Jungheinrich ECE 320, Operating Instructions Manual

Page 1: ...Operating Instructions 51076425 G 03 08 07 08 ECE 320...

Page 2: ...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 materi...

Page 3: ...0108 GB...

Page 4: ...C 4 D Battery Maintenance Charging Replacement 1 Safety regulations for handling acid batteries D 1 2 Battery types D 2 3 Exposing the battery D 2 4 Charging the battery D 3 5 Battery removal and inst...

Page 5: ...4 Maintenance checklist F 4 5 Lubrication Schedule F 6 5 1 Consumables F 7 6 Maintenance Instructions F 8 6 1 Preparing the truck for maintenance and repairs F 8 6 2 Tightening the wheel nuts F 8 6 3...

Page 6: ...06 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 instruct...

Page 7: ...0506 GB 2...

Page 8: ...the industrial truck himself or on whose behalf it is used In special cases e g leasing or renting the proprietor is considered to be the person who in accordance with existing contractual agreements...

Page 9: ......

Page 10: ...r with a Jet Pilot or electric tiller steering o The truck is designed to transport and pick goods on level surfaces Roll cages and open bottom pallets or pallets with transverse boards provided these...

Page 11: ...Main switch isolator emergency disconnect 14 t Forward pedestrian operation button 5 t Controller 15 t Operator platform 6 t Brake button 16 t Lift mechanism 7 o Keypad CANCODE 17 t Tiller 8 o Display...

Page 12: ...with longer forks the load centre is in the centre of the fork Model ECE 320 Q Rated capacity 2000 kg c Load centre distance with standard fork length 1200 mm Travel speed w w o rated load 9 5 12 5 km...

Page 13: ...1505 hb Battery panel height 959 hf Operator platform height 132 b1 Truck width 810 l Track Width 2400 b3 Inside spread 180 b11 Fork length 375 b5 Width across forks 570 e Fork width 195 Ast Working...

Page 14: ...he vertical direction It is calculated when travelling over bumps at constant speed Electromagnetic Compatibility The manufacturer confirms that equipment complies with tolerance levels for electromag...

Page 15: ...ad on the fork should be spread as evenly as possible Item Model 20 Attention Touch Mode warning decal for Touch mode only in drive direction option 21 Test sticker o 22 Truck data plate 23 Warning Do...

Page 16: ...ck s serial no 28 Item Model Item Model 27 Type 33 Manufacturer 28 Serial no 34 Min max battery weight kg 29 Rated capacity kg 35 Output kW 30 Battery Voltage V 36 Load centre of gravity mm 31 Net wei...

Page 17: ...0708 GB B 8...

Page 18: ...2 in case the truck is to be lifted or transported by crane Park the truck securely see Chapter E Open the front panel and put it to one side see chapter F Secure the lifting gear to the attachment p...

Page 19: ...e the truck attach the tensioning belt to the strap points 1 and secure them to the fastening rings Tighten the tensioning belt with the tensioner M Loading must be carried out by specially trained st...

Page 20: ...e the truck after delivery or after transport proceed as follows Make sure the truck s equipment is complete and in a satisfactory condition Install battery where required Do not damage battery cables...

Page 21: ...Prevent the truck from rolling away Open the battery panel see chapter D Open the front panel 3 and put it to one side see chapter F Pull up the anchor plate by screwing in two M5 screws 2 at least 42...

Page 22: ...a light coating of dielectric grease Batteries with non insulated terminals must be covered with a non slip insulating mat Battery Disposal Batteries may only be disposed of in accordance with nation...

Page 23: ...ies F When replacing or installing batteries ensure that the battery is correctly secured in the battery compartment of the truck 3 Exposing the battery F Park the truck securely see Chapter E Pull le...

Page 24: ...ging the tops of the battery cells must be exposed to provide sufficient ventilation Do not place any metal objects on the battery Before charging check all cables and plug connections for visible sig...

Page 25: ...annot collapse on the battery cells Expose the battery see section 3 Pull out the battery plug 4 from the holder Lift back the battery locking mechanism 8 Pull the battery 9 sideways onto the battery...

Page 26: ...aults The supervisor must be immediately informed of any damage or faults to the forklift truck or attachment Trucks which are unsafe for operation e g wheel or brake problems must not be used until t...

Page 27: ...ximum rate until it comes to a halt 6 Controller t Controls the direction of travel and the travel speed 7 Jet Pilot Tiller t o Steers the truck Steers the truck 8 Forward pedestrian walk along operat...

Page 28: ...E 3 04 08 GB 14 11 12 13 15 1 7 3 4 6 3 4 2 2 5 5 2 6 6 4 3 8 4 3 9 10...

Page 29: ...pacity Displays travel parameters and service indicators Shows the service hours completed by the truck Battery discharge indicator t Battery charge status 13 Key switch t Switches the truck on and of...

Page 30: ...E 5 04 08 GB 14 11 12 13 15 1 7 3 4 6 3 4 2 2 5 5 2 6 6 4 3 8 4 3 9 10...

Page 31: ...mechanism for visible signs of damage Visually inspect the battery attachment and cable connections M When entering the truck take care not to apply the controller or the pedestrian o button Switching...

Page 32: ...uck as a lookout Negotiating slopes and inclines Negotiating slopes or inclines is only permitted if such roads are clean and have a non slip surface and providing such journeys are safely undertaken...

Page 33: ...his prevents a fault being cancelled without being rectified F As the steering system is a safety critical component the fault must be rectified by the manufacturer s service department Emergency Disc...

Page 34: ...n 3 Set the controller 6 to the desired travel direction forward V or reverse R Z The truck starts to travel in the direction selected The travel speed is governed by the controller 6 For trucks with...

Page 35: ...fter a short jerk the controller detects downhill motion on an incline The service brake is released again via the controller 6 which is also used to select the speed and the travel direction Steering...

Page 36: ...es to a halt M The mechanical brake is only applied when this brake fails to achieve the necessary braking force The truck can only start again when the controller has been set to 0 Braking with the g...

Page 37: ...an obstacle Z In pedestrian mode the truck can be operated by the operator from all sides while walking alongside In this case the truck travels at a significantly reduced speed There are two methods...

Page 38: ...to the desired travel direction forward V or reverse R The truck moves at reduced speed can be set up to a maximum of 4 km h Travel using the pedestrian button Press the pedestrian buttons 8 10 The tr...

Page 39: ...it does not protrude excessively from the top of the lift mechanism less than 50 mm Lift Lower Z Press the Lift 4 or Lower 3 buttons to activate lifting or lowering at a preset speed Lifting Press the...

Page 40: ...truck on a slope The lift mechanism must always be completely lowered Lower the lift mechanism Set the drive wheel to Straight ahead Jet Pilot t the steering arm is set automatically to forward travel...

Page 41: ...ameters only in conjunction with the display instrument CANDIS o The o key has top priority and restores the truck from any status to its default status without modifying any settings 5 1 Code Lock Wh...

Page 42: ...code is entered LED 21 flashes red for two seconds The correct code can then be entered Z The Set key 22 has no function in operating mode Switching off Press the o key 26 to switch off the truck Z Th...

Page 43: ...d enables you to set the code lock functions and adapt travel programs In addition the battery parameters can also be set Z For trucks without a display instrument CANDIS o only the code lock paramete...

Page 44: ...ny parameter will affect the truck s travel pattern you must carry out a test run in a specially designated work area To enter the master code Press theo key Enter master code Code Lock Parameters Set...

Page 45: ...finish entering press the o key 26 The following parameters may be entered Code Lock Parameter List No Function Setting range Standard setting Comments Procedure Code Lock 000 Change master code The...

Page 46: ...ode Confirm Set LED 24 flashes Enter a new code Confirm Set LED 25 flashes Repeat code entry Confirm 003 Delete user code 0000 9999 or 00000 99999 or 000000 999999 LED 24 flashes Enter a code Confirm...

Page 47: ...nfiguration 4 digit SET Configuration confirmation 4 digit SET 1st digit travel program 1 release 0 or 1 2nd digit travel program 2 release 0 or 1 3rd digit travel program 3 release 0 or 1 4th digit s...

Page 48: ...hange the parameter value according to the parameter list Check the LC display of the indicator instrument CANDIS o confirm with the Set key 22 The LED 23 of the o key 26 switches briefly to continuou...

Page 49: ...meter 100 101 Acceleration in Rider mode 0 9 2 102 Coasting brake in rider mode 0 9 2 103 Coasting brake in Pedestrian mode 0 9 2 Value of parameter 103 Parameter 102 104 Maximum speed in drive direct...

Page 50: ...irection via controller 0 9 8 Depending on travel switch 205 Pedestrian speed in drive direction via controller 0 9 5 Depending on travel switch 206 Pedestrian speed in drive direction via pushbutton...

Page 51: ...irection via controller 0 9 8 Depending on travel switch 305 Pedestrian speed in drive direction via controller 0 9 5 Depending on travel switch 306 Pedestrian speed in drive direction via pushbutton...

Page 52: ...s for the travel parameters The following parameters may be entered Setting 0 1 is to be interpreted as 0 off 1 on 6 ISM o Z If the truck is equipped with an ISM access module see ISM Access Module No...

Page 53: ...ted is at least 70 charged The status display is reset to 100 when the battery type is adjusted Z If the LED flashes red and the truck is not ready for operation inform the manufacturer s service depa...

Page 54: ...ponds to the minimum available capacity If only one LED bar is lit the battery capacity is almost depleted and the Warning indicator 27 is lit The battery must be charged immediately If no more LED ba...

Page 55: ...played one after the other The errors are displayed for as long as they remain always in combination Cxxx Exxx Error messages overwrite the service hour display Most errors cause the emergency stop to...

Page 56: ...nected Isolator Emergency Stop depressed Key switch set to 0 Code lock switched off Battery charge too low Platform switch not applied Faulty fuse Check the battery connector and connect if necessary...

Page 57: ...04 08 GB E 32...

Page 58: ...urer The manufacturer s service department has field technicians specially trained for these tasks We therefore recommend a maintenance contract with the manufacturer s local service centre Lifting an...

Page 59: ...performance of the truck When replacing tyres fitted at the factory only use the manufacturer s original spare parts Otherwise the data sheet specifications of the truck cannot be guaranteed When chan...

Page 60: ...ear The service intervals stated are based on single shift operation under normal operating conditions They must be reduced accordingly if the truck is to be used in conditions of extreme dust tempera...

Page 61: ...heck carbon brush wear replace if necessary k t Power supply 3 1 Visually inspect battery k t 3 2 Check battery cable connections are secure grease terminals if necessary k t 3 3 Check acid density ac...

Page 62: ...f necessary k t 6 5 Check cylinders and piston rods for damage and leaks and make sure they are secure k t 6 6 Check hydraulic oil level k t 6 7 Replace hydraulic oil This may have to be performed via...

Page 63: ...re application 1 Cold store mix ratio 1 1 2 Transmission oil values are guidelines only The spur wheel should be dipped approx 2 mm in the oil Z The quantity specified is provided by the manufacturer...

Page 64: ...n mixing is expressly stipulated in the Operating Instructions Avoid spillage Spilled liquids must be removed immediately with suitable bonding agents and the bonding agent consumable mixture must be...

Page 65: ...en raising the truck also refer to the instructions in the Transport and Commissioning section When working on the parking brake prevent the truck from rolling away 6 2 Tightening the wheel nuts The w...

Page 66: ...front panel Open battery panel see chapter D Remove the screws 5 Lift up the front panel 4 and put it to one side Z Installation is the reverse order F Do not drive the truck unless the panels are clo...

Page 67: ...he table check all fuses for correct rating and damage replace fuses where required Refit front panel Item Model To protect Rating 6 F17 Radio terminal o 10 A 7 3F1 Electric steering control fuse 30 A...

Page 68: ...damaged If the truck is to be out of service for more than 6 months further measures must be taken in consultation with the manufacturer s service department 7 1 Prior to decommissioning Thoroughly cl...

Page 69: ...ast annually refer to national regulations or after any unusual event by a qualified inspector The inspector shall assess the condition of the truck from purely a safety viewpoint without regard to op...

Page 70: ...tive tubular plates type EPzS and EPzB 2 6 Type plate Jungheinrich traction battery 7 Instruction for use Aquamatic BFS III water refilling system 8 12 2 Jungheinrich traction battery Maintenance free...

Page 71: ...d clothes when working on batteries Pay attention to the accident prevention rules as well as DIN EN 50272 3 DIN 50110 1 No smoking Do not expose batteries to naked flames glowing embers or sparks as...

Page 72: ...ucks is the standard which ap plies to the operation traction batteries in industrial trucks 2 1 Discharging Be sure that all breather holes are not sealed or covered Electrical connections e g plugs...

Page 73: ...The containers for batteries with plate protection packs must not be closed until at least half an hour after charging has past 2 3 Equalising charge Equalising charges are used to safeguard the life...

Page 74: ...ound further testing and maintenance by the service department should be requested 3 4 Annually In accordance with DIN VDE 0117 at least once per year the insulation resistance of the truck and the ba...

Page 75: ...be taken into account when considering the life of the battery 6 Malfunctions If malfunctions are found on the battery or the charger our service department should be called in without delay The meas...

Page 76: ...l battery capacity 5 Battery tray number 12 Number of battery cells 6 Delivery date 13 Battery weight 7 Battery manufacturer s logo 14 Safety instructions and warnings Typ 1 T ype Nennspannung 5 Nomin...

Page 77: ...sing batteries which comply with I and II it is important to follow the in structions on maintaining the respective protection class during operation see asso ciated certification Cell series Aquamati...

Page 78: ...d by means of a central sealing coupler through the hose connections in the individual Aquamatic BFS plugs 2 Application The Aquamatic BFS battery water refilling system is used in traction batteries...

Page 79: ...surface 5 2 Pressurised water The pressure reducing valve in the Aquamatic System is set from 0 2 bars to 0 6 bars and from 0 3 bars to 1 8 bars in the BFS system 5 3 Water Refill Trolley serviceMobi...

Page 80: ...ve a diagnostics hole with a 6 5 mm diameter Aquamatic plugs or a 7 5 mm diameter BFS plugs 9 2 Float Different floats are used depending on the cell design and type 9 3 Cleaning The plug systems may...

Page 81: ...en tral supply pipe This is connected to the water supply system at the battery charging station by means of a sealing coupler system On the battery side a closing nipple ident no 50219538 is mounted...

Page 82: ...battery Work on batteries to be carried out by skilled personnel only Use protective glasses and clothes when working on batteries Pay attention to the accident prevention rules as well as DIN EN 5027...

Page 83: ...g plugs must only be made or broken in the open circuit condition To achieve the optimum life for the battery operating discharges of more than 60 of the rated capacity should be avoided deep discharg...

Page 84: ...0 0171 Ex I in areas with a firedamp hazard or Ex II in potentially explosive areas The attention pictograms has to be respected 2 3 Equalising charge Equalising charges are used to safeguard the life...

Page 85: ...1000 4 Care of the battery The battery should always be kept clean and dry to prevent tracking currents Clea ning must be done in accordance with the ZVEI code of practice The Cleaning of Vehicle Trac...

Page 86: ...raction battery CE mark is only for batteries with a nominal voltage greater than 75 volt Item Designation Item Designation 1 Logo 8 Recycling symbol 2 Battery designation 9 Dustbin material 3 Battery...

Page 87: ...0506 GB 18...