Jungheinrich ECE 118 Operating Instructions Manual Download Page 24 | Manualshive

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D 3

0406

.GB

4

Charging the battery

M

To charge the battery, the truck must be parked in a closed and properly ventilated
room. When charging, the tops of the battery cells must be laid open to provide
sufficient ventilation. Do not place any metal objects across the battery. Before
charging, check all cables and plug connections for visible signs of damage.
All safety notices provided by the battery supplier and battery charger supplier must
be strictly observed.

4.1

Charging the battery with a stationary charger

– Expose the battery (see Section 3).
– Connect the battery plug (4) with the charging lead of the stationary charger (5) and

turn on the charger.

4

5

D 3

0406

.GB

4

Charging the battery

M

To charge the battery, the truck must be parked in a closed and properly ventilated
room. When charging, the tops of the battery cells must be laid open to provide
sufficient ventilation. Do not place any metal objects across the battery. Before
charging, check all cables and plug connections for visible signs of damage.
All safety notices provided by the battery supplier and battery charger supplier must
be strictly observed.

4.1

Charging the battery with a stationary charger

– Expose the battery (see Section 3).
– Connect the battery plug (4) with the charging lead of the stationary charger (5) and

turn on the charger.

4

5

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Summary of Contents for ECE 118

Page 1: ...Operating instructions 51092878 ECE 118 G 08 06 07 08...

Page 2: ...iengesellschaft 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 inst...

Page 3: ...0108 GB 0108 GB...

Page 4: ...a stationary charger D 3 5 Battery removal and installation D 4 6 Battery discharge indicator t D 5 I 1 0708 GB Table of Contents A Correct Use and Application B Truck Description 1 Application B 1 2...

Page 5: ...t regular intervals and following any unusual incidents F 12 9 Final de commissioning disposal F 12 0708 GB I 2 E Operation 1 Safety regulations for the operation of industrial trucks E 1 2 Controls a...

Page 6: ...ngheinrich 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 o...

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

Page 8: ...required Approval of the local authorities however does not constitute the manufacturer s approval A 1 0406 GB A Correct Use and Application Z The Guidelines for the Correct Use and Application of In...

Page 9: ...0406 GB A 2 0406 GB A 2...

Page 10: ...he load wheels The capacity of the truck is shown on the data plate or the data capacity plate Qmax B 1 0708 GB B Truck Description 1 Application The ECE 118 is a tiller guided electric truck with an...

Page 11: ...icator 7 t Battery connector t Standard equipment o Optional equipment 1 2 7 8 8 10 3 6 4 5 9 11 12 0708 GB B 2 2 Assemblies Item Description Item Description 1 t Travel switch 8 t Castor wheel 2 t Ti...

Page 12: ...1400 700 2430 3036 1600 2802 2320 1360 1600 1200 2630 3236 2400 3602 3120 2160 2400 1200 3430 4036 B 3 0708 GB 3 Technical specifications Z Technical data specified in accordance with VDI 2198 Subjec...

Page 13: ...0708 GB B 4 Dimensions b1 1006 850 0708 GB B 4 Dimensions b1 1006 850...

Page 14: ...he truck is to be constantly used in conditions of extreme temperature or air humidity fluctuations B 5 0708 GB 3 4 EN standards Noise emission 68 dB A as defined in EN 12053 harmonised by ISO 4871 Z...

Page 15: ...y 17 Attachment point for crane lifting 18 Battery data plate 19 Test sticker o 16 17 18 15 19 1800 0708 GB B 6 4 Identification points and data plates Z The truck data plate 15 is visible when the lo...

Page 16: ...tery kg 30 Year of manufacture 25 Manufacturer s logo 31 Option 26 25 27 24 28 23 29 22 30 21 31 20 B 7 0708 GB 4 1 Truck data plate Z For queries regarding the truck or ordering spare parts always qu...

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

Page 18: ...pter D If necessary adjust the combination instrument to match the battery type see Chapter D 1 1 1 C 1 0406 GB C Transport and Commissioning 1 Lifting by crane F Only use lifting gear with sufficient...

Page 19: ...ning of the contact surface of the tyres This will disappear quickly once the truck is operated 2 3 0406 GB C 2 3 Removing the transport lock There is an instruction decal by the front panel for the t...

Page 20: ...brake released Now turn the screws 4 clockwise as far as the stop The brake is now applied again 4 C 3 0406 GB 4 Moving the truck without using the drive unit F This operation is not permitted on slo...

Page 21: ...I 2703 In each case correct measurements must be made and appropriate safety measures adopted 3 1 4 0406 GB C 4 5 Securing the truck during transport The truck must be lashed securely if transported o...

Page 22: ...ety of the truck The battery equipment is to be replaced only after agreement with the manufacturer D 1 0406 GB D Battery Maintenance Charging Replacement 1 Safety regulations for handling acid batter...

Page 23: ...g 3 EPzS 345 Ah 290 kg 24 V battery increased output 2EPzS 250 Ah 210 kg 3 EPzS 375 Ah 290 kg 3 2 1 0406 GB D 2 2 Battery types The battery types correspond to EN 60254 2 The following table shows the...

Page 24: ...t the battery plug 4 with the charging lead of the stationary charger 5 and turn on the charger 4 5 D 3 0406 GB 4 Charging the battery M To charge the battery the truck must be parked in a closed and...

Page 25: ...the battery panel carefully and slowly Do not reach between the battery panel and the chassis 7 8 6 0406 GB D 4 5 Battery removal and installation F The truck must be level To prevent short circuits b...

Page 26: ...40 50 Red Standard battery residual capacity 0 20 Maintenance free battery residual capacity 0 40 9 D 5 0406 GB 6 Battery discharge indicator t After the truck has been released via the key switch or...

Page 27: ...0406 GB D 6 0406 GB D 6...

Page 28: ...and warning signs Safety devices warning signs and warning instructions shall be strictly observed E 1 0406 GB E Operation 1 Safety regulations for the operation of industrial trucks Permission to op...

Page 29: ...leased Pressure sensitive mat unoccupied The truck coasts t Standard equipment o Optional equipment 0406 GB E 2 2 Controls and indicators Item Control display Function 1 Front panel t The complete hyd...

Page 30: ...E 3 0406 GB 7 8 7 8 6 6 3 4 13 R V 2 9 10 11 12 1 14 3 E 3 0406 GB 7 8 7 8 6 6 3 4 13 R V 2 9 10 11 12 1 14 3...

Page 31: ...e existing battery charge status Test the tiller brake function 5 see section 4 2 6 13 11 12 9 10 5 0406 GB E 4 3 Starting up the truck F Before the truck can be started operated or a load lifted the...

Page 32: ...Use suitable precautions e g a load guard to prevent parts of the load from tipping or falling off E 5 0406 GB 4 Industrial truck operation 4 1 Safety regulations for truck operation Travel routes an...

Page 33: ...to prevent the doors from actuating the collision safety switch 3 Start up the truck see Section 3 0406 GB E 6 4 2 Driving steering braking F Full attention is required when driving and steering espe...

Page 34: ...E 7 0406 GB B R V 13 4 R V 0 3 5 B B B F 14 E 7 0406 GB B R V 13 4 R V 0 3 5 B B B F 14...

Page 35: ...dle the magnetic brake applies Z When the tiller is released it reverts to the upper braking zone B 0406 GB E 8 Steering F In narrow bends the driver extends beyond the geometry of the truck Move the...

Page 36: ...sition of the load handler immediately release the button Lowering Press the Lower button 7 7 8 7 8 E 9 0406 GB 4 3 Lifting and depositing loads M Before collecting a load the driver must ensure that...

Page 37: ...position and remove the key For CANCODE 6 press the o key Remove the battery connector 13 13 11 12 0406 GB E 10 4 4 Parking the truck securely When you leave the truck it must be securely parked even...

Page 38: ...r the first time change the master and operating codes refer to Section 5 4 1 2 3 4 5 6 7 8 9 0 Set E 11 0406 GB 5 Keypad CANCODE o The keypad consists of 10 digit keys a Set key and a o key Activatio...

Page 39: ...ding code lock parameter must be set refer to Section 5 4 1 2 3 4 5 6 7 8 9 0 Set 18 17 16 21 20 19 0406 GB E 12 Start up When the main switch is turned on the LED 16 goes red When you enter the corre...

Page 40: ...ravel program 3 parameters acceleration coasting brake speed etc 4xx Program independent parameters E 13 0406 GB 5 2 Travel programs Press the digit keys 1 2 and 3 to select any of three travel progra...

Page 41: ...LED 18 Key 1 LED 19 Key 2 LED 20 Key 3 Service hours are displayed 284 0 Green flashing Off Off Off 0406 GB E 14 5 4 Parameter settings To change the truck setting you must enter the master code Z The...

Page 42: ...99999 2580 LED 19 flashes Enter a code Confirm Set LED 20 flashes Repeat the code entry Confirm Set E 15 0406 GB Setting procedure for trucks with and without display instrument CANDIS o Enter the thr...

Page 43: ...ic timeout 00 31 00 00 no cutout 01 to 30 Switch off time in minutes 31 Switch off after 10 seconds 0406 GB E 16 LEDs 18 20 are located in key fields 1 3 see Section 5 2 No Function Range Setting valu...

Page 44: ...ravel program not enabled 1 Travel program enabled 030 Display of the number of used operator codes E 17 0406 GB only in conjunction with display instrument CANDIS o The start program determines which...

Page 45: ...ff Changed setting is displayed 101 8 Green flashing Off Off Off Parameter number Parameter setting 0406 GB E 18 5 5 Travel parameters Z For trucks without a display instrument CANDIS o the code lock...

Page 46: ...Maximum speed in fork direction via controller 0 9 4 5 9 km h 8 8 5 km h Depending on travel switch E 19 0406 GB The following parameters can be entered Travel programs speeds and acceleration w o loa...

Page 47: ...e dry 0 2 0 0 Normal wet 1 Enhanced wet 2 Dry maintenance free 412 Discharge monitor function 0 1 1 0406 GB E 20 Battery parameters Z For trucks without a display instrument CANDIS o the code lock par...

Page 48: ...ing below the 20 limit for wet batteries or the 40 limit for maintenance free batteries 23 24 25 22 E 21 0406 GB 6 Display instrument CANDIS o The instrument indicates battery residual charge status L...

Page 49: ...shows the software version of the display instrument briefly the operating hours the charge status 0406 GB E 22 6 1 Discharge monitor function When the discharge monitor function is enabled lifting i...

Page 50: ...low the steps listed under Truck does not start Hydraulic oil too low Check the hydraulic oil level E 23 0406 GB 7 Troubleshooting This chapter is designed to help the user identify and correct basic...

Page 51: ...0406 GB E 24 0406 GB E 24...

Page 52: ...sed water After cleaning the truck carry out the activities detailed in the Recommissioning section F 1 0708 GB F Truck Maintenance 1 Operational safety and environmental protection The servicing and...

Page 53: ...every six years When replacing hydraulic components also replace the hoses in the hydraulic system 0708 GB F 2 Work on the electric system Only suitably trained personnel may operate on the truck s e...

Page 54: ...approx 100 service hours the proprietor must check the wheel nuts bolts and re tighten if necessary F 3 0708 GB 3 Servicing and inspection Thorough and expert servicing is one of the most important pr...

Page 55: ...t 8 2 Check motor mountings t 8 3 Vacuum clean the motor housing and check commutator for wear k t 0708 GB F 4 4 Maintenance checklist Maintenance intervals Standard t W A B C Cold storage k Chassis...

Page 56: ...Test drive with nominal load t 13 2 After maintenance present the truck to the authorised person t F 5 0708 GB Maintenance intervals Standard t W A B C Cold storage k Battery 9 1 Check acid density a...

Page 57: ...ssion fluid filling pipe a Transmission oil drain plug Cold store usage B 0 55 l E E E A 0 7l A C 1 0708 GB F 6 5 Maintenance schedule g Sliding surfaces 1 Compound ratio for cold store usage 1 1 s Gr...

Page 58: ...nt C Worked penetration at 25 C NLG1 class Application temperature C E Lithium 190 265 295 2 40 120 F 7 0708 GB 5 1 Consumables Handling consumables Consumables must always be handled correctly Follow...

Page 59: ...ff the panel 4 and place it next to the truck When the work is finished close the panel 4 1 1 2 3 4 0708 GB F 8 6 Maintenance and repairs 6 1 Preparing the truck for maintenance and repairs All necess...

Page 60: ...l of the correct grade up to the max mark for hydraulic oil specification see Section 5 min max 7 6 F 9 0708 GB 6 4 Replacing the drive wheel Z The drive wheel must only be replaced by authorised serv...

Page 61: ...ft motor 200 A 9 F1 Overall control circuit fuse 10 A 10 6F1 Battery discharge indicator 2 A 10 9 8 0708 GB F 10 6 6 Checking electrical fuses Prepare the truck for maintenance and repairs see Section...

Page 62: ...o avoid depletion of the battery through self discharge The sulfatisation would destroy the battery F 11 0708 GB 6 7 Recommissioning The truck may only be restored to service after cleaning or repair...

Page 63: ...ns governing the disposal of batteries fuels and electronic and electrical systems must be observed 0708 GB F 12 7 3 Returning the truck to operation after decommissioning Thoroughly clean the truck L...

Page 64: ...ith positive tubular plates type EPzV and EPzV BS 13 17 Type plate Jungheinrich traction battery 17 1 0506 GB Instructions for use Jungheinrich traction battery Table of contents 1 Jungheinrich tracti...

Page 65: ...etal parts of the battery are always live Do not place tools or other me tal objects on the battery 0506 GB 2 1 Jungheinrich traction battery with positive tubular plates type EPzS and EPzB Rating Dat...

Page 66: ...nt When charging proper provision must be made for venting of the charging gases steel M 10 23 1 Nm 3 0506 GB Ignoring the operation instructions repair with non original parts or using additives for...

Page 67: ...S G of 1 29 kg l at 30 C The electrolyte must conform to the purity regulations in DIN 43530 part 2 0506 GB 4 Battery container lids and the covers of battery compartments must be opened or re moved T...

Page 68: ...corrosion If it is necessary to remove cells it is best to call in our service department for this 5 0506 GB 3 Maintenance 3 1 Daily Charge the battery after every discharge Towards the end of charge...

Page 69: ...ing process must be disposed of as hazardous waste We reserve the right make technical modification 0506 GB 6 5 Storage If batteries are taken out of service for a lengthy period they should be stored...

Page 70: ...ear of manufacture Jungheinrich AG D 22047 Hamburg Germany 5 Pb Pb 2 3 6 5 11 13 1 14 4 10 12 7 8 9 7 0506 GB 7 Type plate Jungheinrich traction battery CE mark is only for batteries with a nominal vo...

Page 71: ...gth stroke length Aquamatic plug with diagnostics hole Aquamatic plug BFS III with diagnostics hole 0506 GB 8 Aquamatic BFS III water refilling system for Jungheinrich traction battery with EPzS and E...

Page 72: ...with five times the buoyant force and consequently interrupt the water supply reliably at least 3 m 9 0506 GB Diagrammatic view Equipment for the water refilling system 1 Water tank 2 Level switch 3 D...

Page 73: ...ter element optional with a max passage opening of 100 to 300 m into the battery s main supply pipe 0506 GB 10 4 Filling manual automatic The batteries should be filled with battery water as soon as p...

Page 74: ...eatest of care must be employed when prising out the plug to prevent any damage to the plug systems 11 0506 GB 8 Battery hose connections Hose connections for the individual plugs are laid along the e...

Page 75: ...to 0 6 bars in the Aquamatic system and operating pressure range 0 3 to 1 8 bars in the BFS system 0506 GB 12 10 2 1 Clamping ring tool The clamping ring tool is used to push on a clamping ring to in...

Page 76: ...Metal parts of the battery are always live Do not place tools or other metal objects on the battery 13 0506 GB 2 Jungheinrich traction batterie Maintenance free Jungheinrich traction batterie with pos...

Page 77: ...container lids and the covers of battery compartments must be opened or re moved steel M 10 23 1 Nm 0506 GB 14 Ignoring the operation instructions repair with non original parts and non authorised int...

Page 78: ...red 3 Maintenance Don t refill water 3 1 Daily Charge the battery immediately after every discharge 15 0506 GB With the charger switched off connect up the battery ensuring that the polarity is cor re...

Page 79: ...er of cells The storage time should be taken into account when considering the life of the batte ry 0506 GB 16 3 2 Weekly Visual inspection after recharging for signs of dirt and mechanical damage 3 3...

Page 80: ...ear of manufacture Jungheinrich AG D 22047 Hamburg Germany 5 Pb Pb 2 3 6 5 11 13 1 14 4 10 12 7 8 9 17 0506 GB 6 Malfunctions If malfunctions are found on the battery or the charger our service depart...

Page 81: ...0506 GB 18 0506 GB 18...

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