Jungheinrich EJD 220 User manual

EJD 220 01.10
Operating instructions
51132781
04.19
en-GB
EJD 220

2

Declaration of Conformity
Manufacturer
Jungheinrich AG, 22039 Hamburg, Germany
Description
Industrial truck
Type Option Serial no. Year of
manufacture
EJD 220
On behalf of
Date
EU DECLARATION OF CONFORMITY
The undersigned hereby declare that the powered truck described in detail complies
with the current versions of European Directives 2006/42/EG (Machinery Directive)
and 2014/30/EU (Electromagnetic Compatibility - EMC). The manufacturer is
authorised to compile the technical documentation.
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Foreword
Notes on the operating instructions
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter and the pages
are numbered continuously.
The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your
truck model.
Our trucks are subject to ongoing development. We reserve the right to alter the
design, equipment and technical features of the system. No guarantee of particular
features of the truck should therefore be assumed from the present operating
instructions.
Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following
graphics:
DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury and even death.
CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury.
NOTICE
Indicates a material hazard. Failure to comply with this instruction may result in
material damage.
ZUsed before notices and explanations.
tIndicates standard equipment
oIndicates optional equipment
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Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Friedrich-Ebert-Damm 129
22047 Hamburg - Germany
Tel: [phone]
www.jungheinrich.com
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Contents
.
A Correct Use and Application 11
.
1 General 11
2 Correct application 11
3 Approved application conditions 12
3.1 Internal Operation Combined with Brief External or Cold Store
Operation (t) 13
3.2 Internal Operation in Cold Stores with Cold Store Equipment (o) 13
4 Proprietor responsibilities 14
5 Adding attachments and/or optional equipment 14
.
B Truck Description 15
.
1 Application 15
1.1 Truck models and rated capacity 15
2 Travel direction definition 17
3 Assemblies and Functional Description 18
3.1 Assembly Overview 18
3.2 Functional Description 20
4 Technical Specifications 23
4.1 Performance data 23
4.2 Dimensions 24
4.3 Weights 26
4.4 Tyre type 26
4.5 EN norms 27
4.6 Specifications according to RED guideline (Radio Equipment
Directive) for radio units 28
4.7 Conditions of use 28
4.8 Electrical requirements 28
4.9 Safety of trucks 28
5 Identification Points and Data Plates 29
5.1 Indication Points 29
5.2 Data plate 31
5.3 Truck capacity plate 32
5.4 Wind loads 35
5.5 Capacity Plate for Stacking, Transport and Double-Deck Operations 36
.
C Transport and Commissioning 37
.
1 Lifting by crane 37
2 Transport 39
3 Using the Truck for the First Time 40
.
D Battery - Servicing, Recharging, Replacement 41
.
1 Safety Regulations Governing the Handling of Lead-Acid Batteries 41
2 Battery types 43
3 Exposing the battery 44
4 Charging the battery 45
4.1 Charging the battery with a stationary charger 46
4.2 Charging the battery with an on-board charger (o) 47
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5 Battery removal and installation 55
5.1 Lateral battery removal 56
.
E Operation 59
.
1 Safety Regulations for the Operation of Forklift Trucks 59
2 Displays and Controls 61
2.1 Battery discharge monitor 65
2.2 Battery discharge indicator 66
3 Preparing the Truck for Operation 67
3.1 Checks and Operations to Be Performed Before Starting Daily Work 67
3.2 Preparing the truck for operation 68
3.3 Checks and operations to be carried out when the truck is operational 69
3.4 Parking the truck securely 70
4 Industrial Truck Operation 71
4.1 Safety regulations for truck operation 71
4.2 Emergency Disconnect 73
4.3 Automatic braking 75
4.4 Travel 76
4.5 Slow travel 79
4.6 Steering 79
4.7 Brakes 80
4.8 Load handler raise/lower 82
4.9 Lifting, transporting and depositing loads 85
4.10 Use as a Lift Work Table 94
5 Troubleshooting 95
5.1 Truck does not start 96
5.2 Load cannot be lifted 98
6 Operating the truck without its own drive system 99
6.1 Release and activate the drive wheel brake 99
7 Load handler emergency lowering 101
8 Optional equipment 102
8.1 Emergency operation with service key GF60 102
8.2 CanCode Keypad (o) 104
8.3 Setting the truck parameters with CanCode 123
8.4 Parameters 125
8.5 Setting the Battery Parameters with CanCode 130
8.6 CanDis Display Instrument (o) 132
8.7 Display unit (2 inch display) 134
8.8 Keyless Access System 139
8.9 General Information about the Use of Keyless Access Systems 140
8.10 Commissioning the Keypad and the Transponder Reader 140
8.11 Using the Display: 143
8.12 Using the Keypad 148
8.13 Operating the transponder reader 153
8.14 ISM access module (o) 157
.
F Industrial Truck Maintenance 159
.
1 Operational Safety and Environmental Protection 159
2 Maintenance Safety Regulations 160
2.1 Working on the electrical system 161
2.2 Consumables and used parts 161
2.3 Wheels 161
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2.4 Hydraulic system 162
2.5 Lift Chains 163
3 Lubricants and Lubrication Schedule 164
3.1 Handling consumables safely 164
3.2 Lubrication Schedule 166
3.3 Consumables 167
4 Maintenance and repairs 168
4.1 Preparing the truck for maintenance and repairs 168
4.2 Lifting and jacking up the truck safely 169
4.3 Cleaning 170
4.4 Front cover disassembly 173
4.5 Drive panel disassembly and assembly 174
4.6 Checking the hydraulic oil level 175
4.7 Check the gear oil level 176
4.8 Check wheel attachment and wear 177
4.9 Checking electrical fuses 179
4.10 Restoring the truck to service after maintenance and repairs 180
5 Decommissioning the Industrial Truck 181
5.1 Prior to decommissioning 181
5.2 Action to be taken during decommissioning 181
5.3 Restoring the truck to service after decommissioning 182
6 Safety tests to be performed at intervals and after unusual incidents 183
7 Final de-commissioning, disposal 183
8 Human vibration measurement 183
.
G Maintenance and Inspection 185
.
1 Maintenance Contents EJD 220 186
1.1 Owner 186
1.2 Customer Service 190
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1
0506.GB
Appendix
JH Traction Battery Operating Instructions
ZThese operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
1
0506.GB
Appendix
JH Traction Battery Operating Instructions
ZThese operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.

0506.GB
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A Correct Use and Application
1 General
The truck must be used, operated and serviced in accordance with the present
instructions. All other types of use are beyond its scope of application and may result
in damage to personnel, the industrial truck or property.
2 Correct application
NOTICE
The maximum load and load distance are indicated on the capacity plate and must
not be exceeded.
The load must rest on the load handler or be lifted by an attachment approved by the
manufacturer.
The load must be fully raised, see page 85.
– Lifting and lowering loads.
– Stacking / retrieving loads.
– Transporting lowered loads.
– Do not travel with a raised load (>500 mm).
In double-decker mode the load handler must not be raised higher than 1800 mm.
The bottom load must be heavier than the upper load.
– Do not transport or lift passengers.
– Do not push or pull loads.
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3 Approved application conditions
– Operation in industrial and commercial environments.
– Operation only on secure, level surfaces with sufficient capacity.
– Do not exceed the permissible surface and spot load limits on the travel routes.
– Operation only on routes that are visible and approved by the operating company.
– Negotiating inclines up to a maximum of 15%.
– Do not travel across or at an angle on inclines. Travel with the load facing uphill.
– Operation in partially public traffic.
WARNING!
Use under extreme conditions
Using the truck under extreme conditions can result in malfunctions and accidents.
uSpecial equipment and authorisation are required if the truck is to be constantly
used in extreme conditions, especially in dusty or corrosive atmospheres.
uThe truck cannot be used in areas at risk of explosion.
uIn adverse weather conditions (thunder, lightning) the industrial truck must not be
operated outside or in endangered areas.
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3.1 Internal Operation Combined with Brief External or Cold Store
Operation (t)
In addition to the permissible application conditions in industrial and commercial
environments, the truck may also be used in outdoor environments, cold stores and
fresh food areas. Secure parking is only permissible indoors or in a cold store
environment.
– Permissible temperature range -10 °C to +40 °C.
– Secure parking is only permissible at +5 °C to +40 °C.
– Maximum air humidity 95% non-condensing.
– The application areas can be changed, but in general this should be minimised
due to thawing and possible corrosion.
– Thawing is permissible only if the truck can be subsequently dried thoroughly.
– Do not charge the battery below +5 °C.
3.2 Internal Operation in Cold Stores with Cold Store Equipment (o)
In addition to the permissible operating conditions in industrial and commercial
environments, the truck remains primarily in cold stores. The truck should only leave
the cold store briefly to hand over a load.
– Permissible temperature range -28 °C to +25 °C.
– Maximum air humidity 95% non-condensing.
– Thawing is permissible only if the truck can be subsequently dried thoroughly.
– In cold store areas below -10 °C the truck must be operated permanently and
should not be parked securely for more than 15 minutes.
– Do not charge the battery below +5 °C.
NOTICE
Battery damage
As the temperature becomes increasingly cold, the battery can be damaged if the
battery charge is low.
uIf the battery charge is low do not use the truck in areas of -28 °C to -5 °C.
uIf the battery charge is low it is preferable not to use the truck in areas of -5 °C to
+5 °C.
uCharge the battery, see page 45.
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4 Proprietor responsibilities
For the purposes of the present operating instructions the “operating company” is
defined as any natural or legal person who either uses the industrial truck himself, or
on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is
considered the person who, in accordance with existing contractual agreements
between the owner and user of the industrial truck, is charged with operational
duties.
The proprietor must ensure that the industrial truck is used only for the purpose it is
intended 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 operating company
must ensure that all users have read and understood these operating instructions.
NOTICE
Failure to comply with the operating instructions invalidates the warranty. The same
applies if improper work is carried out on the truck by the customer or third parties
without the permission of the manufacturer.
5 Adding attachments and/or optional equipment
The mounting or installation of additional equipment which affects or enhances the
performance of the industrial truck requires the written permission of the
manufacturer. Local authority approval may also need to be obtained.
Local authority approval however does not constitute the manufacturer’s approval.
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B Truck Description
1 Application
The EJD 220 is a three-wheel, electric tiller-operated pallet truck with a steered drive
wheel and coupling unit
It is designed to be used on level surfaces for lifting, stacking and transporting
goods. For transportation, two pallets can be stacked on top of each other. Open
bottom pallets or roll cages can be lifted.
1.1 Truck models and rated capacity
The rated capacity depends on the model. The rated capacity can be derived from
the model name.
EJD220
EJD Model name
2 Series
20 Rated capacity x 100 kg
The rated capacity is not generally the same as the permissible capacity. The
capacity can be found on the capacity plate attached to the truck.
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2 Travel direction definition
The following determinations have been made for travel direction specification:
1
2
3
4
Item Travel direction
1 Left
2 Drive direction
3 Load direction
4 Right
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3 Assemblies and Functional Description
3.1 Assembly Overview
15
5
7
19
18
11
16
17
6
14
13
12
10
8
9
15
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