Jungheinrich EJD K18 Operating Instructions Manual
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Jungheinrich EJD K18 Operating Instructions Manual

Jungheinrich EJD K18 Operating Instructions Manual

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EJD K18
02.05 -
G
Operating Instructions
50468912
03.07

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Summary of Contents for Jungheinrich EJD K18

  • Page 1 EJD K18 02.05 - Operating Instructions 50468912 03.07...
  • 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

    Index Correct use and application Truck Description Application ................... B 1 Assemblies and Functional Description ..........B 2 Truck ....................B 3 Load handling ..................B 4 Standard Version Specifications ............B 5 Performance data for standard trucks ..........B 5 Dimensions ..................
  • Page 5 Operational safety and environmental protection ........ F 1 Maintenance Safety Regulations ............F 1 Servicing and inspection ..............F 3 EJD K18 Maintenance Checklist ............F 4 EJD K18 Lubrication Schedule ............F 6 Fuels, coolants and lubricants ............. F 7 Maintenance Instructions ..............
  • 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 operator manual is an industrial truck designed for lifting and transporting load units.

  • Page 10: B Truck Description

    B Truck Description Application Threewheel, electric tiller operated stacker that can be used for lifting and stacking pallets and horizontal transportation. For horizontal transportation, two pallets can be stacked on top of each other. With its compact design and application as both stacker and for horizontal transportation, the truck is especially suited for use in retail environments, workshops, small warehouses and for assisting lorry loading and unloading.

  • Page 11: Assemblies And Functional Description

    Assemblies and Functional Description Item Description Item Description t Key switch t Mast guard o Key switch t Battery panel (also with second stage for brake release) t Battery connector Discharge monitor Display instrument (emergency disconnect) (CANDIS) o Keypad t Load handler (CANCODE) o On board charger t Front panel...

  • Page 12: Truck

    When the tiller is released it is forced into the brake position by a gas pressure spring. Structure: The EJD K18 is a threewheel truck with a steered drive wheel (15) and two sprung, cushioned and pivoting castor wheels (14) within the enclosed truck geometry.

  • Page 13: Load Handling

    Load handling The load handler consists of the lift mechanism and the attached mast (7). Lift mechanism: The lift mechanism and the outriggers are connected to the chassis via the lift cylinder and the lift linkage. The roller cylinders are raised by the lift cylinder while simultaneously moving the load wheel support of the lift linkage.

  • Page 14: Standard Version Specifications

    Standard Version Specifications Technical data specified in accordance with VDI 2198. Technical modifications and additions reserved. Performance data for standard trucks Description EJD K18 Capacity 1800 Load centre of gravity distance Travel speed 5,79 / 5,98 km/h with / without load...

  • Page 16: En Norms

    EN norms Noise emission: 70 dB(A) in accordance with EN 12053 as harmonised with ISO 4871. The noise emission level is calculated in accordance with standard procedures and takes into account the noise level when travelling, lifting and when idle. The noise level is measured at the driver’s ear.

  • Page 17: Decals

    Decals -Nr. Serien-N r. X.XXXX.XX.XX 1600 kg 1800 HH 3 1000 1660 100 mm HH 2 (kg) HH 1 1880 1000 1000 H (mm) Q max Q max D (mm) Item Description Truck data plate “Danger of trapping” warning Load chart Capacity Qmax Strap point for crane lifting "Do not reach through the mast"...
  • Page 18 Truck data plate Item Description Item Description Type Manufacturer Serial no. Min./max. battery weight (kg) Rated capacity (kg) Output (kW) Battery voltage V Load centre of gravity (mm) Net weight w.o. battery (kg) Year of manufacture Manufacturer’s logo Option The load handler must be raised to check the data plate. For queries regarding the truck or ordering spare parts please quote the truck serial number (30).

  • Page 19: Capacity

    Load chart The capacity plate (19) indicates the capacity (Q kg) of the truck. The permissible load is shown as a function of the load centre of gravity distance (D -Nr. in mm) and the lift height (H in mm) in Serien-Nr.

  • Page 20: 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). – Park the truck securely (see Chapter E). – Attach the crane slings to the strap point (1) so that the truck cannot slip. Commissioning Operate the truck only with battery current.

  • Page 21: Operating The Truck Without Its Own Drive System (Emergency Operation)

    Operating the truck without its own drive system (emergency operation) To operate the truck in emergency conditions, the electromagnetically applied brake must be released. – Remove the front panel (2) (see Chapter F). – Remove the right-hand drive panel (3) (see Chapter F). –...

  • Page 22: Emergency Operation With Service Key 741 (O)

    Emergency operation with service key 741 (o) The EJD can be moved manually if the electrical system is damaged. This requires a connected battery in the truck. The service key 741 (o) (701 is standard) must be set to position 2 of the keyswitch. Key 701 for normal truck operation can only be turned to position 1 of the keyswitch.

  • Page 24: 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. The present operator manual and the manufacturer’s instructions concerning batteries and charging stations must be observed when carrying out the work.

  • Page 25: Battery Types

    Battery types The battery weights can be taken from the battery data plate. Depending on the particular model, the EJD can be fitted with different battery types (see chapter B). Batteries with non insulated terminals must be covered with a non slip insulation mat. When replacing or installing batteries, ensure that the battery is correctly secured in the battery compartment of the truck.

  • Page 26: Exposing The Battery

    Exposing the battery – Park the truck securely (see Chapter E). – Open the battery panel latch (1) with an Allen key. – Open the battery panel (3). To do this, grab the handle (2) and lift it up. – Where necessary remove the insulating mat from the battery. The battery panel is kept open by means of a magnet on the mast lift.

  • Page 27: Charging The Battery With An On-Board Charger O

    Charging the battery with an on-board charger o The charger must not be opened. If damaged, it must be replaced. The switch (6) contains intermediate positions between setting positions “1” to “6” for safety reasons. When the truck is delivered without a battery, it is supplied with a factory-set intermediate position.
  • Page 28 Setting the charging characteristics Set the characteristics as follows: Connect the battery This allows you to adjust via the charger Turn the setting switch to the The red LED flashes rapidly No valid right (clockwise) as far as the characteristics stop selected Turn the setting switch to the...
  • Page 29 – Remove the connector (8) from the socket and store the mains cable back under the battery panel. Charging continues automatically after a mains failure. Charging can be interrupted by removing the mains connector and continued as partial charging. The mains cable must not be opened. Before starting the truck, the battery panel must be firmly closed.

  • Page 30: 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 the battery cable in such a way that they will not get caught on the truck when the battery is removed.

  • Page 31: Battery Discharge Indicator (T)

    Battery Discharge Indicator (t) When the truck has been released via the keyswitch or CANCODE, the battery charge status is displayed. The colours of the LEDs (10) represent the following conditions: LED colour Rating Green Standard battery residual capacity 40 - 100% Maintenance free battery residual capacity 60 - 100% Orange...

  • Page 32: Safety Regulations For The Operation Of Forklift Trucks

    E Operation Safety Regulations for the Operation of Forklift Trucks Driver authorisation: The forklift 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 33: Controls And Displays

    Controls and Displays Item Control / Display EJD 118 Function Key switch Switches control current on and off. Removing the key prevents the truck from being switched on by unauthorised personnel. Key switch with second Releases the brakes to move the truck switch level when non-operational.

  • Page 35: Starting Up The Truck

    Starting up the truck Before the truck can be commissioned, operated or a load unit lifted, the driver must ensure that there is nobody within the hazardous area. Checks and operations to be performed before starting daily work – Inspect the entire truck (especially the wheels and the load handler) for visible signs of damage.

  • Page 36: 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 persons 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 37: Travelling, Steering, Braking

    Travelling, Steering, Braking Never carry passengers. Emergency Disconnect – Remove the battery connector (14). All electrical functions are deactivated. Automatic braking Automatic braking occurs when the tiller is released – the tiller automatically sets itself to the upper brake zone (B). If the tiller moves slowly to the upper brake zone, the cause of this fault must be rectified.
  • Page 38 In hazardous situations brake the truck by immediately releasing the crawl button (6). When you apply the crawl button in the travel range (F) the truck travels with reduced speed and acceleration. Steering – Move the tiller (5) to the left or right.
  • Page 39 Braking The braking pattern of the truck depends largely on the ground conditions. The driver must take this into account when operating the truck. )Braking with the Service Brake: – Set the tiller (5) up or down to one of the brake zones (B).

  • Page 40: Collecting And Depositing Loads

    Collecting and depositing loads Before picking up 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 unit. The lifting and lowering speeds are specified.

  • Page 41: Parking The Truck Securely

    Lifting the outriggers – Press the “Outrigger lift” button (11). Lowering the outriggers – Press the “Outrigger lower” button (12). Avoid dropping the load abruptly, in order to protect the load and the rack surface. Transporting 2 pallets on top of each other Transport one pallet on the outriggers and a second pallet on the load forks.

  • Page 42: Keypad (Cancode) (O)

    Keypad (CANCODE) (o) The keypad consists of 10 number keys, a Set key and a o key. The o key indicates operating statuses via a red/ green LED. It contains the following functions: – Code lock function (commissioning the truck). –...

  • Page 43: Parameters

    Starting the truck for the first time The LED (15) goes red when you connect the battery and if necessary switch on the key switch. When you enter the correct operator code (factory setting 2-5-8-0) the LED (15) turns green. If the wrong code is entered LED (15) flashes red for two seconds.

  • Page 44: 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 45: Comments

    Setting procedure for trucks with and without display instrument (CANDIS (o)): – Enter the three digit parameter number, confirm with the Set key (16). – The display instrument (CANDIS (o)) continues to display the operating hours. If the display changes, cancel the setting procedure with the o key (20) and restart from the beginning.
  • Page 46 Function Range of Standard Comments Setting Setting Procedure Code Lock 002 Change Operator Code 0000 - 9999 (LED 17 flashes) Enter current code 00000 - 99999 Confirm (Set) 000000 - 999999 (LED 18 flashes) Enter new code Confirm (Set) (LED 19 flashes) Repeat code entry confirm...
  • Page 47 Error messages on keypad LED (15) flashes red to indicate the following errors: – New master code is already operator code. – New operator code is already master code. – Operator code to be changed does not exist. – Tried to change the operator code to another user code that already exists. –...
  • Page 48 Comments For trucks without a display instrument (CANDIS (o)) the battery parameters can only be set by the manufacturer's service department. The parameters are set in the same way as for the travel parameters. The following parameters may be entered. Function Range of Standard...

  • Page 49: Display Instrument (Candis) (O)

    Display instrument (CANDIS) (o) The instrument indicates: – Battery residual charge status (LED bars (22)), – Service hours (LC display (24)). In addition, service messages for the electronic components and para- meter changes are displayed. Discharge status display Setting limits for the additional “Warning” (21) and “Stop” (23) displays will depend on the battery type.

  • Page 50: 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 51: Troubleshooting

    Troubleshooting Fault Possible cause Action Truck does – Battery connector not – Check the battery connector and connect not start. connected if necessary – Key switch “0” – Set key switch to “I” position – Incorrect CANCODE – Check code code –...

  • Page 52: F Truck Maintenance

    F Truck Maintenance Operational safety and environmental protection The servicing and inspection operations contained in this chapter must be performed in accordance with the intervals indicated in the servicing checklists. Any modification to the forklift truck assemblies, in particular the safety mechanisms, is prohibited.
  • Page 53 Electrical 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 requirements for the 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: Ejd K18 Maintenance Checklist

    EJD K18 Maintenance Checklist Maintenance intervals Standard = W A B C Cold Store = k Chassis/Super- 1.1 Check all load bearing components for damage structure: 1.2 Check screw connections Drive: 2.1 Check transmission for noise and leakage 2.2 Check transmission oil level 2.3 Change transmission oil...
  • Page 56 Maintenance intervals Standard = W A B C Cold Store = k Battery: 10.1 Check acid density, acid level and cell voltage 10.2 Check terminals are securely attached, and apply grease 10.3 Clean battery connections, make sure they are secure k 10.4 Check battery cables for damage, replace if necessary 11.1 Lubricate truck in accordance with Lubrication Schedule k Lubrication:...

  • Page 57: Ejd K18 Lubrication Schedule

    EJD K18 Lubrication Schedule A + C 0,7 l 0,55 l Contact surfaces Grease nipples Hydraulic oil filler neck Transmission oil filler neck Transmission oil drain plug Transmission oil overflow and dipstick Cold Store Application Compound ratio for cold store usage 1:1...

  • Page 58: Fuels, Coolants And Lubricants

    Fuels, coolants and lubricants 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.

  • Page 59: Maintenance Instructions

    Maintenance Instructions 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: – Park the truck securely (see Chapter E). – Remove the battery connector (1). When working under a raised load fork or a raised truck, secure them to prevent them from lowering, tipping or sliding away.

  • Page 60: Check The Hydraulic Oil Level

    Check the hydraulic oil level – Preparing the truck for maintenance and repairs (see Section 6.1). – Open the front panel. – Check hydraulic oil level in hydraulic reservoir. The oil level must be checked when the load forks and outrigger lift are lowered. –...

  • Page 61: Checking Electrical Fuses

    Checking electrical fuses – Preparing the truck for maintenance and repairs (see Section 6.1). – Remove the front panel (see Section 6.2). – Check all fuse ratings in accordance with the table; replace if necessary. Item Description To protect: Rating On board charger (option) 10 A Overall control fuse...

  • Page 62: Recommissioning

    Recommissioning The truck may only be recommissioned after cleaning or repair work, once the following operations have been performed. – Test horn. – Test emergency disconnect connector operation. – Test brake. – Lubricate the truck in accordance with the lubrication schedule. Decommissioning the industrial truck If the industrial truck is to be decommissioned for more than two months, e.g.

  • Page 63: Restoring The Truck To Operation After Decommissioning

    Restoring the truck to operation after decommissioning – Thoroughly clean the truck. – Lubricate the truck in accordance with the lubrication schedule (see chapter F). – Clean the battery, grease the terminals and connect the battery. – Charge the battery (see Chapter D). –...
  • 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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