Jungheinrich Forklift EKX514 EKX516k EKX516 European version Service Manual

Description

List of Files:
-1 Cover
000 000 000 00095 EN.pdf​
-2 Technical Data
EKX 516k Reach speeds.pdf​
EKX 516k speed profiles without power module (European version).pdf​
EKX 516k Travel s eed reduction based on width of turret head.pdf​
-3 Brakes
Brakes I brake functions 001 000 000 00087 EN.pdf​
Braking deceleration and braking system principle overview 001 000 000 00119 EN.pdf​
Drive brake D 1002 – Setting instructions for magnetic brake (7 Y 3).pdf​
Drive brake Magnetic brake (7Y3) 001 002 216 00001 EN.pdf​
JUDIT — descriptions 009 000 000 00062 EN.pdf​
Stopping distances in relation to speed 001 000 000 00117 EN.pdf​
Wheel brake 7Y67Y7 load wheel magnetic brake 001 038 537 00001 EN.pdf​
-4 Electrical System
Connectors
CAN bus participants (node IDs and installation locations) 002 047 075 00003 EN.pdf​
Connector assignment 002 047 303 00096 EN.pdf​
Dia nostics and CAN bus anal sis 009 000 000 00065 EN.pdf​
MQS connectors 002 047 303 00116 EN.pdf​
SAAB connectors 002 047 303 00036 EN.pdf​
VW connectors 002 047 303 00107 EN.pdf​
Control elements
Changing the access type (key switch – electronic system) 002 041 540 00021 EN.pdf​
Control panel 002 006 050 00002 EN.pdf​
Control panel tilt adjusting unit 002 006 000 00014 EN.pdf​
Deadman switch — rectangular version 002 006 318 00001 EN.pdf​
Controller
Controller JET-MIF (A3) 002 000 000 00114 EN.pdf​
Controller JET-PID (IJ8) 002 000 000 00113 EN.pdf​
JET – emergency stop circuit 002 000 000 00109 EN.pdf​
Switch-on routine 002 000 000 00108 EN.pdf​
Display
Battery discharge indicator 002 003 035 00001 EN.pdf​
Jungheinrich fleet management systems
Arrangement – ISM Online component assembly 002 053 000 00034 EN.pdf​
ISM Online — adjusting the length of the access codes — Group display (EasyAccess) 002 003 020 00017 EN.pdf​
Layout — assembly of the telematics components 002 053 553 00001 EN.pdf​
Miscellaneous electrical
Fuses (control current fuses main current fuse) 002 044 294 00025 EN.pdf​
Temperatures and DC intermediate circuit voltages 002 044 542 00019 EN.pdf​
Service manual item 3 6900.08
Colour coding key — wire colours 3690008g.pdf​
-5 Power Supply
Battery
See section D Battery — Maintenance Recharging Replacement in the operating instructions 52374866_EN.pdf​
Setting the sensor (2B52) for the comfort charging socket (lithium-ion battery) 003 004 504 00044 EN.pdf​
JUDIT — descriptions
Setting and description in JUDIT 003 028 098 00015 EN.pdf​
On-board chargerbus bars
Current collectors bus bars and power transfer distributor boxes 003 028 098 00008 EN.pdf​
On-board charger ATECH Zivan NG9 003 028 098 00004 EN.pdf​
On-board charger GFTI D80-150 HRS – TOP 003 028 098 00007 EN.pdf​
-6 Travel
Drive motor
Drive motor 1M1 004 014 474 00006 EN.pdf​
Electrical system
Combi sensor (speed and temperature) 004 013 000 00013 EN.pdf​
Speed Sensors 1B10 and 1B11 004 013 000 00018 EN.pdf​
JUDIT — descriptions
Adjustment and description of the travel behaviour in JUDI 004 101 000 00001 EN.pdf​
Adjustment and description of the travel functions in JUDI 009 000 000 00062 EN.pdf​
Description of the arameters and controller sets 009 000 000 00080 EN.pdf​
SpeedProfile+ 004 101 000 00003 EN.pdf​
Transmission
Replacing the wheel bolts 004 036 535 00002 EN.pdf​
Single Wheel Transmission 004 036 140 00015 EN.pdf​
Transmission oil re lacement 004 036 140 00005 EN.pdf​
Wheels
drive wheel 004 039 019 00020 EN.pdf​
E1001G Vulkollan Wheel Wear Limits.pdf​
Load wheels 004 039 198 00018 EN.pdf​
Rail guidance rollers 004 039 273 00009 EN.pdf​
-7 Truck Design
Cabin
Cold store cabin (EKX 514 – EKX 516 005 026 269 00004 EN.pdf​
Chassis basic unit
Static eliminator 005 040 539 00001 EN.pdf​
Collision protection
Disassembling assembling and aligning the sensor head 009 058 552 00012 EN.pdf​
Effect of drive wheel wear on the laser scanner beam height 009 058 552 00013 EN.pdf​
Field kits monitoring cases 009 058 552 00007 EN.pdf​
General descri tion 009 058 552 00001 EN.pdf​
JUDIT settings during commissioning and FEM inspection of JET trucks 009 058 552 00010 EN.pdf​
Position and number of reflectors 009 058 552 00002 EN.pdf​
Retrofitting the collision protection function 009 058 552 00003 EN.pdf​
SICK Flexi Soft PLC 009 058 552 00011 EN.pdf​
SICK software description 009 058 552 00005 EN.pdf​
Test specimen checklist 009 058 552 00006 EN.pdf​
Hydraulic Operations\Auxiliary lift
Adjusting the auxiliary mast mechanical 90 end stops 006 051 000 00002 EN.pdf​
Auxiliary lift cylinder cylinder piston 006 051 362 00002 EN.pdf​
Auxiliary lift height sensor (2B53) 006 051 290 00005 EN.pdf​
Disassembly or assembly of the auxiliary mast 006 051 000 00007 EN.pdf​
Replacing the seal kit on the auxiliary lift cylinder head 006 051 362 00001 EN.pdf​
Replacing the sensor comb on the auxiliary lift 006 051 558 00001 EN.pdf​
Hydraulic Operations\Electrical system
3-channel height measurement sensor at operator position (2B43) 006 013 290 00022 EN.pdf​
Combi sensor (speed and temperature) 004 013 000 00013 EN.pdf​
Deflection of spring on mast cable 006 013 000 00007 EN.pdf​
Description of the 3-channel height measurement sensor 006 013 290 00009 EN.pdf​
Main lift sensor bearing 006 013 290 00023 EN.pdf​
Operator position carriage sensor bearing 006 013 290 00022 EN.pdf​
Replacing the sensor bearing 006 013 290 00004 EN.pdf​
Slack chain switch 006 013 274 00005 EN.pdf​
Hydraulic Operations\Floor Pro Sideshift Plus
Component overview 006 043 541 00002 EN.pdf​
Double rod cylinder 006 043 541 00006 EN.pdf​
Floor Pro Sideshift Plus 006 043 541 00009 EN.pdf​
Functional description 006 043 541 00001 EN.pdf​
Initiators 006 043 541 00003 EN.pdf​
Pull cylinder with bolt 006 043 541 00008 EN.pdf​
Push rod 006 043 541 00007 EN.pdf​
Swivel traverse frame in the operator position 006 043 541 00005 EN.pdf​
Terminal diagram and hydraulic control block 006 043 541 00004 EN.pdf​
Hydraulic Operations\Hydraulic system
Aspirating or bleeding the hydraulic system 006 023 106 00012 EN.pdf​
Bleeding the hydraulic cylinders 006 023 106 00003 EN.pdf​
Bleeding the traverse oil motor and rotary drive 006 023 106 00013 EN.pdf​
Changing the hydraulic oil filter 006 023 118 00002 EN.pdf​
Checking the hydraulic hoses 006 023 160 00002 EN.pdf​
Fittin s stem EO-3 with visible indication of assembl 006 023 160 00003 EN.pdf​
Hydraulic control block H1 in drive compartment 006 023 332 00042 EN.pdf​
Hydraulic control block H2 in the operator position 006 023 332 00043 EN.pdf​
Hydraulic motor 2M1 006 023 244 00012 EN.pdf​
Hydraulic oil volumes in the complete hydraulic system and hydraulic reservoir 006 023 000 00046 EN.pdf​
Pressure relief valve on the hydraulic control block H1 in the drive compartment 006 023 000 00060 EN.pdf​
Pressure relief valves on the hydraulic control block H2 in the operator position 006 023 000 00059 EN.pdf​
Hydraulic Operations\JUDIT — descriptions
Description and teach-in of the weigher weight measurement in JUDIT 006 057 000 00001 EN.pdf​
Description of the parameters and controller sets for the combination controller (IJ8) 009 000 000 00080 EN.pdf​
Floor Pro Sideshift Plus 006 043 541 00009 EN.pdf​
Rotate function 006 043 541 00011 EN.pdf​
Rotate traverse function 006 043 541 00012 EN.pdf​
Setpoints of hydraulic controller 009 000 000 00059 EN.pdf​
Hydraulic Operations\Load handler
Fork carriage 006 029 128 00008 EN.pdf​
Fork positioner 006 029 355 00001 EN.pdf​
Forks G140101G.pdf​
Measuring and adjusting the clearance height (mechanical) 006 029 000 00017 EN.pdf​
Secure the load handler (fork carriage) to the auxiliary mast 005 042 000 00024 EN.pdf​
Telescopic tablel 006 029 528 00006 EN.pdf​
Hydraulic Operations\Mast hydraulic
Replacing the gasket set on the lift cylinder head 006 021 000 00002 EN.pdf​
Hydraulic Operations\Mast mechanical
Assembly and disassembly of the mast on the truck chassis 006 022 000 00040 EN.pdf​
Chains (for load-chain elongation testing see G 6355.01 ).pdf​
Disassembling assembling the mast rollers 006 022 222 00005 EN.pdf​
Mast rollers with eccentrics (eccentric rollers) 006 022 222 00007 EN.pdf​
Mast rollers with plastic slide pieces 006 022 000 00005 EN.pdf​
Operator position guide rollers 006 022 000 00041 EN.pdf​
Replacement Of the pulleys 006 021 277 00001 EN.pdf​
Replacing the lift chains 006 022 172 00013 EN.pdf​
Setting the chain tensioner 006 022 172 00005 EN.pdf​
Hydraulic Operations\Swivel traverse
Power supply chain 006 043 000 00021 EN.pdf​
Replacing the support rollers 006 043 000 00004 EN.pdf​
Rotary drive 006 043 000 00016 EN.pdf​
Rotate actual value transmitter (8U28) 006 043 292 00005 EN.pdf​
Swivel-traverse frame 006 043 000 00017 EN.pdf​
Tool 006 043 541 00019 EN.pdf​
Traverse actual value transmitter (8U29) 006 043 291 00006 EN.pdf​
Traverse reference sensor 2B11 006 043 291 00007 EN.pdf​
Turret head Disassembly Assembly Configuration 006 043 000 00019 EN.pdf​
Turret head Replacing the self-aligning bearings 006 043 000 00020 EN.pdf​
Lock washers
Nord-Lock lock washers 005 000 000 00013 EN.pdf​
Operator platform
High-tensile steel S700MC 005 016 112 00007 EN.pdf​
Left and right fall-bar magnetic switches (7B1 – 7B2) 005 016 287 00006 EN.pdf​
Removal and installation of the operator position (DZ mast) 005 016 112 00009 EN.pdf​
Removal and installation of the operator position (Z T mast) 005 016 112 00008 EN.pdf​
Removal and installation of the operator position driver’s seat 005 016 178 00001 EN.pdf​
Replacement of the operator position support rollers 005 016 112 00010 EN.pdf​
Safety devices
Fall Protection Equipment 005 042 000 00015 EN.pdf​
Mast bracing – anchoring 005 042 156 00005 EN.pdf​
Mechanical tilt safety device 005 042 309 00006 EN.pdf​
Personal protection system (PPS) — checklist 005 042 000 00006 EN.pdf​
Personal protection system (PPS) — disassembly or assembly general description 005 042 000 00009 EN.pdf​
Personal protection system (PPS) — front window cleaning and replacement 005 042 000 00003 EN.pdf​
Personal protection system (PPS) — protection field and warning field switching 005 042 000 00007 EN.pdf​
Personal protection system (PPS) — seven-segment and indicator displays 005 042 000 00005 EN.pdf​
Personal protection system (PPS) — software and parameterisation 005 042 000 00004 EN.pdf​
Rescue Equipment 005 042 000 00047 EN.pdf​
Secure the load handler (fork carriage) to the auxiliary mast 005 042 000 00024 EN.pdf​
Securing the operator position and mast 005 042 000 00011 EN.pdf​
Skylotec rescue equipment 005 042 000 00016 EN.pdf​
-8 Commissioning Maintenance Customer Service Department
Commissioning
Assembl and disassembl of the mast on the truck chassis 006 022 000 00040 EN.pdf​
Guided commissioning 007 025 559 00002 EN.pdf​
Instruction 007 025 103 00001 EN.pdf​
Slack chain switch 006 013 274 00005 EN.pdf​
Swivel-traverse frame 006 043 000 00017 EN.pdf​
Miscellaneous maintenance
Crack inspection on weld seams (visual inspection) 007 050 549 00001 EN.pdf​
Safety
J690009g.pdf​
Z000015g.pdf​
-9 Steering
Electrical system
Combi sensor (speed and temperature) 004 013 000 00013 EN.pdf​
Steer an le sensor 3B19 008 013 208 00002 EN.pdf​
Steering actual value transmitter (3U9) 008 013 166 00004 EN.pdf​
Steering actual value transmitter (3U9) 008 013 166 00011 EN.pdf​
JUDIT — descriptions
Adjustment and description of the steering functions in JUDIT 009 000 000 00060 EN.pdf​
Description of the parameters and controller sets for the combination controller (U8) 009 000 000 00080 EN.pdf​
Steering transmission
Steer motor (3M 1) steering transmission 008 032 000 00007 EN.pdf​
-10 System components
Collision protection
Disassembling assembling and aligning the sensor head 009 058 552 00012 EN.pdf​
Effect of drive wheel wear on the laser scanner beam height 009 058 552 00013 EN.pdf​
Field kits monitoring cases 009 058 552 00007 EN.pdf​
General description 009 058 552 00001 EN.pdf​
JUDIT settings during commissioning and FEM inspection of JET trucks 009 058 552 00010 EN.pdf​
Position and number of reflectors 009 058 552 00002 EN.pdf​
Retrofitting the collision protection function 009 058 552 00003 EN.pdf​
SICK Flexi Soft PLC 009 058 552 00011 EN.pdf​
SICK software description 009 058 552 00005 EN.pdf​
Test specimen checklist 009 058 552 00006 EN.pdf​
EKX 514a – EKX 516a – automated moving truck
Apron field configuration 009 000 000 00076 EN.pdf​
Automatic control 009 000 000 00041 EN.pdf​
Current collectors bus bars and power transfer distributor boxes 003 028 098 00008 EN.pdf​
Fine positioning 009 000 000 00075 EN.pdf​
Guide to commissioning 009 000 000 00079 EN.pdf​
On-board charger ATECH Zivan NG9 003 028 098 00004 EN.pdf​
Settin and description in JUDIT 003 028 098 00015 EN.pdf​
Setting up the calibration station 009 000 000 00045 EN.pdf​
System interface 009 000 000 00077 EN.pdf​
Update to the Siemens touch panel 009 000 000 00066 EN.pdf​
Ground system
Horizontal osition detection RFID system 009 008 000 00004 EN.pdf​
Horizontal position detection RFID system 009 008 000 00004 EN.pdf​
Installing the RFID memory modules in the narrow aisle floor 009 008 000 00010 EN.pdf​
L 2002 – WG frequency generator emergency power supply.pdf​
Optical aisle recognition 009 008 130 00001 EN.pdf​
RFID reader 009 008 000 00020 EN.pdf​
WG sensors 009 008 000 00019 EN.pdf​
JUDIT — descriptions
(pararneter file) 009 000 000 00069 EN.pdf​
Adjustment and description of the steering functions in JUDIT 009 000 000 00060 EN.pdf​
Adjustment and description of the travel behaviour in JUDI 004 101 000 00001 EN.pdf​
Adjustment and description of the travel functions in JUDI 009 000 000 00062 EN.pdf​
Changing the access type (key switch electronic system) 002 041 540 00021 EN.pdf​
Description and teach-in of the weigher weight measurement in JUDIT 006 057 000 00001 EN.pdf​
Description of the parameters and controller sets for the combination controller (IJ8) 009 000 000 00080 EN.pdf​
Dia nostics and CAN bus analysis009 000 000 00065 EN.pdf​
EasyAccess Standalone — connection between service computer and Maxi display 009 000 000 00085 EN.pdf​
Error memory 009 000 000 00064 EN.pdf​
Installing operating systems 009 000 000 00057 EN.pdf​
Installing the configuration with formulation (from LS 10 09) 009 000 000 00096 EN.pdf​
Installing the configuration with update files 009 000 000 00097 EN.pdf​
Loading the configuration with formulation (to LS 10 09) 009 000 000 00068 EN.pdf​
Node ID of CAN bus com onents 009 000 000 00058 EN.pdf​
Opening JUDIT 009 000 000 00056 EN.pdf​
Parameter assignment 009 000 000 00034 EN.pdf​
Rotate function 006 043 541 00011 EN.pdf​
Rotate traverse function 006 043 541 00012 EN.pdf​
Service parameters 009 000 000 00061 EN.pdf​
Setpoints of hydraulic controller 009 000 000 00059 EN.pdf​
SpeedProfile+ 004 101 000 00003 EN.pdf​
Warehouse naviation 009 000 000 00005 EN.pdf​