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Jungheinrich ECE 220, Operating Instructions Manual

The Jungheinrich ECE 220 is a versatile and reliable electric pallet truck. To ensure proper use and maintenance, download the free Operating Instructions Manual from manualshive.com. This comprehensive manual will guide you through the features and functions of the ECE 220, making operation safe and efficient.

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Operating Instructions

51051908

G

12.06-

07.08

ECE 220 / 225

ECE 220XL / 225XL

Summary of Contents for ECE 220

Page 1: ...Operating Instructions 51051908 G 12 06 07 08 ECE 220 225 ECE 220XL 225XL...

Page 2: ...iengesellschaft Am Stadtrand 35 22047 Hamburg GERMANY Telephone 49 0 40 6948 0 www jungheinrich com 0108 GB Foreword The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient inst...

Page 3: ...0108 GB 0108 GB...

Page 4: ...es D 2 3 Exposing the battery D 2 4 Charging the battery D 3 5 Battery removal and installation D 4 I 1 0708 GB Index A Correct Application B Truck Description 1 Application B 1 2 Assemblies B 2 3 Sta...

Page 5: ...o post 10 2006 E 32 9 1 Operating hours display E 33 9 2 Power up test E 33 10 Troubleshooting E 34 0708 GB I 2 E Operation 1 Safety Regulations for the Operation of Forklift Trucks E 1 2 Controls and...

Page 6: ...t regular intervals and following any unusual incidents F 12 9 Final de commissioning disposal F 12 I 3 0708 GB F Industrial Truck Maintenance 1 Operational Safety and Environmental Protection F 1 2 M...

Page 7: ...0708 GB I 4 0708 GB I 4...

Page 8: ...ngheinrich battery models If using another brand refer to the manufacturer s operating instructions 1 0506 GB Appendix JH Traction Battery Operating Instructions Z These operating instructions apply o...

Page 9: ...0506 GB 2 0506 GB 2...

Page 10: ...required Approval of the local authorities however does not constitute the manufacturer s approval A 1 1206 GB A Correct Application Z The Guidelines for the Correct Use and Application of Industrial...

Page 11: ......

Page 12: ...the battery panel The rated capacity can be found on the data pate or the capacity data plate Qmax B 1 0708 GB B Truck Description 1 Application The ECE 220 225 is a four wheel electric pallet truck...

Page 13: ...ton t Standard equipment o Optional Equipment 2 6 13 3 4 1 17 18 16 7 8 9 12 14 19 11 10 15 5 5 5 6 0708 GB B 2 2 Assemblies Item Model Item Model 1 t Front panel 11 o Stop button 2 t Main switch isol...

Page 14: ...f h r h 14 h k y e 95 c l h 3 b 1 l2 a 2 a 2 h 13 30 218 l1 l6 b3 b11 b5 Wa 253 380 412 s b10 Ast X B 3 0708 GB 3 Standard Version Specifications Z Technical specification details in accordance with V...

Page 15: ...0 2667 1891 842 1400 2109 2867 1450 2717 1941 892 1450 2159 2917 1600 2867 2463 1042 1600 2309 3067 0708 GB B 4 3 2 Dimensions all dimensions in mm ECE 220 aisle widths all dimensions in mm 1 with the...

Page 16: ...4117 3099 2050 2850 3317 4317 2900 4167 3149 2100 2900 3367 4367 3100 4367 3349 2300 3100 3567 4567 B 5 0708 GB ECE 225 aisle widths all dimensions in mm 1 with the load section raised the values are...

Page 17: ...he truck is to be constantly used in conditions of extreme temperature or air humidity fluctuations 0708 GB B 6 3 3 EN norms Noise level 67 dB A in accordance with EN 12053 as harmonized with ISO 4871...

Page 18: ...oint of crane loading inside hook symbol enhanced 25 Capacity Qmax 22 23 25 24 21 20 20 Qmax XXX kg B 7 0708 GB 4 Identification points and data plates Z The capacity plate 25 indicates the maximum ca...

Page 19: ...tery kg 36 Year of Manufacture 31 Manufacturer s logo 37 Option 32 31 33 30 34 29 35 28 36 27 37 26 0708 GB B 8 4 1 Truck data plate Z For queries relating to the truck or spare part orders please sta...

Page 20: ...stances and cannot come into contact with any attachments of the truck when the truck is lifted 2 1 C 1 1206 GB C Transport and Commissioning 1 Lifting by crane F Only use lifting gear with sufficient...

Page 21: ...703 In each case correct measurements shall be determined and appropriate safety measures adopted 1 1206 GB C 2 2 Securing the truck during transport F The truck must be securely fastened when transpo...

Page 22: ...g surface of the tyres will flatten The flattening will disappear after a short period of operation C 3 1206 GB 3 Using the truck for the first time M Only operate the truck with battery current Recti...

Page 23: ...the brakes released Remove the screws 2 The brake is now applied again Refit the front panel 3 3 2 1206 GB C 4 4 Operating the truck without its own drive system F This operating mode is not permitte...

Page 24: ...l safety of the truck Battery equipment may only be replaced with the agreement of the manufacturer D 1 1206 GB D Battery Maintenance Charging Replacement 1 Safety regulations for handling acid batter...

Page 25: ...erate again 24 V PzS battery 3 PzS 420 Ah L 24 V PzS battery high performance 3 PzS 450 Ah HX 1 2 3 1206 GB D 2 2 Battery types The truck will be equipped with different battery types depending on the...

Page 26: ...serving the instructions provided by the battery supplier and by the battery charger supplier 6 4 5 D 3 1206 GB 4 Charging the battery F To charge the battery the truck must be parked in a closed and...

Page 27: ...attery locking mechanism 8 back into the recess The battery panel must be closed securely 7 8 4 9 7 1206 GB D 4 5 Battery removal and installation F The truck must be parked on level ground To prevent...

Page 28: ...and warning signs Safety devices warning signs and warning instructions shall be strictly observed E 1 1007 GB E Operation 1 Safety Regulations for the Operation of Forklift Trucks Driver authorisati...

Page 29: ...in pedestrian mode in the reverse direction R slow travel t Standard equipment o Optional Equipment 1007 GB E 2 2 Controls and Displays Item Control Display Function 1 Main switch isolator emergency d...

Page 30: ...E 3 1007 GB S T O P 5 10 9 8 11 12 13 8 9 10 14 2 15 1 6 7 6 4 3 3 4 6 3 4 2 2 5 16 E 3 1007 GB S T O P 5 10 9 8 11 12 13 8 9 10 14 2 15 1 6 7 6 4 3 3 4 6 3 4 2 2 5 16...

Page 31: ...he height of the seat can be set to one of four positions t Standard equipment o Optional Equipment 1007 GB E 4 Item Control Display Function 11 Code Lock o Replaces the key switch Switches control vo...

Page 32: ...E 5 1007 GB S T O P 5 10 9 8 11 12 13 8 9 10 14 2 15 1 6 7 6 4 3 3 4 6 3 4 2 2 5 16 E 5 1007 GB S T O P 5 10 9 8 11 12 13 8 9 10 14 2 15 1 6 7 6 4 3 3 4 6 3 4 2 2 5 16...

Page 33: ...r the display instrument CANDIS 12 o shows the battery charge status 6 6 2 2 1 2 11 6 12 R R V V 13 1007 GB E 6 3 Starting up the truck F Before the truck can be started operated or a load lifted the...

Page 34: ...Use suitable precautions e g a load guard to prevent parts of the load from tipping or falling down E 7 1007 GB 4 Industrial Truck Operation 4 1 Safety regulations for truck operation Travel routes an...

Page 35: ...ontroller 6 Slow speed travel approx 2km h see section 4 3 by pressing the Pedestrian button 8 10 o 1007 GB E 8 4 2 Travel steering braking F Be extremely careful when driving and steering especially...

Page 36: ...e truck can be operated at reduced speed without having to stand on the platform 15 1 6 R R V V 6 6 E 9 1007 GB Travel F Do not drive the truck unless the panels are closed and properly locked Start u...

Page 37: ...with tiller steering the tiller will protrude outside the geometry of the truck around narrow bends 1007 GB E 10 Travelling on inclines M Loads must always be carried on the end of the truck facing up...

Page 38: ...ove in the opposite direction Z The brake force depends on the position of the controller 5 6 5 6 6 E 11 1007 GB Braking F The brake pattern of the truck depends largely on the ground conditions The d...

Page 39: ...n option pedestrian mode is only available for forward travel via button 8 6 R R V V 8 10 5 6 5 6 6 1007 GB E 12 4 3 Pedestrian operation o F When travelling in pedestrian mode you must make sure whil...

Page 40: ...d ensuring that it does not protrude excessively from the top of the lift mechanism less than 50 mm E 13 1007 GB Travel using the controller Set the controller 6 to the desired travel direction forwar...

Page 41: ...h the desired lift height Lowering Press the Lower 3 button to lower the lift mechanism 3 4 3 4 3 4 1007 GB E 14 Lift Lower Z Press the Lift 4 or Lower 3 buttons to activate lifting or lowering at a p...

Page 42: ...hen standing on the battery panel A rail 20 o for the battery panel will improve safety 17 19 20 18 E 15 1007 GB 4 5 2nd level stockpicking o The operator position is designed so that the driver can c...

Page 43: ...ch 14 OFF 0 and remove the key For CANCODE press the o key Set the isolator emergency stop 1 OFF 16 1007 GB E 16 4 6 Seat o XL only The seat 16 is incorporated into the backrest when folded up When un...

Page 44: ...ck for the first time change the master and operating codes see section 5 4 1 2 3 4 5 6 7 8 9 0 Set E 17 1007 GB 5 Keypad CANCODE o The keypad consists of 10 digit keys a Set key and a o key Activatio...

Page 45: ...esponding code lock parameter must be set see section 5 4 1 2 3 4 5 6 7 8 9 0 Set 23 22 21 26 25 24 1007 GB E 18 Commissioning When the main switch is turned on the LED 21 goes red When you enter the...

Page 46: ...ravel program 3 parameters acceleration coasting brake speed etc 4xx Program independent parameters E 19 1007 GB 5 2 Travel programs Press the digit keys 1 2 and 3 to select any of three travel progra...

Page 47: ...LED 23 Key 1 LED 24 Key 2 LED 25 Key 3 Service hours are displayed 284 0 Green Flashing Off Off Off 1007 GB E 20 5 4 Parameter Settings To change the truck setting you must enter the master code Z The...

Page 48: ...00 999999 2580 LED 24 flashes Enter a code Confirm Set LED 25 flashes Repeat code entry Confirm Set E 21 1007 GB Setting procedure for trucks with and without display instrument CANDIS o Enter the thr...

Page 49: ...010 Automatic timeout 00 31 00 00 No cutout 01 to 30 Cutout time in minutes 31 cutout in 10 seconds 1007 GB E 22 LEDs 23 25 are located in key fields 1 3 see Section 5 2 No Function Setting range Stan...

Page 50: ...parameter number is entered the number of user codes used is shown on the CANDIS displayinstrument E 23 1007 GB Start Travel Program Setting with Code Lock pre 06 07 only in conjunction with display...

Page 51: ...on Setting range Standard setting Comments Procedure Code Lock 024 User code configuration 0 3 1112 1007 GB E 24 Start Travel Program Setting with Code Lock post 06 07 The travel programs are connecte...

Page 52: ...ment CANDIS LED 21 o key LED 23 Key 1 LED 24 Key 2 LED 25 Key 3 Parameter number Para meter setting E 25 1007 GB 5 5 Travel parameters Z For trucks without a display instrument CANDIS o the code lock...

Page 53: ...speed in fork direction via pushbutton in backrest 0 9 3 Not dependant on travel switch fixed speed 1007 GB E 26 Z Travel is disabled while the parameters are being entered If the setting is to be che...

Page 54: ...speed in fork direction via pushbutton in backrest 0 9 3 Not dependant on travel switch fixed speed E 27 1007 GB No Function Setting range Standard setting Comments Travel program 2 200 Acceleration i...

Page 55: ...speed in fork direction via pushbutton in backrest 0 9 3 Not dependant on travel switch fixed speed 1007 GB E 28 No Function Setting range Standard setting Comments Travel program 3 300 Acceleration i...

Page 56: ...2 0 0 Normal wet 1 high performance wet 2 Dry maintenance free 412 Discharge monitor function 0 1 1 E 29 1007 GB Program independent parameters Z For trucks without a display instrument CANDIS o theBA...

Page 57: ...acity minimum level Flashing red 1 Hz Error decimal digits Flashing red 0 5 Hz Error unit digits 12 1007 GB E 30 7 Battery discharge indicator 7 1 Battery Discharge Indicator t When the truck has been...

Page 58: ...available capacity has been reached On On Below battery residual capacity minimum level 27 28 29 30 E 31 1007 GB 8 Display instrument CANDIS o pre 10 2006 The instrument indicates Residual battery cha...

Page 59: ...s set to maintenance free battery 32 Battery charge display on board charger only 27 31 32 28 29 30 1007 GB E 32 9 Display instrument CANDIS o post 10 2006 The instrument indicates In addition service...

Page 60: ...shows the software version of the display instrument briefly the operating hours the charge status E 33 1007 GB 9 1 Operating hours display Hourmeter The hourmeter 30 contained in the battery dischar...

Page 61: ...ve Check hydraulic oil level Charge the battery Check fuse 2F1 Note maximum capacity see data plate 1007 GB E 34 10 Troubleshooting This chapter is designed to help the user identify and rectify basic...

Page 62: ...sed water After cleaning the truck carry out the activities detailed in the Recommissioning section F 1 0708 GB F Industrial Truck Maintenance 1 Operational Safety and Environmental Protection The che...

Page 63: ...d every six years When replacing hydraulic components also renew the hoses in this hydraulic system 0708 GB F 2 Electrical System Only suitably trained personnel may operate on the truck s electrical...

Page 64: ...fter approx 100 service hours the owner must check the wheel nuts bolts and re tighten if necessary F 3 0708 GB 3 Servicing and Inspection Thorough and expert servicing is one of the most important re...

Page 65: ...Test the operator platform and check for damage t 5 2 Check chassis for damage t 5 3 Check labels t 0708 GB F 4 4 Maintenance checklist Maintenance Intervals Standard t W A B C Cold store k Brake 1 1...

Page 66: ...t 7 2 Test run t 7 3 Demonstration after servicing k t Steering system 8 1 Test electric steering t F 5 0708 GB Maintenance Intervals Standard t W A B C Cold store k Hydraulic operation 6 1 Visually i...

Page 67: ...s may result from the manufacture of the gear unit housing casting A B 1 05 l s E A C 0 7 l 1 E a 2 0708 GB F 6 5 Lubrication Schedule g Contact surfaces s Grease nipple Gear oil filler neck a Gear oi...

Page 68: ...nt C Worked penetration at 25 C NLG1 class Application temperature C E Lithium 220 280 310 2 35 120 F 7 0708 GB 5 1 Consumables Handling consumables Consumables must always be handled correctly Follow...

Page 69: ...emove the socket wrench from the opening 2 after the wheel nuts have been tightened 1 3 5 2 4 3 2 1 0708 GB F 8 6 Maintenance Instructions 6 1 Preparing the truck for maintenance and repairs All neces...

Page 70: ...is the reverse order F Do not drive the truck unless the panels are closed and properly locked 4 5 F 9 0708 GB 6 3 Remove the front panel Open battery panel see chapter D Remove the screws 5 Lift up...

Page 71: ...arge indicator battery hourmeter 2 A 10 1F1 Drive motor 300 A 11 2F1 Pump motor 150 A 6 7 8 9 10 11 0708 GB F 10 6 4 Checking electrical fuses Prepare the truck for maintenance and repairs see Chapter...

Page 72: ...o avoid depletion of the battery through self discharge The sulfatisation would destroy the battery F 11 0708 GB 6 5 Recommissioning The truck may only be restored to service after cleaning or repair...

Page 73: ...ns governing the disposal of batteries fuels and electronic and electrical systems must be observed 0708 GB F 12 7 3 Returning the truck to operation after decommissioning Thoroughly clean the truck L...

Page 74: ...ith positive tubular plates type EPzV and EPzV BS 13 17 Type plate Jungheinrich traction battery 17 1 0506 GB Instructions for use Jungheinrich traction battery Table of contents 1 Jungheinrich tracti...

Page 75: ...etal parts of the battery are always live Do not place tools or other me tal objects on the battery 0506 GB 2 1 Jungheinrich traction battery with positive tubular plates type EPzS and EPzB Rating Dat...

Page 76: ...nt When charging proper provision must be made for venting of the charging gases steel M 10 23 1 Nm 3 0506 GB Ignoring the operation instructions repair with non original parts or using additives for...

Page 77: ...S G of 1 29 kg l at 30 C The electrolyte must conform to the purity regulations in DIN 43530 part 2 0506 GB 4 Battery container lids and the covers of battery compartments must be opened or re moved T...

Page 78: ...corrosion If it is necessary to remove cells it is best to call in our service department for this 5 0506 GB 3 Maintenance 3 1 Daily Charge the battery after every discharge Towards the end of charge...

Page 79: ...ing process must be disposed of as hazardous waste We reserve the right make technical modification 0506 GB 6 5 Storage If batteries are taken out of service for a lengthy period they should be stored...

Page 80: ...ear of manufacture Jungheinrich AG D 22047 Hamburg Germany 5 Pb Pb 2 3 6 5 11 13 1 14 4 10 12 7 8 9 7 0506 GB 7 Type plate Jungheinrich traction battery CE mark is only for batteries with a nominal vo...

Page 81: ...gth stroke length Aquamatic plug with diagnostics hole Aquamatic plug BFS III with diagnostics hole 0506 GB 8 Aquamatic BFS III water refilling system for Jungheinrich traction battery with EPzS and E...

Page 82: ...with five times the buoyant force and consequently interrupt the water supply reliably at least 3 m 9 0506 GB Diagrammatic view Equipment for the water refilling system 1 Water tank 2 Level switch 3 D...

Page 83: ...ter element optional with a max passage opening of 100 to 300 m into the battery s main supply pipe 0506 GB 10 4 Filling manual automatic The batteries should be filled with battery water as soon as p...

Page 84: ...eatest of care must be employed when prising out the plug to prevent any damage to the plug systems 11 0506 GB 8 Battery hose connections Hose connections for the individual plugs are laid along the e...

Page 85: ...to 0 6 bars in the Aquamatic system and operating pressure range 0 3 to 1 8 bars in the BFS system 0506 GB 12 10 2 1 Clamping ring tool The clamping ring tool is used to push on a clamping ring to in...

Page 86: ...Metal parts of the battery are always live Do not place tools or other metal objects on the battery 13 0506 GB 2 Jungheinrich traction batterie Maintenance free Jungheinrich traction batterie with pos...

Page 87: ...container lids and the covers of battery compartments must be opened or re moved steel M 10 23 1 Nm 0506 GB 14 Ignoring the operation instructions repair with non original parts and non authorised int...

Page 88: ...red 3 Maintenance Don t refill water 3 1 Daily Charge the battery immediately after every discharge 15 0506 GB With the charger switched off connect up the battery ensuring that the polarity is cor re...

Page 89: ...er of cells The storage time should be taken into account when considering the life of the batte ry 0506 GB 16 3 2 Weekly Visual inspection after recharging for signs of dirt and mechanical damage 3 3...

Page 90: ...ear of manufacture Jungheinrich AG D 22047 Hamburg Germany 5 Pb Pb 2 3 6 5 11 13 1 14 4 10 12 7 8 9 17 0506 GB 6 Malfunctions If malfunctions are found on the battery or the charger our service depart...

Page 91: ...0506 GB 18 0506 GB 18...

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