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Jungheinrich Electric Three-way StockPicker Type EKX-410 (11.2003-05.2012) Workshop Manual
Original factory manuals for Jungheinrich Forklift Trucks, contains high quality images, circuit diagrams and instructions to help you to operate and repair your truck. All Manuals Printable and contains Searchable Text
Covered models:
EKX-410 (11.2003-05.2012)
Format: PDF, 720 Pages
Language: English
Contents:
Using the truck for the first time
Operating Instructions
A Correct use and application of the truck
B Truck Description
1 Application
2 Assemblies and Operational Description
2.1 Truck
3 Standard Version Specifications
3.1 Performance data
3.2 Dimensions (as per data plate)
3.3 EKX 410 mast version
3.4 EKX 513 515 mast version
3.5 EN norms
3.6 Conditions of use
4 Identification points and data plates
4.1 Truck data plate
4.2 Capacity
C Transport and Commissioning
1 Transport
2 Lifting by crane
2.1 Crane points
2.2 Lifting the battery by crane
3 Securing the Truck for Transport.
3.1 Basic truck transport safety
3.2 Mast transport safety
3.3 Mast assembled
3.4 Transport retaining device: truck with folded mast (EKX 513 - 515)
4 Commissioning
4.1 Moving the truck without a battery
4.2 Installing and removing the mast
5 Commissioning
D Battery Maintenance, Charging & Replacement
1 Safety Regulations for handling acid batteries
2 Battery types
3 Charging the battery
4 Battery removal and installation
5 Battery checking conditid acid level
6 Battery discharge indicator
E Operation
1 Safety Regulations for the Operation of Forklift Trucks
2 Operating and Display Equipment
2.1 Operating and display equipment on control panel
2.2 Display unit controls and displays
2.3 Lower range symbols and keys
2.4 Truck operational status symbols
3 Starting up the truck
4 Lift truck operation
4.1 Safety regulations for truck operation
4.2 Travelling, Steering, Braking
4.3 Lifting Lowering Reaching Traversing outside the rack aisles
4.4 Lifting Lowering Reaching Traversing inside the rack aisles
4.5 Order picking and stacking
4.6 Park the truck securely
5 Troubleshooting
5.1 Emergency stop device
5.2 Drivers cab / Aux. Liftemergency lowering
5.3 Exiting the driver's cab with the emergency abseil device
5.4 Bypassing the chain slack safety device
5.5 Bypassing the travel cutout (o)
5.6 Lift cutout (o)
5.7 Aisle end safety device (o)
5.8 WG emergency operation
5.9 Recovering the truck froma narrow aisle / Moving the truck without a battery
F Maintenance of the forklift truck
1 Operational safety and environmental protection
2 Maintenance Safety Regulations
3 Servicing and inspection
4 EKX maintenance checklist
4.1 Lubrication Schedule
4.2 Fuels, coolants and lubricants
5 Maintenance and Repairs
5.1 Preparing the truck for maintenance and repairs
5.2 Securing the drivers position carriage
5.3 Maintaining the lift chains
5.4 Inspecting the lift chains
5.5 Hydraulic oil
5.6 Hydraulic hoses
5.7 Checking the brake fluid (EKX 513 - 515)
5.8 Checking electrical fuses (EKX 410)
5.9 Checking electrical fuses (EKX 513 - 515)
5.10 Recommissioning
6 Decommissioning the forklift truck
6.1 Prior to decommissioning:
6.2 During decommissioning:
6.3 Recommissioning
7 Safety checks to be performed at regular intervals and following any unusual incidents
8 Final de-commissioning, disposal
Technical Description of Components
Notes on how to avoid accidents and material damage
Overview of components
A Overview
Control panel
Cabin
Drive compartment
Wire guidance
B Drive system
Electric motor (1 M1)
D Brake system
Magnetic brake
Operational description
Emergency recovery
E Wheel
Wheel bearings, load wheel
F Steering system
Steering system components
Steering system electric motor (3M1)
Sensor system 1
Potentiometer 3U9, 8U28 and 8U29
Distance sensor
Angle sensor 3U9, 8U28 and 8U29
Sensor system 2
Steering wheel transmission table
G Mast
Mast sensor system
Sensor bearing
Power supply to sensor bearing
Attachment
Aux. lift sensor system
Sideshift sensor system
Swivel sensor system
I Hydraulic system
Setting and bleeding
Overpressure setting
Suctioning the hydraulic system
Hydraulic motor (2M1)
Hydraulic control block H1 assembly (drive compartment) .
Hydraulic control block H2 assembly (cabin)
J Electrical system
Component Arrangement
Operational description
Computer
RIO A (A2) drive compartment computer
RIO C (A3) cabin computer
Drive compartment and cabin computer error flashing
codes
I.O junction (A11)
Power Supply -> Fuses in Computer
Control panel computer A4
Control panel computer A4
Input/Output
Communication
Displays
Control panel computer error flashing codes
Drive compartment travel switch distributor (U14)
Cabin distributor (U12)
General Description of Controller and Drive System
Operating principles of threephase drive system
Operational description of lift, travel and steering drive threephase controller
Test and Setting Values
Torques
Screw-in valve torques
Control block 1 (main lift)
Control block 2 (traverse/reach with aux. lift)
Electrical Protection
Power circuit protection
Controller fuse rating
Fuses in the control panel PCB
Electrical fuse rating for RIO A (A2) computer
EKX410 F Speed Profile
EKX 410 1 1S Speed Profile
Speed profile reduced
Brake retardation
Braking distances
Braking in proportion to speed
Hydraulic speeds
Main lift
Traverse
Traverse/swivel cycle
Swivel
Truck Maintenance
Judit Diagnostic Software (EKX 410/EKX 5xx(ETX-K)/EKS 310 (Kms)/EKS 314)
General
Installing the diagnostic software from disk
Password/Workgroup
Simulation or online?
PIN number (online mode)
Installing the operating system
Installing the operating system via Can-Bus (control panel)
Loading the Control Panel Computer Operating System
Installing the operating system via components
Loading the program in the truck
Loading hyperterminal antenna / IO nodes
Assembly
Assigning hyperterminal antenna (or IO nodes)
Status Diagnostics
Status (ST) Parameters
Parameter Control
Plug'n'Play
CanOpen Description Status (ST)
CanOpen EKS 3xx Status (ST)
EKS 3xx driver's position
EKS 3xx travel switch
CanOpen EKX 410 status (ST)
EKX 410 driver's position
EKX 41 0 travel switch
CanOpen EKX 5xx status (ST)
EKX 5xx driver's position
EKX 5xx travel switch
CanOpen Status Info Status (ST)
PDO (1)
SDO (2)
PRU (3)
MID (module ID) (EKS 3xx)
MID (module ID) (EKX 410)
MID (module ID) (EKX 5xx)
EKS 3xx
EKS 3xx - hT1 / hT2 (5)
EKS 3xx - hR1 / hR2 (6)
EKX 410
EKX 410 - hT1 / hT2 (5)
EKX 410 - hR1 / hR2 (6)
EKX 5xx
EKX 5xx - hT1 / hT2 (5)
EKX 5xx - hR1 / hR2 (6)
Truck Status
Emergency Stop Circuit (EKS 3xx) Status (ST)
Emergency Stop Circuit (EKS 3xx) Figure Description
Emergency Stop Circuit (EKS 3xx) Figure Description
Emergency Stop Circuit (EKX 410, EKX 5xx) Status (ST)
Emergency Stop Circuit (EKX 410, EKX 5xx) Figure Descripti
30
Emergency Stop Circuit (EKX 410, EKX 5xx) Figure Descripti
31
Status (ST) PSS (Personal Safety System)
From Truck to PSS
From PSS to Truck
Scanner release (1) height
Test Functions
TST_Emergency Stop Reactions
Emergency Stop Reaction Test
Wire break safety device test
Steering and Travel Test
TST Emergency Stop Displays
Displays
Administering Parameter Lists
Storing parameters
Saving to Disk
Saving to Computer
Viewing / Editing Parameter List
Loading a Parameter List
Warehouse zone Ground System through
Transponder 38
Warehouse zone parameter setting
Requirement
Transponder Figure Description
Transponder data
Warehouse zone commissioning
Transponder programming
Programming and Assigning Warehouse Zones
1. Programming and Assigning Warehouse Zones
2. Programming and Assigning Warehouse Zones
3. Programming and Assigning Warehouse Zones
4. Programming and Assigning Warehouse Zones
5. Programming and Assigning Warehouse Zones
Assigning alternately in load direction (LD) and drive directioon (DD) on entry
6. Special Programming
Example: Entry in load direction with sufficient clearance height in a zone
7. Special Programming
Example: Entry in load direction with sufficient clearance height in a zone
8. Special procedure
Example: Entry in load direction with sufficient clearance height in a zone
9. Special Programming
Example: Entry in load direction with sufficient clearance height in a zone
10. Special Programming
Example: Entry in load direction with sufficient clearance height in a zone
11. Special Programming
Example: Entry in load direction with sufficient clearance height in a zone
12. Special Programming
Example: Entry in load direction with sufficient clearance height in a zone
Error messages
Service Instructions
Ground Systems and Warehouse Zones
A Ground Systems
Functional Description F1
Functional Description F2
Functional Description F3
Functional Description F4
Functional Description F5
Functional Description F6
Functional Description F7
Functional Description F8
Functional Description F9
Functional Description F18
Functional Description F61
Functional Description F101
Functional Description F200
Functional Description F201
Functional Description F202
Functional Description F203
Functional Description F204
Functional Description F205
B Warehouse Areas / Track Assignment
Tracks and Track Values
Warehouse zone 0
Warehouse zone 1
Warehouse zone 2
Warehouse zone 3
Warehouse zone 4
Warehouse zone 5
Warehouse zone 6
Warehouse zone 7
Warehouse zone 8
C Warehouse Zone I Area Recognition via
Transponders 8.31
Requirement
Function
Creating a diagram
Transponder
Routing
Transponder and Entry Direction
Entry only in load direction (LD)
Entry only in drive direction (DD)
Entry in LD and DD
Electrical Diagrams
Hydraulic diagrams
Service Manual Items
Tilt Safety Device / Support Pillar
Settings
Drive motor sensor bearing
Disassembly/Assembly
AC-3 Power Control
Magnetic Brake Setting
Vulkolan Wheel Wear Limits
Load chains
Cleaning / Inspection / Lubrication
Pump Motor Sensor Bearing
Disassembly/Assembly
Notes on how to avoid accidents and material damage during maintenance, test and repair work on industrial trucks with electronic components
Wire guidance line driver with emergency power supply (Dataschalt)
Wire guidance line driver with emergency power supply (INRO)
Notes on how to avoid malfunctions and material damage when cleaning an industrial truck
Colour Coding Key
Brake delay (table) + Brake system principle overview
Brake Record
Magnetic Brake
Connector Layout (with AC 3 Power Control Combination Controller)
Gearbox Oil Change
Drive Wheel Disassembly/Assembly
Rail Guidance Wheel Disassembly/Assembly
Nord-Lock Lockwashers
RG 16-E Rescue Belt
Description / Maintenance / Testing
Abseil Device AG 10 / AG 1 0 S
Description / Maintenance / Testing
Adjusting the Tension Spring Path on the Mast Cable
Marker Ring Adjustment on Dipstick
Bleeding the Hydraulic Cylinders
Adjusting the Clearance Height
Mast Tilt Measurement and Adjustment
Conversion of Traverse
Potentiometer (8U29) to Traverse Angle Sensor (8U29)
Conversion of Traverse/Rotate
Potentiometer (8U28) to a Traverse/ Rotate Angle Sensor (8U28)
Commissioning Record
User instruction guidelines
Disassembly/Assembly of the Sensor Bearing (3B17) on the Steer Motor (3M1)
Steering Actual Value Transmitter (3U9)
Conversion of Steer Potentiometer (3U9) to Steer Angle Sensor (3U9)
Description of steering setpoint device (3U9), rotate/traverse setpoint device (8U28) and traverse setpoint device (8U29)
Electronic lock
Wire Guidance Commissioning
Wire guidance - test distance measurement and safety cutout (cutout limits)
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