Jungheinrich EJE 225 User manual

EJE 220/225/230/235/220r/225r 05.07
Operating instructions
51040446
04.19
en-GB
EJE 220
EJE 225
EJE 230
EJE 235
EJE 220r
EJE 225r

2

Declaration of Conformity
Manufacturer
Jungheinrich AG, 22039 Hamburg, Germany
Description
Industrial truck
Type Option Serial no. Year of
manufacture
EJE 220
EJE 225
EJE 230
EJE 235
EJE 220r
EJE 225r
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 16
3 Assemblies and Functional Description 17
3.1 Assembly Overview 17
3.2 Functional Description 19
4 Technical Specifications 21
4.1 Performance data 21
4.2 Dimensions 22
4.3 Weights 27
4.4 Tyre type 28
4.5 EN norms 29
4.6 Conditions of use 30
4.7 Electrical Requirements 30
5 Identification Points and Data Plates 31
5.1 Indication Points 31
5.2 Data plate 32
5.3 Truck capacity plate 33
.
C Transport and Commissioning 35
.
1 Lifting by crane 35
2 Transport 37
3 Using the Truck for the First Time 38
.
D Battery - Servicing, Recharging, Replacement 39
.
1 Safety Regulations Governing the Handling of Lead-Acid Batteries 39
2 Battery types 41
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) 46
5 Battery removal and installation 52
5.1 Changing the battery from the top 53
5.2 Lateral battery removal 56
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.
E Operation 57
.
1 Safety Regulations for the Operation of Forklift Trucks 57
2 Displays and Controls 59
2.1 EJE 220r / EJE 225r Tiller 65
2.2 Battery discharge indicator 66
2.3 Battery discharge monitor 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 Making the EJE 220r / 225r operational 69
3.4 Checks and operations to be carried out when the truck is operational 70
3.5 Parking the truck securely 71
4 Industrial Truck Operation 73
4.1 Safety regulations for truck operation 73
4.2 Emergency Disconnect 75
4.3 Automatic braking 77
4.4 Travel 78
4.5 Slow travel 80
4.6 Steering 81
4.7 Brakes 81
4.8 Load handler raise/lower 83
4.9 Lifting, transporting and depositing loads 88
5 Troubleshooting 97
5.1 Truck does not start 98
5.2 Load cannot be lifted 99
6 Operating the truck without its own drive system 100
6.1 Release and activate the drive wheel brake 100
7 Optional equipment 103
7.1 Emergency operation with service key GF60 103
7.2 Tiller with buttons on both faces 105
7.3 Keypad (CanCode) (o) 106
7.4 Setting the truck parameters with CanCode 125
7.5 Parameters 127
7.6 Setting the Battery Parameters with CanCode 129
7.7 CanDis Display Instrument (o) 131
7.8 Display unit (2 inch display) 133
7.9 General Information about the Use of Keyless Access Systems 138
7.10 Using the Display: 139
7.11 ISM access module (o) 143
.
F Industrial Truck Maintenance 145
.
1 Operational Safety and Environmental Protection 145
2 Maintenance Safety Regulations 146
2.1 Working on the electrical system 147
2.2 Consumables and used parts 147
2.3 Wheels 147
2.4 Hydraulic system 148
3 Lubricants and Lubrication Schedule 150
3.1 Handling consumables safely 150
3.2 Lubrication Schedule 152
3.3 Consumables 153
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4 Maintenance and repairs 154
4.1 Preparing the truck for maintenance and repairs 154
4.2 Lifting and jacking up the truck safely 154
4.3 Cleaning 155
4.4 Front cover disassembly 159
4.5 Drive panel disassembly and assembly 160
4.6 Tightening the wheel nuts 161
4.7 Checking the hydraulic oil level 162
4.8 Check the gear oil level 163
4.9 Checking electrical fuses 164
4.10 Restoring the truck to service after maintenance and repairs 166
5 Decommissioning the Industrial Truck 167
5.1 Prior to decommissioning 167
5.2 Action to be taken during decommissioning 167
5.3 Restoring the truck to service after decommissioning 168
6 Safety tests to be performed at intervals and after unusual incidents 169
7 Final de-commissioning, disposal 169
8 Human vibration measurement 169
.
G Maintenance, Inspection and Changing of Maintenance
Parts Requiring Replacement 171
.
1 Maintenance Contents EJE 235 172
1.1 Owner 172
1.2 Customer Service 176
2 Maintenance Contents EJE 220r-225r 182
2.1 Owner 182
2.2 Customer Service 186
3 Maintenance Contents EJE 230 192
3.1 Owner 192
3.2 Customer Service 196
4 Maintenance Contents EJE 220/225 201
4.1 Owner 201
4.2 Customer Service 205
.
H Traction battery 211
.
1 Correct Use and Application 211
2 Data plate 211
3 Safety Instructions, Warning Indications and other Notes 212
4 Lead acid batteries with armour plated cells and liquid electrolyte 213
4.1 Description 213
4.2 Operation 215
4.3 Servicing lead-acid batteries with armour plated cells 218
5 PzV and PzV-BS lead-acid batteries with sealed armour plated cells 220
5.1 Description 220
5.2 Operation 221
5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour
plated cells 224
6 Aquamatik water replenishment system 225
6.1 Water replenishment system design 225
6.2 Functional Description 226
6.3 Adding water 226
6.4 Water pressure 226
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6.5 Filling time 227
6.6 Water quality 227
6.7 Battery tubing 227
6.8 Operating temperature 227
6.9 Cleaning measures 227
6.10 Service mobile vehicle 227
7 Electrolyte circulation 228
7.1 Functional Description 228
8 Cleaning batteries 230
9 Storing the battery 232
10 Troubleshooting 232
11 Disposal 232
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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 88.
The following operations are in accordance with regulations and are permitted:
– Lifting and lowering of loads.
– Stacking and retrieving loads.
– Transporting lowered loads.
The following operations are prohibited:
– Carrying and lifting passengers.
– Pushing or pulling loads.
– Transverse lifting of long loads.
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3 Approved application conditions
ZThe permissible operating conditions change if the truck is equipped with a lithium-
ion battery (o), see the manufacturer's operating instructions.
– 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 20 %.
– 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 EJE 220/225/230/235/220r/225r is designed to transport goods on level
surfaces. It can lift open-bottom pallets or pallets with transverse boards outside
area the load-wheel area, as well as roll cages. The capacity is shown on the
capacity plate, Qmax.
EJE 220r / 225r
The EJE 220r / 225r with ramp lift is particularly suitable for loading and unloading
on ramps. In particular, it can be used for lifting and depositing palletised goods right
up to the pitch bend.
1.1 Truck models and rated capacity
The rated capacity depends on the model. The rated capacity can be derived from
the model name.
EJE220
EJE Model name
2 Series
20 Rated capacity x 100 kg
The rated capacity is not generally the same as the maximum 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
6
9
10
11
5
7
8
12
13
14
15
16
17
18
17
Item Description Ite
m
Description
5tCollision safety switch 14 tKey switch
6tTravel switch oKeypad (CanCode)
7tSlow-travel button oKey switch (also with second
stage for brake release)
8tTiller oISM access module
9tBattery panel oKeypad
10 tEmergency disconnect oTransponder reader
11 tLoad handler 15 tFront panel
12 oOn-board battery charger
24 V / 30 A
(including safety switch)
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13 tDischarge indicator 16 tTwo-section drive panel
oDisplay instrument (CanDis) 17 tSupport wheels
oDisplay unit (2-inch display) 18 tDrive wheel
t = Standard equipment o = Optional equipment
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3.2 Functional Description
Safety mechanisms
An enclosed, smooth truck geometry with rounded edges ensures safe handling of
the truck. The wheels are surrounded by a solid skirt.
The long tiller provides a maximum safety distance to the truck. When it is released
and in hazardous situations a gas pressure spring forces the tiller up into the brake
position. The collision safety switch in the tiller head responds to body contact, the
travel direction changes and the truck moves away from the operator.
Activating the Emergency Disconnect switch rapidly cuts out all electrical functions in
hazardous situations.
Emergency stop safety concept
The emergency stop is activated by the traction controller. Each time the truck is
switched on, the system carries out a self-diagnosis. If an error is detected, the truck
automatically brakes to a halt. Indicator lights on the CanDis display instrument (o)
or on the display unit (2-inch display) (o) indicate the emergency stop.
CAUTION!
The truck brakes automatically
If the truck detects that signals which are required have not been received, or if it
detects an error, the system reacts by triggering an emergency stop, either by
braking the truck to a halt or until a valid signal status has been reached.
uRemain at a suitable distance from the truck during operation.
Hydraulic system
Pressing the lifting button starts the pump unit, supplying hydraulic oil from the oil
reservoir to the lift cylinder. Pressing the lifting button raises the load handler at a
constant speed; pressing the lowering button lowers the load handler.
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Drive system
A fixed AC three-phase motor actuates the drive wheel via a bevel spur gearbox.
The electronic traction controller ensures smooth drive-motor-speed control and
hence smooth starting, powerful acceleration and electrically controlled braking with
energy regeneration. The driver can choose from 3 travel programs depending on
the load and the environment: from high-performance to energy-saving.
Tiller
The driver steers with an ergonomic tiller. All travel and lift operations can be
performed sensitively without having to reach. The tiller has a steer angle of 180°.
Electrical system
The truck has an electronic traction controller. The operating voltage of the truck's
electrical system is 24 volts.
Controls and displays
Ergonomic controls ensure fatigue-free operation for sensitive application of the
travel and hydraulic operations. The battery discharge indicator shows the available
battery capacity. The CanDis display instrument (o) or the display unit (2-inch
display) (o) shows the operator key information such as the service hours, battery
capacity and event messages.
3.2.1 Hourmeter
ZPrepare the truck for operation, see page 68 or see page 106.
Service hours are counted while the truck is operational and one of the following
controls is applied:
– Tiller in travel zone "F", see page 78.
– "Slow travel button", see page 80.
– "Lift" button, see page 84.
– "Lower" button, see page 85.
On the EJE 220r / 225r the service hours are also counted when one of the following
controls is applied:
– "Ramp lift raise" button, see page 86.
– "Ramp lift lower" button, see page 87.
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