EKS 513 - 515
EKS 410
Operating instructions
52025221
EKS 410/513/515k/515
G
12.03 -
07.08
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.
Z
Used before notices and explanations.
t Used to indicate standard equipment.
o Used to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the truck. No guarantee of
particular features of the truck should therefore be inferred from the present operating
instructions.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
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.
Z
Used before notices and explanations.
t Used to indicate standard equipment.
o Used to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the truck. No guarantee of
particular features of the truck should therefore be inferred from the present operating
instructions.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
0108.GB
0108.GB
I 1
0708.GB
Index
A Correct use and application
B Truck Description
1 Application ...........................................................................................B 1
2 Assemblies and Functional Description .............................................. B 2
2.1 Truck ...................................................................................................B 3
3 Standard Version Specifications ......................................................... B 4
3.1 Performance data ................................................................................ B 4
3.2 Dimensions (as per data plate) ........................................................... B 6
3.3 EKS 410 mast version ......................................................................... B 7
3.4 EKS 513 – 515 mast version ............................................................... B 7
3.5 EN norms ............................................................................................B 8
3.6 Conditions of use ................................................................................B 8
4 Identification points and data plates ....................................................B 9
4.1 Truck data plate ..................................................................................B 11
4.2 Capacity ..............................................................................................B 11
C Transport and Commissioning
1 Transport ............................................................................................. C 1
2 Lifting by crane .................................................................................... C 1
2.1 Crane points ........................................................................................ C 2
2.2 Lifting the battery by crane .................................................................. C 2
3 Securing the truck during transport ..................................................... C 2
3.1 Basic truck transport safety ................................................................. C 3
3.2 Mast transport safety ........................................................................... C 4
3.3 Mast assembled .................................................................................. C 5
3.4 Safely transporting the truck with the mast folded (EKS 513 - 515) .... C 5
4 Commissioning .................................................................................... C 6
4.1 Moving the truck without a battery ...................................................... C 6
4.2 Installing and removing the mast ........................................................ C 6
5 Starting the truck for the first time ....................................................... C 6
D Battery Maintenance, Charging & Replacement
1 Safety regulations for handling acid batteries ..................................... D 1
2 Battery types ....................................................................................... D 2
3 Charge the battery .............................................................................. D 2
4 Battery removal and installation .......................................................... D 3
5 Battery – checking condition and acid level ........................................ D 7
6 Battery discharge indicator .................................................................. D 7
I 1
0708.GB
Index
A Correct use and application
B Truck Description
1 Application ...........................................................................................B 1
2 Assemblies and Functional Description .............................................. B 2
2.1 Truck ...................................................................................................B 3
3 Standard Version Specifications ......................................................... B 4
3.1 Performance data ................................................................................ B 4
3.2 Dimensions (as per data plate) ........................................................... B 6
3.3 EKS 410 mast version ......................................................................... B 7
3.4 EKS 513 – 515 mast version ............................................................... B 7
3.5 EN norms ............................................................................................B 8
3.6 Conditions of use ................................................................................B 8
4 Identification points and data plates ....................................................B 9
4.1 Truck data plate ..................................................................................B 11
4.2 Capacity ..............................................................................................B 11
C Transport and Commissioning
1 Transport ............................................................................................. C 1
2 Lifting by crane .................................................................................... C 1
2.1 Crane points ........................................................................................ C 2
2.2 Lifting the battery by crane .................................................................. C 2
3 Securing the truck during transport ..................................................... C 2
3.1 Basic truck transport safety ................................................................. C 3
3.2 Mast transport safety ........................................................................... C 4
3.3 Mast assembled .................................................................................. C 5
3.4 Safely transporting the truck with the mast folded (EKS 513 - 515) .... C 5
4 Commissioning .................................................................................... C 6
4.1 Moving the truck without a battery ...................................................... C 6
4.2 Installing and removing the mast ........................................................ C 6
5 Starting the truck for the first time ....................................................... C 6
D Battery Maintenance, Charging & Replacement
1 Safety regulations for handling acid batteries ..................................... D 1
2 Battery types ....................................................................................... D 2
3 Charge the battery .............................................................................. D 2
4 Battery removal and installation .......................................................... D 3
5 Battery – checking condition and acid level ........................................ D 7
6 Battery discharge indicator .................................................................. D 7
0708.GB
I 2
E Operation
1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1
2 Operating and Display Equipment ......................................................E 2
2.1 Operating and display equipment on control panel .............................E 2
2.2 Display unit controls and displays .......................................................E 4
2.3 Lower range symbols and keys ........................................................... E 5
2.4 Truck operational status symbols ........................................................E 7
3 Starting up the truck ............................................................................ E 8
3.1 Setting the time ...................................................................................E 9
4 Industrial truck operation .....................................................................E 10
4.1 Safety regulations for truck operation .................................................E 10
4.2 Travelling, Steering, Braking ...............................................................E 11
4.3 Lifting–- lowering outside narrow aisles .............................................. E 16
4.4 Lifting–- lowering within narrow aisles ................................................. E 16
4.5 Order picking and stacking ..................................................................E 17
4.6 Parking the truck securely ...................................................................E 19
5 Troubleshooting ..................................................................................E 20
5.1 Emergency stop device .......................................................................E 22
5.2 Driver’s cab / Aux. Lift emergency lowering ........................................ E 22
5.3 Exiting the driver's cab with the emergency abseil device .................. E 23
5.4 Bypassing the chain slack safety device .............................................E 24
5.5 Bypassing the travel cutout (o) .......................................................... E 24
5.6 Lift cutout (o) ......................................................................................E 25
5.7 Aisle end safety device (o) .................................................................E 25
5.8 WG emergency operation ................................................................... E 26
5.9 Recovering the truck from a narrow aisle / Moving the truck
without a battery ..................................................................................E 27
0708.GB
I 2
E Operation
1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1
2 Operating and Display Equipment ......................................................E 2
2.1 Operating and display equipment on control panel .............................E 2
2.2 Display unit controls and displays .......................................................E 4
2.3 Lower range symbols and keys ........................................................... E 5
2.4 Truck operational status symbols ........................................................E 7
3 Starting up the truck ............................................................................ E 8
3.1 Setting the time ...................................................................................E 9
4 Industrial truck operation .....................................................................E 10
4.1 Safety regulations for truck operation .................................................E 10
4.2 Travelling, Steering, Braking ...............................................................E 11
4.3 Lifting–- lowering outside narrow aisles .............................................. E 16
4.4 Lifting–- lowering within narrow aisles ................................................. E 16
4.5 Order picking and stacking ..................................................................E 17
4.6 Parking the truck securely ...................................................................E 19
5 Troubleshooting ..................................................................................E 20
5.1 Emergency stop device .......................................................................E 22
5.2 Driver’s cab / Aux. Lift emergency lowering ........................................ E 22
5.3 Exiting the driver's cab with the emergency abseil device .................. E 23
5.4 Bypassing the chain slack safety device .............................................E 24
5.5 Bypassing the travel cutout (o) .......................................................... E 24
5.6 Lift cutout (o) ......................................................................................E 25
5.7 Aisle end safety device (o) .................................................................E 25
5.8 WG emergency operation ................................................................... E 26
5.9 Recovering the truck from a narrow aisle / Moving the truck
without a battery ..................................................................................E 27
I 3
0708.GB
F Maintenance of the forklift truck
1 Operational safety and environmental protection ................................F 1
2 Maintenance Safety Regulations ........................................................F 1
3 Servicing and inspection ..................................................................... F 3
4 EKS Maintenance Checklist ................................................................F 4
4.1 Lubrication Schedule ........................................................................... F 7
4.2 Fuels, coolants and lubricants .............................................................F 9
5 Maintenance and Repairs ................................................................... F 11
5.1 Prepare the truck for maintenance and repairs ................................... F 11
5.2 Securing the driver’s position carriage ................................................ F 11
5.3 Lift Chain Servicing ............................................................................. F 12
5.4 Inspecting the lift chains ...................................................................... F 12
5.5 Hydraulic oil ......................................................................................... F 13
5.6 Hydraulic hoses ................................................................................... F 14
5.7 Check brake fluid (EKS 513 - 515) ......................................................F 14
5.8 Checking electrical fuses (EKS 410) ...................................................F 15
5.9 Checking electrical fuses (EKS 513 - 515) .......................................... F 16
5.10 Recommissioning ................................................................................F 17
6 Decommissioning the industrial truck ..................................................F 17
6.1 Prior to decommissioning: ...................................................................F 17
6.2 During decommissioning: ....................................................................F 18
6.3 Restoring the truck to operation after decommissioning ..................... 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
I 3
0708.GB
F Maintenance of the forklift truck
1 Operational safety and environmental protection ................................F 1
2 Maintenance Safety Regulations ........................................................F 1
3 Servicing and inspection ..................................................................... F 3
4 EKS Maintenance Checklist ................................................................F 4
4.1 Lubrication Schedule ........................................................................... F 7
4.2 Fuels, coolants and lubricants .............................................................F 9
5 Maintenance and Repairs ................................................................... F 11
5.1 Prepare the truck for maintenance and repairs ................................... F 11
5.2 Securing the driver’s position carriage ................................................ F 11
5.3 Lift Chain Servicing ............................................................................. F 12
5.4 Inspecting the lift chains ...................................................................... F 12
5.5 Hydraulic oil ......................................................................................... F 13
5.6 Hydraulic hoses ................................................................................... F 14
5.7 Check brake fluid (EKS 513 - 515) ......................................................F 14
5.8 Checking electrical fuses (EKS 410) ...................................................F 15
5.9 Checking electrical fuses (EKS 513 - 515) .......................................... F 16
5.10 Recommissioning ................................................................................F 17
6 Decommissioning the industrial truck ..................................................F 17
6.1 Prior to decommissioning: ...................................................................F 17
6.2 During decommissioning: ....................................................................F 18
6.3 Restoring the truck to operation after decommissioning ..................... 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
0708.GB
I 4
0708.GB
I 4
1
0506.GB
Appendix
JH Traction Battery Operating Instructions
Z
These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
1
0506.GB
Appendix
JH Traction Battery Operating Instructions
Z
These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
0506.GB 20506.GB
2
A 1
1004.GB
A Correct use and application
Z
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
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 areas threatened by
corrosion or excessive dust.
Proprietor responsibilities: For the purposes of the present operator manual the
“proprietor” 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 manufacturer’s customer service department.
Attaching accessories: 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 constitute the manufacturer’s
approval.
A 1
1004.GB
A Correct use and application
Z
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
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 areas threatened by
corrosion or excessive dust.
Proprietor responsibilities: For the purposes of the present operator manual the
“proprietor” 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 manufacturer’s customer service department.
Attaching accessories: 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 constitute the manufacturer’s
approval.
1004.GB
A 2
1004.GB
A 2
B 1
0708.GB
B Truck Description
1 Application
The EKS is an electric stockpicker. It is designed to be used on level surfaces in
accordance with DIN 15185 to transport and pick goods.
Loads can be stacked and unstacked and transported over long distances.
The driver's cab is raised together with the load handler to provide excellent visibility
and easy access to the rack levels to be operated.
The racks must be suitable for the EKS. 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 provided 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 inductive 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.
Travel direction definition
The following determinations have been made for travel direction specification.
Type Capacity Load centre of gravity
EKS 410 1,000 kg 600 mm
EKS 513 1,250 kg 600 mm
EKS 515k/515 1,500 kg 600 mm
Left
Drive
direction
Load
direction
Right
B 1
0708.GB
B Truck Description
1 Application
The EKS is an electric stockpicker. It is designed to be used on level surfaces in
accordance with DIN 15185 to transport and pick goods.
Loads can be stacked and unstacked and transported over long distances.
The driver's cab is raised together with the load handler to provide excellent visibility
and easy access to the rack levels to be operated.
The racks must be suitable for the EKS. 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 provided 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 inductive 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.
Travel direction definition
The following determinations have been made for travel direction specification.
Type Capacity Load centre of gravity
EKS 410 1,000 kg 600 mm
EKS 513 1,250 kg 600 mm
EKS 515k/515 1,500 kg 600 mm
Left
Drive
direction
Load
direction
Right
0708.GB
B 2
2 Assemblies and Functional Description
Item Description
1
t
Mast
2
t
Aux. lift
3
t
Control panel
4
t
Height-adjustable driver’s position
5
t
Chassis
t = Standard equipment o = Optional Equipment
2
2
1
1
3
3
4
4
5
5
EKS 513 / 515k / 515
EKS 410
0708.GB
B 2
2 Assemblies and Functional Description
Item Description
1
t
Mast
2
t
Aux. lift
3
t
Control panel
4
t
Height-adjustable driver’s position
5
t
Chassis
t = Standard equipment o = Optional Equipment
2
2
1
1
3
3
4
4
5
5
EKS 513 / 515k / 515
EKS 410
B 3
0708.GB
2.1 Truck
Safety mechanisms: An enclosed truck geometry 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 disable all truck
movements as soon as they are opened.
Travelling and lifting 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:
– The truck can be braked gently and wear-free by pulling back the travel control
button or steering in the opposite direction. This feeds energy into the battery
(operating brake).
– The electromagnetic spring pressure brake acting on the drive motor serves as a
parking brake and handbrake.
– EKS 513-515 only:
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:
Particularly smooth steering with threephase drive system. The handy 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 Displays
The functions are activated via ergonomic thumb movement to ensure fatigue-free
operation without stressing 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 inductive guidance status etc.
B 3
0708.GB
2.1 Truck
Safety mechanisms: An enclosed truck geometry 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 disable all truck
movements as soon as they are opened.
Travelling and lifting 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:
– The truck can be braked gently and wear-free by pulling back the travel control
button or steering in the opposite direction. This feeds energy into the battery
(operating brake).
– The electromagnetic spring pressure brake acting on the drive motor serves as a
parking brake and handbrake.
– EKS 513-515 only:
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:
Particularly smooth steering with threephase drive system. The handy 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 Displays
The functions are activated via ergonomic thumb movement to ensure fatigue-free
operation without stressing 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 inductive guidance status etc.
0708.GB
B 4
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. During 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:
– To configure all the key truck data (limit position damping, lift cutout, retardation
and acceleration patterns, cut-outs etc.) rapidly and reliably.
– To read off the error log to analyse fault causes.
– To simulate and analyse program operations.
– Simple functional extension by releasing code numbers.
The controller is fitted with a CAN Bus and a continually measuring sensor system.
The controller provide smooth start-up and braking of the load in all limit positions
through limit position and intermediate cushioning.
Highly efficient threephase technology with energy retention for the drive 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 EKS
410
EKS
513
EKS
515k/515
Q Capacity (where C = 600 mm) 1000 1250 1500 kg
c Load centre of gravity distance 600 600 600 mm
Travel speed without load (RG) 9 10,5 10,5 km/h
Travel speed with load (RG) 9 10,5 10,5 km/h
Travel speed without load (IG) 7 9 9 km/h
Travel speed with load (IG) 7 9 9 km/h
Lift speed without load 0,40 0,45 0,47 m/s
Lift speed with load 0,36 0,40 0,42 m/s
Lowering speed w / w.o. load 0,40 0,40 0,40 m/s
0708.GB
B 4
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. During 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:
– To configure all the key truck data (limit position damping, lift cutout, retardation
and acceleration patterns, cut-outs etc.) rapidly and reliably.
– To read off the error log to analyse fault causes.
– To simulate and analyse program operations.
– Simple functional extension by releasing code numbers.
The controller is fitted with a CAN Bus and a continually measuring sensor system.
The controller provide smooth start-up and braking of the load in all limit positions
through limit position and intermediate cushioning.
Highly efficient threephase technology with energy retention for the drive 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 EKS
410
EKS
513
EKS
515k/515
Q Capacity (where C = 600 mm) 1000 1250 1500 kg
c Load centre of gravity distance 600 600 600 mm
Travel speed without load (RG) 9 10,5 10,5 km/h
Travel speed with load (RG) 9 10,5 10,5 km/h
Travel speed without load (IG) 7 9 9 km/h
Travel speed with load (IG) 7 9 9 km/h
Lift speed without load 0,40 0,45 0,47 m/s
Lift speed with load 0,36 0,40 0,42 m/s
Lowering speed w / w.o. load 0,40 0,40 0,40 m/s
B 5
0708.GB
A
st
W
a
h
15
h
10
h
3
h
9
h
7
h
6
h
1
h
4
b
2
l
1
l
2
m
2
R
b
5
l
B 5
0708.GB
A
st
W
a
h
15
h
10
h
3
h
9
h
7
h
6
h
1
h
4
b
2
l
1
l
2
m
2
R
b
5
l
0708.GB
B 6
3.2 Dimensions (as per data plate)
1)
ZT mast performance data measured for 400 ZT.
2)
ZT mast performance data measured for 350 ZT.
3)
ZT mast performance data measured for 500 ZT.
Description EKS
410
EKS
513
EKS
515k
EKS
515
h1Mast height
(retracted)
3100
1)
2955
2)
2955
2)
3705
3)
mm
h3Lift 4000
1)
3500
2)
3500
2)
5000
3)
mm
h4Mast height
(extended)
6550
1)
6050
2)
6050
2)
7550
3)
mm
h7Seat height / standing height 395 470 470 470 mm
h9Aux. lift 840 840 840 840 mm
h10Overall lift 4840
1)
4340
2)
4340
2)
5840
3)
mm
h15Stockpicking height 5995
1)
5570
2)
5570
2)
7070
3)
mm
Ast Working aisle width for
pallets 1000 x 1200 traverse
1640 1640 1640 1640 mm
b2Overall width 1440 1450 1500 1500 mm
b5Distance between forks,
outer
(PAL width 1200)
793 535 535 535 mm
b6Width across guide rollers 1620 1540 1540 1540 mm
l1Overall length w.o. load
(PAL width 1200)
3577 3340 3440 3736 mm
l2Length including fork back
(PAL width 1200)
3273 3200 3300 3596 mm
l Fork length 1200 1200 1200 1200 mm
WaTurning radius 2035 2101 2201 2497 mm
m2Ground clearance centre
wheelbase
80 85 85 85 mm
Net weight incl. battery, w.o.
load
5218 6499 6926 8083 kg
0708.GB
B 6
3.2 Dimensions (as per data plate)
1)
ZT mast performance data measured for 400 ZT.
2)
ZT mast performance data measured for 350 ZT.
3)
ZT mast performance data measured for 500 ZT.
Description EKS
410
EKS
513
EKS
515k
EKS
515
h1Mast height
(retracted)
3100
1)
2955
2)
2955
2)
3705
3)
mm
h3Lift 4000
1)
3500
2)
3500
2)
5000
3)
mm
h4Mast height
(extended)
6550
1)
6050
2)
6050
2)
7550
3)
mm
h7Seat height / standing height 395 470 470 470 mm
h9Aux. lift 840 840 840 840 mm
h10Overall lift 4840
1)
4340
2)
4340
2)
5840
3)
mm
h15Stockpicking height 5995
1)
5570
2)
5570
2)
7070
3)
mm
Ast Working aisle width for
pallets 1000 x 1200 traverse
1640 1640 1640 1640 mm
b2Overall width 1440 1450 1500 1500 mm
b5Distance between forks,
outer
(PAL width 1200)
793 535 535 535 mm
b6Width across guide rollers 1620 1540 1540 1540 mm
l1Overall length w.o. load
(PAL width 1200)
3577 3340 3440 3736 mm
l2Length including fork back
(PAL width 1200)
3273 3200 3300 3596 mm
l Fork length 1200 1200 1200 1200 mm
WaTurning radius 2035 2101 2201 2497 mm
m2Ground clearance centre
wheelbase
80 85 85 85 mm
Net weight incl. battery, w.o.
load
5218 6499 6926 8083 kg
B 7
0708.GB
3.3 EKS 410 mast version
3.4 EKS 513 – 515 mast version
Description EKS 410
h1Retracted height (ZT) 2550 - 4100 mm
h3Lift 2500 - 6000 mm
h4Extended height 5050 - 8550 mm
h6Height above overhead
guard
2550 mm
h9Aux. lift 840 mm
h10Overall lift height 3340 - 6840 mm
h15Stockpicking height 4495 - 7995 mm
Description EKS
513
EKS
515k
EKS
515
h1Retracted height (ZT) 2705 - 5055 2705 - 6155 2705 - 6405 mm
h1Retracted height (DZ) 2595 - 3895 2595 - 4695 2595 - 5795 mm
h3Lift (ZT) 3000 - 7500 3000 - 9500 3000 - 10000 mm
h3Lift (DZ) 4250 - 7500 4250 - 9500 4250 - 12500 mm
h4Extended height (ZT) 5550 - 10050 5550 - 12050 5550 - 12550 mm
h4Extended height (DZ) 6800 - 10050 6800 - 12050 6800 - 15050 mm
h6Height above overhead
guard
2550 2550 2550 mm
h9Aux. lift 840 840 840 mm
h10Overall lift height (ZT) 3840 - 8340 3840 - 10340 3840 - 10840 mm
h10Overall lift height (DZ) 5090 - 8340 5090 - 10340 5090 - 13340 mm
h15Picking height (ZT) 5070 - 9570 5070 - 11570 5070 - 12070 mm
h15Picking height (DZ) 6320 - 9570 6320 - 11570 5070 - 14570 mm
B 7
0708.GB
3.3 EKS 410 mast version
3.4 EKS 513 – 515 mast version
Description EKS 410
h1Retracted height (ZT) 2550 - 4100 mm
h3Lift 2500 - 6000 mm
h4Extended height 5050 - 8550 mm
h6Height above overhead
guard
2550 mm
h9Aux. lift 840 mm
h10Overall lift height 3340 - 6840 mm
h15Stockpicking height 4495 - 7995 mm
Description EKS
513
EKS
515k
EKS
515
h1Retracted height (ZT) 2705 - 5055 2705 - 6155 2705 - 6405 mm
h1Retracted height (DZ) 2595 - 3895 2595 - 4695 2595 - 5795 mm
h3Lift (ZT) 3000 - 7500 3000 - 9500 3000 - 10000 mm
h3Lift (DZ) 4250 - 7500 4250 - 9500 4250 - 12500 mm
h4Extended height (ZT) 5550 - 10050 5550 - 12050 5550 - 12550 mm
h4Extended height (DZ) 6800 - 10050 6800 - 12050 6800 - 15050 mm
h6Height above overhead
guard
2550 2550 2550 mm
h9Aux. lift 840 840 840 mm
h10Overall lift height (ZT) 3840 - 8340 3840 - 10340 3840 - 10840 mm
h10Overall lift height (DZ) 5090 - 8340 5090 - 10340 5090 - 13340 mm
h15Picking height (ZT) 5070 - 9570 5070 - 11570 5070 - 12070 mm
h15Picking height (DZ) 6320 - 9570 6320 - 11570 5070 - 14570 mm
0708.GB
B 8
3.5 EN norms
EKS 410 EKS 513 - 515
Noise emission: 61 dB(A) 68 dB(A)
in accordance with EN 12053 as harmonised with ISO
4871.
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
level is measured at the driver’s ear.
EKS 410 EKS 513 - 515
Vibration: 0.79 m/s2 in accordance with EN 130590.79 m/s2 in
accordance with EN 13059
Seat vibration: 0.56 m/s
2
0.64 m/s
2
Z
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 when travelling 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 electric or electronic components or their arrangement may be made
without the written agreement of the manufacturer.
3.6 Conditions of use
Ambient temperature
operating at 5°C to 40 °C
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:
– Ambient temperature in 24-hour mode: max. 25 °C
– max. air humidity (inside) 70%, non-condensing.
0708.GB
B 8
3.5 EN norms
EKS 410 EKS 513 - 515
Noise emission: 61 dB(A) 68 dB(A)
in accordance with EN 12053 as harmonised with ISO
4871.
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
level is measured at the driver’s ear.
EKS 410 EKS 513 - 515
Vibration: 0.79 m/s2 in accordance with EN 130590.79 m/s2 in
accordance with EN 13059
Seat vibration: 0.56 m/s
2
0.64 m/s
2
Z
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 when travelling 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 electric or electronic components or their arrangement may be made
without the written agreement of the manufacturer.
3.6 Conditions of use
Ambient temperature
operating at 5°C to 40 °C
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:
– Ambient temperature in 24-hour mode: max. 25 °C
– max. air humidity (inside) 70%, non-condensing.
B 9
0708.GB
4 Identification points and data plates
F
Warning and information labels, such as capacity diagrams, attachment points and
identification plates, must be readable at all times or be replaced, if necessary.
EKS 410
Item Description
6 Strap points for crane lifting
7 Truck data plate
8 Capacity plate
9 Decal: “Abseil device”
10 Decal: “No passengers”
11 Test sticker (o)
12 Decal: Do not step onto or beneath the load, risk of trapping
13 Jack contact points
14 Serial number (engraved in chassis underneath the battery cover)
15 “Add hydraulic oil” notice
16 “Emergency drain” decal
17 “Emergency drain key” decal
18 Decal: “Caution: Low voltage electronics system"
19 “Read operating instructions" notice
6
18
6
mV
1,5 V
12
16
17
13
15
11
10
8
7
D (mm)
h3 (mm) Q (kg)
14
9
9
6
19
13
B 9
0708.GB
4 Identification points and data plates
F
Warning and information labels, such as capacity diagrams, attachment points and
identification plates, must be readable at all times or be replaced, if necessary.
EKS 410
Item Description
6 Strap points for crane lifting
7 Truck data plate
8 Capacity plate
9 Decal: “Abseil device”
10 Decal: “No passengers”
11 Test sticker (o)
12 Decal: Do not step onto or beneath the load, risk of trapping
13 Jack contact points
14 Serial number (engraved in chassis underneath the battery cover)
15 “Add hydraulic oil” notice
16 “Emergency drain” decal
17 “Emergency drain key” decal
18 Decal: “Caution: Low voltage electronics system"
19 “Read operating instructions" notice
6
18
6
mV
1,5 V
12
16
17
13
15
11
10
8
7
D (mm)
h3 (mm) Q (kg)
14
9
9
6
19
13
0708.GB
B 10
EKS 513 - 515
Item Description
6 Strap points for crane lifting
7 Truck data plate
8 Capacity plate
9 Decal: “Abseil device”
10 Decal: “No passengers”
11 Test sticker (o)
12 Decal: Do not step onto or beneath the load, risk of trapping
13 Jack contact points
14 Serial number (engraved in chassis underneath the battery cover)
15 “Add hydraulic oil” notice
16 “Emergency drain” decal
17 “Emergency drain key” decal
18 Decal: “Caution: Low voltage electronics system"
19 “Read operating instructions" notice
8
7
11
10
D (mm)
h3 (mm) Q (kg)
12
6
13
13
15
16
17
18
mV
1,5 V
6
14
9
9
19
0708.GB
B 10
EKS 513 - 515
Item Description
6 Strap points for crane lifting
7 Truck data plate
8 Capacity plate
9 Decal: “Abseil device”
10 Decal: “No passengers”
11 Test sticker (o)
12 Decal: Do not step onto or beneath the load, risk of trapping
13 Jack contact points
14 Serial number (engraved in chassis underneath the battery cover)
15 “Add hydraulic oil” notice
16 “Emergency drain” decal
17 “Emergency drain key” decal
18 Decal: “Caution: Low voltage electronics system"
19 “Read operating instructions" notice
8
7
11
10
D (mm)
h3 (mm) Q (kg)
12
6
13
13
15
16
17
18
mV
1,5 V
6
14
9
9
19
B 11
0708.GB
4.1 Truck data plate
For queries relating to the truck or spare parts orders, please state the truck serial no.
(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.
Item Description Item Description
20 Type 26 Manufacturer
21 Serial no. 27 Min./max. battery weight (kg)
22 Rated capacity (kg) 28 Drive output (kW)
23 Battery voltage (V) 29 Load centre of gravity (mm)
24 Net weight w.o. battery (kg) 30 Year of manufacture
25 Manufacturer’s logo 31 Option
26
25
27
24
28
23
29
22
30
21
31
20
8
D (mm)
h3 (mm) Q (kg)
B 11
0708.GB
4.1 Truck data plate
For queries relating to the truck or spare parts orders, please state the truck serial no.
(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.
Item Description Item Description
20 Type 26 Manufacturer
21 Serial no. 27 Min./max. battery weight (kg)
22 Rated capacity (kg) 28 Drive output (kW)
23 Battery voltage (V) 29 Load centre of gravity (mm)
24 Net weight w.o. battery (kg) 30 Year of manufacture
25 Manufacturer’s logo 31 Option
26
25
27
24
28
23
29
22
30
21
31
20
8
D (mm)
h3 (mm) Q (kg)
0708.GB
B 12
0708.GB
B 12
C 1
1004.GB
C Transport and Commissioning
1 Transport
Transport can be carried out in two different ways, depending on the height of the
mast and the local conditions.
– Vertically, with mast and load lifting device assembled (for low heights)
– Vertically, with mast and load lifting device disassembled (for large heights)
– EKS 513-515 only: vertically, 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.
– Parking the truck securely
(see Chapter E).
M
Attach the crane slings to the strap points (1-3) so that the truck cannot slip.
2
1
3
1
2
3
4
5
7
8
6
EKS 410
EKS 513 - 515
C 1
1004.GB
C Transport and Commissioning
1 Transport
Transport can be carried out in two different ways, depending on the height of the
mast and the local conditions.
– Vertically, with mast and load lifting device assembled (for low heights)
– Vertically, with mast and load lifting device disassembled (for large heights)
– EKS 513-515 only: vertically, 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.
– Parking the truck securely
(see Chapter E).
M
Attach the crane slings to the strap points (1-3) so that the truck cannot slip.
2
1
3
1
2
3
4
5
7
8
6
EKS 410
EKS 513 - 515
1004.GB
C 2
2.1 Crane points
EKS 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. 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.
EKS 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:
– Crane points for complete truck with mast assembled:
points (1) and (2) (for weight see data plate)
– Crane points for the basic truck:
items (2) and (3) (weight 2000 kg (EKS 410), 3000 kg (EKS 513-515)
– Mast crane points including driver’s cab and load handler:
items (1) and (3) (weight 2,600 kg (EKS 410), 6,500 kg (EKS 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 during transport
F
The truck must be securely fastened when being transported on a lorry or a trailer.
The lorry / trailer must have fastening rings.
M
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.
1004.GB
C 2
2.1 Crane points
EKS 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. 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.
EKS 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:
– Crane points for complete truck with mast assembled:
points (1) and (2) (for weight see data plate)
– Crane points for the basic truck:
items (2) and (3) (weight 2000 kg (EKS 410), 3000 kg (EKS 513-515)
– Mast crane points including driver’s cab and load handler:
items (1) and (3) (weight 2,600 kg (EKS 410), 6,500 kg (EKS 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 during transport
F
The truck must be securely fastened when being transported on a lorry or a trailer.
The lorry / trailer must have fastening rings.
M
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.
C 3
1004.GB
3.1 Basic truck transport safety
M
The mast must only be disassembled by the manufacturer’s authorised service
department.
To ensure secure transport of a disassembled EKS, use the prescribed attachment
points for fastening/quick release belts.
Z
With the EKS 410 only use straps with a rated capacity of > 5 tonnes and with the
EKS 513-515 only straps with a rated capacity of > 9 tonnes.
M
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).
M
If the truck’s battery is supplied in the chassis, disconnect the battery.
Fastening belts should be attached to at least 4 different lorry eyes (12).
Belts placed over “sharp” edges must be protected 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.
9
12
10
13
11
C 3
1004.GB
3.1 Basic truck transport safety
M
The mast must only be disassembled by the manufacturer’s authorised service
department.
To ensure secure transport of a disassembled EKS, use the prescribed attachment
points for fastening/quick release belts.
Z
With the EKS 410 only use straps with a rated capacity of > 5 tonnes and with the
EKS 513-515 only straps with a rated capacity of > 9 tonnes.
M
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).
M
If the truck’s battery is supplied in the chassis, disconnect the battery.
Fastening belts should be attached to at least 4 different lorry eyes (12).
Belts placed over “sharp” edges must be protected 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.
9
12
10
13
11
1004.GB
C 4
3.2 Mast transport safety
M
Use a transport retaining device (20) to prevent the operator compartment carriage
(14) from sliding.
If the mast is stored on a pallet(s), fasten them securely to the mast (18).
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 as the "mast top” strap point.
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.
14
15
16
17
18
1717
20
19
1004.GB
C 4
3.2 Mast transport safety
M
Use a transport retaining device (20) to prevent the operator compartment carriage
(14) from sliding.
If the mast is stored on a pallet(s), fasten them securely to the mast (18).
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 as the "mast top” strap point.
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.
14
15
16
17
18
1717
20
19
C 5
1004.GB
3.3 Mast assembled
Safely transporting the truck with the mast assembled
M
If the truck’s battery is supplied in the
chassis, disconnect the battery.
M
When transporting, always relieve
the drive wheel by placing the entire
surface of a wooden beam (23)
underneath the counterweight
(minimum chassis width). In addition,
secure the load wheels with a wedge
(24).
Z
Only use belts with a rated capacity
of .
EKS 410 > 5 to
EKS 513 > 9 to
At least 4 belts, 2 on the left and 2 on
the right (20, 21) must be attached to
the mast.
3.4 Safely transporting the truck with
the mast folded
(EKS 513 - 515)
M
If the truck’s battery is supplied in the
chassis, disconnect the battery.
Z
Only use belts with a rated capacity
of >9 tonnes.
Fastening belts should be attached to
at least 4 different lorry / truck eyes
(25).
F
Attention Risk of tipover through high
centre of gravity.
The tensioning belts are tensioned on the mast.
Using wooden planks, a pallet or a rubber mat (27) from the outrigger to the front of
the transporter, ensure a positive fit.
Z
Place the entire surface area of a wooden beam (26) underneath the counterweight,
the chassis width as minimum, to discharge the drive wheel.
21
22
23
24
25
25
27
26
C 5
1004.GB
3.3 Mast assembled
Safely transporting the truck with the mast assembled
M
If the truck’s battery is supplied in the
chassis, disconnect the battery.
M
When transporting, always relieve
the drive wheel by placing the entire
surface of a wooden beam (23)
underneath the counterweight
(minimum chassis width). In addition,
secure the load wheels with a wedge
(24).
Z
Only use belts with a rated capacity
of .
EKS 410 > 5 to
EKS 513 > 9 to
At least 4 belts, 2 on the left and 2 on
the right (20, 21) must be attached to
the mast.
3.4 Safely transporting the truck with
the mast folded
(EKS 513 - 515)
M
If the truck’s battery is supplied in the
chassis, disconnect the battery.
Z
Only use belts with a rated capacity
of >9 tonnes.
Fastening belts should be attached to
at least 4 different lorry / truck eyes
(25).
F
Attention Risk of tipover through high
centre of gravity.
The tensioning belts are tensioned on the mast.
Using wooden planks, a pallet or a rubber mat (27) from the outrigger to the front of
the transporter, ensure a positive fit.
Z
Place the entire surface area of a wooden beam (26) underneath the counterweight,
the chassis width as minimum, to discharge the drive wheel.
21
22
23
24
25
25
27
26
1004.GB
C 6
4 Commissioning
4.1 Moving the truck without a battery
M
This operation must only be performed by suitably trained maintenance personnel.
M
This operation is forbidden on slopes and inclines (no brakes).
See also chapter E, “Recovering the truck from a narrow aisle / Moving the truck
without a battery”.
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.
5 Starting the truck for the first time
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 long.
To prepare the truck after delivery or after transport, proceed as follows:
– Install and charge the battery if necessary (see Chapter D, Sections 4 and 3).
– Commission the truck as per instructions (See Chapter E, Section 3).
Z
With the EKS 410/513/515k/515 a tipover retaining device (30) is fitted, depending on
the tipover test. When a tipover retaining device is used, an X (29) is engraved on the
truck chassis on the right hand side of the battery compartment, after the serial
number.
M
Before operating, check the trucks to ensure the tilt safety devices (30) are present
(if required).
M
Check that all safety devices are present and operational.
29
30
1004.GB
C 6
4 Commissioning
4.1 Moving the truck without a battery
M
This operation must only be performed by suitably trained maintenance personnel.
M
This operation is forbidden on slopes and inclines (no brakes).
See also chapter E, “Recovering the truck from a narrow aisle / Moving the truck
without a battery”.
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.
5 Starting the truck for the first time
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 long.
To prepare the truck after delivery or after transport, proceed as follows:
– Install and charge the battery if necessary (see Chapter D, Sections 4 and 3).
– Commission the truck as per instructions (See Chapter E, Section 3).
Z
With the EKS 410/513/515k/515 a tipover retaining device (30) is fitted, depending on
the tipover test. When a tipover retaining device is used, an X (29) is engraved on the
truck chassis on the right hand side of the battery compartment, after the serial
number.
M
Before operating, check the trucks to ensure the tilt safety devices (30) are present
(if required).
M
Check that all safety devices are present and operational.
29
30
D 1
1004.GB
D Battery Maintenance, Charging &
Replacement
1 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. The present operator manual and the manufacturer’s instructions
concerning batteries and charging stations must be observed when carrying out the
work.
Fire protection: Smoking and naked flames must be avoided when working with
batteries Wherever an industrial truck is parked for charging there shall be no
inflammable material or lubricants 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.
Battery Disposal: Batteries may only be disposed of in accordance with national
environmental protection regulations or disposal laws. The manufacturer’s disposal
instructions must be followed.
M
Before closing the battery cover make sure that the battery lead cannot be damaged.
F
Batteries contain an acid solution which is poisonous and corrosive. Therefore,
always wear protective clothing and eye protection when carrying out work on
batteries. Above all avoid any 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 - where 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.
F
The weight and dimensions of the battery have a considerable effect on the
operational safety of the industrial truck. Battery equipment may only be replaced with
the agreement of the manufacturer.
D 1
1004.GB
D Battery Maintenance, Charging &
Replacement
1 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. The present operator manual and the manufacturer’s instructions
concerning batteries and charging stations must be observed when carrying out the
work.
Fire protection: Smoking and naked flames must be avoided when working with
batteries Wherever an industrial truck is parked for charging there shall be no
inflammable material or lubricants 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.
Battery Disposal: Batteries may only be disposed of in accordance with national
environmental protection regulations or disposal laws. The manufacturer’s disposal
instructions must be followed.
M
Before closing the battery cover make sure that the battery lead cannot be damaged.
F
Batteries contain an acid solution which is poisonous and corrosive. Therefore,
always wear protective clothing and eye protection when carrying out work on
batteries. Above all avoid any 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 - where 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.
F
The weight and dimensions of the battery have a considerable effect on the
operational safety of the industrial truck. Battery equipment may only be replaced with
the agreement of the manufacturer.
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