Jungheinrich ECP 100-3 Operating Instructions Manual Download

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Operating instructions

50114168

ECP 100-3

05.98 -

08.03

Summary of Contents for ECP 100-3

Page 1: ...Operating instructions 50114168 ECP 100 3 G 05 98 08 03...

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: ...he battery D 3 5 Removing and installing the battery D 4 6 Information and service display LISA D 5 I 1 0803 GB Table of contents A Correct use and application of the truck B Description of the truck...

Page 5: ...ntervals and following any untoward incidents D Accident prevention check according to BGV D27 F 13 0803 GB I 2 E Operation 1 Safety regulations governing the operation of the fork lift truck E 1 2 De...

Page 6: ...obtained from local authorities does not however make the approval by the manufacturer unnecessary A 1 0600 GB A Correct use and application of the truck A The Guidelines for the Correct Use and Appl...

Page 7: ...0600 GB A 2 0600 GB A 2...

Page 8: ...s of the fork are designed according to the type and num ber of pallets or trolleys to be picked up B 1 0201 GB B Description of the truck 1 Design and application The truck described in the present o...

Page 9: ...31 32 33 3 1 2 15 14 4 5 23 11 8 9 10 7 6 19 20 21 16 17 18 12 13 22 25 26 27 28 29 24 30 34 35 36 0201 GB B 2 2 Assemblies Item Designation Item Designation 1 o Key Two hand operation 10 o Key opera...

Page 10: ...brake When the electrical system is switched off the spring pressure brake acts as a par king brake B 3 0201 GB 2 1 Truck Safety installations Enclosed truck contour The drive wheel 34 is protected by...

Page 11: ...31 32 33 3 1 2 15 14 4 5 23 11 8 9 10 7 6 19 20 21 16 17 18 12 13 22 25 26 27 28 29 24 30 34 35 36 0201 GB B 4 Item Designation Item Designation 19o Controller 2nd operating console 28 o 2 Master swi...

Page 12: ...pacity 1000 kg C Load centre distance 600 mm Travelling speed with without rated load 9 5 10 5 km h B 5 0201 GB Hydraulic system The lifting and lowering functions are controlled by means of ope ratin...

Page 13: ...0201 GB B 6 Ast b1 Wa h3 h9 h7 l y h12 h1 h4 h1 h4 Q C a 2 a 2 l2 l1 h13 0201 GB B 6 Ast b1 Wa h3 h9 h7 l y h12 h1 h4 h1 h4 Q C a 2 a 2 l2 l1 h13...

Page 14: ...eight 15901 21901 2490 2270 2270 h4 Height of mast when extended 2590 3270 3790 3870 4170 4640 5070 B 7 0201 GB 3 2 Dimensions all dimensions in mm 1 If equipped with the auxiliary lifting unit o valu...

Page 15: ...temperatures below 5 C or in cold stores respectively with extreme temperatures or humidity changes 0201 GB B 8 3 3 EN standards Continuous sound level 63 dB A according to prEN 12053 as stipulated in...

Page 16: ...ick up points for lifting jack 47 Truck identification plate 47 42 37 46 46 45 38 40 41 43 39 39 44 B 9 0201 GB 4 Labels Item Designation 37 Accident prevention inspection label D only 38 Prohibitive...

Page 17: ...Order no 60 Manufacturer logo 54 Load centre distance in mm 48 49 50 51 52 53 55 59 58 57 56 54 60 0201 GB B 10 4 1 Truck identification plate A In the event of queries relating to the truck or spare...

Page 18: ...the tyres will flatten The flattening will disappear after a short operating time of the truck 1 2 C 1 0201 GB C Transportation and commissioning 1 Transportation by crane f Only lifting gear of adeq...

Page 19: ...s 4 and tighten the screws 3 The brake has now been released and the truck can be moved 3 4 5 7 7 6 0201 GB C 2 3 Moving the truck with the drive unit inoperative f This operating mode is not permitte...

Page 20: ...screws 3 by approx 1 cm and lock them by tightening the lock nuts 4 The brake is now applied again C 3 0201 GB To steer the wheels mechanically e g in narrow aisles proceed as follows m The truck may...

Page 21: ...0201 GB C 4 0201 GB C 4...

Page 22: ...he truck Changing the battery equipment is not permitted without prior approval by the manufacturer D 1 0201 GB D Battery Servicing recharging replace ment 1 Safety regulations governing the handling...

Page 23: ...zS 480 Ah L 24 V PzS battery 3 PzS 560 Ah L 24 V PzS battery performance enhanced 3 PzS 600 Ah HX 1 0201 GB D 2 2 Battery types Depending on the truck version the truck will be supplied with different...

Page 24: ...erving the in structions provided by the battery supplier and by the battery charger supplier 3 3 4 D 3 0201 GB 4 Charging the battery f To charge the battery the truck must be parked in a closed and...

Page 25: ...any damage caused by sudden movements of the truck The battery hood must be securely locked 6 7 5 3 0201 GB D 4 5 Removing and installing the battery f The truck must be parked on level ground To prev...

Page 26: ...attery The operating hour meter shows the total time of the travelling and lifting movements 8 9 10 D 5 0201 GB 6 Information and service display LISA Battery discharge indicator The charging state of...

Page 27: ...0201 GB D 6 0201 GB D 6...

Page 28: ...ning labels and warning notes described in the present operating instructions must always be heeded E 1 0803 GB E Operation 1 Safety regulations governing the operation of the fork lift truck Driving...

Page 29: ...fork is lifted together with the driver standing platform t Standard equipment o Optional equipment 0803 GB E 2 2 Description of the operating controls and indicators Item Operating control or indica...

Page 30: ...803 GB 21 16 12 13 14 15 28 29 27 18 17 26 11 3 2 4 23 24 22 20 19 25 5 6 7 8 9 10 30 33 31 32 1 34 E 3 0803 GB 21 16 12 13 14 15 28 29 27 18 17 26 11 3 2 4 23 24 22 20 19 25 5 6 7 8 9 10 30 33 31 32...

Page 31: ...ipment Pedestrian controlled operation The fork is lifted t Standard equipment o Optional equipment 0803 GB E 4 Item Operating control or indica tor Function 14 Key operated control Operator walking d...

Page 32: ...803 GB 21 16 12 13 14 15 28 29 27 18 17 26 11 3 2 4 23 24 22 20 19 25 5 6 7 8 9 10 30 33 31 32 1 34 E 5 0803 GB 21 16 12 13 14 15 28 29 27 18 17 26 11 3 2 4 23 24 22 20 19 25 5 6 7 8 9 10 30 33 31 32...

Page 33: ...The fork is lifted 34 Key Lowering o The fork is lowered t Standard equipment o Optional equipment 0803 GB E 6 Item Operating control or indica tor Function 24 Steering wheel 2nd operating console o...

Page 34: ...803 GB 21 16 12 13 14 15 28 29 27 18 17 26 11 3 2 4 23 24 22 20 19 25 5 6 7 8 9 10 30 33 31 32 1 34 E 7 0803 GB 21 16 12 13 14 15 28 29 27 18 17 26 11 3 2 4 23 24 22 20 19 25 5 6 7 8 9 10 30 33 31 32...

Page 35: ...ible damage Visually check the battery attachment and the cable connections 4 6 9 16 28 11 19 10 17 0803 GB E 8 3 Starting up the truck f Before starting or operating the truck or before lifting any l...

Page 36: ...tery capacity and the operating hours Check the brakes for correct functioning refer to section 4 2 E 9 0803 GB Switching on the truck A When the truck is parked the running surface of the tyres will...

Page 37: ...that safe driving and braking of the truck and the trailer is guaranteed for all driving movements 0803 GB E 10 4 Operation of the fork lift truck 4 1 Safety regulations applicable when operating the...

Page 38: ...ing system is a safety relevant component the fault must be eliminated by trained service personnel E 11 0803 GB f To avoid falling down The driver must not leave the driver position while the driver...

Page 39: ...g and lifting main lift is only possible when the safety barriers 18 are closed 6 16 28 11 19 18 17 0803 GB E 12 Emergency stop Press the master switch 6 This will switch off all electric functions De...

Page 40: ...height above 450 mm the speed is reduced to 2 5 km h cut back speed 1 0 4 3 24 16 R R V V 26 0 V R E 13 0803 GB Driving f Do not drive the truck unless the hoods are closed and locked in the stipulat...

Page 41: ...to a stop A The intensity of deceleration can be adjusted by the manufacturer s service person nel 0803 GB E 14 Steering Turn the steering wheel 3 to the left or the right A Depending on the lifting...

Page 42: ...ion Depress the master switch emergency stop 11 19 to the OFF position 16 11 14 15 19 21 20 V R V R E 15 0803 GB 4 3 Key operated control of the truck Operator walking o f When the truck is under key...

Page 43: ...ght has been rea ched Lowering o Press the Lowering key 13 22 o the fork is lowered 22 23 12 13 7 8 0803 GB E 16 4 4 Picking up and setting down loads m Before picking up a load the driver has to make...

Page 44: ...5 is only possible in connection with the release but ton Two hand operation 2 13 12 34 33 32 31 35 E 17 0803 GB 4 5 Auxiliary lift o A The controls for operating the auxiliary lifting function are in...

Page 45: ...sition OFF 0 and remove the key Depress the master switch emergen cy stop 6 to the OFF position 6 9 0803 GB E 18 4 6 Safe parking of the truck If the truck is left unattended even for only short perio...

Page 46: ...3 24 to steer the truck Always lower the load for travelling out side narrow aisles 36 37 3 2 24 25 E 19 0803 GB 4 7 Entering narrow aisles f Do not enter any aisle unless it is vacant Stop the truck...

Page 47: ...cted menu item storing of modified parameters acknowledging a query with YES q 40 39 38 41 42 43 44 0803 GB E 20 5 Information and service display LISA The display 40 of the LC information and service...

Page 48: ...rer s service personnel This parameter can only be adjusted by the manufacturer s service personnel E 21 0803 GB 5 3 Displays The display shows operating data and fault messages The user menu permits...

Page 49: ...ting parameters are read out 2 S the selected parameter can be changed using keys and 3 no function 0803 GB E 22 5 4 Changing truck parameters f Changing truck parameters will also change the driving...

Page 50: ...charge the battery Check fuses 2F1 and 2F2 o Heed the maximum capacity see the identification plate E 23 0803 GB 6 Fault location This chapter enables the operator to locate and rectify minor faults a...

Page 51: ...0803 GB E 24 0803 GB E 24...

Page 52: ...mpletion of cleaning work the operations detailed in the section Recommis sioning must be performed F 1 0803 GB F Maintenance of the fork lift truck 1 Operational safety and environmental protection T...

Page 53: ...every six years When replacing hy draulic components also renew the hoses in this hydraulic system 0803 GB F 2 Work on the electric system Work on the electric system of the truck must only be perfor...

Page 54: ...nnections for leakages and retighten if required Check glide pieces at mast and adjust if necessary F 3 0803 GB 3 Servicing and inspection Thorough and expert servicing is one of the most important pr...

Page 55: ...chment t 8 3 Clean motor housing by means of a vacuum cleaner and check the commutator for wear l t 0803 GB F 4 4 Maintenance intervals Maintenance intervals standard t W M M M cold store k 1 3 6 12 C...

Page 56: ...13 2 Upon completion of servicing operations demonstrate the vehicle to the person responsible l t F 5 0803 GB a Wheel bolts to be first checked for tightness after approx 100 operating hours tighten...

Page 57: ...oil filling leve Lift height in mm Filling level in l 1000 2 3 1600 3 7 1900 4 2 2400 8 9 2900 10 1 0803 GB F 6 5 Lubrication schedule g Gliding surfaces s Grease nipples Filler plug for hydraulic oil...

Page 58: ...ked penetr at 25 C NLG1 class Service tempe rat C E Lithium 185 265 295 2 35 120 F 310 340 1 52 100 F 7 0803 GB 5 1 Fuels coolants and lubricants Handling consumption type material Consumption type ma...

Page 59: ...e front hood 1 to the front lift it off remove it by pulling it upwards and deposit it safely 2 3 1 0803 GB F 8 6 Instructions for the servicing operations 6 1 Preparing the truck for the performance...

Page 60: ...5 A The drive current control system and the truck fuses can be accessed for servicing purposes 4 5 F 9 0803 GB A The drive unit and the hydraulic system can be accessed for servicing purposes Install...

Page 61: ...aches the upper edge of the opening Then screw the drain plug for transmission oil 8 in again 6 7 8 0803 GB F 10 6 5 Checking the transmission oil level changing the transmission oil f Always be espec...

Page 62: ...ry lift o 160 A 19 2F1 Pump motor 150 A 20 1F1 Drive motor 150 A 12 11 13 14 15 16 17 20 9 10 19 18 F 11 0803 GB 6 6 Checking the electric fuses Prepare the truck for the ser vicing and maintenance op...

Page 63: ...f discharging would occur Owing to sulfatisation this will result in the destruction of the battery 0803 GB F 12 6 7 Recommissioning the truck Recommissioning of the truck following the performance of...

Page 64: ...laque is affixed to it This plaque indicates in which month of which year the next test will be due F 13 0803 GB 7 3 Recommissioning the truck Thoroughly clean the fork lift truck Lubricate the fork l...

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Jungheinrich ECP 100-3, Operating Instructions Manual

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