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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