Jungheinrich EJD K18 Operating Instructions Manual Download

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Operating Instructions

50468912

EJD K18

02.05 -

03.07

Summary of Contents for EJD K18

Page 1: ...Operating Instructions 50468912 EJD K18 G 02 05 03 07...

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: ...Transport and Commissioning 1 Lifting by crane C 1 2 Commissioning C 1 3 Operating the truck without its own drive system emergency operation C 2 3 1 Emergency operation with service key 741 o C 3 D...

Page 5: ...F Truck Maintenance 1 Operational safety and environmental protection F 1 2 Maintenance Safety Regulations F 1 3 Servicing and inspection F 3 4 EJD K18 Maintenance Checklist F 4 5 EJD K18 Lubrication...

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 the person who in accordance with existing contractual agreements betwe...

Page 9: ...0205 GB A 2...

Page 10: ...ontal transportation two pallets can be stacked on top of each other With its compact design and application as both stacker and for horizontal transportation the truck is especially suited for use in...

Page 11: ...t o Discharge monitor Display instrument CANDIS 10 t Battery connector emergency disconnect 3 o Keypad CANCODE 11 t Load handler 4 o On board charger 24 volt 30 A including safety switch 12 t Front p...

Page 12: ...on motor operates the drive wheel 15 via a bevel gear system The truck can be plugged by changing travel direction with the controller in the tiller arm Steering The tiller 16 is used for steering It...

Page 13: ...utriggers are connected to the chassis via the lift cylinder and the lift linkage The roller cylinders are raised by the lift cylinder while simultaneously moving the load wheel support of the lift li...

Page 14: ...w o load 12 22 cm s Lowering speed w w o load 24 17 cm s Max gradeability 5 min rating with without load 6 12 Description EJD K18 Short version Long version h1 Mast height retracted 1295 mm h3 Lift 16...

Page 15: ...0205 GB B 6 h 1 b 1 b 4 h 4 l1 l2 150 y e b 5 W a Q c l h 13 h 3 h 5 1268...

Page 16: ...es to the limits for electromagnetic emissions and resistance as well as the static electricity discharge test in accordance with EN 12895 as well as the standardised instructions contained therein Z...

Page 17: ...h the mast warning 23 Do not step under the load handler warning 24 No passengers warning 25 Serial no engraved in truck chassis 26 UVV test sticker only D 27 Attention Read operator manual 20 22 23 2...

Page 18: ...outriggers without mast lift C Double decker mode Max lift height 1 660 mm Max capacity for high level lifting as indicated by entry Max capacity for high and low level lifting both max 1 800 kg Item...

Page 19: ...icates the capacity Q kg of the truck The permissible load is shown as a function of the load centre of gravity distance D in mm and the lift height H in mm in tabular form X XXXX XX XX 1880 1000 1000...

Page 20: ...must be less than 6m long Z When the truck is parked the running surface of the tyres will flatten The flattening will disappear after a short time operating the truck To prepare the truck after deliv...

Page 21: ...agnetically applied brake must be released Remove the front panel 2 see Chapter F Remove the right hand drive panel 3 see Chapter F Turn the screws 4 anti clockwise as far as the stop The truck can no...

Page 22: ...ry in the truck The service key 741 o 701 is standard must be set to position 2 of the keyswitch Z Key 701 for normal truck operation can only be turned to position 1 of the keyswitch The creep switch...

Page 23: ...0205 GB C 4...

Page 24: ...coating of dielectric grease Batteries with non insulated terminals must be covered with a non slip insulation mat Battery Disposal Batteries may only be disposed of in accordance with national envir...

Page 25: ...e battery compartment of the truck 3 Batteries and Motor Output Z The abbreviations S shor version and L long version on the data plate indicate the actual version of the truck Depending on the type o...

Page 26: ...closed and properly ventilated room When charging 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 a...

Page 27: ...ot be charged Selecting the charging curve for the onboard charger Use the switch 6 on the charger to adapt the charge curves to the particular battery used in accordance with the following table M Be...

Page 28: ...tor must remain plugged Connect the mains cable to the char ger and insert the mains connector 8 into a mains socket The flashing LED indicates the charge status or a fault for flashing codes see LED...

Page 29: ...charging is complete Partial charging The charger is designed to automatically adapt to partially charged batteries This keeps battery wear to a minimum Green LED charge status Red LED fault Display...

Page 30: ...late on the battery container The crane lifting gear must exert a vertical pull The hooks of the lifting gear must never fall into the battery cells Expose the battery see Section 4 Remove the battery...

Page 31: ...f 10 within 3 minutes The displayed status cannot rise again during the present operation The status display is reset to 100 when the battery type is adjusted If the LED flashes red and the truck is n...

Page 32: ...and Faults The supervisor must be immediately informed of any damage or faults to the forklift truck or attachment Trucks not safe for operation e g wheel or brake problems must not be used until the...

Page 33: ...including safety switch o Charges the battery by inserting the mains connector in a mains socket 5 Tiller t Used to steer and brake the truck 6 Crawl button t Pressing the crawl button reduces the tra...

Page 34: ...E 3 0205 GB 13 6 9 9 10 7 12 8 11 14 1 2 3 5 4...

Page 35: ...for visible signs of damage Visually inspect the battery attachment and cable connections Switching on the truck Make sure the battery is connected 14 Insert the key in the key switch 1 and turn it to...

Page 36: ...ken in accordance with the technical specifications for the truck in question The truck must always be driven with the load unit facing uphill The industrial truck must not be turned operated at an an...

Page 37: ...nels are closed and properly locked Start up the truck refer to section 3 The travel speed is governed by the travel switch 10 Set the tiller 5 to the travel range F and press the controller 9 in the...

Page 38: ...brake the truck by immediately releasing the crawl button 6 When you apply the crawl button in the travel range F the truck travels with reduced speed and acceleration Steering Move the tiller 5 to th...

Page 39: ...ng The 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...

Page 40: ...d It is forbidden to collect long loads at an angle Fully insert the truck and the load handler underneath the load unit Z The lifting and lowering speeds are specified Lift Press the Lift 8 button un...

Page 41: ...d raise with button 8 Now position the outriggers under the second pallet and raise the outriggers with button 11 Z To transport the truck the load forks with the load must be lowered as near as possi...

Page 42: ...o switch has top priority and resets the truck from any condition to its default condition without modifying any settings 5 1 Code Lock When the correct code has been entered the machine is ready for...

Page 43: ...automatically after a pre determined time To do this you need to set the corresponding code lock parameter see Section 5 4 5 2 Parameters In programming mode you can set the code lock functions via th...

Page 44: ...ce changing any 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 the o key Enter master code Code Lock...

Page 45: ...complete your entry press the o key 20 The following parameters may be entered Code Lock Parameter List No Function Range of Setting Standard Setting Comments Procedure Code Lock 000 Change Master Co...

Page 46: ...e Confirm Set LED 18 flashes Enter new code Confirm Set LED 19 flashes Repeat code entry confirm 003 Delete Operator Code 0000 9999 or 00000 99999 or 000000 999999 LED 18 flashes Enter code Confirm Se...

Page 47: ...llowing errors New master code is already operator code New operator code is already master code Operator code to be changed does not exist Tried to change the operator code to another user code that...

Page 48: ...ent The parameters are set in the same way as for the travel parameters The following parameters may be entered Setting 0 1 is to be interpreted as 0 off 1 on No Function Range of Setting Standard Set...

Page 49: ...top 23 displays will depend on the battery type No of bars Charge status Wet battery Maintenance free battery LED yellow Warning LED red Stop LED yellow Warning LED red Stop 10 90 1 100 Off Off Off Of...

Page 50: ...n E for error with alternating three digit error number If several errors occur simultaneously they are displayed one after the other The errors are displayed as long as they are present always in com...

Page 51: ...or not connected Check the battery connector and connect if necessary Key switch in 0 position Set key switch to I Incorrect CANCODE code Check code Battery charge too low Check battery charge charge...

Page 52: ...ned personnel 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 L...

Page 53: ...erformance 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 chang...

Page 54: ...y 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 car...

Page 55: ...and lubricate if necessary k t Lift mechanism 6 1 Check operation wear and setting t 6 2 Visually inspect rollers slide pieces and stops k t 6 3 Check forks and fork carriage for wear and damage k t...

Page 56: ...10 4 Check battery cables for damage replace if necessary t Lubrication 11 1 Lubricate truck in accordance with Lubrication Schedule k t General Measure ments 12 1 Check electrical system for frame l...

Page 57: ...surfaces s Grease nipples Hydraulic oil filler neck b Transmission oil filler neck a Transmission oil drain plug Transmission oil overflow and dipstick Cold Store Application Compound ratio for cold s...

Page 58: ...tipulated in the Operating Manual Avoid spillage Spilled liquids must be removed immediately with suitable bonding agents and the bonding agent consumable mixture must be disposed of in accordance wit...

Page 59: ...them from lowering tipping or sliding away When raising the truck also refer to the instructions in the Transport and Commissioning section When working on the parking brake prevent the truck from ro...

Page 60: ...owered If necessary add transmission oil of the correct grade see table M If there is a loss of oil immediately determine the cause If a leak is discovered coming from the castor wheel hydraulics cast...

Page 61: ...s see Section 6 1 Remove the front panel see Section 6 2 Check all fuse ratings in accordance with the table replace if necessary Item Description To protect Rating 7 F10 On board charger option 10 A...

Page 62: ...are not 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 Thor...

Page 63: ...be inspected at least annually 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 operational o...

Page 64: ...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 65: ...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 66: ...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 67: ...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 68: ...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 69: ...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 70: ...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 71: ...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 72: ...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 73: ...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 74: ...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 75: ...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 76: ...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 77: ...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 78: ...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 79: ...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 80: ...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 81: ...0506 GB 18...

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