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Jungheinrich EJE 220, Руководство по эксплуатации

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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.

15

04.19 en-GB

Содержание EJE 220

Страница 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...

Страница 2: ...2...

Страница 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...

Страница 4: ...4 04 19 en GB...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 34: ...34 04 19 en GB...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 64: ...64 04 19 en GB...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 91: ...91 04 19 en GB...

Страница 92: ...92 04 19 en GB...

Страница 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...

Страница 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...

Страница 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...

Страница 96: ...96 04 19 en GB...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 144: ...144 04 19 en GB...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 170: ...170 04 19 en GB...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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