Jungheinrich Forklift EJE 110 EJE 116 EJE 118 EJE 120 Operating instructions Manual 51040407 – PDF D

EJE 110 / 116 / 118 / 120 Operating instructions

04.07 -

G

51040407 11.14

EJE 110 EJE 116 EJE 118 EJE 120

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2

Declaration of Conformity

Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg Manufacturer or his authorized representative in the Community Type

Option

Serial No.

Year of construction

EJE 110 EJE 116 EJE 118 EJE 120

Additional information

Authorised signatory

Date

G EU Declaration of Conformity The signatories hereby certify that the specified powered industrial truck conforms to the EU Directive 2006/42/EC (Machine Directive) and 2004/108/EEC (ElectroMagnetic Compatibility, EMC) including their amendments as translated into national legislation of the member countries. The signatories are individually empowered in each case to compile the technical documentation.

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4

Foreword Notes on the operating instructions The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter and the pages are numbered continuously.

The operator manual details different industrial truck models. When operating and servicing the industrial truck, make sure that the particular section applies to your truck model.

Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the system. No guarantee of particular features of the truck 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! Indicates an extremely hazardous situation. Failure to comply with this instruction will result in severe irreparable injury and even death.

WARNING! Indicates an extremely hazardous situation. Failure to comply with this instruction may result in severe irreparable injury and even death.

CAUTION! Indicates a hazardous situation. Failure to comply with this instruction may result in slight to medium injury.

NOTE Indicates a material hazard. Failure to comply with this instruction may result in material damage.

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Used before notices and explanations. t o

Indicates standard equipment Indicates optional equipment

Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG.

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Jungheinrich Aktiengesellschaft Am Stadtrand 35 22047 Hamburg - Germany Tel: +49 (0) 40/6948-0 www.jungheinrich.com

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Table of Contents A

Correct Use and Application ...................................................

9

1 2 3 4 5

General....................................................................................................

Correct application...................................................................................

Approved application conditions ..............................................................

Proprietor responsibilities ........................................................................

Adding attachments and/or accessories..................................................

9 9 9 10 10

B

Truck Description ....................................................................

11

1 1.1 2 2.1 2.2 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 4 4.1

Application ...............................................................................................

Truck models and rated capacity.............................................................

Assemblies and Functional Description...................................................

Assembly Overview .................................................................................

Functional Description .............................................................................

Technical Specifications ..........................................................................

Performance data ....................................................................................

Dimensions..............................................................................................

Weights....................................................................................................

Tyre type..................................................................................................

EN norms.................................................................................................

Conditions of use.....................................................................................

Electrical requirements ............................................................................

Identification points and data plates ........................................................

Data plate ................................................................................................

11 11 12 12 13 14 14 15 17 17 18 19 19 20 21

C

Transport and Commissioning ................................................

23

1 2 3

Lifting by crane ........................................................................................

Transport .................................................................................................

Using the Truck for the First Time ...........................................................

23 24 25

D

Battery - Servicing, Recharging, Replacement .......................

27

1 2 3 4 4.1 4.2 5 5.1 5.2

Safety Regulations Governing the Handling of Lead-Acid Batteries .......

Battery types............................................................................................

Exposing the battery................................................................................

Charging the battery ................................................................................

Charging the battery with a stationary charger ........................................

Charging the battery with an on-board charger .......................................

Battery removal and installation ..............................................................

Changing the battery from the top ...........................................................

Lateral battery removal............................................................................

27 29 30 31 32 33 38 39 40

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E

Operation ................................................................................

41

1 2 2.1 3 3.1 3.2 3.3 3.4 4 4.1 4.2 4.3 5 5.1 5.2 6 7 7.1 7.2 7.3 7.4 7.5 7.6

Safety Regulations for the Operation of the Forklift Truck.......................

Displays and Controls..............................................................................

Battery discharge indicator ......................................................................

Starting up the truck ................................................................................

Checks and operations to be performed before starting daily operation .

Preparing the truck for operation .............................................................

Parking the truck securely .......................................................................

Battery discharge monitor........................................................................

Industrial Truck Operation .......................................................................

Safety regulations for truck operation......................................................

Emergency Disconnect, Travel, Steering, Braking ..................................

Lifting, transporting and depositing loads ................................................

Troubleshooting.......................................................................................

Truck does not start .................................................................................

Load cannot be lifted ...............................................................................

Operating the truck without its own drive system ....................................

Optional equipment .................................................................................

Emergency operation with service key GF60 ..........................................

CanCode keypad .....................................................................................

Setting the truck parameters with CanCode............................................

Parameters ..............................................................................................

CANDIS display instrument .....................................................................

ISM access module (o)...........................................................................

41 42 45 46 46 47 48 48 49 49 51 56 59 59 59 60 61 61 63 68 70 72 73

F

Industrial Truck Maintenance ..................................................

75

1 2 3 4 4.1 4.2 5 5.1 5.2 5.3 6 6.1 6.2 6.3 6.4 6.5 7 7.1 7.2 7.3 8 9

Operational Safety and Environmental Protection...................................

Maintenance Safety Regulations.............................................................

Servicing and Inspection .........................................................................

Maintenance checklist .............................................................................

Owner ......................................................................................................

Customer Service ....................................................................................

Lubricants and Lubrication Schedule ......................................................

Handling consumables safely..................................................................

Lubrication Schedule ...............................................................................

Consumables...........................................................................................

Maintenance and repairs .........................................................................

Preparing the truck for maintenance and repairs ....................................

Removing the front panel ........................................................................

Removing the drive panel ........................................................................

Checking electrical fuses.........................................................................

Restoring the truck to service after maintenance and repairs .................

Decommissioning the industrial truck ......................................................

Prior to decommissioning ........................................................................

Action to be taken during decommissioning ............................................

Restoring the truck to service after decommissioning .............................

Safety tests to be performed at intervals and after unusual incidents .....

Final de-commissioning, disposal............................................................

75 75 79 80 80 81 84 84 86 87 88 88 88 89 90 91 92 93 93 94 95 95

A Correct Use and Application 1

General The industrial truck described in the present operating instructions is designed for lifting, lowering and transporting load units.

It must be used, operated and serviced in accordance with the present instructions.

Any other type of use is beyond the scope of application and can result in damage to personnel, the industrial truck or property.

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Correct application NOTE The maximum load and load distance are indicated on the load chart and must not be exceeded.

The load must rest on the load handler or be lifted by an attachment approved by the manufacturer.

The load must rest on the back of the fork carriage and centrally between the forks.

raised load (>500 mm). l load units.

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Approved application conditions and commercial environments. e range 5°C to 40°C. rfaces with sufficient capacity. visible and approved by the proprietor. to a maximum of 15 %. at an angle. Transporting loads downhill.

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Special equipment and authorisation are required if the truck is to be used in extreme conditions.

The truck is not authorised for use in areas at risk of explosion.

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4

Proprietor responsibilities For the purposes of the present operating any natural or legal person who either uses 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 between the owner and user of the industrial truck, is charged with operational duties.

The proprietor must ensure that the industrial truck is used only for the purpose for which it is intended and that there is no danger to life and limb of the user and third 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 understood these operating instructions.

NOTE Failure to comply with the operating instructions shall invalidate the warranty. The same applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufacturer.

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Adding attachments and/or accessories Adding accessories The mounting or installation of additional equipment which affects or enhances the performance of the forklift truck requires the written permission of the manufacturer.

Local authority approval may also need to be obtained.

Local authority approval does not however constitute

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B Truck Description 1

Application The EJE 110 / 116 / 118 / 120 is designed to transport goods on level surfaces. It can lift open bottom or diagonal board pallets as well as roll cages beyond the area of the load wheels. The capacity is shown on the capacity plate, Qmax.

1.1

Truck models and rated capacity The rated capacity depends on the model. The rated capacity can be derived from the model description.

EJE110 EJE 1 10

Model name Series Rated capacity x 100 kg

The rated capacity does not generally match the permissible capacity. The capacity can be found on the load chart attached to the rack.

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2

Assemblies and Functional Description

2.1

Assembly Overview 1

2

3 4

5 6

7

8

9

10

11

12

13

14

13

Ite m 1

Description t Safety collision switch

Ite m 8

2

t Travel switch

9

3

t Slow travel button

10

Description o On-board charger 24 V / 30 A (including safety switch) t Discharge indicator o Display instrument (CANDIS) t Key switch o CANCODE keypad

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t Tiller

11

o Key switch (also with second stage for brake release) t Front panel

5 6 7

t Battery cover t Emergency Disconnect t Fork tines

12 13 14

t Two-section drive panel t Castor wheels t Drive wheel

t = Standard equipment

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o = Optional equipment

2.2

Functional Description Safety Mechanisms rounded edges ensures safe handling of the truck. dly cuts out all electrical functions in hazardous situations.

Emergency Stop safety feature by the traction controller. itched on the system performed an automatic diagnosis.

Operator Position ions can be performed sensitively without having to reach.

Hydraulic system ts to operate, supplying hydraulic oil from the oil reservoir to the lift cylinder. ssed the wheel arms are raised at an even speed; when the lower button is pressed the wheel arms are lowered.

Drive system r actuates the drive wheel via a bevel spur gearbox. res smooth drive motor speed control and hence smooth travel, powerful acceleration and electrically controlled braking with energy regeneration. programs, depending on the load and the environment. from maximum performance to energy saving.

Steering an ergonomic control handle. an be pivoted +/- 90°.

Electrical system control is standard.

Controls and Displays tigue-free operation for sensitive application of the travel operations. s the available battery capacity. show the key driver information and travel program, service hours, battery capacity and event messages.

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