Jungheinrich EJC 14, EJC 16, EJC-Z 14, EJC-Z 16 Operating Instructions Manual

Operating instructions
10004249
EJC/EJC-Z 14/16
G
06.98 -
01.06
0108.GB
Foreword
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. Each chapter starts with page 1. The page identification consists of a chapter letter and a page number. For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing the truck, make sure that the instructions apply to your truck model.
Safety instructions and important 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 material damage.
A
Used before notices and explanations.
t Used to indicate standard equipment. o Used to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. No guarantee of particular features of the truck should therefore be inferred from the present operating instructions.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35 22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
0108.GB
I 1
0401.GB
Table of contents
A Correct use and application of the truck
B Truck description
1 Description of application .................................................................... B 1
2 Assembly groups ................................................................................. B 2
3 Technical data ..................................................................................... B 3
3.1 Performance data EJC 14/16 / EJC-Z 14/16 ....................................... B 3
3.2 Dimensions EJC 14/16 ........................................................................ B 3
3.3 Dimensions EJC-Z 14/16 .................................................................... B 4
3.4 EN standards ...................................................................................... B 6
3.5 Conditions for application .................................................................... B 6
4 Location of instruction labels and identification labels ........................ B 7
4.1 Truck identification label ...................................................................... B 8
4.2 Load capacity ...................................................................................... B 8
4.3 Load capacity, wheel-arm lifting device .............................................. B 9
4.4 Label/Order/Inventory/Service No. ...................................................... B 9
C Transportation and commissioning
1 Transportation by crane ...................................................................... C 1
2 First commissioning ............................................................................ C 2
3 Moving the truck without own drive ..................................................... C 3
D Battery - Servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ........ D 1
2 Battery types ....................................................................................... D 2
3 Open battery hood .............................................................................. D 2
4 Charging the battery ............................................................................ D 3
4.1 Charging the battery with stationary battery charger .......................... D 3
4.2 Recharging the battery with integrated battery charger (o) ................ D 4
5 Removing and installing the battery .................................................... D 7
5.1 Remove battery by lifting it upwards
(truck without wheel-arm lifting device) ............................................... D 7
5.2 Remove battery by lifting it upwards
(truck with wheel-arm lifting device) .................................................... D 8
5.3 Lateral battery change (o) .................................................................. D 9
6 Combined instrument .......................................................................... D 10
0401.GB
I 2
EOperation
1 Safety regulations governing the operation of the fork lift truck .......... E 1
2 Description of controls and indicating instruments .............................. E 2
3 Putting vehicle in operation ................................................................. E 4
4 Operation of the fork lift truck .............................................................. E 5
4.1 Safety regulations applicable when operating the truck ...................... E 5
4.2 Driving, steering, braking .................................................................... E 6
4.3 Picking up or lowering load units ......................................................... E 9
4.4 Safe parking of the truck ..................................................................... E 11
4.5 Fault location ....................................................................................... E 11
F Maintenance of the fork lift truck
1 Operational safety and environmental protection .................................F 1
2 Safety regulations applicable to truck maintenance .............................F 1
3 Servicing and inspection ......................................................................F 3
4 Maintenance checklist ..........................................................................F 4
5 Lubrication schedule ...........................................................................F 6
5.1 Fuels, coolants and lubricants ..............................................................F 7
6 Notes on maintenance .........................................................................F 8
6.1 Preparation of the truck for servicing and maintenance operation .......F 8
6.2 Open the battery hood .........................................................................F 8
6.3 Open the front hood .............................................................................F 8
6.4 Check hydraulic oil level .......................................................................F 9
6.5 Check the transmission oil level ...........................................................F 9
6.6 Exchanging the coarse sieve ...............................................................F 9
6.7 Checking the electric fuses ..................................................................F 10
6.8 Recommissioning the truck ..................................................................F 11
7 Decommissioning the fork lift truck ......................................................F 11
7.1 Operations to be performed prior to decommissioning ........................F 11
7.2 Measures to be taken during decommissioning ...................................F 11
7.3 Recommissioning the truck ..................................................................F 12
8 Safety checks to be performed at regular
intervals and following any untoward incidents
(D: Accident prevention check according to VBG 36) ......................F 12
A 1
0600.GB
A Correct use and application of the truck
A
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are included in the scope of delivery for this truck. The guidelines are part of these ope- rating instructions and must always be heeded. National regulations are fully applica- ble.
The fork lift truck described in these operating instructions is a truck that is suitable for lifting and transporting loads. It must be used, operated and maintained according to the information in these ope- rating instructions. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. admis- sible load to be picked up is indicated on the identification plate or load diagram label shown on the truck. The fork lift truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres pre- vail.
Duties of the user: A “user within the meaning of these operating instructions is de- fined as any natural or legal person who either uses the fork lift truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is conside- red the person, who, in accordance with existing contractual agreements between the owner and the user of the fork lift truck, is charged with the observance of the opera- ting duties. The user must ensure that the truck is not abused and only used within its design li- mits and that all danger to life and limb of the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety-related provisions, as well as the operating, servicing and mainte- nance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions.
m
If these operating instructions are not observed the warranty becomes void. The same app- lies if improper works are carried out at the device by the customer and/or third parties without permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after writ- ten approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained. Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary.
0600.GB
A 2
B 1
0401.GB
B Truck description
1 Description of application
The truck is a four-wheel electric lift truck with control shaft and controlled drive wheel. It is conceived for lifting and transporting palleted goods on level ground. Either open- ground pallets or trolleys can be picked up. A wheel-arm lifting device is available as an option, extending the ground clearance during transports on uneven ground. The nominal load capacity can be found on the identification label. The load capacity in relation to lifting height and load centre distance is specified on the load capacity label.
0401.GB
B 2
2 Assembly groups
Pos. EJC
14/16
EJC-Z
14/16
Description
1 ttKey switch
2 ooCombined instrument
(battery discharge monitor and operating hour meter)
3 ttControl shaft with control shaft head
4 tt“Shunt driving” button
5 ttDriving regulator
6 ttCollision-guard button
7 ttHoist frame
8 ttProtective pane
9 ttBattery hood 10 ttMaster switch (emergency stop) 11 o-Battery charger 12 ttLifting device 13 ttFront hood 14 ttSupporting wheel 15 ttDrive wheel 16 ooDocument case
1
15
2
3
4
55
6
10
9
11
13
14
12
7
8
16
B 3
0401.GB
3 Technical data
A
Specification of technical data according to VDI 2198. Technical modifications and supplements reserved.
3.1 Performance data EJC 14/16 / EJC-Z 14/16
3.2 Dimensions EJC 14/16
Description EJC 14
EJC-Z 14
EJC 16
EJC-Z 16 Q Nominal load capacity 1400 1600 kg C Load centre distance at standard fork length 600 600 mm
Driving speed with / without load 6.0 / 6.0 6.0 / 6.0 km/h Lifting speed with / without load 15 / 23 14 / 23 cm/s Lowering speed with / without load 40 / 40 40 / 40 cm/s Max. hill-climbing ability with / without load 8 / 16 7 / 16 %
Description Version
1)
EJC 14 EJC 16
h
1
Overall height (depending on mast)
2)
1700 - 2600 1700 - 2600 mm
h
2
Free lifting capacity
3)
100 100 mm
h
3
Lifting height (depending on mast)
short
long
2500 - 4300 2500 - 5350
2400 - 4200 2400 - 5250
mm
h
4
height with mast protruded (depending on mast type)
7)
short
long
2981 - 4781 2981 - 5831
2931 - 4731 2931 - 5781
mm
h
5
Free lifting capacity (double-lifting device)
4) 8)
(depending on mast type)
1219 - 2119 1169 - 2069 mm
h
13
Fork lowered 90 90 mm
y Wheel base
short
long
1217 1357
1217 1357
mm
l
1
Truck length (= l2 + l)
6)
short
long
1836 1976
1836 1976
mm
l
2
Length of front section
5) 6)
short
long
686 826
686 826
mm
B Truck width 800 800 mm
b
5
Overall distance of fork 560 560 mm
m2Ground clearance 30 30 mm
A
st
Working corridor width
5) 6)
800 x 1200 longitudinal
short
long
2140 2278
2140 2278
mm
A
st
Working corridor width
5) 6)
800 x 1200 longitudinal (according to VDI)
short
long
2277 2416
2277 2416
mm
W
a
Turning circle for shunt driving (raised control shaft)
short
long
1428 1567
1428 1567
mm
0401.GB
B 4
3.3 Dimensions EJC-Z 14/16
1)
short/long” version refers to the length of the battery compartment (see chap. D)
2)
for ZT hoist frame with 100 mm free lifting capacity (h2) : (h1) = + 50 mm
3)
onyl telescope hoist frame (ZT)
4)
only ZZ and DZ hoist frame
5)
with load guard: (l2)= + 15 mm
6)
with DZ hoist frame: (l2) = + 38 mm (EJC 14) + 43 mm (EJC 16)
7)
with LSG + 610 mm (EJC 14) + 560 mm (EJC/EJC(-Z)16)
8)
with LSG - 610 mm (EJC 14) - 560 mm (EJC 16)
9)
Wheel-arm lifting height with lowered wheel arm
Description Version1)EJC-Z 14 EJC-Z 16
h1Overall height (depending on mast)
2)
1700 - 2600 1700 - 2600 mm
h2Free lifting capacity
3)
100 100 mm
h3Lifting height (depending on mast) short
long
2500 - 4300 2500 - 5350
2400 - 4200 2400 - 5250
mm
h4height with mast protruded
7)
(depending on mast type)
short
long
2981 - 4781 2981 - 5831
2931 - 4731 2931 - 5781
mm
h5Free lifting capacity (double-lifting de-
vice) (depending on mast type)
4) 8)
1219 - 2119 1169 - 2069 mm
h13Fork lowered 90 90 mm
y Wheel position (lowered/lifted) short
long
1457/1397 1597/1537
1457/1397 1597/1537
mm
l
1
Truck length (= l2 + l)
6)
short
long
1868 2008
1868 2008
mm
l2Length of front section
5) 6)
short
long
718 858
718 858
mm
B Truck width 830 830 mm
b
5
Overall distance of fork 560 560 mm
m2Ground clearance
9)
20 20 mm
AstWorking corridor width
5) 6)
800 x 1200 longitudinal
short
long
2171 2310
2171 2310
mm
AstWorking corridor width
5) 6)
800 x 1200 longitudinal (according to VDI)
short
long
2348 2487
2348 2487
mm
WaTurning circle for shunt driving
(raised control shaft) Wheel arms lowered/raised
short
long
1668/1608 1807/1747
1668/1608 1807/1747
mm
h31Lifting height of wheel-arm 122 122 mm
B 5
0401.GB
h
4
h
3
h
1
l
2
l
1
l
c
y
Q
h
5
h2h
31
h
13
b
5
A
st
W
a
B
m
2
0401.GB
B 6
3.4 EN standards
Continuous sound level: 65 dB(A)
according to prEN 12053 as stipulated in ISO 4871.
A
The continuous sound level is a value averaged according to standard regulations, taking the sound pressure level into account when driving, lifting and idling. The sound pressure level is measured at the ear.
Electromagnetic compatibility (EMC)
The manufacturer confirms compliance with the limit values for electromagnetic emission and interference immunity as well as testing of static electricity dischar- ge according to prEN 12895 and the references to other standards contained therein.
A
Electrical or electronic components and their arrangement may only be modified after written approval by the manufacturer has been obtained.
3.5 Conditions for application
Ambient temperature:
- during operation 5 °C to 40 °C
A
Industrial trucks must be specially equipped and approved for continuous use in en- vironments with temperatures below 5 °C or in cold stores respectively with extreme temperatures or humidity changes.
B 7
0401.GB
4 Location of instruction labels and identification labels
Item Description
17 Load capacity wheel-arm lifting device 18 Load capacity 19 Prohibition signDo not transport other persons” 20 Truck identification label 21 Limit-stop for crane loading (21a only EJC-Z) 22 Prohibition sign “Keep away from under the load lifting device 23 Prohibition signDo not put your hands through the hoist frame” 24 UVV control label 25 Identification label, battery 26 Warning sign “Caution: Low-voltage electronics”
18
17
22
26
21
23
24
19
20
25
21a
kg
kg mm kg
Xxx Xxxx
Xxxxxxx Xxxxxxxxx
Xxxxxxxxx Xxxxxxxxxx
Xxxxx Xxxx
Xxxxxxx Xxxxxx
Xxxxxx Xxxxxx
Xxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
VkW
Xxxxxxxxx Xxxxxxxxxx
xxxxxxxxxx
xxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
0401.GB
B 8
4.1 Truck identification label
A
In the event of queries relating to the truck or spare part orders, please state the serial no. (28) of the truck.
4.2 Load capacity
f
The label (18) includes a table indicating the loading capacity (Q in kg) in relation to the load centre di- stance (D in mm) and the lifting height (H in mm).
The arrow-shaped markings on the inner mast (40) and outer mast (41) show the driver when he has reached the lifting height limits that is defined on the load capacity label (18).
Item Designation Item Designation
27 Type 34 Drive power in kW
28 Serial No. 35 Customer no.
29 Rated capacity in kg 36 Min./max. battery weight in kg
30 Battery: Voltage V
Ampere hours Ah
37 Dead weight without battery in kg
31 Manufacturer 38 Year of manufacture
32 Order no. 39 Manufacturer logo
33 Load centre distance in mm
27
28
29
30
31
32
34
38
37
36
35
33
39
18
41
40
B 9
0401.GB
4.3 Load capacity, wheel-arm lifting device
Trucks with a wheel-arm lifting device are provided with an extra label (17) indicating the permissible assignment to wheel-arm lifting device and main lifting device.
4.4 Label/Order/Inventory/Service No.
A
This label contains the Full Service No. and is only handed out when a service con- tract is being concluded.
Item Description
42 Order no. 43 Inventory No. 44 Full Service No.
42
43
44
0401.GB
B 10
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