Jungheinrich EJC B14 Operating Instructions Manual Download

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09.05 -

03.11

50470432

EJC B14 / B16

Operating instructions

EJC B16

EJC B14

Summary of Contents for EJC B14

Page 1: ...09 05 03 11 50470432 EJC B14 B16 Operating instructions G EJC B16 EJC B14...

Page 2: ...he signatories hereby certify that the specified powered industrial truck conforms to the EU Directive 2006 42 EC Machine Directive and 2004 108 EEC Electro Magnetic Compatibility EMC including their...

Page 3: ...03 11 EN 4...

Page 4: ...ruck should therefore be assumed from the present operating instructions Safety notices and text mark ups Safety instructions and important explanations are indicated by the following graphics DANGER...

Page 5: ...03 11 EN 6 Jungheinrich Aktiengesellschaft Am Stadtrand 35 22047 Hamburg Germany Tel 49 0 40 6948 0 www jungheinrich com...

Page 6: ...mast version EJC B14 17 3 4 Standard mast version EJC B16 17 3 5 Weights 18 3 6 Tyre type 18 3 7 EN norms 19 3 8 Conditions of use 20 3 9 Electrical requirements 20 4 Identification points and data p...

Page 7: ...3 CANDIS display instrument 63 F Industrial Truck Maintenance 65 1 Operational Safety and Environmental Protection 65 2 Maintenance Safety Regulations 65 3 Servicing and Inspection 70 4 Maintenance ch...

Page 8: ...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 9: ...0506 GB 2...

Page 10: ...st rest on the back of the fork carriage and centrally between the forks Lifting and lowering of loads Transporting lowered loads Do not travel with a raised load 500 mm Do not carry or lift passenger...

Page 11: ...ird parties Furthermore accident prevention regulations safety regulations and operating servicing and repair guidelines must be followed The proprietor must ensure that all users have read and unders...

Page 12: ...lift and transport goods Open bottom pallets or roll cages can be lifted 1 1 Truck models and rated capacity The rated capacity depends on the model The rated capacity can be derived from the model de...

Page 13: ...rview Item EJC B14 B16 Name 2 t Slow travel button 1 t Mast 3 t Travel switch 4 t Mast guard o Mesh for cold store operation 5 t Collision safety switch 6 t Battery panel 7 t Tiller 8 t Emergency Disc...

Page 14: ...arge unit o CANDIS display instrument 10 o CANCODE keypad 11 o Load backrest 12 t Key switch 13 t Fork tines 14 o Document storage compartment 16 t Drive wheel 17 t Front panel 18 t Castor wheel t Sta...

Page 15: ...tuates the drive wheel via a bevel spur gearbox The electronic traction controller ensures smooth drive motor speed control and hence smooth travel powerful acceleration and electrically controlled br...

Page 16: ...tions and additions reserved 3 1 Performance data Description EJC B14 EJC B16 Q Rated capacity 1400 1600 kg Travel speed w w o rated load 6 0 6 0 6 0 6 0 km h Lift speed with without rated load 15 23...

Page 17: ...03 11 EN 16 3 2 Dimensions h4 h3 h1 l2 l1 l c y Q h s h8 b5 Ast W a B m2 20 5 h2 b4...

Page 18: ...2162 2162 mm Ast Working aisle width for pallet 800x1200 longit 1 2362 2362 mm Wa Turning radius lowered raised 1629 1629 mm 1 wit DZ mast 4 mm Description Telescopic mast ZT Twin reach mast ZZ Tripl...

Page 19: ...load front rear battery 810 1820 870 2030 kg Axle load w o load front rear battery 830 430 840 460 kg Battery weight 243 297 243 297 kg EJC B14 EJC B16 Tyre size drive 230x70 230x70 mm Tyre size load...

Page 20: ...ons and resistance as well as the static electricity discharge test in accordance with EN 12895 as well as the standardised instructions contained therein Z No changes to electric or electronic compon...

Page 21: ...be constantly used in conditions of extreme temperature or air humidity fluctuations 3 9 Electrical requirements The manufacturer certifies compliance with the requirements for the design and manufact...

Page 22: ...gh the mast warning 20 Do not step under the load handler warning 21 Attachment points for lifting by crane with ZZ mast in the middle 22 Truck data plate 23 Decal No passengers 25 Test plaque 24 Capa...

Page 23: ...rial number 29 28 29 31 30 32 39 35 38 37 36 34 33 Item Description Item Description 28 Type 34 Year of manufacture 29 Serial number 35 Load centre mm 30 Rated capacity kg 36 Output 31 Battery voltage...

Page 24: ...ntal load Example of calculating the maximum capacity With a load centre of gravity distance C of 600 mm and a maximum lift height H of 3600 mm the max capacity Q is 1105 kg The arrow shaped marks 41...

Page 25: ...03 11 EN 24...

Page 26: ...e XDo not stand under a swaying load XDo not walk into or stand in a hazardous area XAlways use lifting gear with sufficient capacity for truck weight see truck data plate XAlways attach the crane sli...

Page 27: ...asures adopted XThe truck must be securely fastened when transported on a lorry or a trailer XThe lorry trailer must have fastening rings XUse wedges to prevent the truck from moving XUse only tension...

Page 28: ...and installation on page 35 Charge the battery see Charging the battery on page 33 The truck can now be started see Starting up the truck on page 42 NOTE Cold store trucks XTrucks designed for use in...

Page 29: ...03 11 EN 28...

Page 30: ...ng there shall be no inflammable material or lubricants capable of creating sparks within 2 m around the truck The room must be ventilated Fire protection equipment must be on hand Battery maintenance...

Page 31: ...alise any spilled battery acid immediately with plenty of water XOnly batteries with a sealed battery container may be used XFollow national guidelines and legislation WARNING Using unsuitable batteri...

Page 32: ...ulating mat Battery type Capacity Weight 24 v battery 624x284x627 3 EPzS 375 Aq Comp 288 kg 24 v battery 624x284x537 mm 3 EPzS 270 Ah 245 kg 24 v battery 660x146x682 mm Maintenance free 3 EPzV 240 Ah...

Page 33: ...el surface In special cases the truck may need to be secured with wedges XAlways fully lower the mast and forks XSelect a place to park where no other people are at risk of injury from lowering forks...

Page 34: ...and the battery cell surfaces must be exposed during charging to ensure adequate ventilation XDo not smoke and avoid naked flames when handling batteries XWherever an industrial truck is parked for ch...

Page 35: ...s been interrupted the full battery capacity will not be available Requirements Battery charging is complete Procedure Complete charging in accordance with the charger operating instructions Disconnec...

Page 36: ...cated in the truck s battery compartment Removing the battery Requirements Park the truck securely see Parking the truck securely on page 44 Expose the battery see Exposing the battery on page 32 Proc...

Page 37: ...03 11 EN 36...

Page 38: ...med of any damage or faults to the truck or attachment Trucks which are unsafe for operation e g wheel or brake problems must not be used until they have been rectified Repairs The driver must not car...

Page 39: ...03 11 EN 38 2 Displays and Controls 7 9 10 12 8 14 50 47 48 49 3 5 3 2...

Page 40: ...Emergency Disconnect battery switch t t Disconnects the battery supply All electronic functions are cut out and the truck decelerates 9 Battery charge discharge indicator t t Indicates the charge dis...

Page 41: ...olled by the stroke of the button 8 mm 49 Fork lift switch t t Raises the forks The lift speed can be infinitely controlled via the stroke of the button 8 mm 50 Document storage compartment t t Paper...

Page 42: ...is red load units can 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 man...

Page 43: ...pections Procedure Check the whole of the outside of the truck for signs of damage and leaks Damaged hoses must be replaced immediately Check the battery attachment and wire connections for damage and...

Page 44: ...witch it on Switch on the truck to do this Insert the key in the key switch 5 and turn it as far right as it will go Enter the code in the code lock o Test the warning signal button 47 Test lifting op...

Page 45: ...load handler Turn off the key switch and remove the key For CanCode press the O key Press the Emergency Disconnect The truck is parked 3 4 Battery discharge monitor Z The standard setting for the batt...

Page 46: ...lift truck and the vehicle in front and must be in control of the truck at all times Abrupt stopping except in emergencies rapid U turns and overtaking at dangerous or blind spots are not permitted Do...

Page 47: ...t with the walls of the lift shaft People travelling in the lift with the forklift truck must only enter the lift after the truck has come to a halt and must exit the lift before the truck The driver...

Page 48: ...ing the Emergency Disconnect Procedure Pull the Emergency Disconnect 8 to unlock it All electrical functions are enabled and the truck is operational again assuming the truck was not operational befor...

Page 49: ...er 7 to the travel range F and press the travel switch 3 in the desired direction fwd or rev Control the travel speed with the travel switch 3 Z When the travel switch is released it automatically ret...

Page 50: ...ht tiller 7 e g in congested areas elevator Activating slow travel Procedure Press the slow travel switch 2 Set the travel switch 3 to the required direction fwd or rev The brake is released The truck...

Page 51: ...ds largely on the travel route conditions The driver must take this into account The truck can brake in three different ways With the service brake tiller By inversion braking travel switch By regener...

Page 52: ...n the opposite direction Z The brake force depends on the position of the travel switch 3 NOTE If the controller or drive unit fail plugging has no effect Regenerative braking Procedure On releasing t...

Page 53: ...load handler XDo not lift other people on the load handler XInsert the forks as far as possible underneath the load NOTE With the two stage Duplex mast ZZ the short centre mounted free lift cylinder i...

Page 54: ...On slopes and inclines always carry the load facing uphill never approach at an angle or turn 4 3 3 Lowering the load unit Depositing load units NOTE Loads must not be deposited on travel or escape ro...

Page 55: ...k serial number Error number on the display unit if applicable Error description Current location of truck 5 1 Truck does not start 5 2 Load cannot be lifted Possible Cause Action Emergency Disconnect...

Page 56: ...e released Releasing the brake Requirements Park the truck securely see Parking the truck securely on page 44 Tools and Material Required Two M5x42 screws Spanner wrench Procedure Prevent the truck fr...

Page 57: ...to your supervisor XTag out and decommission a faulty lift truck XOnly return the truck to service when you have identified and rectified the fault Load handler emergency lowering Requirements Load h...

Page 58: ...re of gravity must be located centrally between the forks Adjusting the forks Requirements Park the truck securely see Parking the truck securely on page 44 Procedure Lift up the locking lever 55 Push...

Page 59: ...rk carriage XAfter replacing the forks fit the retaining bolts 54 and make sure the bolts are seated correctly Retaining bolt torque 70 Nm Replacing the forks Requirements Load handler lowered and for...

Page 60: ...using the truck for the first time Z Set different codes for rider and pedestrian trucks Starting the Truck Procedure Switch on the Emergency Disconnect The LED 64 lights up red Enter the code When yo...

Page 61: ...t different codes for rider and pedestrian trucks Changing the truck settings Procedure Press the O key 62 Enter the master code Enter the three digit parameter number Confirm with the SET key 63 Ente...

Page 62: ...0 flashes Enter new code Set 63 LED 61 flashes Repeat new code Set 63 001 Add code max 250 0000 9999 or 00000 99999 or 000000 999999 2580 LED 60 flashes Confirm code entry Set 63 LED 61 flashes repeat...

Page 63: ...03 11 EN 62 010 Automatic timeout 00 31 00 00 No timeout 01 30 Timeout in minutes 31 Timeout after 10 seconds No Function Setting range Standard setting Procedure LEDs 59 61 are located in keypads 1 3...

Page 64: ...indicator 67 is lit The battery must be charged immediately If no more LED bars are illuminated the Stop indicator 68 lights up Lifting is now inhibited The battery must be charged 8 3 1 Discharge mon...

Page 65: ...tarts with an E for Error and a three digit error number If several errors occur simultaneously they are displayed one after the other The errors are displayed until they are rectified Error messages...

Page 66: ...epartment To ensure safe and reliable operation of the truck use only the manufacturer s spare parts For safety reasons only components which have been specially agreed by the manufacturer for this tr...

Page 67: ...over e g wedges wooden blocks Cleaning CAUTION Fire hazard Do not use flammable liquids to clean the industrial truck XAlways disconnect the battery before starting cleaning work XCarry out all necess...

Page 68: ...ronmental hazard Used parts oils and fuels must be disposed of in accordance with the relevant environmental protection regulations To change the oil contact the manufacturer s customer service depart...

Page 69: ...rn the truck to service when you have identified and rectified the fault XSpilled fluids must be removed immediately with an appropriate bonding agent The bonding agent consumable mixture must be disp...

Page 70: ...always be clean and well lubricated XLift chains should only be cleaned with paraffin derivatives e g petroleum or diesel fuels XNever clean chains with steam jet high pressure cleaners cold or chemic...

Page 71: ...d 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 temperature fluctuations or multiple shifts The...

Page 72: ...d control switches t 2 4 Test the switch setting t 2 5 Check contactors and relays t 2 6 Check fuse ratings t 2 7 Carry out a frame leakage test t 2 8 Check carbon brush wear drive and hydraulic motor...

Page 73: ...he hydraulic function controls and make sure the labels are present and complete k t 6 2 Check cylinders and piston rods for damage and leaks and make sure they are secure k t 6 3 Check settings and w...

Page 74: ...performance levels 7 1 Carry out a test run with rated load t 7 2 Demonstration after servicing k t 7 3 Lubricate truck according to the lubrication schedule k t Maintenance intervals Standard t W A B...

Page 75: ...XThe bonding agent consumable mixture must be disposed of in accordance with regulations WARNING Oils chain spray hydraulic oil are flammable and poisonous XDispose of used oils in accordance with re...

Page 76: ...zard Used parts oils and fuels must be disposed of in accordance with the relevant environmental protection regulations To change the oil contact the manufacturer s customer service department who hav...

Page 77: ...03 11 EN 76 5 2 Lubrication Schedule g Contact surfaces Cold Store Application b Transmission oil filler neck a Transmission oil drain plug Hydraulic oil filler neck B 1 4l MA 105 Nm B C G A A C E F...

Page 78: ...ctionality The Jungheinrich hydraulic oil may be mixed with one of the named alternative hydraulic oils Code Order no Package quantity Description Used for A 29 200 670 5 0 l H LP 46 DIN 51524 Hydraul...

Page 79: ...he battery to prevent the truck from being switched on accidentally When working under a raised lift truck secure it to prevent it from lowering tipping or sliding away WARNING Risk of accidents when...

Page 80: ...EN 6 2 Removing the front panel Disassembling the panel Procedure Remove the two screws 71 Carefully lift off the front panel 17 The front panel is now disassembled Z Assembly is the reverse order 17...

Page 81: ...panel on page 79 Check the oil level in the hydraulic reservoir Z There are markings on the hydraulic reservoir The oil level must be checked when the load forks are lowered If necessary add transmis...

Page 82: ...level It should reach the filler neck Add the correct grade of transmission oil as required The transmission oil level is now checked 6 5 Replacing the gauze filter flushing the gauze filter Replacing...

Page 83: ...ved see Removing the front panel on page 79 Procedure Check the fuse ratings against the table and replace if necessary The fuses are now checked Item Name To protect EJC B14 B16 76 6F1 Battery charge...

Page 84: ...lace if necessary Z The manufacturer s customer service department is specially trained to carry out these operations WARNING Faulty brakes can cause accidents As soon as the truck has been started te...

Page 85: ...es on page 21 XWhen jacking up the truck take appropriate measures to prevent it from slipping or tipping over e g wedges wooden blocks When the truck is out of service it must be jacked up so that al...

Page 86: ...85 03 11 EN Spay all exposed electrical contacts with a suitable contact spray...

Page 87: ...g NOTE Full discharge can damage the battery Self discharge can cause the battery to fully discharge Full discharge shortens the useful life of the battery XCharge the battery at least every 2 months...

Page 88: ...ediately to your supervisor XTag out and decommission a faulty lift truck XOnly return the truck to service when you have identified and rectified the fault Start up the truck see Starting up the truc...

Page 89: ...omic circumstances The inspector shall be sufficiently instructed and experienced to be able to assess the condition of the truck and the effectiveness of the safety mechanisms based on the technical...

Page 90: ...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 91: ...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 92: ...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 93: ...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 94: ...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 95: ...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 96: ...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 97: ...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 98: ...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 99: ...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 100: ...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 101: ...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 102: ...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 103: ...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 104: ...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 105: ...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 106: ...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 107: ...0506 GB 18...

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