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Jungheinrich EJE 220, Operating Instructions Manual

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Jungheinrich EJE 220 Operating Instructions Manual Download Page 171

G Maintenance, Inspection and Changing of

Maintenance Parts Requiring

Replacement

WARNING!

Lack of maintenance can result in accidents

Failure to perform regular maintenance and inspections can lead to truck failure and
poses a potential hazard to personnel and equipment.

u

Thorough and expert maintenance and inspections are among the most important
requirements for the safe operation of the industrial truck.

NOTICE

The  application  conditions  of  an  industrial  truck  have  a  considerable  impact  on
component  wear.  The  following  service,  inspection  and  replacement  intervals  are
based  on  single-shift  operation  under  normal  operating  conditions.  The  intervals
must  be  reduced  accordingly  if  more  stringent  requirements  are  placed  on  the
equipment,  e.g.,  use  in  conditions  of  extreme  dust,  temperature  fluctuations  or
multiple shifts.

u

To  prevent  damage  due  to  wear,  the  manufacturer  recommends  an  on-site
application analysis to agree on appropriate intervals.

The following chapter defines the tasks to be performed, the respective intervals to
be observed and the maintenance parts for which replacement is recommended.

171

04.19 en-GB

Summary of Contents for EJE 220

Page 1: ...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...

Page 2: ...2...

Page 3: ...0 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 Dire...

Page 4: ...4 04 19 en GB...

Page 5: ...lar 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 follo...

Page 6: ...ht Copyright of these operating instructions remains with JUNGHEINRICH AG Jungheinrich Aktiengesellschaft Friedrich Ebert Damm 129 22047 Hamburg Germany Tel 49 0 40 6948 0 www jungheinrich com 6 04 19...

Page 7: ...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 Indicat...

Page 8: ...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 Emergen...

Page 9: ...ance 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 Mainten...

Page 10: ...g 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 batter...

Page 11: ...tance 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 p...

Page 12: ...ting 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 extre...

Page 13: ...n 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 o...

Page 14: ...ed 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 understo...

Page 15: ...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 rat...

Page 16: ...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 16 04 19 en G...

Page 17: ...y switch 14 t Key switch 6 t Travel switch o Keypad CanCode 7 t Slow travel button o Key switch also with second stage for brake release 8 t Tiller o ISM access module 9 t Battery panel o Keypad 10 t...

Page 18: ...t Discharge indicator 16 t Two section drive panel o Display instrument CanDis 17 t Support wheels o Display unit 2 inch display 18 t Drive wheel t Standard equipment o Optional equipment 18 04 19 en...

Page 19: ...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 instrumen...

Page 20: ...trical 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...

Page 21: ...without rated load 0 05 0 05 0 05 0 05 0 05 0 05 0 05 0 05 m s Max gradeability 5 min rating with without rated load 10 20 8 20 6 20 6 20 For longer load handler lengths the load centre of gravity is...

Page 22: ...4 2 Dimensions D 22 04 19 en GB...

Page 23: ...th front 508 m m b11 Track width rear 368 m m s e l Load handler dimensions 55 172 1150 m m m2 Ground clearance centre wheelbase 30 m m x Load distance 911 m m Wa Turning radius short long 1538 1610 1...

Page 24: ...Diagonal in accordance with the German directive Data Sheets for Industrial Trucks 386 mm 24 04 19 en GB...

Page 25: ...t 508 m m b11 Track width rear 368 m m s e l Load handler dimensions 55 172 1150 m m m2 Ground clearance centre of wheelbase 30 m m x Load distance 911 m m Wa Turning radius short long 1538 1610 m m A...

Page 26: ...Diagonal in accordance with the German directive Data Sheets for Industrial Trucks 386 mm 26 04 19 en GB...

Page 27: ...xle load axle m 876 1664 990 2060 1154 2426 1300 2750 kg Axle loading unladen drive end load end m 423 117 427 123 457 123 427 123 kg Component EJE 220r EJE 225r Net weight 540 550 kg Axle loading wit...

Page 28: ...85x85 85x85 85x85 mm Additional wheels dimensions 100x40 100x40 100x40 100x40 mm Wheels number drive end load end x driven 1x 2 2 or 4 1x 2 4 Model EJE 220r EJE 225r Tyre size drive side 230 x 70 230...

Page 29: ...issions and resistance as well as the static electricity discharge test in accordance with EN 12895 as well as the standardised instructions contained therein Z No changes to electric or electronic co...

Page 30: ...n are required if the truck is to be used continually in conditions of extreme temperature or condensing air humidity fluctuations 4 7 Electrical Requirements The manufacturer certifies compliance wit...

Page 31: ...tes must be legible at all times Replace if necessary 5 1 Indication Points 22 25 20 21 23 26 24 19 Item Component 19 Serial number 20 Capacity Qmax 21 Prohibition plate No passengers 22 Truck data pl...

Page 32: ...kg 36 Min max battery weight kg 30 Battery voltage V 37 Manufacturer 31 Net weight w o battery kg 38 QR code 32 Option 39 Manufacturer s logo 33 Year of manufacture Z For queries regarding the truck...

Page 33: ...5 3 Truck capacity plate 20 The capacity plate 20 gives the maximum load bearing capacity Q of the truck in kg assuming the load on the load handler is evenly distributed 33 04 19 en GB...

Page 34: ...34 04 19 en GB...

Page 35: ...he truck to crash when being loaded by crane Prevent the truck from hitting other objects during lifting and avoid uncontrolled movements If necessary secure the truck with guide ropes uThe truck may...

Page 36: ...e provided for transporting the truck with crane lifting gear Lifting the truck by crane Requirements Park the truck securely see page 71 Tools and Material Required Lifting gear Crane lifting gear Pr...

Page 37: ...ges to prevent the truck from moving uUse only fastening belts with sufficient strength uUse non slip materials to securing the load aids pallet wedges e g non slip mats Securing the truck for transpo...

Page 38: ...with an external battery If the truck is delivered in multiple parts setup and commissioning must only be performed by trained authorised personnel Procedure Check the equipment is complete If necess...

Page 39: ...ust be ventilated Fire protection equipment must be available CAUTION The use of unsuitable fire protection equipment can result in scalding Extinguishing fires with water can cause a reaction with th...

Page 40: ...by Jungheinrich for the truck can be hazardous The design weight and dimensions of the battery have a considerable effect on the operational safety of the truck in particular its stability and capaci...

Page 41: ...4 V 2PzV 220 Ah wf Hawker 218 623X211X627 24 V 2PzW 220 Ah 220 624X212X627 24 V 2PzS 250 Ah 220 624X212X627 24 V 2PzS 250 Ah 220 621X209X627 24 V 2PzM 250 Ah 222 621X209X625 24 V LIB 110 Ah 210 624X20...

Page 42: ...623X211X537 24 V 2PzS 180 Ah 180 624X212X537 24 V 2PzM 180 Ah 180 621X209X537 24 V 2PzV 200 Ah wf Exide 215 621X209X627 24 V 2PzV 220 Ah wf Hawker 218 623X211X627 24 V 2PzW 220 Ah 220 624X212X627 24...

Page 43: ...90 621X281X627 24 V XFC 316 Ah 288 624X284X627 24 V 3PzV 330 Ah wf Hawker 300 623X283X627 24 V 3PzW 330 Ah 288 624X284X627 24 V 3PzS 345 Ah Lib Silver 282 621X284X627 24 V 3PzS 375 Ah 288 624X284X627...

Page 44: ...akes are not working place wedges underneath the wheels of the truck to prevent it from moving CAUTION A closing battery panel can pose a trapping hazard If the battery cover is not opened fully it ca...

Page 45: ...isible signs of damage uVentilate the room in which the truck is being charged uThe battery cover must be open and the battery cell surfaces must be exposed during charging to ensure adequate ventilat...

Page 46: ...ete charging in accordance with the charger operating instructions Disconnect the battery connector 41 from the charging cable 42 of the stationary charger Attach the battery connector 41 to the indus...

Page 47: ...rgers simultaneously 4 2 1 Setting the charging characteristics ELG 2430 Z The factory setting for trucks without a battery is the 0 position A battery discharge indicator a charge discharge indicator...

Page 48: ...0 Ah Wet cell battery PzS with pulse characteristic 200 414 Ah 6 Jungheinrich 100 300 Ah NOTICE uAll other switch positions 43 block the charger and the battery is not charged uFor PzM batteries with...

Page 49: ...ult for flashing codes see LED Display table The battery is charged Z When the mains connector 45 is attached to the mains all the truck s electrical functions are disconnected electric immobilizer Th...

Page 50: ...duration of charge depends on the battery capacity Z Charging continues automatically after a mains failure Charging can be interrupted by removing the mains connector and continued as partial chargi...

Page 51: ...teristic curve set Red LED fault Lit Overtemperature Charging is interrupted Flashes slowly Safety charging time exceeded Charging is cancelled Mains must be disconnected for charging to restart Rapid...

Page 52: ...sure the crane lifting gear has sufficient capacity to replace the battery uUse only approved battery replacement devices battery roller stand replacement trolley etc uMake sure the battery is securel...

Page 53: ...cable on the tray so that it cannot be severed when the battery is pulled out Attach the crane lifting gear to the eyes 47 Z The hooks must be fitted in such a way that when the crane lifting gear is...

Page 54: ...en the battery is inserted Attach the battery connector to the truck connector CAUTION Trapping hazard There is a risk of trapping when you close the battery cover uDo not reach between the battery co...

Page 55: ...alling the battery make sure that the auxiliary hydraulics components valves hoses and electrical connecting cables are not trapped Attach the battery connector to the truck connector CAUTION Trapping...

Page 56: ...n the battery lock 48 as far as the stop Pull the battery out from the side The battery is now removed 48 Z Installation is the reverse order When reinstalling the battery note the proper installation...

Page 57: ...structions Safety shoes must be worn on pedestrian operated trucks Unauthorised use of truck The operator is responsible for the truck during the time it is in use The operator must prevent unauthoris...

Page 58: ...are still within the hazardous area stop the truck immediately Safety devices warning signs and warning instructions Safety devices warning signs see page 31 and warning instructions in the present op...

Page 59: ...2 Displays and Controls 6 5 53 7 12 6 52 50 10 8 13 54 55 14 56 51 49 59 04 19 en GB...

Page 60: ...sed for steering and braking 10 Emergency disconnect switch t Disconnects the battery supply All electrical functions are deactivated and the truck is braked 12 Cable connection On board battery charg...

Page 61: ...6 5 53 7 12 6 52 50 10 8 13 54 55 14 56 51 49 61 04 19 en GB...

Page 62: ...y charge status Battery capacity Service hours Travel program Warning indicators Event messages Soft keys under the display unit 56 CanCode o Replaces the key switch Entering the appropriate code acti...

Page 63: ...6 5 53 7 12 6 52 50 10 8 13 54 55 14 56 51 49 63 04 19 en GB...

Page 64: ...64 04 19 en GB...

Page 65: ...58 Ite m Control display Function 50 Load handler lower button t Lowers the load handler 52 Load handler raise button t Raises the load handler 57 Ramp lift lower button t Lowers ramp lift 58 Ramp li...

Page 66: ...Battery discharge monitor Z The standard setting for the battery discharge indicator discharge monitor is based on standard batteries When using maintenance free or special batteries the display and c...

Page 67: ...return the industrial truck to service until you have identified and rectified the fault Inspection before daily operation Procedure Check the whole of the outside of the truck for signs of damage an...

Page 68: ...the ISM access module and depending on the setting press the green button on the ISM access module o Z The tiller 8 must be in the upper braking zone B If event message E 0914 is displayed on the Can...

Page 69: ...nCode o 56 Hold the card or transponder in front of the ISM access module and depending on the setting press the green button on the ISM access module o Z The tiller 8 must be in the upper braking zon...

Page 70: ...fault Procedure Test warning indicators and safety devices Test the emergency disconnect function by pressing the emergency disconnect switch The main circuit is disconnected and no truck operations c...

Page 71: ...ndler uIf the brakes are not working place wedges underneath the wheels of the truck to prevent it from moving EJE 220 225 230 235 Park the truck securely Procedure Park the truck on a level surface F...

Page 72: ...7 Using the tiller 8 turn the drive wheel to forward travel Switch off the truck to do this Turn the key in the key switch 14 anti clockwise as far as it will go Remove the key from the key switch 14...

Page 73: ...peed to local conditions The truck must be driven at slow speed when negotiating bends or narrow passageways when passing through swing doors and at blind spots The operator must always observe an ade...

Page 74: ...lifts with the load in front and must take up a position which does not allow it to come into contact with the walls of the lift shaft Persons riding in the lift with the forklift truck must only ent...

Page 75: ...es CAUTION Faulty or non accessible Emergency Disconnect switches can cause accidents A faulty or non accessible Emergency Disconnect switch can cause accidents In dangerous situations the operator ca...

Page 76: ...isconnect switch on in emergencies Releasing the Emergency Disconnect switch Procedure Pull the Emergency Disconnect switch 10 to unlock it All electrical functions are enabled and the truck is operat...

Page 77: ...f collision due to a defective tiller Operating the truck with a defective tiller can lead to collisions with persons or objects uIf the tiller returns to the brake position slowly or not at all the t...

Page 78: ...drive direction Control the travel speed with the travel switch 6 The further the travel switch 6 is rotated the greater the travel speed Control the travel speed by rotating the travel switch 6 furth...

Page 79: ...el switch is released in time uAfter setting off in the opposite direction apply the travel switch gently or not at all uDo not perform any sudden steering operations uAlways face in the direction of...

Page 80: ...king Z The truck can be operated with an upright tiller 8 e g in confined spaces elevators Switch on the slow travel function Procedure Press and hold down the slow travel button 7 Rotate the travel s...

Page 81: ...The truck s braking distance increases when the ground is wet or dirty uThe operator must be aware of floor conditions and take them into account when braking uBrake with care to prevent the load from...

Page 82: ...y when the truck comes to rest 4 7 2 Regenerative braking Procedure If the travel switch 6 is set to 0 the truck automatically brakes regeneratively The truck brakes to a halt regeneratively via the c...

Page 83: ...other people to move out of the hazardous area of the truck Stop working with the truck if people do not leave the hazardous area uIf people do not leave the hazardous area despite the warning prevent...

Page 84: ...until you reach the desired lift height NOTICE Risk of material damage to the hydraulic unit When the mechanical end stop of the load has been reached release the Raise load handler button Otherwise t...

Page 85: ...ring the load handler Requirements Prepare the truck for operation see page 68 Procedure Press the Lower load handler button 50 until you reach the desired lift height The load handler is lowered 85 0...

Page 86: ...dler is raised with the load handler raise button it cannot change directly to ramp lift When the ramp lift raise button is applied the load handler is first fully lowered and then raised to ramp lift...

Page 87: ...ed lift height The load handler is lowered from ramp lift Z When you release the ramp lift lower button 57 or the load handler lower button a lag time of 1 to 2 seconds begins If the ramp lift raise b...

Page 88: ...eople do not leave the hazardous area uOnly carry loads that have been correctly secured and positioned Use suitable precautions to prevent parts of the load from tipping over or falling off the truck...

Page 89: ...s against the back of the load handler see graphic to the right Z The load must not extend by more than 50 mm beyond the load handler tips Raise the load handler until the desired height is reached se...

Page 90: ...slowly up to the pallet Raise ramp lift see page 86 Slowly insert the load handler into the pallet and lower the ramp lift incrementally Insert the load handler into the pallet until the pallet is res...

Page 91: ...91 04 19 en GB...

Page 92: ...92 04 19 en GB...

Page 93: ...load you are transporting Travel at a constant speed Be prepared to brake at all times Brake gently in normal circumstances Only stop suddenly in dangerous situations Watch out for other traffic at cr...

Page 94: ...ad Procedure Drive the truck carefully up to the storage location Lowers the load handler Z To avoid damaging the load and the load handler avoid setting the load down abruptly Lower the load handler...

Page 95: ...e carefully up to the storage location Lower the load handler fully see page 85 Z Avoid lowering the load suddenly to prevent the load and load handler from damage Carefully remove the load handler fr...

Page 96: ...96 04 19 en GB...

Page 97: ...the electronics system is displayed with a corresponding error code contact the manufacturer s service department Troubleshooting must only be performed by the manufacturer s customer service departme...

Page 98: ...y unit 2 inch display o event message E 0914 appears Swing the tiller into the top or the bottom brake zone Raise load handler button Lower load handler button not in home position when truck switched...

Page 99: ...he bottom brake zone Raise load handler button Lower load handler button not in home position when truck switched on for CanDis or on the display unit 2 inch display o event message E 2951 appears Do...

Page 100: ...uck can move without its own drive system see page 103 6 1 Release and activate the drive wheel brake WARNING Accidental truck movement When the brakes are de activated the truck must be parked on a l...

Page 101: ...Remove the right hand drive panel 63 see page 160 Use wedges to prevent the truck from moving Insert two M5x45 screws 61 as far as they will go in the brake 62 and lift up the anchor plate Z The two M...

Page 102: ...must be closed during operation Refit the right hand drive panel 63 see page 160 Install the front panel 15 see page 159 The brake has been reactivated The brake is now be applied without current WAR...

Page 103: ...quirements Truck prevented from rolling away Charged battery in truck Tools and Material Required Service key GF60 with lock bar Procedure Insert the service key GF60 in the key switch Z The service k...

Page 104: ...ck bar returns to its original position The brake is now activated again WARNING Only return the truck to service when you have identified and rectified the fault Z The GF30 key without lock bar is fo...

Page 105: ...es EJE 220 225 230 235 Tiller from above 52 50 51 49 Tiller from below 52 50 51 49 Item Control 50 t Load handler lower button 52 t Load handler raise button 49 o Load handler lower button 51 o Load h...

Page 106: ...s the settings in the code lock can be changed Parameter Description 0 0 0 Change master code see page 109 0 0 1 Add user codes see page 111 0 0 2 Change a user code see page 113 0 0 3 Delete a user c...

Page 107: ...y Pressing the o key switches the truck off and sets it to non operational status The o key indicates the follow operating conditions via a red green LED 68 Code lock function commissioning the truck...

Page 108: ...n Z If the LED 68 flashes red this means the wrong code has been entered Enter the code again The Set key 67 has no function in operating mode 7 3 3 Switching off the truck with the keypad CanCode Swi...

Page 109: ...the SET key 67 The LEDs 64 68 flash green Enter the valid master code again with the digit keys Confirm with the SET key 67 The LEDs 65 68 flash green Enter the valid master code with the digit keys Z...

Page 110: ...t the required master code can be used see page 113 Delete the user code so that the required master code can be used see page 115 The master codes to be changed do not match Switch off the truck see...

Page 111: ...r code must also be different from the existing master code Confirm with the SET key 67 The LEDs 66 68 flash green Enter the new user code again with the digit keys Confirm with the SET key 67 Wait un...

Page 112: ...master code is the same length as the user code New user code is already occupied by a master code Switch off the truck see page 108 Choose a different user code see page 111 The newly entered user c...

Page 113: ...s that of the previously entered master code The new user code must also be different from the existing master code Confirm with the SET key 67 The LEDs 66 68 flash green Enter the new user code again...

Page 114: ...aster code is the same length as the user code Operator code to be changed does not exist Switch off the truck see page 108 Check the user code entered The user codes to be changed do not match Switch...

Page 115: ...eys Confirm with the SET key 67 The LEDs 66 68 flash green Enter the user code to be deleted again with the digit keys Confirm with the SET key 67 Wait until the LED 68 flashes green The user code is...

Page 116: ...e Switch off the truck see page 108 Repeat the entry making sure that the master code is the same length as the user code Tried to delete an operator code that does not exist Switch off the truck see...

Page 117: ...flash green Enter the code 3 2 6 5 with the digit keys Confirm with the SET key 67 Wait until the LED 68 flashes green All user codes are deleted Press the O key 69 The truck is switched off and the...

Page 118: ...can be changed all user codes must be deleted The length of the user code 4 6 digit is always determined by the length of the master code Requirements To prepare the truck for operation see page 108 P...

Page 119: ...s 1 minute maximum cutout time is 30 minutes 31 After 10 seconds the truck cuts out automatically Confirm with the SET key 67 Wait until the LED 68 flashes green The setting is saved Press the O key 6...

Page 120: ...ic cutout period of the truck For the following events the LED 68 flashes red Cause Remedy Cutout time entered is out of range Switch off the truck see page 108 Enter the time again while making sure...

Page 121: ...the 64 65 66 LEDs LED 64 lit travel program 1 activated LED 65 lit travel program 2 activated LED 66 lit travel program 3 activated The configuration code is four digit and is comprised as follows 1s...

Page 122: ...th digit 0 When the truck has been switched on with the selected user code no travel program is activated 1 When the truck has been switched on with the selected user code travel program 1 is activate...

Page 123: ...configuration code 4 digit for the travel programs again using the digit keys Confirm with the SET key 67 Wait until the LED 68 flashes green The travel programs are now assigned to the user code Pre...

Page 124: ...rograms For the following events the LED 68 flashes red Cause Remedy Blocked travel program defined as start travel program Switch off the truck see page 108 Try again making sure the configuration co...

Page 125: ...Set key 67 Enter subindex enter 2 and confirm with the Set key 67 Z The parameter and sub index are displayed alternately with the current reading 0256 2 0000 3 Enter the parameter according to the pa...

Page 126: ...To continue setting reconfirm with the Set key 67 Saving travel parameters Requirements Enter all parameters Procedure Run SaveParameters by pressing 1 2 3 Set Confirm with the O key 69 126 04 19 en G...

Page 127: ...2 0 m s2 5 1 2 m s2 0276 Coasting brake 0 9 0 2 1 1 m s2 6 0 8 m s2 0280 Maximum speed in drive direction using travel switch 0 9 0 5 6 0 km h 9 6 0 km h depending on travel switch 0284 Maximum speed...

Page 128: ...Function Range Standard setting Comments 1377 Battery type 0 9 1 0 Normal wet 1 High performance wet 2 Dry maintenance free 9 XFC Special battery 1389 Discharge monitor function 0 1 1 0 Not active 1 A...

Page 129: ...d alternately with the current reading E g 1377 2 0000 1 corresponds to battery type high performance wet Enter parameter 2 according to the parameter list and confirm with the Set key The LED of the...

Page 130: ...code Enter the four digit parameter number 1377 and confirm with the Set key Enter sub index 2 and confirm with the Set key The parameter with subindex are displayed alternately with the current read...

Page 131: ...it LCD Service hours Parameter entry and changes Event messages Charge status display The charge status is shown through eight LED bars Eight lit LED bars correspond to a fully charged battery One lit...

Page 132: ...l batteries the T 74 symbol flashes in the service hour display 7 7 3 Event Messages The service hours display is also used to display event messages The event messages overwrite the service hour disp...

Page 133: ...the symbols see page 136 79 Battery type characteristics Displays the set battery type or set battery characteristic curve 1 1 Maintenance free gel dry cell battery 2 Special battery for example XFC...

Page 134: ...ction of the information line 76 The right section of the information line shows the truck speed in km h or mph Z The manufacturer s customer service department can change the information line from kg...

Page 135: ...main menu Symbol Meaning Menu change Changes to the next operator menu Travel program up t Changes the travel program in rider mode No symbol o Uses the pre set travel program in rider mode The defaul...

Page 136: ...ing lowering and or travel functions reduced Battery indicator low residual capacity Yellow Battery capacity 30 for wet cell batteries and lithium ion batteries battery capacity 50 for maintenance fre...

Page 137: ...tes if the lifting functions are shut off due to insufficient battery capacity Tiller position Yellow Lights up on power up with tiller in travel zone Illuminates with travel switch operated and tille...

Page 138: ...code is to be found on a sticker When using for the first time change the set up code and remove the sticker Default code 1 2 3 4 Factory set up code 2 4 1 2 Z When allocating the codes ensure the rid...

Page 139: ...nnect switch see page 75 Enter the access code with the buttons below the display 55 The truck is switched on 7 10 2 Switching off the truck Procedure Press the key under the Switch off symbol 84 in t...

Page 140: ...s Press the key below the Delete symbol 87 The set up code is deleted Enter the new set up code using the keys below the display unit 55 Z The new set up code must be different from existing access co...

Page 141: ...are displayed Press the key below the Add symbol 91 Enter the new access code using the keys below the display unit 55 Z The new access code must be different from existing access codes Press the key...

Page 142: ...e set up code is requested Enter the set up code using the keys below the display unit 55 All the access codes are displayed Select the access code to be deleted using the key below the Down selection...

Page 143: ...ys below the display unit 55 The set up code entered is shown as filled in circles To scroll forward press the button under the Down selection symbol 92 as many times as necessary The display area mov...

Page 144: ...144 04 19 en GB...

Page 145: ...ting in the field and there is no successor to the business operating companies must however Ensure that the changes to be made are planned tested and performed by an engineer specialising in industri...

Page 146: ...e able to carry out maintenance and repairs independently Customer Services are aware of the relevant standards guidelines and safety regulations as well as potential risks Operating company The maint...

Page 147: ...l hazard Used parts and consumables must be disposed of in accordance with the applicable environmental protection regulations Oil changes should be carried out by the manufacturer s customer service...

Page 148: ...ure must be disposed of in accordance with regulations WARNING Faulty hydraulic hoses can result in injury and infection Pressurised hydraulic oil can escape from fine holes or hairline cracks in the...

Page 149: ...l operating conditions a precautionary replacement of the hydraulic hoses is recommended after 6 years The owner must carry out a risk assessment to ensure safe prolonged use The resulting protection...

Page 150: ...containers uAlways fill consumables in clean containers uDo not mix up different grades of consumable The only exception to this is when mixing is expressly stipulated in the operating instructions C...

Page 151: ...when handling oil uAvoid contact and digestion If you swallow oil do not induce vomiting but seek medical assistance immediately uSeek fresh air after breathing in oil fumes or vapours uIf oil has com...

Page 152: ...0 9 l E E E 0 55 l g Running surfaces Cold store application Mixing ratio 1 1 s Grease nipple a Transmission oil drain plug b Transmission oil filler neck Gear oil overflow and dipstick Hydraulic oil...

Page 153: ...l the Jungheinrich hydraulic oil with a blue colouration and the cold store hydraulic oil red colouration The Jungheinrich hydraulic oil can only be obtained from the Jungheinrich service department T...

Page 154: ...hem to prevent the truck from from lowering tipping or sliding away uWhen raising the truck follow the instructions see page 35 When working on the parking brake prevent the truck from accidentally ro...

Page 155: ...drive chassis On the right hand side of the load handler On the left hand side of the drive chassis On the left hand side of the load handler Raise the truck Support the truck with hard wooden blocks...

Page 156: ...ircuiting CAUTION Risk of component damage when cleaning the truck Cleaning with a pressure washer can result in malfunctions due to humidity uCover all electronic system assemblies controllers sensor...

Page 157: ...ater based solvents and water Use a sponge or cloth to clean In particular clean the following areas Window s Oil filler ports and their surroundings Grease nipples before lubrication Dry the truck af...

Page 158: ...lectrical system assemblies Requirements Prepare the truck for maintenance and repairs see page 154 Tools and Material Required Compressor with water separator Non conductive antistatic brush Procedur...

Page 159: ...the Allen key Lift and remove the front panel 15 Place the front panel 15 safely to one side The front cover has been removed 95 15 Front panel assembly Tools and Material Required Allen key size 8 Pr...

Page 160: ...left limit position Release the second half 97 and carefully remove it The drive panel is now disassembled 97 63 96 96 Drive panel assembly Tools and Material Required Allen key Procedure Turn the ti...

Page 161: ...intenance and repairs see page 154 Tools and Material Required Torque wrench Procedure Position the drive wheel 99 so that the wheel nuts 98 can be pulled through the hole 100 Tighten all the wheel nu...

Page 162: ...between the markings see page 153 Turn the lid 102 clockwise on the hydraulic reservoir 103 Install the front panel see page 159 To restore the industrial truck to service after maintenance or repair...

Page 163: ...n tray underneath the transmission 105 Remove the front panel 15 see page 159 Turn the tiller 8 to the right limit position Check transmission oil level and if necessary top up with the correct grade...

Page 164: ...Check the fuse ratings against the table and replace if necessary The fuses have been checked EJE 220 225 230 235 107 108 109 110 Item Description To protect Rating 107 F13 Solenoid magnetic brake con...

Page 165: ...tect Rating 107 F13 Solenoid magnetic brake control fuse 10 A 108 1F9 Travel lift electronics control fuse 5 A 109 6F1 Discharge indicator control fuse 2 A 110 F15 Travel lift fuse 200 A 111 9F17 EJE...

Page 166: ...age 67 WARNING Faulty brakes can cause accidents As soon as the truck has been started test the brakes several times uReport any defects immediately to your supervisor uTag out and decommission the fa...

Page 167: ...ent 5 1 Prior to decommissioning Procedure Thoroughly clean the truck see page 155 Prevent the truck from rolling away accidentally Check the hydraulic oil level and replenish if necessary see page 16...

Page 168: ...7 WARNING Faulty brakes can cause accidents As soon as the truck has been started test the brakes several times uReport any defects immediately to your supervisor uTag out and decommission the faulty...

Page 169: ...ssioning or disposal of the truck in must be performed in accordance with the regulations of the country of use In particular regulations governing the disposal of batteries consumables and electronic...

Page 170: ...170 04 19 en GB...

Page 171: ...uck have a considerable impact on component wear The following service inspection and replacement intervals are based on single shift operation under normal operating conditions The intervals must be...

Page 172: ...To be performed every 50 service hours but at least once a week 1 1 1 Maintenance contents 1 1 1 1 Standard equipment Brakes Test the function of the brakes Hydraulic operations Correct the hydraulic...

Page 173: ...equipment Lead acid battery international Power supply Correct the battery acid level using demineralised water Lead acid battery Power supply Correct the battery acid level using demineralised water...

Page 174: ...e function and secure seating of the battery connector and for damage Travel The function of the collision safety switch and for damage Wheels for wear and damage Chassis structure Industrial truck fo...

Page 175: ...ard charger Battery charger The mains plug and mains cable for damage Lead acid battery international Power supply Battery and battery components for damage Battery cable connections are secure Lead a...

Page 176: ...stem Test the contactors and or relays Carry out a chassis insulation resistance test Chassis structure Check that the panels and covers as well as mounting brackets are secure Ensure they function co...

Page 177: ...options and special parts such as radio data and access modules ISM must be recorded in the test report Lead acid battery international Power supply Clean and grease the battery terminals Clean the b...

Page 178: ...ge Wheels for wear damage and secure mounting Chassis structure Industrial truck for damage and leaks The secure seating of the chassis and screw connections and for damage Labels are legible complete...

Page 179: ...for leaks Lateral battery removal Power supply The function of the battery latch and battery attachment and for damage Shock sensor data recorder Electrical system The shock sensor data recorder is s...

Page 180: ...ating of the battery battery cables and cell connectors and for damage The presence of safety labels are present and for damage Lead acid battery Power supply The secure seating of the battery battery...

Page 181: ...intervals 1 2 3 1 Standard equipment maintenance part service hours months Hydraulic oil 2000 12 Hydraulic system breather filter 2000 12 Transmission oil 10000 1 2 3 2 Optional equipment Cold store...

Page 182: ...ner To be performed every 50 service hours but at least once a week 2 1 1 Maintenance contents 2 1 1 1 Standard equipment Brakes Test the function of the brakes Hydraulic operations Correct the hydrau...

Page 183: ...equipment Lead acid battery international Power supply Correct the battery acid level using demineralised water Lead acid battery Power supply Correct the battery acid level using demineralised water...

Page 184: ...ge Power supply Battery and battery components for damage The function and secure seating of the battery connector and for damage Travel The function of the collision safety switch and for damage Whee...

Page 185: ...ard charger Battery charger The mains plug and mains cable for damage Lead acid battery international Power supply Battery and battery components for damage Battery cable connections are secure Lead a...

Page 186: ...e microswitches Test the contactors and or relays Carry out a chassis insulation resistance test Clean the motor engine with compressed air Hydraulic operations Test ramp lift and cut off Adjust the l...

Page 187: ...acid battery international Power supply Clean and grease the battery terminals Clean the battery Measure the acid density and battery voltage Correct the battery acid level using demineralised water...

Page 188: ...ge Travel Drivetrain bearings for wear and damage Transmission for noise and leaks Wheel bearings and attachment for wear and damage Wheels for wear damage and secure mounting Chassis structure Indust...

Page 189: ...Battery refill system Power supply The function of the battery refill system and for leaks Lateral battery removal Power supply The function of the battery latch and battery attachment and for damage...

Page 190: ...ating of the battery battery cables and cell connectors and for damage The presence of safety labels are present and for damage Lead acid battery Power supply The secure seating of the battery battery...

Page 191: ...intervals 2 2 3 1 Standard equipment maintenance part service hours months Hydraulic oil 2000 12 Hydraulic system breather filter 2000 12 Transmission oil 10000 2 2 3 2 Optional equipment Cold store...

Page 192: ...To be performed every 50 service hours but at least once a week 3 1 1 Maintenance contents 3 1 1 1 Standard equipment Brakes Test the function of the brakes Hydraulic operations Correct the hydraulic...

Page 193: ...equipment Lead acid battery international Power supply Correct the battery acid level using demineralised water Lead acid battery Power supply Correct the battery acid level using demineralised water...

Page 194: ...ge Power supply Battery and battery components for damage The function and secure seating of the battery connector and for damage Travel The function of the collision safety switch and for damage Whee...

Page 195: ...ard charger Battery charger The mains plug and mains cable for damage Lead acid battery international Power supply Battery and battery components for damage Battery cable connections are secure Lead a...

Page 196: ...l system Adjust the microswitches Test the contactors and or relays Carry out a chassis insulation resistance test Clean the motor engine with compressed air Hydraulic operations Correct the hydraulic...

Page 197: ...acid battery international Power supply Clean and grease the battery terminals Clean the battery Measure the acid density and battery voltage Correct the battery acid level using demineralised water...

Page 198: ...vel Drivetrain bearings for wear and damage Transmission for noise and leaks Wheel bearings and attachment for wear and damage Wheels for wear damage and secure mounting Chassis structure Industrial t...

Page 199: ...battery latch and battery attachment and for damage Shock sensor data recorder Electrical system The shock sensor data recorder is secure and for damage Access module Electrical system Access module i...

Page 200: ...intervals 3 2 3 1 Standard equipment maintenance part service hours months Hydraulic oil 2000 12 Hydraulic system breather filter 2000 12 Transmission oil 10000 3 2 3 2 Optional equipment Cold store...

Page 201: ...04 24 12 00 4 1 Owner To be performed every 50 service hours but at least once a week 4 1 1 Maintenance contents 4 1 1 1 Standard equipment Hydraulic operations Correct the hydraulic oil level Steerin...

Page 202: ...equipment Lead acid battery international Power supply Correct the battery acid level using demineralised water Lead acid battery Power supply Correct the battery acid level using demineralised water...

Page 203: ...e function and secure seating of the battery connector and for damage Travel The function of the collision safety switch and for damage Wheels for wear and damage Chassis structure Industrial truck fo...

Page 204: ...ard charger Battery charger The mains plug and mains cable for damage Lead acid battery international Power supply Battery and battery components for damage Battery cable connections are secure Lead a...

Page 205: ...system Test the contactors and or relays Carry out a chassis insulation resistance test Chassis structure Check that the panels and covers as well as mounting brackets are secure Ensure they function...

Page 206: ...options and special parts such as radio data and access modules ISM must be recorded in the test report Lead acid battery international Power supply Clean and grease the battery terminals Clean the b...

Page 207: ...ge Wheels for wear damage and secure mounting Chassis structure Industrial truck for damage and leaks The secure seating of the chassis and screw connections and for damage Labels are legible complete...

Page 208: ...for leaks Lateral battery removal Power supply The function of the battery latch and battery attachment and for damage Shock sensor data recorder Electrical system The shock sensor data recorder is s...

Page 209: ...ating of the battery battery cables and cell connectors and for damage The presence of safety labels are present and for damage Lead acid battery Power supply The secure seating of the battery battery...

Page 210: ...d intervals 4 2 3 1 Standard equipment maintenance part service hours months Hydraulic oil 2000 12 Hydraulic system breather filter 2000 12 Transmission oil 1000 4 2 3 2 Optional equipment Cold store...

Page 211: ...g during operation for batteries in accordance with Ex I and Ex II see relevant certification 2 Data plate 112 113 116 118 37 30 33 114 117 115 120 39 121 119 112 Model battery name 33 Production week...

Page 212: ...rom naked flames and strong heat sources Always wear protective clothing e g safety goggles and safety gloves when working on cells and batteries Always wash your hands after completing the work Use o...

Page 213: ...ctrolyte Battery cell width 158 mm PzS Lib Lead acid battery with Standard armour plated cells and liquid electrolyte Lead acid battery with extended maintenance interval Battery cell width 198 mm PzM...

Page 214: ...5 Nominal electrolyte density 2 1 29 kg l 6 Nominal temperature 3 30 C 7 System rated electrolyte level up to Max electrolyte level marking Limit temperature 4 55 C 2 Reached within the first 10 cycl...

Page 215: ...e the terminals are correct positive to positive and negative to negative and check that contacts on the battery terminal conducting system are secure Check the M10 terminal screws of the conductors a...

Page 216: ...y in terms of voltage charge capacity and battery technology uBefore charging check all cables and plug connections for visible signs of damage uVentilate the room in which the truck is being charged...

Page 217: ...ng the terminals are connect positive to positive and negative to negative Switch on the charger The battery is charged Z Charging is considered to be complete when the electrolyte density and battery...

Page 218: ...duction of electrolyte 4 3 2 Daily Battery cell cross section Top view of a battery cell 122 123 124 122 123 124 Charge the battery after each discharge After charging check the electrolyte level of e...

Page 219: ...ensity and the electrolyte temperature in all the cells Compare the results with the previous ones Z If you find significant differences compared with the previous measurements or differences between...

Page 220: ...sulphuric acid which is fixed in gel The density of the electrolyte cannot be measured Name Explanation PzV Lead acid battery with Standard closed armour plated cells and electrolyte in gel compound B...

Page 221: ...plosions The battery gives off a mixture of oxygen and hydrogen electrolytic gas during charging Gassing is a chemical process This gas mixture is highly explosive and must not be ignited uAlways disc...

Page 222: ...s charge the battery with DC current uAll DIN 41773 charging procedures are permitted in the format approved by the manufacturer uAlways connect the battery to a charger that is appropriate to the siz...

Page 223: ...C per C The battery is charged Z Charging is considered to be complete when the electrolyte density and battery voltage remain constant for more than 2 hours Compensation charging Compensation chargin...

Page 224: ...ry out the measurements after full charging and subsequent resting for at least 5 hours Z If you find significant differences compared with the previous measurements or differences between the cells c...

Page 225: ...t system 6 1 Water replenishment system design 125 126 127 128 129 130 3 m 125 Water container 126 Tap connection with ball cock 127 Flow indicator 128 Shut off cock 129 Locking coupling 130 Battery l...

Page 226: ...lug systems have an optical level indicator a diagnostic port to measure the temperature and electrolyte density and a degassing port 6 3 Adding water Water should be added to the batteries just befor...

Page 227: ...ndividual plugs is in accordance with the existing electric circuit No changes should be made 6 8 Operating temperature Batteries with automatic water replenishment systems should only be stored in ro...

Page 228: ...d replaced if necessary Battery connection A hose is attached to the pump module which together with the charge leads is routed from the charger to the charging connector The air is passed on to the b...

Page 229: ...emperature fluctuations the electrolyte may flow back into the hose system uAttach a separate coupling system to the air inlet line such as locking coupling to the battery side and through coupling to...

Page 230: ...nage system for processing the electrolytic rinsing water All health and safety as well as water and waste disposal regulations are observed when disposing of used electrolyte or rinsing water Protect...

Page 231: ...ure does not exceed 60 C at a distance of 30cm behind the outlet nozzle Observe the maximum operating pressure of 50 bar Observe a minimum distance of 30 cm from the top of the battery The battery sho...

Page 232: ...V batteries If the battery is to be taken out of service for a long period 3 months it should as far as possible be charged to 50 of its charge level and stored in a dry room protected from frost 10 T...

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