Jungheinrich ECE 118 Operating Instructions Manual
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Jungheinrich ECE 118 Operating Instructions Manual

Jungheinrich ECE 118 Operating Instructions Manual

Tiller guided electric truck with an operator position and a backrest
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ECE 118
08.06-
G
Operating instructions
51092878
07.08

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Summary of Contents for Jungheinrich ECE 118

  • Page 1 ECE 118 08.06- Operating instructions 51092878 07.08...
  • Page 2 Used to indicate standard equipment. 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.

  • Page 4: Table Of Contents

    Table of Contents Correct Use and Application Truck Description Application ................... B 1 Assemblies ..................B 2 Technical specifications ..............B 3 Performance data ................B 3 Dimensions ..................B 3 Table of dimensions ................B 3 EN standards ..................B 5 Operating conditions ................
  • Page 5 Operation Safety regulations for the operation of industrial trucks ...... E 1 Controls and indicators ............... E 2 Starting up the truck ................E 4 Switching on the truck ................. E 4 Industrial truck operation ..............E 5 Safety regulations for truck operation ..........E 5 Driving, steering, braking ..............
  • Page 6 Appendix JH Traction Battery Operating Instructions These operating instructions apply only to Jungheinrich battery models. If using another brand, refer to the manufacturer's operating instructions.

  • Page 8: A Correct Use And Application

    A Correct Use and Application The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are supplied with the truck. The guidelines form part of these operating instructions and must be observed. National regulations apply in full. The truck described in the present operating instructions is an industrial truck designed for lifting and transporting loads.

  • Page 10: B Truck Description

    B Truck Description Application The ECE 118 is a tiller guided electric truck with an operator position and a backrest. The truck is designed for lifting and transporting goods on a level surface. The truck can lift open-bottom or diagonal-board pallets or roll cages that extend beyond the area of the load wheels.

  • Page 11: Assemblies

    Assemblies 4, 5 3, 6 Item Description Item Description t Travel switch t Castor wheel t Tiller t Drive wheel o Display instrument t Operator position with pressure sensitive mat (CANDIS) t Key switch t Backrest o Keypad t Forks (CANCODE) t Battery discharge indicator...

  • Page 12: Technical Specifications

    Technical specifications Technical data specified in accordance with VDI 2198. Subject to technical modifications and addenda Performance data Description Capacity 1,800 Load centre of gravity distance Travel speed, operator position mode Maximum / standard* 10.5 / 10.5 km/h Travel speed, pedestrian mode Maximum / standard* 7.0 / 4.5 km/h...
  • Page 13 Dimensions 1006...

  • Page 14: En Standards

    EN standards Noise emission: 68 dB(A) as defined in EN 12053, harmonised by ISO 4871. The noise emission level is calculated by standard procedures, and takes into account the noise level when travelling, lifting and idling. The noise level is measured at the driver’s ear.

  • Page 15: Identification Points And Data Plates

    Identification points and data plates 1800 Item Description Truck data plate Nominal load capacity Attachment point for crane lifting Battery data plate Test sticker (o) The truck data plate (15) is visible when the load section is raised. The battery data plate (18) can be seen on the battery (see Chapter D).
  • Page 16 Truck data plate Item Description Item Description Model Manufacturer Serial no. Min./max. battery weight (kg) Rated capacity (kg) Drive power in kW Battery: Voltage (V) Load centre of gravity (mm) Unloaded weight w.o. battery (kg) Year of manufacture Manufacturer’s logo Option For queries regarding the truck or ordering spare parts always quote the truck serial number (21).

  • Page 18: C Transport And Commissioning

    C Transport and Commissioning Lifting by crane Only use lifting gear with sufficient capacity (for truck weight see truck data plate, Chapter B). Lifting gear attachment points (1) are provided on the chassis and the fork in case the truck is to be lifted or transported by crane.

  • Page 19: Removing The Transport Lock

    Removing the transport lock There is an instruction decal by the front panel for the transport retainer (2), this must be removed once the battery has been installed. – Fold down the driver’s platform. – Open the front panel (see Chapter F). –...

  • Page 20: Moving The Truck Without Using The Drive Unit

    Moving the truck without using the drive unit This operation is not permitted on slopes and gradients. If the truck has to be moved after a failure occurs preventing driving operations, proceed as follows: – Set the key switch to the “Off” position and remove the key. –...

  • Page 21: Securing The Truck During Transport

    Securing the truck during transport The truck must be lashed securely if transported on a lorry or trailer. The lorry / trailer must be fitted with lashing rings. Fold the side protection and the folding platform in or up so that they do not protrude beyond the geometry of the truck. –...

  • Page 22: D Battery Maintenance, Charging & Replacement

    D Battery Maintenance, Charging & Replacement Safety regulations for handling acid batteries Park the truck securely before carrying out any work on the batteries (see Chapter E). Maintenance personnel: Batteries may only be charged, serviced or replaced by trained personnel. Follow these operating instructions and the instructions of the manufacturer of the battery and charging station when carrying out the work.

  • Page 23: Battery Types

    Battery types The battery types correspond to EN 60254-2. The following table shows the combinations to be used, with reference to their capacity: Battery type Battery Weight Battery Weight compartment compartment approx. 227 mm approx. 299 mm 24 V battery 3EPzS 230 Ah 210 kg 3 EPzS 345 Ah...

  • Page 24: Charging The Battery

    Charging the battery To charge the battery, the truck must be parked in a closed and properly ventilated room. When charging, the tops of the battery cells must be laid open to provide sufficient ventilation. Do not place any metal objects across the battery. Before charging, check all cables and plug connections for visible signs of damage.

  • Page 25: Battery Removal And Installation

    Battery removal and installation The truck must be level. To prevent short circuits, batteries with exposed terminals or connectors must be covered with a rubber mat. Place the battery connector or battery cable in such a way that they do not catch on the truck when the battery is removed. When transporting batteries using a crane, ensure that the crane is of adequate capacity (the battery weight is indicated on the battery data plate on the battery container).

  • Page 26: Battery Discharge Indicator (T)

    Battery discharge indicator (t) After the truck has been released via the key switch or CANCODE, the battery charge status is displayed. The colours of the LEDs (9) represent the following conditions: LED colour Value Green Standard battery residual capacity 40 - 100 % Maintenance free battery residual capacity 60 - 100 %...

  • Page 28: Safety Regulations For The Operation Of Industrial Trucks

    E Operation Safety regulations for the operation of industrial trucks Permission to operate: The industrial truck may only be used by suitably trained personnel, who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to operate the truck by the proprietor or his representative.

  • Page 29: Controls And Indicators

    Controls and indicators Item Control / display Function t The complete hydraulics and control electronics Front panel are located behind the front panel. t Important control elements are located in the tiller Tiller arm. t The truck brakes at the maximum rate until it Brake button comes to a halt.
  • Page 30 11, 12 9, 10...

  • Page 31: Starting Up The Truck

    Starting up the truck Before the truck can be started, operated or a load lifted, the driver must ensure that there is nobody within the hazardous area. Daily checks and operations to be performed before starting work – Complete visual inspection of the truck (especially wheels and load handler) for visible signs of damage.

  • Page 32: Industrial Truck Operation

    Industrial truck operation Safety regulations for truck operation Travel routes and work areas: Only use lanes and routes specifically designated for truck traffic. Unauthorised third parties must stay away from work areas. Loads must only be stored in places specially designated for this purpose. Driving conduct: The driver must adapt the travel speed to local conditions.

  • Page 33: Driving, Steering, Braking

    Driving, steering, braking Full attention is required when driving and steering, especially when outside of the truck envelope. In walk-along mode make sure you have sufficient distance from the truck. Emergency Off – Remove the battery connector (13). All electrical functions are shut down. Emergency Stop Automatic braking (emergency stop) occurs when the tiller (5) is released –...
  • Page 35 Steering In narrow bends the driver extends beyond the geometry of the truck. – Move the tiller (5) to the left or right. Brakes The braking characteristics of the truck depends largely on the track conditions. The driver must allow for these when operating the truck. The truck can be braked in two different ways: –...

  • Page 36: Lifting And Depositing Loads

    Lifting and depositing loads Before collecting a load, the driver must ensure that it is correctly palletised and that the capacity of the truck is not exceeded. It is forbidden to collect long loads at an angle. – Fully insert the truck and the load handler underneath the load.

  • Page 37: Parking The Truck Securely

    Parking the truck securely When you leave the truck it must be securely parked even if you only intend to leave it for a short time. – Do not park the truck on an incline. – Fully lower the load forks. –...

  • Page 38: Keypad (Cancode) (O)

    Keypad (CANCODE) (o) The keypad consists of 10 digit keys, a Set key and a o key. Activation of the travel programs via switches 1, 2, 3 is indicated by green LEDs. The o key indicates operating statuses via a red/ green LED.
  • Page 39 Start-up When the main switch is turned on the LED (16) goes red. When you enter the correct operator code (factory setting 2-5-8-0) the LED (16) turns green. If the wrong code is entered the LED (16) flashes red for two seconds. The correct code can then be entered again.

  • Page 40: Travel Programs

    Travel programs Press the digit keys 1, 2, and 3 to select any of three travel programs. The activated program is indicated by the green LEDs (18), (19), (20) in the corresponding key. The travel programs differ with respect to travel speed, acceleration and deceleration force.

  • Page 41: Parameter Settings

    Parameter settings To change the truck setting you must enter the master code. The factory setting for the master code is 7-2-9-5. When starting the truck for the first time, change the master code (see Section 5.1). Safety instructions for trucks with a display instrument (CANDIS (o)) –...
  • Page 42 Setting procedure for trucks with and without display instrument (CANDIS (o)): – Enter the three-digit parameter number and confirm with Set key (17). – The display instrument (CANDIS (o)) continues to display the operating hours. If the display changes, cancel the setting with the o key (21) and restart from the beginning.
  • Page 43 Function Range Standard Comments Setting value Setting Procedure value Code lock 002 Changing an operator 0000 - 9999 (LED 18 flashes) code Enter the current code 00000 - 99999 Confirm (Set) 000000 - 999999 (LED 19 flashes) Enter a new code Confirm (Set) (LED 20 flashes) Repeat the...
  • Page 44 Function Range Standard Comments Setting value Setting Procedure value Code lock 020 Start travel program ** 1 - 3 Pre-selected travel program 1 = 1 (soft operation) 2 = 2 3 = 3 021 Travel program 1 0 or 1 0 = Travel program Release not enabled...

  • Page 45: Travel Parameters

    Travel parameters For trucks without a display instrument (CANDIS (o)) the code lock parameters can only be set by the manufacturer's service department. The following example shows the parameter setting for the acceleration of travel program 1 (parameter 101). Acceleration example Display instrument LED (16) LED (18)
  • Page 46 The following parameters can be entered. Travel programs (speeds and acceleration w.o. load) Function Range Standard Comments Setting value Setting value Travel program 1 101 Acceleration 0 - 9 (0.13 – 1.88 m/s 0.67 m/s 102 Coasting brake 0 - 9 (0.11 –...
  • Page 47 Function Range Standard Comments Setting value Setting value Travel program 3 301 Acceleration 0 - 9 (0.13 – 1.88 m/s (1.62 m/s 302 Coasting brake 0 - 9 (0.11 – 1.79 m/s 1.79 m/s 304 Maximum speed in tiller 0 - 9 Depending on travel direction via controller switch...

  • Page 48: Display Instrument (Candis) (O)

    Display instrument (CANDIS) (o) The instrument indicates: – battery residual charge status (LED bars (23), – Service hours (LCD display (25)). In addition, service messages for the electronic components parameterchanges are displayed. Discharge status display Setting limits for the additional “Warning” (22) and “Stop” (24) displays will depend on the battery type.

  • Page 49: Discharge Monitor Function

    Discharge monitor function When the discharge monitor function is enabled, lifting is cut out when the discharge limit is reached (the Stop LED is lit). Travel and lowering are still possible. For wet batteries the residual capacity is 20 %, for maintenance-free batteries it is 40 %. The batteries should be recharged when they reach 30 % (for wet batteries) or 50 % (for maintenance-free batteries).

  • Page 50: Troubleshooting

    Troubleshooting This chapter is designed to help the user identify and correct basic faults or the results of incorrect operation. To locate a fault, proceed in the order shown in the table. Fault Probable cause Action Truck does – Battery connector not –...
  • Page 51 E 24...

  • Page 52: F Truck Maintenance

    F Truck Maintenance Operational safety and environmental protection The servicing and inspection duties contained in this chapter must be performed in accordance with the intervals indicated in the servicing checklists. Any modification to the industrial truck assemblies, in particular the safety mechanisms, is prohibited.
  • Page 53 Work on the electric system: Only suitably trained personnel may operate on the truck’s electrical system. Before working on the electrical system, take all precautionary measures to avoid electric shocks. For battery-operated trucks, also de-energise the truck by removing the battery connector. Welding: To avoid damaging electric or electronic components, remove these from the truck before performing welding operations.

  • Page 54: Servicing And Inspection

    Servicing and inspection Thorough and expert servicing is one of the most important preconditions for safe operation of the industrial truck. Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment. The service intervals stated are based on single shift operation under normal operating conditions.

  • Page 55: Maintenance Checklist

    Maintenance checklist Maintenance intervals = t W A B C Standard Cold storage = k Chassis/ 1.1 Check all load bearing parts for damage body: 1.2 Check screw connections 1.3 Test the operator platform and check for damage Drive: 2.1 Check transmission for noise and leaks 2.2 Check transmission fluid level 2.3 Replace transmission fluid Wheels:...
  • Page 56 Maintenance intervals = t W A B C Standard Cold storage = k Battery: 9.1 Check acid density, acid level and battery voltage 9.2 Check terminals are securely attached, and apply grease 9.3 Clean the battery connections, ensure they are securely attached 9.4 Check battery cables for damage, and replace if necessary...

  • Page 57: Maintenance Schedule

    Maintenance schedule 0,7l 0,55 l g Sliding surfaces 1) Compound ratio for cold store usage 1 : 1 Grease nipple Hydraulic oil filling pipe 2) 1.25 – 1.3 litres depending on the type of transmission (always up to the lower mark of b Transmission fluid filling pipe the filler neck) a Transmission oil drain plug...

  • Page 58: Consumables

    Consumables Handling consumables: Consumables must always be handled correctly. Follow the manufacturer’s instructions. Improper handling is hazardous to health, life and the environment. Consumables must only be stored in appropriate containers. They may be flammable and must therefore not come into contact with hot components or naked flames. Only use clean containers when filling up with consumables.

  • Page 59: Maintenance And Repairs

    Maintenance and repairs Preparing the truck for maintenance and repairs All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made: – Parking the truck securely (see Chapter E). Opening the battery panel (see chapter D).

  • Page 60: Replacing The Drive Wheel

    Replacing the drive wheel The drive wheel must only be replaced by authorised service personnel. Checking the hydraulic oil level – Prepare the truck for maintenance and repairs (see section 6.1). – Open the front panel (see Section 6.3). – Check hydraulic oil level in hydraulic reservoir (7).

  • Page 61: Checking Electrical Fuses

    Checking electrical fuses – Prepare the truck for maintenance and repairs (see Section 6.1). – Dismantle the front panel (see Section 6.3). – Referring to the table, check that fuse ratings are correct, and replace if necessary. Item Description To protect: Value Drive / Lift motor 200 A...

  • Page 62: Recommissioning

    Recommissioning The truck may only be restored to service after cleaning or repair work, once the following operations have been performed. – Test horn. – Test battery connector function. – Test brakes. – Lubricate the truck in accordance with the maintenance schedule. Decommissioning the industrial truck If the industrial truck is to be decommissioned for more than two months, e.g.

  • Page 63: Returning The Truck To Operation After Decommissioning

    Carry out a safety check in accordance with national regulations. Junheinrich recommends checks in accordance with FEM Guideline 4.004. Jungheinrich has a special safety department with trained personnel to carry out such checks. The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector.
  • Page 64 Jungheinrich traction battery Table of contents Jungheinrich traction battery ..........2-6 with positive tubular plates type EPzS and EPzB Type plate Jungheinrich traction battery..........7 Instruction for use ............8-12 Aquamatic/BFS III water refilling system Jungheinrich traction battery Maintenance free traction batteries with positive tubular plates type EPzV ....................13-17...

  • Page 65: Jungheinrich Traction Battery

    Jungheinrich traction battery with positive tubular plates type EPzS and EPzB Rating Data 1. Nominal capacity C5: See type plate 2. Nominal voltage: 2,0 V x No of cells 3. Discharge current:: C5/5h 4. Nominal S.G. of electrolyte* Type EPzS:...
  • Page 66 Ignoring the operation instructions, repair with non-original parts or using additives for the electrolyte will render the warranty void. For batteries in classes I and II the instructions for maintaining the appropriate protection class during operation must be complied with (see relevant certificate). 1.
  • Page 67 Battery container lids and the covers of battery compartments must be opened or re- moved. The vent plugs should stay on the cells and remain closed. With the charger switched off connect up the battery, ensuring that the polarity is cor- rect.
  • Page 68 3. Maintenance 3.1 Daily Charge the battery after every discharge. Towards the end of charge the electrolyte level should be checked and if necessary topped up to the specified level with purified water. The electrolyte level must not fall below the anti-surge baffle or the top of the separator or the electrolyte „min“...
  • Page 69 5. Storage If batteries are taken out of service for a lengthy period they should be stored in the fully charged condition in a dry, frost-free room. To ensure the battery is always ready for use a choice of charging methods can be made: 1.

  • Page 70: 7. Type Plate, Jungheinrich Traction Battery

    7. Type plate, Jungheinrich traction battery Baujahr T ype Year of manufacture Serien-Nr. Lieferanten Nr. Serial-Nr. Supplier No. Nennspannung Kapazität Nominal V oltage Capacity Zellenzahl Batteriegewicht min/max Number of Cells Battery mass min/max Hersteller Jungheinrich AG, D-22047 Hamburg, Germany Manufacturer...

  • Page 71: Aquamatic/Bfs Iii Water Refilling System

    Aquamatic/BFS III water refilling system for Jungheinrich traction battery with EPzS and EPzB cells with tubular positive plates Aquamatic plug arrangement for the Operating Instructions Cell series* Aquamatic plug type (length) EPzS EPzB Frötek (yellow) (black) 2/120 – 10/ 600 2/ 42 –...
  • Page 72 Diagrammatic view Equipment for the water refilling system 1. Water tank 2. Level switch 3. Discharge point with ball valve 4. Discharge point with sole- noid valve 5. Charger 6. Sealing coupler 7. Closing nipple 8. Ion exchange cartridge with conductance meter and solenoid valve 9.
  • Page 73 4. Filling (manual/automatic) The batteries should be filled with battery water as soon as possible before the battery charging comes to an end; this ensures that the refilled water quantity is mixed with the electrolyte. In normal operation it is usually sufficient to fill once a week. 5.
  • Page 74 8. Battery hose connections Hose connections for the individual plugs are laid along the existing electric circuit. No changes may be made. 9. Operating temperature The temperature limit for battery operation is set at 55° C. Exceeding this temperature damages the batteries. The battery filling systems may be operated within a tempe- rature range of >...
  • Page 75 10.2.1 Clamping ring tool The clamping ring tool is used to push on a clamping ring to increase the contact pres- sure of the hose connection on the plugs' hose couplings and to loosen it again. 10.3 Filter element For safety reasons a filter element (ident no.: 50307282) can be fitted into the batte- ry's main supply pipe for supplying battery water.

  • Page 76: Jungheinrich Traction Battery

    Jungheinrich traction batterie Maintenance free Jungheinrich traction batterie with positive tubular plates type EPzV and EPzV-BS Rating Data 1. Nominal capacity C5: See type plate 2. Nominal voltage: 2,0 Volt x No of cells 3. Discharge current: C5/5h 4. Rated temperature: 30°...
  • Page 77 Ignoring the operation instructions, repair with non-original parts and non authorised interventions will render the warranty void. For batteries in classes I and II the instructions for maintaining the appropriate protection class during operation must be complied with (see relevant certificate). 1.
  • Page 78 With the charger switched off connect up the battery, ensuring that the polarity is cor- rect (positive to positive, negative to negative). Now switch on the charger. When charging the temperature of the battery rises by about 15° C, so charging should only begin if the battery temperature is below 35°...
  • Page 79 3.2 Weekly Visual inspection after recharging for signs of dirt and mechanical damage. 3.3 Quarterly After the end of the charge and a rest time of 5 h following should be measured and recorded: • the voltages of the battery •...

  • Page 80: 7. Type Plate, Jungheinrich Traction Battery

    Batteries with this sign must be recycled. Batteries which are not returned for the recycling process must be disposed of as hazardous waste! We reserve the right make technical modification. 7. Type plate, Jungheinrich traction battery Baujahr T ype Year of manufacture Serien-Nr.

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