Operating instructions GOperating instructions

51159397

EJE 07.09 -

11.13 EJE 120n

EJE 116n

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Foreword

The present ORIGINAL OPERATING INSTRUCTIONS are designed to providesufficient instruction for the safe operation of the industrial truck. The information isprovided clearly and concisely. The chapters are arranged by letter. Each chapterstarts with page 1. The page identification consists of a chapter letter and a pagenumber.For example: Page B 2 is the second page in chapter B.

The operating instructions detail different truck models. When operating and servicingthe truck, make sure that the instructions apply to your truck model.

Safety instructions and important explanations are indicated by the followinggraphics:

F Used before safety instructions which must be observed to avoid danger topersonnel.

M Used before notices which must be observed to avoid material damage.

Z 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 toalter the design, equipment and technical features of the truck. No guarantee ofparticular features of the truck should therefore be inferred from the present operatinginstructions.

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Am Stadtrand 3522047 Hamburg - GERMANY

Telephone: +49 (0) 40/6948-0

www.jungheinrich.com

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Foreword

The present ORIGINAL OPERATING INSTRUCTIONS are designed to providesufficient instruction for the safe operation of the industrial truck. The information isprovided clearly and concisely. The chapters are arranged by letter. Each chapterstarts with page 1. The page identification consists of a chapter letter and a pagenumber.For example: Page B 2 is the second page in chapter B.

The operating instructions detail different truck models. When operating and servicingthe truck, make sure that the instructions apply to your truck model.

Safety instructions and important explanations are indicated by the followinggraphics:

F Used before safety instructions which must be observed to avoid danger topersonnel.

M Used before notices which must be observed to avoid material damage.

Z 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 toalter the design, equipment and technical features of the truck. No guarantee ofparticular features of the truck should therefore be inferred from the present operatinginstructions.

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Am Stadtrand 3522047 Hamburg - GERMANY

Telephone: +49 (0) 40/6948-0

www.jungheinrich.com

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Table of Contents

A Correct Application

B Truck Description

1 Application ........................................................................................... B 1

2 Assemblies and Functional Description .............................................. B 2

3 Standard Version Specifications ......................................................... B 3

3.1 Performance data for standard trucks ................................................. B 3

3.2 Dimensions ......................................................................................... B 3

3.3 EN norms ............................................................................................ B 5

3.4 Conditions of use ................................................................................ B 5

4 Decals ................................................................................................. B 6

4.1 Truck data plate .................................................................................. B 7

C Transport and Commissioning

1 Lifting by crane .................................................................................... C 1

2 Using the truck for the first time .......................................................... C 1

3 Operating the truck without its own drive system (emergency operation) ............................................................................................ C 2

3.1 Emergency operation with service key GF60 (o) ............................... C 3

D Battery Maintenance, Charging & Replacement

1 Safety regulations for handling acid batteries ..................................... D 1

2 Battery types ....................................................................................... D 2

3 Batteries and Motor Output ................................................................. D 2

4 Exposing the battery ........................................................................... D 3

5 Charging the battery ............................................................................ D 3

5.1 Charging the battery with a stationary charger ................................... D 3

5.2 Charging the battery with an on-board charger (o) ............................ D 4

6 Battery removal and installation .......................................................... D 7

6.1 Changing the battery from the top ....................................................... D 7

6.2 Lateral Battery Removal (o) ............................................................... D 8

7 Battery Discharge Indicator (t) .......................................................... D 9

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Table of Contents

A Correct Application

B Truck Description

1 Application ........................................................................................... B 1

2 Assemblies and Functional Description .............................................. B 2

3 Standard Version Specifications ......................................................... B 3

3.1 Performance data for standard trucks ................................................. B 3

3.2 Dimensions ......................................................................................... B 3

3.3 EN norms ............................................................................................ B 5

3.4 Conditions of use ................................................................................ B 5

4 Decals ................................................................................................. B 6

4.1 Truck data plate .................................................................................. B 7

C Transport and Commissioning

1 Lifting by crane .................................................................................... C 1

2 Using the truck for the first time .......................................................... C 1

3 Operating the truck without its own drive system (emergency operation) ............................................................................................ C 2

3.1 Emergency operation with service key GF60 (o) ............................... C 3

D Battery Maintenance, Charging & Replacement

1 Safety regulations for handling acid batteries ..................................... D 1

2 Battery types ....................................................................................... D 2

3 Batteries and Motor Output ................................................................. D 2

4 Exposing the battery ........................................................................... D 3

5 Charging the battery ............................................................................ D 3

5.1 Charging the battery with a stationary charger ................................... D 3

5.2 Charging the battery with an on-board charger (o) ............................ D 4

6 Battery removal and installation .......................................................... D 7

6.1 Changing the battery from the top ....................................................... D 7

6.2 Lateral Battery Removal (o) ............................................................... D 8

7 Battery Discharge Indicator (t) .......................................................... D 9

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E Operation

1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1

2 Controls and Displays ......................................................................... E 2

3 Starting up the truck ............................................................................ E 4

4 Industrial Truck Operation ................................................................... E 5

4.1 Safety regulations for truck operation ................................................. E 5

4.2 Travelling, Steering, Braking ............................................................... E 6

4.3 Lifting and depositing loads ................................................................. E 9

4.4 Parking the truck securely ................................................................... E 9

5 Keypad (CanCode) (o) ....................................................................... E 10

5.1 Code Lock ........................................................................................... E 10

5.2 Travel programs .................................................................................. E 12

5.3 Parameters .......................................................................................... E 12

5.4 Parameter Settings ............................................................................. E 13

5.5 Travel parameters ............................................................................... E 17

6 Display instrument (CanDis) (o) ......................................................... E 20

6.1 Discharge monitor function ................................................................. E 21

6.2 Operating hours display ...................................................................... E 21

6.3 Power up test ...................................................................................... E 21

6.4 Troubleshooting .................................................................................. E 22

F Truck Maintenance

1 Operational Safety and Environmental Protection .............................. F 1

2 Maintenance Safety Regulations ........................................................ F 1

3 Servicing and Inspection ..................................................................... F 3

4 EJE 116n / 120n Maintenance Checklist ............................................ F 4

5 EJE 116n / 120n Lubrication Schedule ............................................... F 6

5.1 Consumables ...................................................................................... F 7

6 Maintenance Instructions .................................................................... F 8

6.1 Preparing the truck for maintenance and repairs ................................ F 8

6.2 Removing the front panel .................................................................... F 8

6.3 Removing the drive panel ................................................................... F 8

6.4 Checking electrical fuses .................................................................... F 9

6.5 Recommissioning ................................................................................ F 10

7 Decommissioning the industrial truck .................................................. F 10

7.1 Prior to decommissioning: ................................................................... F 10

7.2 During decommissioning: .................................................................... F 10

7.3 Returning the truck to operation after decommissioning ..................... F 11

8 Safety checks to be performed at regular intervals and following any unusual incidents ................................................................................ F 11

9 Final de-commissioning, disposal ....................................................... F 11

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E Operation

1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1

2 Controls and Displays ......................................................................... E 2

3 Starting up the truck ............................................................................ E 4

4 Industrial Truck Operation ................................................................... E 5

4.1 Safety regulations for truck operation ................................................. E 5

4.2 Travelling, Steering, Braking ............................................................... E 6

4.3 Lifting and depositing loads ................................................................. E 9

4.4 Parking the truck securely ................................................................... E 9

5 Keypad (CanCode) (o) ....................................................................... E 10

5.1 Code Lock ........................................................................................... E 10

5.2 Travel programs .................................................................................. E 12

5.3 Parameters .......................................................................................... E 12

5.4 Parameter Settings ............................................................................. E 13

5.5 Travel parameters ............................................................................... E 17

6 Display instrument (CanDis) (o) ......................................................... E 20

6.1 Discharge monitor function ................................................................. E 21

6.2 Operating hours display ...................................................................... E 21

6.3 Power up test ...................................................................................... E 21

6.4 Troubleshooting .................................................................................. E 22

F Truck Maintenance

1 Operational Safety and Environmental Protection .............................. F 1

2 Maintenance Safety Regulations ........................................................ F 1

3 Servicing and Inspection ..................................................................... F 3

4 EJE 116n / 120n Maintenance Checklist ............................................ F 4

5 EJE 116n / 120n Lubrication Schedule ............................................... F 6

5.1 Consumables ...................................................................................... F 7

6 Maintenance Instructions .................................................................... F 8

6.1 Preparing the truck for maintenance and repairs ................................ F 8

6.2 Removing the front panel .................................................................... F 8

6.3 Removing the drive panel ................................................................... F 8

6.4 Checking electrical fuses .................................................................... F 9

6.5 Recommissioning ................................................................................ F 10

7 Decommissioning the industrial truck .................................................. F 10

7.1 Prior to decommissioning: ................................................................... F 10

7.2 During decommissioning: .................................................................... F 10

7.3 Returning the truck to operation after decommissioning ..................... F 11

8 Safety checks to be performed at regular intervals and following any unusual incidents ................................................................................ F 11

9 Final de-commissioning, disposal ....................................................... F 11

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Appendix

JH Traction Battery Operating Instructions

Z These operating instructions apply only to Jungheinrich battery models. If usinganother brand, refer to the manufacturer's operating instructions.

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Appendix

JH Traction Battery Operating Instructions

Z These operating instructions apply only to Jungheinrich battery models. If usinganother brand, refer to the manufacturer's operating instructions.

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A Correct Application

Z The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) aresupplied with the truck. The guidelines form part of these operating instructions andmust be observed. National regulations apply in full.

The truck described in the present operating instructions is an industrial truckdesigned for lifting and transporting loads.It must be applied, operated and serviced in accordance with the instructionscontained in the present manual. All other types of use lie beyond the scope ofapplication and can result in damage to personnel, the truck or property. In particular,avoid overloading the truck with loads which are too heavy or placed on one side. Thedata plate attached to the truck or the load chart are binding for the maximum loadcapacity. The industrial truck must not be used in fire or explosion endangered areas,or areas threatened by corrosion or excessive dust.

Proprietor responsibilities: For the purposes of the present operator manual the“proprietor” is defined as any natural or legal person who either uses the industrialtruck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting)the proprietor is considered to be the person who, in accordance with existingcontractual agreements between the owner and user of the industrial truck, ischarged with operational duties.The proprietor must ensure that the industrial truck is used only for the purpose it isintended for and that danger to life and limb of the user and third parties are excluded.Furthermore, accident prevention regulations, safety regulations and operating,servicing and repair guidelines must be followed. The owner must ensure that alltruck users have read and understood these operating instructions.

M Failure to comply with the operating instructions shall invalidate the warranty. Thesame applies if improper work is carried out on the truck by the customer or thirdparties without the permission of the manufacturer’s customer service department.

Attaching accessories: The mounting or installation of additional equipment whichaffects or enhances the performance of the industrial truck requires the writtenpermission of the manufacturer. In some cases, local authority approval shall berequired.Approval of the local authorities however does not constitute the manufacturer’sapproval.

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A Correct Application

Z The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) aresupplied with the truck. The guidelines form part of these operating instructions andmust be observed. National regulations apply in full.

The truck described in the present operating instructions is an industrial truckdesigned for lifting and transporting loads.It must be applied, operated and serviced in accordance with the instructionscontained in the present manual. All other types of use lie beyond the scope ofapplication and can result in damage to personnel, the truck or property. In particular,avoid overloading the truck with loads which are too heavy or placed on one side. Thedata plate attached to the truck or the load chart are binding for the maximum loadcapacity. The industrial truck must not be used in fire or explosion endangered areas,or areas threatened by corrosion or excessive dust.

Proprietor responsibilities: For the purposes of the present operator manual the“proprietor” is defined as any natural or legal person who either uses the industrialtruck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting)the proprietor is considered to be the person who, in accordance with existingcontractual agreements between the owner and user of the industrial truck, ischarged with operational duties.The proprietor must ensure that the industrial truck is used only for the purpose it isintended for and that danger to life and limb of the user and third parties are excluded.Furthermore, accident prevention regulations, safety regulations and operating,servicing and repair guidelines must be followed. The owner must ensure that alltruck users have read and understood these operating instructions.

M Failure to comply with the operating instructions shall invalidate the warranty. Thesame applies if improper work is carried out on the truck by the customer or thirdparties without the permission of the manufacturer’s customer service department.

Attaching accessories: The mounting or installation of additional equipment whichaffects or enhances the performance of the industrial truck requires the writtenpermission of the manufacturer. In some cases, local authority approval shall berequired.Approval of the local authorities however does not constitute the manufacturer’sapproval.

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B Truck Description

1 Application

The truck is designed for transporting goods on level surfaces. The truck can lift openbottom or diagonal board pallets as well as roll cages beyond the area above the loadwheels. The capacity is shown on the capacity plate, Qmax.

Truck types, capacity and motor output:

Type Capacity Motor output

EJE 116n 1600 kg 1,0 kW

EJE 120n 2000 kg 1,0 kW

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B Truck Description

1 Application

The truck is designed for transporting goods on level surfaces. The truck can lift openbottom or diagonal board pallets as well as roll cages beyond the area above the loadwheels. The capacity is shown on the capacity plate, Qmax.

Truck types, capacity and motor output:

Type Capacity Motor output

EJE 116n 1600 kg 1,0 kW

EJE 120n 2000 kg 1,0 kW

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B 2

2 Assemblies and Functional Description

Item Description Item Description

1 t

o

o

Key switch

CanCodekeypad

Key switch(also with second stage for brake release)

8 t Battery panel

2 t

o

Discharge indicator

Display instrument (CanDis)

9 t Emergency Disconnect

3 o On-board charger24 V / 30 A

(including safety switch)

10 t Load handler

4 t Tiller 11 t Castors

5 t Crawl button 12 t Drive wheel

6 t Collision safety switch 13 t Two-section drive panel

7 t Travel switch 14 t Front panel

t = Standard equipment o = Optional Equipment

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3

2

1

14

11 12 11

13

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5

6

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B 2

2 Assemblies and Functional Description

Item Description Item Description

1 t

o

o

Key switch

CanCodekeypad

Key switch(also with second stage for brake release)

8 t Battery panel

2 t

o

Discharge indicator

Display instrument (CanDis)

9 t Emergency Disconnect

3 o On-board charger24 V / 30 A

(including safety switch)

10 t Load handler

4 t Tiller 11 t Castors

5 t Crawl button 12 t Drive wheel

6 t Collision safety switch 13 t Two-section drive panel

7 t Travel switch 14 t Front panel

t = Standard equipment o = Optional Equipment

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7

89

3

2

1

14

11 12 11

13

4

5

6

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B3 Standard Version Specifications

Z Technical specification details in accordance with VDI 2198. Technical modifications and additions reserved.

3.1 Performance data for standard trucks

*) For longer fork lengths the load centre of gravity is in the centre of the forks

3.2 Dimensions

* Load section raised / lowered +53 mm

** Diagonal in accordance with VDI +204 mm

Description EJE 116n EJE 120n

Q Capacity 1600 2000 kg

C Load centre distance for standard fork length *)

600 600 mm

Travel speed w / w.o. load

6,0 / 6,0 6,0 / 6,0 km/h

Lift speed w / w.o. load

4 / 5 4 / 5 cm/sec

Lower speedw / w.o. load

5 / 4 5 / 4 cm/sec

Max. gradeability (5 min) w / w.o. load

8 / 20 8 / 20 %

Description EJE 116n

EJE 120n

h3 Lift 122 mm

h13 Load handler lowered 85 mm

h14 Tiller height in min/max travel position 797 / 1313 mm

Y* Wheel base (short / long) 1255 / 1326 mm

l1 Overall length (short / long) 1644 / 1715 mm

l2 Length including fork shank (short, long) 494 / 565 mm

l Standard fork length 1150 mm

b1 Truck width 720 mm

b5 Width across forks 540 mm

b10 Track width, front 508 mm

b11 Gauge, rear 368 mm

e Fork width 172 mm

sec Fork thickness 55 mm

m2 Ground clearance from centre of wheelbase 30 mm

x Load distance 911 mm

Wa* Turning radius 1440 / 1511 mm

Ast* Aisle width, pallet 800x1200 longitudinal (short/long) 1929** / 2000** mm

Ast* Aisle width, pallet 1000x1200 longitudinal (short/long) 1879 / 1950 mm

a Safety distance 200 mm

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3 Standard Version Specifications

Z Technical specification details in accordance with VDI 2198. Technical modifications and additions reserved.

3.1 Performance data for standard trucks

*) For longer fork lengths the load centre of gravity is in the centre of the forks

3.2 Dimensions

* Load section raised / lowered +53 mm

** Diagonal in accordance with VDI +204 mm

Description EJE 116n EJE 120n

Q Capacity 1600 2000 kg

C Load centre distance for standard fork length *)

600 600 mm

Travel speed w / w.o. load

6,0 / 6,0 6,0 / 6,0 km/h

Lift speed w / w.o. load

4 / 5 4 / 5 cm/sec

Lower speedw / w.o. load

5 / 4 5 / 4 cm/sec

Max. gradeability (5 min) w / w.o. load

8 / 20 8 / 20 %

Description EJE 116n

EJE 120n

h3 Lift 122 mm

h13 Load handler lowered 85 mm

h14 Tiller height in min/max travel position 797 / 1313 mm

Y* Wheel base (short / long) 1255 / 1326 mm

l1 Overall length (short / long) 1644 / 1715 mm

l2 Length including fork shank (short, long) 494 / 565 mm

l Standard fork length 1150 mm

b1 Truck width 720 mm

b5 Width across forks 540 mm

b10 Track width, front 508 mm

b11 Gauge, rear 368 mm

e Fork width 172 mm

sec Fork thickness 55 mm

m2 Ground clearance from centre of wheelbase 30 mm

x Load distance 911 mm

Wa* Turning radius 1440 / 1511 mm

Ast* Aisle width, pallet 800x1200 longitudinal (short/long) 1929** / 2000** mm

Ast* Aisle width, pallet 1000x1200 longitudinal (short/long) 1879 / 1950 mm

a Safety distance 200 mm

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B 4

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B 4

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B3.3 EN norms

Noise level: 70 dB(A)

in accordance with EN 12053 as harmonized with ISO4871.

M The noise emission level is calculated in accordance with standard procedures andtakes into account the noise level when travelling, lifting and when idle. The noiselevel is measured at the driver’s ear.

Electromagnetic Compatibility (EMC)

The manufacturer confirms that equipment complies withtolerance levels for electromagnetic emissions andresistance as well as static electricity discharge testing inaccordance with EN 12895 including the normativeprocedures contained therein.

Z No changes to electric or electronic components or their arrangement may be madewithout the written agreement of the manufacturer.

3.4 Conditions of use

Ambient temperature- during operation 5°C to 40 °C

Z Special equipment and authorisation is required if the truck is to operate constantlybelow 5 °C or in a cold store or in extreme temperatures or conditions of fluctuatingair humidity.

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3.3 EN norms

Noise level: 70 dB(A)

in accordance with EN 12053 as harmonized with ISO4871.

M The noise emission level is calculated in accordance with standard procedures andtakes into account the noise level when travelling, lifting and when idle. The noiselevel is measured at the driver’s ear.

Electromagnetic Compatibility (EMC)

The manufacturer confirms that equipment complies withtolerance levels for electromagnetic emissions andresistance as well as static electricity discharge testing inaccordance with EN 12895 including the normativeprocedures contained therein.

Z No changes to electric or electronic components or their arrangement may be madewithout the written agreement of the manufacturer.

3.4 Conditions of use

Ambient temperature- during operation 5°C to 40 °C

Z Special equipment and authorisation is required if the truck is to operate constantlybelow 5 °C or in a cold store or in extreme temperatures or conditions of fluctuatingair humidity.

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B 6

4 Decals

Item Description

16 Truck data plate

17 Capacity Qmax

18 "No passengers” warning

19 Strap point for crane lifting

1816

19

17

QmaxXXX kg

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4 Decals

Item Description

16 Truck data plate

17 Capacity Qmax

18 "No passengers” warning

19 Strap point for crane lifting

1816

19

17

QmaxXXX kg

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B4.1 Truck data plate

Z The load handler must be raised to check the data plate.

For queries regarding the truck or ordering spare parts please quote the truck serialnumber (35).

Item Description Item Description

20 Type 29 Manufacturer’s logo

21 Name 30 Max. battery weight in kg

22 Battery: Voltage (V) 31 Min. battery weight in kg

23 Rated capacity (kg) 32 Output (kW)

24 Net weight w.o. battery (kg) 33 Load centre (mm)

25 Net weight with battery (kg) 34 Year of manufacture

26 Manufacturer 35 Serial No.

27 Production 36 Option

28 Production address

31

30

24

3223

3322

3421

20

36 35

25

26

27 28 29

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4.1 Truck data plate

Z The load handler must be raised to check the data plate.

For queries regarding the truck or ordering spare parts please quote the truck serialnumber (35).

Item Description Item Description

20 Type 29 Manufacturer’s logo

21 Name 30 Max. battery weight in kg

22 Battery: Voltage (V) 31 Min. battery weight in kg

23 Rated capacity (kg) 32 Output (kW)

24 Net weight w.o. battery (kg) 33 Load centre (mm)

25 Net weight with battery (kg) 34 Year of manufacture

26 Manufacturer 35 Serial No.

27 Production 36 Option

28 Production address

31

30

24

3223

3322

3421

20

36 35

25

26

27 28 29

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C Transport and Commissioning

1 Lifting by crane

M Only use lifting gear with sufficient capacity (Loading weight = net weight + battery weight; see truck data plate).

Z Strap points (1) are provided for transporting the truck with crane lifting gear.

– Park the truck securely (see Chapter E).

– Open the battery panel.

– Secure the lifting slings to theattachment points (1).

M Attach the crane slings to the strap pointsso that the truck cannot slip. Lifting slingsshould be fastened to the harness in sucha way that they do not come into contactwith any parts of the truck when it is beingraised.

2 Using the truck for the first time

M Only operate the truck with batterycurrent. Rectified AC current will damagethe electronic components. The batteryleads (tow cable) must be less than 6mlong.

To prepare the truck after delivery or transport the following tasks must be carriedout:

– Make sure the truck is fully equipped and in a satisfactory condition.

– Install battery (where required). Do not damage battery cable.

– Charge the battery (see Chapter D).

– If the customer uses a maintenance-free battery, the discharge indicator settingmust match the battery type (manufacturer’s service department to check).

– Start up the truck in accordance with instructions (see Chapter E).

Z When the truck is parked, the surface of the tyres will flatten. The flattening willdisappear after a short period of operation.

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C Transport and Commissioning

1 Lifting by crane

M Only use lifting gear with sufficient capacity (Loading weight = net weight + battery weight; see truck data plate).

Z Strap points (1) are provided for transporting the truck with crane lifting gear.

– Park the truck securely (see Chapter E).

– Open the battery panel.

– Secure the lifting slings to theattachment points (1).

M Attach the crane slings to the strap pointsso that the truck cannot slip. Lifting slingsshould be fastened to the harness in sucha way that they do not come into contactwith any parts of the truck when it is beingraised.

2 Using the truck for the first time

M Only operate the truck with batterycurrent. Rectified AC current will damagethe electronic components. The batteryleads (tow cable) must be less than 6mlong.

To prepare the truck after delivery or transport the following tasks must be carriedout:

– Make sure the truck is fully equipped and in a satisfactory condition.

– Install battery (where required). Do not damage battery cable.

– Charge the battery (see Chapter D).

– If the customer uses a maintenance-free battery, the discharge indicator settingmust match the battery type (manufacturer’s service department to check).

– Start up the truck in accordance with instructions (see Chapter E).

Z When the truck is parked, the surface of the tyres will flatten. The flattening willdisappear after a short period of operation.

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C 2

3 Operating the truck without its own drive system (emergency operation)

F This operating mode is not permitted when negotiating inclines and gradients.If the truck has to be moved after a failure has rendered it immobile, proceed asfollows:

– Set the isolator “OFF”.

– Set the key switch “OFF” (“0”) and remove the key.

– Prevent the truck from rolling away.

– Remove the front panel (2) (see Chapter F).

– Remove the right-hand drive panel (3) (see Chapter F).

– Pull up the anchor plate by screwing in two M5 screws (4, at least 35 mm long) asfar as the stop.

The brake is now released and the truck can move.

F On reaching your destination, ensure that the brake is restored to its initial state. Thetruck must never be parked with the brakes released.

– Remove the screws (4).

The brake is now applied again.

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3

4

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3 Operating the truck without its own drive system (emergency operation)

F This operating mode is not permitted when negotiating inclines and gradients.If the truck has to be moved after a failure has rendered it immobile, proceed asfollows:

– Set the isolator “OFF”.

– Set the key switch “OFF” (“0”) and remove the key.

– Prevent the truck from rolling away.

– Remove the front panel (2) (see Chapter F).

– Remove the right-hand drive panel (3) (see Chapter F).

– Pull up the anchor plate by screwing in two M5 screws (4, at least 35 mm long) asfar as the stop.

The brake is now released and the truck can move.

F On reaching your destination, ensure that the brake is restored to its initial state. Thetruck must never be parked with the brakes released.

– Remove the screws (4).

The brake is now applied again.

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3

4

C 3

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B3.1 Emergency operation with service key GF60 (o)

The truck can be moved manually if the electrical system is damaged. To do this, thebattery in the truck must be connected.

The GF60 service key with the bar (o) (GF30 is standard) must beset to position 2 of the key switch. You can only move from position1 to position 2 with the service key if you also move the bar on thekey head. When you switch back from level 2 to level 1 the barreturns to its original position.

Z Key GF30 without a bar for normal truck operation can only beturned to position 1 of the key switch.

F Service key GF60 must not remain on the truck for normal truckoperation; it must be kept separately by an authorised person(e.g. warehouse supervisor).

Z Key GF30 without a bar can be inserted and turned on both sides.Key GF60 with a bar can only be inserted and turned on one side.Key GF60 cannot be turned in the wrong direction.

F In key switch position 2 the brake is immediately energised and thebrake is ventilated, allowing the truck to move. Extreme caution isrequired on a ramp or incline as the truck could roll away when thebrake is released.When the key switch is set to position 2 (brake released), the truckcannot brake through the usual mechanisms (e.g. inversion braking or tiller switch).The truck can only brake by turning the service key to position 1 or pressing theEmergency Disconnect.

GF 60

GF 30

C 3

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3.1 Emergency operation with service key GF60 (o)

The truck can be moved manually if the electrical system is damaged. To do this, thebattery in the truck must be connected.

The GF60 service key with the bar (o) (GF30 is standard) must beset to position 2 of the key switch. You can only move from position1 to position 2 with the service key if you also move the bar on thekey head. When you switch back from level 2 to level 1 the barreturns to its original position.

Z Key GF30 without a bar for normal truck operation can only beturned to position 1 of the key switch.

F Service key GF60 must not remain on the truck for normal truckoperation; it must be kept separately by an authorised person(e.g. warehouse supervisor).

Z Key GF30 without a bar can be inserted and turned on both sides.Key GF60 with a bar can only be inserted and turned on one side.Key GF60 cannot be turned in the wrong direction.

F In key switch position 2 the brake is immediately energised and thebrake is ventilated, allowing the truck to move. Extreme caution isrequired on a ramp or incline as the truck could roll away when thebrake is released.When the key switch is set to position 2 (brake released), the truckcannot brake through the usual mechanisms (e.g. inversion braking or tiller switch).The truck can only brake by turning the service key to position 1 or pressing theEmergency Disconnect.

GF 60

GF 30

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D Battery Maintenance, Charging &

Replacement

1 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 bytrained personnel. The present operator manual and the manufacturer’s instructionsconcerning batteries and charging stations must be observed when carrying out thework.

Fire protection: Smoking and naked flames must be avoided when working withbatteries Wherever a truck is parked for charging there shall be no inflammablematerial or operating fluids capable of creating sparks within 2 metres around thetruck. The area must be well ventilated. Fire protection equipment must be provided.

Battery maintenance: The battery cell covers must be kept dry and clean. Theterminals and cable shoes must be clean, secure and have a light coating of dielectricgrease. Batteries with non insulated terminals must be covered with a non slipinsulating mat.

Battery Disposal: Batteries may only be disposed of in accordance with nationalenvironmental protection regulations or disposal laws. The manufacturer’s disposalinstructions must be followed.

M Before closing the battery panel make sure that the battery lead cannot be damaged.

F Batteries contain an acid solution which is poisonous and corrosive. Therefore,always wear protective clothing and eye protection when carrying out work onbatteries. Avoid all contact with battery acid.Should however clothing, skin or eyes come in contact with acid the affected partsshould be rinsed with plenty of clean water - where the skin or eyes are affected calla doctor immediately. Immediately neutralise any spilled battery acid.

M Only batteries with a sealed battery container may be used.

F The weight and dimensions of the battery have considerable affect on the operationalsafety of the truck. Battery equipment may only be replaced with the agreement of themanufacturer.

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D Battery Maintenance, Charging &

Replacement

1 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 bytrained personnel. The present operator manual and the manufacturer’s instructionsconcerning batteries and charging stations must be observed when carrying out thework.

Fire protection: Smoking and naked flames must be avoided when working withbatteries Wherever a truck is parked for charging there shall be no inflammablematerial or operating fluids capable of creating sparks within 2 metres around thetruck. The area must be well ventilated. Fire protection equipment must be provided.

Battery maintenance: The battery cell covers must be kept dry and clean. Theterminals and cable shoes must be clean, secure and have a light coating of dielectricgrease. Batteries with non insulated terminals must be covered with a non slipinsulating mat.

Battery Disposal: Batteries may only be disposed of in accordance with nationalenvironmental protection regulations or disposal laws. The manufacturer’s disposalinstructions must be followed.

M Before closing the battery panel make sure that the battery lead cannot be damaged.

F Batteries contain an acid solution which is poisonous and corrosive. Therefore,always wear protective clothing and eye protection when carrying out work onbatteries. Avoid all contact with battery acid.Should however clothing, skin or eyes come in contact with acid the affected partsshould be rinsed with plenty of clean water - where the skin or eyes are affected calla doctor immediately. Immediately neutralise any spilled battery acid.

M Only batteries with a sealed battery container may be used.

F The weight and dimensions of the battery have considerable affect on the operationalsafety of the truck. Battery equipment may only be replaced with the agreement of themanufacturer.

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2 Battery types

The battery weights can be taken from the battery data plate.

Depending on the particular model, the EJE can be fitted with different battery types(see chapter B).

M Batteries with non insulated terminals must be covered with a non slip insulating mat.When replacing or installing batteries, ensure that the battery is correctly secured inthe battery compartment of the truck.

3 Batteries and Motor Output

Z The abbreviations “S” (shor version) and “L” (long version) on the data plate indicatethe actual version of the truck.

Depending on the type of battery used, it is also possible to use models withenhanced performance or maintenance-free batteries.

M When replacing or installing batteries, ensure that the battery is correctly secured inthe battery compartment of the truck.

Battery EJEn

24 V - PzS VCI 150 Ah2EPzS 240 Ah

Motor output 1,0 kW

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D 2

2 Battery types

The battery weights can be taken from the battery data plate.

Depending on the particular model, the EJE can be fitted with different battery types(see chapter B).

M Batteries with non insulated terminals must be covered with a non slip insulating mat.When replacing or installing batteries, ensure that the battery is correctly secured inthe battery compartment of the truck.

3 Batteries and Motor Output

Z The abbreviations “S” (shor version) and “L” (long version) on the data plate indicatethe actual version of the truck.

Depending on the type of battery used, it is also possible to use models withenhanced performance or maintenance-free batteries.

M When replacing or installing batteries, ensure that the battery is correctly secured inthe battery compartment of the truck.

Battery EJEn

24 V - PzS VCI 150 Ah2EPzS 240 Ah

Motor output 1,0 kW

D 3

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B4 Exposing the battery

– Park the truck securely (see Chapter E).

– Open the battery panel (2).To do this hold the panel by the handle mould (1) and lift it up.

– Where necessary remove the insulating mat from the battery.

M The battery panel (1) is held up by its own weight.

5 Charging the battery

M To charge the battery, the truck must be parked in a closed and properly ventilatedroom. When charging, the tops of the battery cells must be exposed to providesufficient ventilation. Do not place any metal objects on the battery. Before charging,check all cables and plug connections for visible signs of damage.All safety instructions given by the battery and battery charger manufacturers mustbe strictly observed.

5.1 Charging the battery with a stationary charger

– Disconnect the battery connector from the truck connector.

– Expose the battery (see Section 4).

– Connect the battery connector (4) with the charging lead of the stationary chargerand turn on the charger.

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4 Exposing the battery

– Park the truck securely (see Chapter E).

– Open the battery panel (2).To do this hold the panel by the handle mould (1) and lift it up.

– Where necessary remove the insulating mat from the battery.

M The battery panel (1) is held up by its own weight.

5 Charging the battery

M To charge the battery, the truck must be parked in a closed and properly ventilatedroom. When charging, the tops of the battery cells must be exposed to providesufficient ventilation. Do not place any metal objects on the battery. Before charging,check all cables and plug connections for visible signs of damage.All safety instructions given by the battery and battery charger manufacturers mustbe strictly observed.

5.1 Charging the battery with a stationary charger

– Disconnect the battery connector from the truck connector.

– Expose the battery (see Section 4).

– Connect the battery connector (4) with the charging lead of the stationary chargerand turn on the charger.

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D 4

5.2 Charging the battery with an on-board charger (o)

F The charger must not be opened. If damaged, it must be replaced.

Z The factory setting for trucks without a battery is the 0 position. The red LED flashesto indicate the battery cannot be charged.

Z The battery discharge indicator is connected at the factory to the plug connector (6).Optionally, a bipolar LED can be connected to the plug connector (6).

Selecting the charging curve for the onboard charger

Use the switch (5) on the charger to adapt the charge curves to the particular batteryused, in accordance with the following table.

M Before setting the appropriate curve, disconnect the mains plug.

As soon as a battery is connected, the new setting is acknowledged through the LEDs(see display) and becomes immediately effective.

Switch (5) Position Selected charge curves (characteristics)

1 Wet cell batteries: 100 - 300 Ah

2 Maintenance-free: 100 -149 Ah

3 Maintenance-free: 150 -199 Ah

4 Maintenance-free: 200 - 300 Ah

5 Pulse characteristic curve 200 - 400 Ah

6 Jungheinrich 100 - 300 Ah

5 6

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D 4

5.2 Charging the battery with an on-board charger (o)

F The charger must not be opened. If damaged, it must be replaced.

Z The factory setting for trucks without a battery is the 0 position. The red LED flashesto indicate the battery cannot be charged.

Z The battery discharge indicator is connected at the factory to the plug connector (6).Optionally, a bipolar LED can be connected to the plug connector (6).

Selecting the charging curve for the onboard charger

Use the switch (5) on the charger to adapt the charge curves to the particular batteryused, in accordance with the following table.

M Before setting the appropriate curve, disconnect the mains plug.

As soon as a battery is connected, the new setting is acknowledged through the LEDs(see display) and becomes immediately effective.

Switch (5) Position Selected charge curves (characteristics)

1 Wet cell batteries: 100 - 300 Ah

2 Maintenance-free: 100 -149 Ah

3 Maintenance-free: 150 -199 Ah

4 Maintenance-free: 200 - 300 Ah

5 Pulse characteristic curve 200 - 400 Ah

6 Jungheinrich 100 - 300 Ah

5 6

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BSetting the charging characteristics

Set the characteristics as follows:

Starting to charge with the onboard charger

– Park the truck securely (see Chapter E).

F When charging, the tops of the battery cells must be exposed to provide sufficientventilation. Do not place any metal objects on the battery. Before charging, check allcables and plug connections for visible signs of damage. It is essential to follow thesafety regulations of the battery and charger station manufacturers.

Mains connection

Mains voltage: 220 V (+10/-15%)Mains frequency: 50 Hz / 60 Hz

The charger (7) mains cable can be accessed from the outside.

– Expose the battery (see Section 4).

– Where necessary remove theinsulating mat from the battery.

– The battery connector must remainplugged.

– Attach the mains connector (7) to amains socket.

– Pull the EMERGENCY DISCONNECTbutton up.

The flashing LED indicates the chargestatus or a fault (for flashing codes see“LED Display” table).

Z If the mains connector (7) is connectedto the mains, all the truck’s electricalfunctions will be interrupted (electrical start-up protection). The truck cannot beoperated.

– Remove the connector (7) from the socket and store it in the battery compartmentwith the cable.

Z Charging continues automatically after a mains failure.Charging can be interrupted by removing the mains connector and continued aspartial charging.

F The mains cable must not be damaged.The battery cover must be properly closed before it can be used again.

Charging times

The duration of charge depends on the battery capacity.

Connect the battery This allows you to adjust via the charger

Turn the setting switch to the right to select the desired characteristic curve

If the characteristic curve is valid, the green LED flashes according to the set position.

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Setting the charging characteristics

Set the characteristics as follows:

Starting to charge with the onboard charger

– Park the truck securely (see Chapter E).

F When charging, the tops of the battery cells must be exposed to provide sufficientventilation. Do not place any metal objects on the battery. Before charging, check allcables and plug connections for visible signs of damage. It is essential to follow thesafety regulations of the battery and charger station manufacturers.

Mains connection

Mains voltage: 220 V (+10/-15%)Mains frequency: 50 Hz / 60 Hz

The charger (7) mains cable can be accessed from the outside.

– Expose the battery (see Section 4).

– Where necessary remove theinsulating mat from the battery.

– The battery connector must remainplugged.

– Attach the mains connector (7) to amains socket.

– Pull the EMERGENCY DISCONNECTbutton up.

The flashing LED indicates the chargestatus or a fault (for flashing codes see“LED Display” table).

Z If the mains connector (7) is connectedto the mains, all the truck’s electricalfunctions will be interrupted (electrical start-up protection). The truck cannot beoperated.

– Remove the connector (7) from the socket and store it in the battery compartmentwith the cable.

Z Charging continues automatically after a mains failure.Charging can be interrupted by removing the mains connector and continued aspartial charging.

F The mains cable must not be damaged.The battery cover must be properly closed before it can be used again.

Charging times

The duration of charge depends on the battery capacity.

Connect the battery This allows you to adjust via the charger

Turn the setting switch to the right to select the desired characteristic curve

If the characteristic curve is valid, the green LED flashes according to the set position.

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LED display (8).

Green LED (charge status)

Red LED (fault)

Float Charge

The float charge starts automatically when charging is complete.

Partial charging

The charger is designed to automatically adapt to partially charged batteries. Thiskeeps battery wear to a minimum.

Lit Charging complete, battery full. (Charge interval, float or compensation charge)

Flashes slowly Charging

Rapid flash Display at beginning of charge or after setting a new characteristic curve. Number of flash pulses corresponds to the characteristiccurve set.

Lit Overtemperature. Charging is interrupted.

Flashes slowly Safety charging time exceeded. Charging is cancelled. Mains must be disconnected for charging to restart.

Rapid flash Invalid characteristic curve setting.

8

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D 6

LED display (8).

Green LED (charge status)

Red LED (fault)

Float Charge

The float charge starts automatically when charging is complete.

Partial charging

The charger is designed to automatically adapt to partially charged batteries. Thiskeeps battery wear to a minimum.

Lit Charging complete, battery full. (Charge interval, float or compensation charge)

Flashes slowly Charging

Rapid flash Display at beginning of charge or after setting a new characteristic curve. Number of flash pulses corresponds to the characteristiccurve set.

Lit Overtemperature. Charging is interrupted.

Flashes slowly Safety charging time exceeded. Charging is cancelled. Mains must be disconnected for charging to restart.

Rapid flash Invalid characteristic curve setting.

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B6 Battery removal and installation

6.1 Changing the battery from the top

F The truck must be level. To prevent short circuits, batteries with exposed terminals orconnectors must be covered with a rubber mat. Place the battery connector or thebattery cable in such a way that they will not get caught on the truck when the batteryis removed.

Z When transporting batteries using a crane, ensure that the crane is of adequatecapacity (the battery weight is indicated on the battery data plate on the batterycontainer). The crane lifting gear must exert a vertical pull. The hooks of the liftinggear must never fall into the battery cells.

– Expose the battery (see Section 4).

– Disconnect the battery connector from the truck connector.

M Place the battery cable on the tray so that it cannot be severed when the battery ispulled out.

– Strap the crane lifting gear to the eyes (9).

– Pull the battery up out of the container.

M Installation is the reverse order. When reinstalling the battery, note the properinstallation position and make sure the battery is connected correctly. Place thebattery cable on the tray so that it cannot be severed when the battery is inserted.

– After installing the battery, check all cables and plug connections for visible signsof damage.

F Closely the battery panel slowly and carefully.Do not reach between the battery panel and the chassis.

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6 Battery removal and installation

6.1 Changing the battery from the top

F The truck must be level. To prevent short circuits, batteries with exposed terminals orconnectors must be covered with a rubber mat. Place the battery connector or thebattery cable in such a way that they will not get caught on the truck when the batteryis removed.

Z When transporting batteries using a crane, ensure that the crane is of adequatecapacity (the battery weight is indicated on the battery data plate on the batterycontainer). The crane lifting gear must exert a vertical pull. The hooks of the liftinggear must never fall into the battery cells.

– Expose the battery (see Section 4).

– Disconnect the battery connector from the truck connector.

M Place the battery cable on the tray so that it cannot be severed when the battery ispulled out.

– Strap the crane lifting gear to the eyes (9).

– Pull the battery up out of the container.

M Installation is the reverse order. When reinstalling the battery, note the properinstallation position and make sure the battery is connected correctly. Place thebattery cable on the tray so that it cannot be severed when the battery is inserted.

– After installing the battery, check all cables and plug connections for visible signsof damage.

F Closely the battery panel slowly and carefully.Do not reach between the battery panel and the chassis.

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6.2 Lateral Battery Removal (o)

F The truck must be level. To prevent short circuits,batteries with exposed terminals or connectorsmust be covered with a rubber mat. Place thebattery connector or the battery cable in such away that they will not get caught on the truckwhen the battery is removed.

Battery removal

– Expose the battery (see Section 4).

– Disconnect the battery connector from the truckconnector.

– Turn the battery lock (11) as far as the stop.

– Pull the battery out from the side.

Battery installation

– Installation is the reverse order. Whenreinstalling the battery, note the properinstallation position and make sure the batteryis connected correctly.

– After installing the battery, check all cables andplug connections for visible signs of damage.

F Closely the battery panel slowly and carefully.Do not reach between the battery panel and thechassis.

11

11

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D 8

6.2 Lateral Battery Removal (o)

F The truck must be level. To prevent short circuits,batteries with exposed terminals or connectorsmust be covered with a rubber mat. Place thebattery connector or the battery cable in such away that they will not get caught on the truckwhen the battery is removed.

Battery removal

– Expose the battery (see Section 4).

– Disconnect the battery connector from the truckconnector.

– Turn the battery lock (11) as far as the stop.

– Pull the battery out from the side.

Battery installation

– Installation is the reverse order. Whenreinstalling the battery, note the properinstallation position and make sure the batteryis connected correctly.

– After installing the battery, check all cables andplug connections for visible signs of damage.

F Closely the battery panel slowly and carefully.Do not reach between the battery panel and thechassis.

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B7 Battery Discharge Indicator (t)

After the truck has been released via the keyswitch or CanCode, the battery charge statusis displayed.

The colours of the LEDs (10) represent the following conditions:

Z If the LED is red, load units can no longer be lifted. Lifting is only released when thebattery connected is at least 70 % charged.

If the charge status calculated when the truck is switched on is at least 70% of that ofa fully charged battery, the display is reset to 100%. The display reduces as a functionof the battery charge.

The displayed status cannot rise again during the present operation.

The status display is reset to 100% when the battery type is adjusted.

If the LED flashes red and the truck is not ready for operation, inform themanufacturer's service department. Red flashing is a fault code of the truck controller.The flashing sequence indicates the type of fault.

LED colour Rating

Green Capacitance 40 - 100 %

Orange Capacitance 30 - 40 %

Green/orange

Flashing. 1Hz

Capacitance 20 - 30 %

Red Capacitance 0 - 20 %

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7 Battery Discharge Indicator (t)

After the truck has been released via the keyswitch or CanCode, the battery charge statusis displayed.

The colours of the LEDs (10) represent the following conditions:

Z If the LED is red, load units can no longer be lifted. Lifting is only released when thebattery connected is at least 70 % charged.

If the charge status calculated when the truck is switched on is at least 70% of that ofa fully charged battery, the display is reset to 100%. The display reduces as a functionof the battery charge.

The displayed status cannot rise again during the present operation.

The status display is reset to 100% when the battery type is adjusted.

If the LED flashes red and the truck is not ready for operation, inform themanufacturer's service department. Red flashing is a fault code of the truck controller.The flashing sequence indicates the type of fault.

LED colour Rating

Green Capacitance 40 - 100 %

Orange Capacitance 30 - 40 %

Green/orange

Flashing. 1Hz

Capacitance 20 - 30 %

Red Capacitance 0 - 20 %

10

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E Operation

1 Safety Regulations for the Operation of Forklift Trucks

Driver authorisation The forklift truck may only be used by suitably trainedpersonnel, who have demonstrated to the proprietor or his representative that theycan drive and handle loads and have been authorised to operate the truck by theproprietor or his representative.

Driver’s rights, obligations and responsibilities: The driver must be informed ofhis duties and responsibilities and be instructed in the operation of the truck and shallbe familiar with the operator manual. The driver shall be afforded all due rights. Safety shoes must be worn for pedestrian operated trucks.

Unauthorised use of truck: The driver is responsible for the truck during the time itis in use. The driver must prevent unauthorised persons from driving or operating thetruck. Do not carry passengers or lift other people.

Damage and faults: The supervisor must be immediately informed of any damageor faults to the forklift 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 carry out any repairs or alterations to the industrial truckwithout the necessary training and authorisation to do so. The driver must neverdisable or adjust safety mechanisms or switches.

Hazardous area: A hazardous area is defined as the area in which a person is at riskdue to truck movement, lifting operations, the load handler (e.g. forks or attachments)or the load itself. This also includes areas which can be reached by falling loads orlowering operating equipment.

F Unauthorised persons must be kept away from the hazardous area. Where there isdanger to personnel, a warning must be sounded with sufficient notice. Ifunauthorised personnel are still within the hazardous area the truck shall be broughtto a halt immediately.

Safety devices and warning signs: Safety devices, warning signs and warninginstructions shall be strictly observed.

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E Operation

1 Safety Regulations for the Operation of Forklift Trucks

Driver authorisation The forklift truck may only be used by suitably trainedpersonnel, who have demonstrated to the proprietor or his representative that theycan drive and handle loads and have been authorised to operate the truck by theproprietor or his representative.

Driver’s rights, obligations and responsibilities: The driver must be informed ofhis duties and responsibilities and be instructed in the operation of the truck and shallbe familiar with the operator manual. The driver shall be afforded all due rights. Safety shoes must be worn for pedestrian operated trucks.

Unauthorised use of truck: The driver is responsible for the truck during the time itis in use. The driver must prevent unauthorised persons from driving or operating thetruck. Do not carry passengers or lift other people.

Damage and faults: The supervisor must be immediately informed of any damageor faults to the forklift 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 carry out any repairs or alterations to the industrial truckwithout the necessary training and authorisation to do so. The driver must neverdisable or adjust safety mechanisms or switches.

Hazardous area: A hazardous area is defined as the area in which a person is at riskdue to truck movement, lifting operations, the load handler (e.g. forks or attachments)or the load itself. This also includes areas which can be reached by falling loads orlowering operating equipment.

F Unauthorised persons must be kept away from the hazardous area. Where there isdanger to personnel, a warning must be sounded with sufficient notice. Ifunauthorised personnel are still within the hazardous area the truck shall be broughtto a halt immediately.

Safety devices and warning signs: Safety devices, warning signs and warninginstructions shall be strictly observed.

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E 2

2 Controls and Displays

Item Control / Display

EJE 116n EJE 120n

Function

1 EMERGENCY DISCONNECT

t Disconnects the circuit, all electrical functions are deactivated. The truck automatically brakes.

2 Key switch t Switches control current on and off.Removing the key prevents the truck from being switched on by unauthorised personnel.

Key switch with second switch level

o Releases the brakes to move the truck when non-operational.

3 CanCode keypad

o Switch current on and off.Code settings.

Release and select the travel programs.

Enter travel parameters.

4 Battery discharge indicator

t Battery charge status.

5 Display instrument (CanDis)

o Hourmeter.

Battery charge status.

Displays service messages and travel parameters in combination with CanCode.

6 Tiller t Used to steer and brake the truck.

7 On-board charger (with safety switch)

o Charges the battery by inserting the mains connector into a mains socket.

8 Crawl button t Pressing the crawl button reduces the travel speed and acceleration. If the tiller is set to the brake zone, you can press this button to override braking; the truck will travel at slow speed .

9 Load handlerlower button t Lowers the load handler.

10 Load handler raise button

t Raises the load handler.

11 Travel switch t Controls travel direction and speed.

12 Collision safety switch t Truck moves away from operator.

13 Warning button t Activates an audible signal.

t = Standard equipment o = Optional Equipment

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E 2

2 Controls and Displays

Item Control / Display

EJE 116n EJE 120n

Function

1 EMERGENCY DISCONNECT

t Disconnects the circuit, all electrical functions are deactivated. The truck automatically brakes.

2 Key switch t Switches control current on and off.Removing the key prevents the truck from being switched on by unauthorised personnel.

Key switch with second switch level

o Releases the brakes to move the truck when non-operational.

3 CanCode keypad

o Switch current on and off.Code settings.

Release and select the travel programs.

Enter travel parameters.

4 Battery discharge indicator

t Battery charge status.

5 Display instrument (CanDis)

o Hourmeter.

Battery charge status.

Displays service messages and travel parameters in combination with CanCode.

6 Tiller t Used to steer and brake the truck.

7 On-board charger (with safety switch)

o Charges the battery by inserting the mains connector into a mains socket.

8 Crawl button t Pressing the crawl button reduces the travel speed and acceleration. If the tiller is set to the brake zone, you can press this button to override braking; the truck will travel at slow speed .

9 Load handlerlower button t Lowers the load handler.

10 Load handler raise button

t Raises the load handler.

11 Travel switch t Controls travel direction and speed.

12 Collision safety switch t Truck moves away from operator.

13 Warning button t Activates an audible signal.

t = Standard equipment o = Optional Equipment

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1

2, 3

4, 5

6

7

8

12 1311 11

10 109 9

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1

2, 3

4, 5

6

7

8

12 1311 11

10 109 9

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E 4

3 Starting up the truck

F Before the truck can be started, operated or a load lifted, the driver must ensure thatthere 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 signsof damage.

– Visually inspect the battery attachment and cable connections.

Switching on the truck.

– Pull the EMERGENCY DISCONNECT button (1) up.

– Insert the key in the key switch (2) and turn it to the right as far as it will go (position“I”) or for CanCode (3, o) enter the release code(see section 5).

– Test the warning button (13).

The truck is now operational.

t The battery discharge indicator (4) indicates the current battery charge status.

o The display instrument (CanDis (5)) indicates the available battery capacity.

– Test the braking operation of the tiller (6) (see section 4.2).

2, 3

4, 5

6

1

13

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E 4

3 Starting up the truck

F Before the truck can be started, operated or a load lifted, the driver must ensure thatthere 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 signsof damage.

– Visually inspect the battery attachment and cable connections.

Switching on the truck.

– Pull the EMERGENCY DISCONNECT button (1) up.

– Insert the key in the key switch (2) and turn it to the right as far as it will go (position“I”) or for CanCode (3, o) enter the release code(see section 5).

– Test the warning button (13).

The truck is now operational.

t The battery discharge indicator (4) indicates the current battery charge status.

o The display instrument (CanDis (5)) indicates the available battery capacity.

– Test the braking operation of the tiller (6) (see section 4.2).

2, 3

4, 5

6

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B4 Industrial Truck Operation

4.1 Safety regulations for truck operation

Travel routes and work areas: Only use lanes and routes specifically designated fortruck traffic. Unauthorised third parties must stay away from work areas. Loads mustonly be stored in places specially designated for this purpose.

Driving conduct: The driver must adapt the travel speed to local conditions. Thetruck must be driven at slow speed when negotiating bends or narrow passageways,when passing through swing doors and at blind spots. The driver must alwaysobserve an adequate braking distance between the forklift truck and the vehicle infront and must be in control of the truck at all times. Abrupt stopping (except inemergencies), rapid U turns and overtaking at dangerous or blind spots are notpermitted. It is forbidden to lean out of or reach beyond the working and operatingarea.

Travel visibility: The driver must look in the direction of travel and must always havea clear view of the route ahead. Loads that affect visibility must be positioned at therear of the truck. If this is not possible, a second person must walk in front of the truckas a lookout.

Negotiating slopes and inclines: Slopes or inclines may only be negotiated if theyare designated traffic routes, are clean and have a non-slip surface and providingthey can be safely negotiated in accordance with the technical specifications of thetruck. The truck must always be driven with the load unit facing uphill. The industrialtruck must not be turned, operated at an angle or parked on inclines or slopes.Inclines must only be negotiated at slow speed, with the driver ready to brake at anymoment.

Negotiating lifts and docks: Lifts and docks must only be used if they have sufficientcapacity, are suitable for driving on and authorised for truck traffic by the owner. Thedriver must satisfy himself of the above before entering these areas. The truck mustenter lifts with the load in front and must take up a position which does not allow it tocome into contact with the walls of the lift shaft. .People travelling in the lift with the forklift truck must only enter the lift after the truckhas come to a halt and must exit the lift before the truck.

Nature of loads to be carried: The operator must make sure that the load is in asatisfactory condition. Only carry loads that are positioned safely and carefully. Usesuitable precautions, e.g. a load guard, to prevent parts of the load from tipping orfalling down.

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4 Industrial Truck Operation

4.1 Safety regulations for truck operation

Travel routes and work areas: Only use lanes and routes specifically designated fortruck traffic. Unauthorised third parties must stay away from work areas. Loads mustonly be stored in places specially designated for this purpose.

Driving conduct: The driver must adapt the travel speed to local conditions. Thetruck must be driven at slow speed when negotiating bends or narrow passageways,when passing through swing doors and at blind spots. The driver must alwaysobserve an adequate braking distance between the forklift truck and the vehicle infront and must be in control of the truck at all times. Abrupt stopping (except inemergencies), rapid U turns and overtaking at dangerous or blind spots are notpermitted. It is forbidden to lean out of or reach beyond the working and operatingarea.

Travel visibility: The driver must look in the direction of travel and must always havea clear view of the route ahead. Loads that affect visibility must be positioned at therear of the truck. If this is not possible, a second person must walk in front of the truckas a lookout.

Negotiating slopes and inclines: Slopes or inclines may only be negotiated if theyare designated traffic routes, are clean and have a non-slip surface and providingthey can be safely negotiated in accordance with the technical specifications of thetruck. The truck must always be driven with the load unit facing uphill. The industrialtruck must not be turned, operated at an angle or parked on inclines or slopes.Inclines must only be negotiated at slow speed, with the driver ready to brake at anymoment.

Negotiating lifts and docks: Lifts and docks must only be used if they have sufficientcapacity, are suitable for driving on and authorised for truck traffic by the owner. Thedriver must satisfy himself of the above before entering these areas. The truck mustenter lifts with the load in front and must take up a position which does not allow it tocome into contact with the walls of the lift shaft. .People travelling in the lift with the forklift truck must only enter the lift after the truckhas come to a halt and must exit the lift before the truck.

Nature of loads to be carried: The operator must make sure that the load is in asatisfactory condition. Only carry loads that are positioned safely and carefully. Usesuitable precautions, e.g. a load guard, to prevent parts of the load from tipping orfalling down.

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4.2 Travelling, Steering, Braking

F Never carry passengers.Emergency Disconnect

– Press the EMERGENCY DISCONNECT switch (1) down.

All electrical functions are deactivated.

Automatic braking

Automatic braking occurs when the tiller is released – the tiller automatically setsitself to the upper brake zone (B).

F If the tiller moves slowly to the upper brake zone, the cause of this fault must berectified. If necessary, replace the gas pressure spring.

Travel

M Do not drive the truck unless the panels are closed and properly locked.

– Start up the truck (see section 3).

The travel speed is governed by the travel switch (11).

– Set the tiller (6) to the travel range (F) and press the controller (11) in the desireddirection (fwd. or rev.).

Creep Mode

F The driver must be particularly careful when applying the “Crawl speed” switch (8).The truck can be operated with a vertical tiller (6) (e.g. in congested areas / travelseat).

– Press the crawl speed button (8).

– Set the controller (11) to the required direction (fwd. or rev.).

The brake is released. The truck travels at slow speed.

M The brake is only activated with the crawl speed switch is released; with crawl speedyou can only brake by plugging (travel switch (11)).

F In hazardous situations brake the truck by immediately releasing the crawl speedswitch (8).

When you apply the crawl button in the travel range (F) the truck travels at reducedspeed and acceleration.

o Reduced speed when forks are fully lowered

When the forks are fully lowered the truck will only travel at reduced speed. The forksmust be raised in order to use the maximum available speed.

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4.2 Travelling, Steering, Braking

F Never carry passengers.Emergency Disconnect

– Press the EMERGENCY DISCONNECT switch (1) down.

All electrical functions are deactivated.

Automatic braking

Automatic braking occurs when the tiller is released – the tiller automatically setsitself to the upper brake zone (B).

F If the tiller moves slowly to the upper brake zone, the cause of this fault must berectified. If necessary, replace the gas pressure spring.

Travel

M Do not drive the truck unless the panels are closed and properly locked.

– Start up the truck (see section 3).

The travel speed is governed by the travel switch (11).

– Set the tiller (6) to the travel range (F) and press the controller (11) in the desireddirection (fwd. or rev.).

Creep Mode

F The driver must be particularly careful when applying the “Crawl speed” switch (8).The truck can be operated with a vertical tiller (6) (e.g. in congested areas / travelseat).

– Press the crawl speed button (8).

– Set the controller (11) to the required direction (fwd. or rev.).

The brake is released. The truck travels at slow speed.

M The brake is only activated with the crawl speed switch is released; with crawl speedyou can only brake by plugging (travel switch (11)).

F In hazardous situations brake the truck by immediately releasing the crawl speedswitch (8).

When you apply the crawl button in the travel range (F) the truck travels at reducedspeed and acceleration.

o Reduced speed when forks are fully lowered

When the forks are fully lowered the truck will only travel at reduced speed. The forksmust be raised in order to use the maximum available speed.

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Steering

– Move the tiller (6) to the left or right.

0

R

V

B

F

B

11

6

8

R

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Steering

– Move the tiller (6) to the left or right.

0

R

V

B

F

B

11

6

8

R

V

1

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Braking

F The braking pattern of the truck depends largely on the track conditions. The drivermust take this into account when operating the truck.

Braking with the Service Brake:

– Set the tiller (6) up or down to one of the brakezones (B).

M The service brake is the generator brake. Onlywhen this brake fails to achieve the necessarybrake force is the mechanical brake applied.

Plugging:

– You can set the travel switch (11) to the opposite direction when traveling.

– The truck brakes regeneratively until it starts to move in the opposite direction.

Braking with the Coasting Brake:

If the travel switch is set to 0, the truck automatically brakes regeneratively.

F In hazardous situations set the tiller to the brake position.

Travelling on inclines

M Loads must always be carried on the end of the truck facing uphill.

Preventing the truck from “rolling downhill”:

With the controller set to zero, the brake automatically engages after a short jerk (thecontroller detects the truck is rolling back on the slope). The service brake is releasedagain via the controller, which is also used to select the speed and the travel direction.

11 11

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Braking

F The braking pattern of the truck depends largely on the track conditions. The drivermust take this into account when operating the truck.

Braking with the Service Brake:

– Set the tiller (6) up or down to one of the brakezones (B).

M The service brake is the generator brake. Onlywhen this brake fails to achieve the necessarybrake force is the mechanical brake applied.

Plugging:

– You can set the travel switch (11) to the opposite direction when traveling.

– The truck brakes regeneratively until it starts to move in the opposite direction.

Braking with the Coasting Brake:

If the travel switch is set to 0, the truck automatically brakes regeneratively.

F In hazardous situations set the tiller to the brake position.

Travelling on inclines

M Loads must always be carried on the end of the truck facing uphill.

Preventing the truck from “rolling downhill”:

With the controller set to zero, the brake automatically engages after a short jerk (thecontroller detects the truck is rolling back on the slope). The service brake is releasedagain via the controller, which is also used to select the speed and the travel direction.

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B4.3 Lifting and depositing loads

M Before a load can be lifted, the drivermust ensure that it is correctlypalletised and that the capacity of thetruck is not exceeded. Do not lift longloads at an angle.

– Fully insert the truck and the loadhandler underneath the load.

Z The lifting and lowering speeds arespecified.

Lift

– Press the “Raise load handler” (10)button until you reach the desired liftheight.

M When you reach the limit position of theload handler, immediately release thebutton.

Lower

– Press the “Lower load handler”button (9).

4.4 Parking the truck securely

F Always park the truck securely.Do not park the truck on inclines. The load handler must always be fullylowered to the floor.

– Lower the load handler.

– Press the EMERGENCYDISCONNECT switch (1) down.

– Set the key switch (2) to “0” andremove the key or press “Off” forCanCode (3, o).

99 1010

1010 99

View of underside of tiller

2, 3

1

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4.3 Lifting and depositing loads

M Before a load can be lifted, the drivermust ensure that it is correctlypalletised and that the capacity of thetruck is not exceeded. Do not lift longloads at an angle.

– Fully insert the truck and the loadhandler underneath the load.

Z The lifting and lowering speeds arespecified.

Lift

– Press the “Raise load handler” (10)button until you reach the desired liftheight.

M When you reach the limit position of theload handler, immediately release thebutton.

Lower

– Press the “Lower load handler”button (9).

4.4 Parking the truck securely

F Always park the truck securely.Do not park the truck on inclines. The load handler must always be fullylowered to the floor.

– Lower the load handler.

– Press the EMERGENCYDISCONNECT switch (1) down.

– Set the key switch (2) to “0” andremove the key or press “Off” forCanCode (3, o).

99 1010

1010 99

View of underside of tiller

2, 3

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5 Keypad (CanCode) (o)

The keypad consists of 10 digit keys, a Setkey and a o key.Activation of the travel programs is indicatedthrough green LEDs on keys 1, 2 and 3.The o key indicates operational statusthrough a red/green LED.

It contains the following functions:

– Code lock function (commissioning thetruck).

– Travel program selection.

– Travel and battery parameter adjustment.

The o switch has t