Jungheinrich EJC M10, Operating Instructions Manual

Page 1: ...Operating instructions 51145321 EJC M10 G 05 09 05 09...

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: ...ergency operation C 3 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 Chargi...

Page 5: ...1 Consumables F 7 6 Maintenance Instructions F 8 6 1 Preparing the truck for maintenance and repairs F 8 6 2 Removing the front panel F 8 6 3 Removing the drive panel F 8 6 4 Checking the hydraulic oi...

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: ...e 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...

Page 9: ...1004 GB A 2...

Page 10: ...a steered drive wheel It is designed for use on level floors to lift and transport palletised goods Open bottom pallets or roll cages can be lifted The capacity can be obtained from the data plate Th...

Page 11: ...4 t Shunt button 5 t Controller 6 t Collision safety switch 7 t Mast 8 t Mast guard auxiliary mast guard 9 t Battery cover 10 t Battery connector Emergency Disconnect 11 t Lift mechanism 12 t Front p...

Page 12: ...ering speed w rated load w o load 11 11 cm sec Max gradeability 5 min rating w w o load 8 Description EJC M10 h1 Height 1950 mm h2 Free lift 100 mm h3 Lift 2900 mm h4 Mast height extended 3373 mm h13...

Page 13: ...0509 GB B 4 h1 h14 h2 h3 h4 l1 l l2 h13 m2 y c Q b5 Ast W a B s...

Page 14: ...nt 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...

Page 15: ...city 17 Data plate 18 Strap point for crane lifting 19 Do not reach through the mast warning 20 Do not step under the load handler warning 21 Battery data plate 22 Serial number 23 Truck description 2...

Page 16: ...n mm in diagram form The lower plate 16b 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 The arrow shape ma...

Page 17: ...0509 GB B 8...

Page 18: ...Crane slings should be fastened in such a way that they do not come into contact with any parts of the truck when it is being raised 2 Securing the Truck for Transport F The truck must be securely fas...

Page 19: ...ter 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 cable see Chapter D...

Page 20: ...h OFF 0 and remove the key Prevent the truck from rolling away Remove the front panel 2 see Chapter F Remove the right hand drive panel 3 see Chapter F Pull up the anchor plate by screwing in two M5 s...

Page 21: ...0509 GB C 4...

Page 22: ...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 national environmental...

Page 23: ...the battery compartment of the truck The following table shows which combinations are included as standard 3 Exposing the battery Park the truck securely see Chapter E Remove the battery connector 1...

Page 24: ...ns connector 3 from its receptacle and insert it in a suitable mains socket The LED 4 flashes green or a permanent yellow to indicate that the charger is connected to the mains Z When the mains connec...

Page 25: ...This keeps battery wear to a minimum A red flashing LED 4 means that the battery is faulty or the charge current circuit has been interrupted Lit Charging complete battery fully charged charge interva...

Page 26: ...fficient ventilation Do not place any metal objects on the battery Before charging check all cables and plug connections for visible signs of damage All safety instructions as provided by the battery...

Page 27: ...hat the battery container is not compressed The hooks must be attached to the eyes 5 of the battery in such a way that they cannot fall onto the battery cells when the lifting gear is discharged Attac...

Page 28: ...n no longer be lifted Lifting is only enabled again when the battery connected is at least 70 charged If the LED flashes red and the truck is not ready for operation inform the manufacturer s service...

Page 29: ...0509 GB D 8...

Page 30: ...engers or lift other people Damage and Faults The supervisor must be immediately informed of any damage or faults to the truck or attachment Trucks which are unsafe for operation e g wheel or brake pr...

Page 31: ...ges and travel parameters in combination with CanCode 4 Tiller t Used for steering and braking 5 Shunt button t If the tiller is in the upper braking zone braking can be overridden by pressing the swi...

Page 32: ...E 3 0509 GB 2 1 11 3 4 5 7 6 6 8 9 10 7 6 6 8 9 10 8 9 t o...

Page 33: ...re it is secure Check the mains connector and mains cable for damage Check labels for legibility and completion see chapter B Test warning indicators and safety devices Test hydraulic system Test the...

Page 34: ...e a second person must walk in front of the truck as a lookout Negotiating slopes and inclines Slopes or inclines may only be negotiated if they are designated traffic routes are clean and have a non...

Page 35: ...tiller moves slowly to the upper brake zone the cause of this fault must be rectified If necessary replace the gas pressure spring Travel M Travel with raised forks raised load beyond 500 mm above the...

Page 36: ...n fwd or rev The brake is released The truck travels at slow speed M The brake is only activated when the crawl speed button is released with crawl speed you can only brake by plugging travel switch 6...

Page 37: ...truck brakes regeneratively until it starts to move in the opposite direction Braking with the coasting brake If the travel switch is set to 0 the truck automatically brakes regeneratively F In hazar...

Page 38: ...you reach the the load handler limit position immediately release the button Lowering Press the lower load handler button 9 until you reach the required lifting height M Avoid depositing the load sudd...

Page 39: ...n the front panel see Chapter F Remove the screw gradually 14 The lift mechanism lowers Insert the screw 14 as far as the stop F Only operate the truck once the fault has been removed 5 1 Parking the...

Page 40: ...of travel program 1 parameter 101 Travel program 1 Function Setting range Standard setting Comments Acceleration 0 9 0 1 1 0 m s2 3 0 4 m s2 Coasting brake 0 9 0 1 1 0 m s2 3 0 4 m s2 Maximum speed i...

Page 41: ...ds to the minimum available capacity If only one LED bar is lit the battery capacity is almost depleted and the Warning indicator 20 is lit The battery must be charged immediately If no more LED bars...

Page 42: ...ously they are displayed one after the other The events are displayed until they are rectified Event messages overwrite the service hour display Most events cause the emergency stop to be activated Th...

Page 43: ...k does not start Battery connector not plugged in Check battery connector and insert if necessary Key switch in 0 position Set key switch to I Battery charge too low Check battery charge charge batter...

Page 44: ...rer s service department has field technicians specially trained for these tasks We therefore recommend that you enter into a maintenance contract with the manufacturer s local service centre Lifting...

Page 45: ...erformance of the truck When replacing factory fitted tyres only used original manufacturer s spare parts as otherwise the truck will not comply with the data plate specifications When changing wheels...

Page 46: ...ngly if the truck is to be used in conditions of extreme dust temperature fluctuations or multiple shifts The following maintenance checklist states the tasks and intervals after which they should be...

Page 47: ...dings check settings and adjust if necessary t 2 10 Read the logbook and then clear it t Power supply 3 1 Visually inspect battery and battery components t 3 2 Check battery cable connections are secu...

Page 48: ...k that hose and pipe lines and their connections are secure check for leaks and damage t 6 9 Test the emergency lowering t 6 10 Check hydraulic oil level and top up if necessary t 6 11 Replace the hyd...

Page 49: ...9 GB F 6 5 Lubrication Schedule g Contact surfaces h Hydraulic oil filler neck b Transmission oil filler neck Gear oil overflow and dipstick a Transmission oil drain plug 0 55 l 4 5 l min max G B A C...

Page 50: ...in accordance with regulations M The trucks are factory equipped with a special hydraulic oil the Jungheinrich hydraulic oil with a blue colouration and the cold store hydraulic oil red colouration Th...

Page 51: ...d lift truck secure it to prevent it from tipping or sliding away When raising the industrial truck also refer to the instructions in the Transport and Commissioning section 6 2 Removing the front pan...

Page 52: ...ove the front panel see section 6 2 Check hydraulic oil level in hydraulic reservoir M There are markings on the hydraulic reservoir The oil level must be checked when the load forks are lowered If ne...

Page 53: ...e front panel see section 6 2 Check the fuse rating and condition in accordance with the table replace if necessary Item Description To protect Rating 7 2F1 Pump motor fuse 100 A 8 1F1 Drive motor fus...

Page 54: ...e 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 clean the truck...

Page 55: ...after any unusual event by a qualified inspector be sure to comply with national regulations The inspector shall assess the condition of the truck from purely a safety viewpoint without regard to ope...

Page 56: ...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 57: ...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 58: ...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 59: ...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 60: ...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 61: ...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 62: ...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 63: ...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 64: ...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 65: ...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 66: ...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 67: ...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 68: ...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 69: ...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 70: ...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 71: ...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 72: ...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 73: ...0506 GB 18...