing and mainte- nance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions.
m
If these Operating Instruction are not observed the warranty becomes void. The same applies if improper work is carried out on the device by the customer and/or third par- ties without permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after writ- ten approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained. Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary.
0600.GB
A 2
B 1
1002.GB
B Truck description
1 Application description
The truck is an electric four-wheel sideways seat fork-lift truck with two drive units and electric steering with two steering motors. The truck is a pallet truck designed for transporting goods on level ground. It can pick up pallets with an open bottom or with cross pieces or trolleys outside the load wheel area. The capacity is indicated on the identification plate and also on the capacity plate Qmax. The fork dimensions match the type and number of pallets or trolleys to be picked up. Great emphasis has been placed on the ergonomic driver position and on-the-job safety. The controls are evidently and clearly arranged and have been matched to the transport task.
Truck types and capacity:
Type Capacity
EKE 30-2 ac 3000kg
1002.GB
B 2
2 Description of assembly groups and functions
Item Designation Item Designation
1 t Information and
service display (LISA)
8 t Accelerator pedal
2 t Hydraulics control
knob
9 t Driver seat
3 t Parking brake 10 t Lifting device 4 t Key switch 11 t Drive wheels 5 t Main switch
(EMERGENCY STOP)
12 t Emergency steering switch
6 t Driver door 13 t Safety seat belt 7 t Brake pedal
t = Series equipment o = Optional equipment
1
6
11
2 43 5
10
9
8
7
13
12
B 3
1002.GB
2.1 Truck
Safety devices Closed, smooth truck contour. The drive wheels (11) are protected
by a sturdy collision guard. It protects the load against collisions. All electric functions can be disabled in case of danger using the key switch (4) or the main switch (EMERGENCY STOP) (5). The driving function is disabled when the driver door is open.
Superstructure: The fork-lift truck is a 4-wheel truck with two steered drive wheels (11). Easy to open balcony with integrated instruments, easy to open drive compartment covering and hinged flap provide easy access to all units for servicing. The controls are ergonomically arranged.
Drive system: The two complete drive units are screwed into the truck chassis. Two stationary three-phase motors with a performance of 6 kW each act on the drive wheels (11) via evel gears. The electronic drive controllers allow the drive motor speed to be continuously regulated and thus ensure smooth, joltless starting, powerful acceleration and electronically controlled braking with energy regeneration. The energy regeneration ratio can be set with the LISA.
Steering: Bevel gear steering with two steering drive units and fully electronic controller as series feature. The pivoted gears can be swiveled by 90° to both sides.
Controls and indicators: Controls and indicators are clearly arranged at the driver position. The hydraulics control knob (2) allows single-handed operation of the travel direction, lifting/lowering and horn functions. In conjunction with the accelerator pedal, it is also is used for diagonal travel. Information and service display (LISA) (1) with large LC display, integrated operating hours counter and battery discharge indicator with lift cut-off function.
Hydraulic system: The hydraulics control knob activates the lifting and lowering functions. By activating the lifting function, the pump unit starts and feeds hydraulic oil from the oil oil reservoir into the lifting cylinder.
Electric system: 48-Volt two-wire system. Two electronic drive current controllers and two electric steering controllers are series features.
Brake system: Two independent brake systems act on the drive wheel. The service brake, being a hydraulic drum brake with asbestos-free brake shoes is activated with the foot pedal. The parking brake (3) acts mechanically (pressure spring) on the drum brake via cables. The information and service display (LISA) monitors the brake fluid level. A warning indicator lights up when the parking brake is applied. Malfunctions of the steering and parking brake system (EMERGENCY STOP activation) are displayed on the information and service display (LISA).
1002.GB
B 4
3 Technical data - standard version
A
Indication of technical data according to VDI 2198. Subject to modification and supplementing.
3.1 Performance data
*) Even distribution across the entire fork length.
Designation EKE 30-2ac
Q Rated load capacity 3000 kg
c
Load centre distance at standard fork length *
)
1800 mm
Travel speed with/without rated load
18.1 / 18.3 km/h
Lifting speed with/without rated load
2.6 / 3.0 cm/s
Lowering speed with/without rated load
3.0 / 2.9 cm/s
h
3
h
13
m
2
l
2
l
1
l
y
1000 kg 1000 kg 1000 kg
290
h
7
b10b
2
b
5
e
1745
1980
s
a
_ 2
a
_ 2
A
st
W
a
b11
B 5
1002.GB
3.2 Dimensions
(all dimensions in mm)
Designation Standard
h
3
Lifting height 115
h
7
Seating height 1450
h
13
Lowered height of fork 90 +5
l
1
Overall length 4855
l
2
Front section length 1255
b
2
Truck width 1000
b
5
Distance between forks, outside 580
b
10
Track width, drive 604
b
11
Track width, load section 380
W
a
Turning radius 3900
A
st
Aisle width with pallet 1000 x 1200 in longitudinal direction
5055
a Safety distance 200
Dead weight: see truck identification plate
1002.GB
B 6
3.3 EN standards
Continuous sound level: 68 dB(A)
according to EN 12053 as stipulated in ISO 4871
A
The continuous sound level is a value averaged according to standard regulations, taking the sound pressure level into account when driving, lifting and idling. The sound pressure level is measured at the ear.
Vibration: 0.96 m/s
2
according to EN 13059
A
The swinging acceleration acting on the body in its operating position is, according to standard regulations, the linear integrated, weighted acceleration in the vertical plane. It is determined by driving over bumps with a constant speed.
Electromagnetic compatibility (EMC)
The manufacturer confirms compliance with the limit val- ues for electromagnetic emission and interference immu- nity as well as testing of static electricity discharge ac- cording to EN 12895 and the references to other standards contained therein.
A
Electrical or electronic components and their arrangement may only be modified after written approval by the manufacturer has been obtained.
3.4 Conditions for application
Ambient temperature:
- during operation: 5°C to 40°C
Industrial trucks must be specially equipped and approved for continuous use in environments with temperatures below 5°C or in cold stores respectively with extreme temperatures or humidity changes.
B 7
1002.GB
3.5 Technical description – load lifting devicet
Lifting device: The lifting cylinder and the lifting linkage connect the lifting device
(10) with the fork and the chassis. The fork is raised by extending the lifting cylinder while the lifting linkage simultaneously swivels the load bearing wheel holders.
4 Label positions and identification plates
Item Designation
14 Truck identification plate 15 Carrying capacity Qmax 16 Eye for crane loading 17 Label “Danger of squeezing” 18 UVV test plaque
17
16
16
15
18
Q
max
3000
kg
14
kg
kg mm kg
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1002.GB
B 8
4.1 Truck identification plate
A
In the event of queries relating to the truck or spare part orders, please state the serial No. (20) of the truck.
Item Designation Item Designation
19 Type 26 Driving power in kW 20 Serial no. 27 Customer No. 21 Rated carrying capacity in kg 28 Min./max. battery weight in kg 22 Battery: Voltage in V 29 Dead weight without battery in kg 23 Manufacturer 30 Year of manufacture 24 Order No. 31 Manufacturer's logo 25 Load centre distance in mm
kg
kg mm kg
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