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Jungheinrich
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ECE 220 XL

Jungheinrich ECE 220 Standard, ECE 220 Rapid drive, ECE 220 XL, ECE 220 XL Rapid drive, 50435801 Operating Instructions Manual

Operating instructions
50435801
G
04.04-
03.07
ECE 220
0108.GB
Foreword
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter. Each chapter starts with page 1. The page identification consists of a chapter letter and a page number. For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following graphics:
F
Used before safety instructions which must be observed to avoid danger to personnel.
M
Used before notices which must be observed to avoid material damage.
Z
Used before notices and explanations.
t Used to indicate standard equipment.
o Used to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. No guarantee of particular features of the truck should therefore be inferred from the present operating instructions.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35 22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
0108.GB
I 1
0404.GB
Table of contents
A Correct use and application of the truck
B Description of the truck
1 Design and application ........................................................................ B 1
2 Assemblies ......................................................................................... B 2
3 Technical data - standard version ....................................................... B 3
3.1 Performance data ................................................................................ B 3
3.2 Dimensions ......................................................................................... B 4
3.3 EN standards ...................................................................................... B 6
3.4 Conditions for application .................................................................... B 6
4 Identification locations and identification plates ................................. B 7
4.1 Truck identification plate ..................................................................... B 8
C Transportation and commissioning
1 Transportation by crane ...................................................................... C 1
2 Commissioning .................................................................................... C 1
3 Operating the truck without its own drive system ................................ C 2
D Battery - Servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ........ D 1
2 Battery types ....................................................................................... D 2
3 Exposing the battery ........................................................................... D 2
4 Charging the battery ............................................................................ D 3
5 Removing and installing the battery .................................................... D 4
0404.GB
I 2
E Operation
1 Safety regulations governing the operation of the fork lift truck .......... E 1
2 Description of the operating controls and indicators ........................... E 2
3 Starting up the truck ............................................................................ E 6
4 Operation of the fork lift truck .............................................................. E 7
4.1 Safety regulations applicable when operating the truck ...................... E 7
4.2 Driving, steering, braking .................................................................... E 8
4.3 Pedestrian-controlled operation (o) .................................................... E 12
4.4 Picking up and setting down loads ...................................................... E 13
4.5 Order-picking up to the second level ................................................... E 14
4.6 Seat o (XL only) ................................................................................. E 15
4.7 Safe parking of the truck ..................................................................... E 15
5 Keyboard (CANCODE) (o) ................................................................. E 16
5.1 Code lock ............................................................................................ E 16
5.2 Travel programmes ............................................................................. E 18
5.3 Parameters .......................................................................................... E 18
5.4 Parameter settings .............................................................................. E 19
5.5 Travel parameters ............................................................................... E 23
6 Display instrument (CANDIS) (o) ....................................................... E 28
6.1 Discharge monitor function ................................................................. E 29
6.2 Operating hours display ...................................................................... E 29
6.3 Switch-on test ...................................................................................... E 29
7 Fault location ....................................................................................... E 30
F Maintenance of the fork lift truck
1 Operational safety and environmental protection ................................ F 1
2 Safety regulations applicable to truck maintenance ............................ F 1
3 Servicing and inspection ..................................................................... F 3
4 Maintenance checklist ......................................................................... F 4
5 Lubrication schedule ECE 220 ............................................................ F 6
5.1 Fuels, coolants and lubricants ............................................................. F 7
6 Instructions for the servicing operations .............................................. F 8
6.1 Preparing the truck for the performance of servicing and
maintenance operations ...................................................................... F 8
6.2 Tightening the wheel screws ............................................................... F 8
6.3 Removing the front hood ..................................................................... F 9
6.4 Checking the electric fuses ................................................................. F 10
6.5 Recommissioning the truck ................................................................. F 11
7 Decommissioning the fork lift truck ..................................................... F 11
7.1 Operations to be performed prior to decommissioning ....................... F 11
7.2 Measures to be taken during decommissioning .................................. F 11
7.3 Recommissioning the truck ................................................................. F 12
8 Safety checks to be performed at regular intervals and following
any untoward incidents (D: Accident prevention check
according to BGV D27) ....................................................................... F 12
1
0506.GB
Appendix
JH Traction Battery Operating Instructions
Z
These operating instructions apply only to Jungheinrich battery models. If using another brand, refer to the manufacturer's operating instructions.
2
A 1
0404.GB
A Correct use and application of the truck
Z
The „Guidelines for the Correct Use and Application of Industrial Trucks“ (VDMA) are included in the scope of delivery for this truck. The guidelines are part of these oper- ating instructions and must always be heeded. National regulations are fully applica- ble.
The fork lift truck described in these operating instructions is a truck that is suitable for lifting and transporting loads. It must be used, operated and maintained according to the information in these oper- ating instructions. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. admis- sible load to be picked up is indicated on the identification plate or load diagram label shown on the truck. The fork lift truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres pre- vail.
Duties of the user: A „user“ within the meaning of these operating instructions is de- fined as any natural or legal person who either uses the fork lift truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is consid- ered the person, who, in accordance with existing contractual agreements between the owner and the user of the fork lift truck, is charged with the observance of the op- erating duties. The user must ensure that the truck is not abused and only used within its design lim- its and that all danger to life and limb of the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety-related provisions, as well as the operating, servicing and mainte- nance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions.
M
If these operating instructions are not observed the warranty becomes void. The same applies if improper works are carried out at the device by the customer and/or third parties without permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after writ- ten approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained. Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary.
0404.GB
A 2
B 1
1106.G B
B Description of the truck
1 Design and application
The truck is an electric pallet truck in four-wheel version with driver stand and equip- ped with tiller-shaft steering or Jet Pilot (o). The truck is designed for use on level surfaces for transporting and order-picking goods. Pallets with open ground support or pallets fitted with lateral boards (provided that the boards are outside the range of the load-bearing wheels) can be picked up. The second picking level can be reached via a step (o) in the backrest and by stan- ding on the battery cover. The rated capacity of the truck is shown on the identification plate or on the capacity label Qmax.
1106.G B
B 2
2 Assemblies
Item Designation Item Designation
1 t Front hood 11 o Stop button 2 t Battery hood 12 o Forward “pedestrian / walk-
along operation” button
3 t Control shaft 13 o Storage compartment 4 t Master switch
(emergency stop)
14 o Lift mechanism
5 t Controller 15 t Jet Pilot 6 t Brake key 16 t Seat (XL version only) 7 o Keyboard
(CANCODE)
17 o Castor wheel
8 o Display instrument
(CANDIS)
18 o Drive wheel
9 t Key switch
10 o Reverse “pedestrian
operation” button
t = Standard equipment o = Optional equipment
4 5 63
16
2
1
20
19
7, 8 9
15
14
13
12
10
11
17
18
B 3
1106.G B
3 Technical data - standard version
Z
Indication of technical data according to VDI 2198, subject to modification and supplementing.
3.1 Performance data
*) For trucks with longer forks the load centre is in the centre of the fork.
Designation
ECE 220
Standard
ECE 220
Rapid
drive
ECE 220
XL
ECE 220
XL
Rapid
drive
Q Rated capacity 2000 2000 2000 2000 kg
c
Load centre distance with standard fork length *
)
600 600 600 600 mm
Travelling speed
with / without rated load
8,5 / 10,5 9,5 / 12,5 8,5 / 10,5 9,5 / 12,5 km/h
Lifting speed
with / without rated load
5,0 / 6,0 5,0 / 6,0 5,0 / 6,0 5,0 / 6,0 cm/s
Lowering speed
with / without rated load
6,0 / 4,0 6,0 / 4,0 6,0 / 4,0 6,0 / 4,0 cm/s
Max. climbing capacity (5 min.) with / without load
6 / 10 6 / 10 6 / 10 6 / 10 %
h
b
h
f
h
r
h
k
y
e
95
c
l
h
3
b
1
l
2
a
/
2
a
/
2
h
13
30
218
(l1)
l
6
b3b11b
12
W
a
253l
b
l
f
1106.G B
B 4
3.2 Dimensions
(all dimensions in mm)
Designation Standard XL
l2Design length of front 1267 1434 lbDistance wheel <-> battery 388 506
lfLength of driver standing plat-
form
408 457
h13Height of fork when lowered 90 90
h3Lift 125 125
hkHeight of backrest “order-pick-
ing on 2nd level”
1867 1877
hrHeight of backrest without “or-
der-picking on 2nd level”
1255 1266
hbHeight of battery hood 959 1009
hfHeight of driver standing plat-
form
132 142
b1Truck width 805 805
b3Distance between forks, inside 170 / 200 / 330 170 / 200 / 330 b11Track, rear 340 / 370 / 500 340 / 370 / 500 b12Distance between forks,
outside
510 / 540 / 670 510 / 540 / 670
e Fork width 170 170 a Safety distance 200 200
Dead weight: Refer to truck identifi-
cation label
Refer to truck identifi-
cation label
B 5
1106.G B
Working aisle widths ECE 220 Standard
(all dimensions in mm)
Working aisle widths ECE 220 XL
1)
with the load part lifted, the values are reduced by 89mm.
ll1y
1)
x
1)
l
6
W
a
1)
A
st3
1000 2267 1863 814 1000 2081 2467
1150 2417 2013 964 1200 2231 2667
1400 2667 2263 1214 1400 2481 2867
1400 2667 1891 842 1400 2109 2867
1450 2717 1941 892 1450 2159 2917
1600 2867 2463 1414 1600 2681 3067
1600 2867 2091 1042 1600 2309 3067
1950 3217 2441 1392 2000 2659 3467
2180 3447 2671 1622 2180 2889 3647
2310 3577 3173 2124 2330 3391 3797
2400 3667 2889 1840 2400 3107 3867
2400 3667 2649 1600 2400 2867 3867
2430 3697 2579 1530 2438 2797 3905
2550 3817 2799 1750 2550 3017 4017
2850 4117 3099 2050 2850 3317 4317
2900 4167 3149 2100 2900 3367 4367
3100 4367 3349 2300 3100 3567 4567
ll
1
y
1)
x
1)
l
6
W
a
1)
A
st3
1000 2434 2030 814 1000 2248 2634
1150 2584 2180 964 1200 2398 2834
1400 2834 2430 1214 1400 2648 3034
1400 2834 2058 842 1400 2276 3034
1450 2884 2108 892 1450 2326 3084
1600 3034 2630 1414 1600 2848 3234
1600 3034 2258 1042 1600 2476 3234
1950 3384 2608 1392 2000 2826 3634
2180 3614 2838 1622 2180 3056 3814
2310 3744 3340 2124 2330 3558 3964
2400 3834 3056 1840 2400 3274 4034
2400 3834 2816 1600 2400 3034 4034
2430 3864 2746 1530 2438 2964 4072
2550 3984 2966 1750 2550 3184 4184
2850 4284 3266 2050 2850 3484 4484
2900 4334 3316 2100 2900 3534 4534
3100 4534 3516 2300 3100 3734 4734
1106.G B
B 6
3.3 EN standards
Continuous sound level: 69 dB(A)
according to EN 12053 as stipulated in ISO 4871
Z
The continuous sound level is a value averaged according to standard regulations, taking the sound pressure level into account when driving, lifting and idling. The sound pressure level is measured at the ear.
Vibration: 0.75 m/s
2
according to EN 13059
Z
The swinging acceleration acting on the body in its operating position is, according to standard regulations, the linear integrated, weighted acceleration in the vertical plane. It is determined by driving over bumps with a constant speed.
Electromagnetic compatibility (EMC)
The manufacturer confirms compliance with the limit val- ues for electromagnetic emission and interference immu- nity as well as testing of static electricity discharge ac- cording to EN 12895 and the references to other standards contained therein.
Z
Electrical or electronic components and their arrangement may only be modified after written approval by the manufacturer has been obtained.
3.4 Conditions for application
Ambient temperature:
- during operation: -10 °C to 40 °C
Z
Special equipment and a special approval are required if fork-lifttrucks are operated under continued extreme temperature or humidity fluctuations.
)
B 7
1106.G B
4 Identification locations and identification plates
Z
The capacity label (25) indicates the maximum capacity of the truck as Qmax. The rated capacity indicated must not be exceeded and the load should be distributed as evenly as possible on the forks.
Item Model
19 Truck data plate
20 “Attention Touch Mode” warning decal
*) for “Touch mode only in drive direction” option
21 Accident prevention inspection label (Donly)
22 Capacity Qmax / load distribution
23 Attachment point of hooks for transportation by crane (inside)
“Read operating instructions” warning
24
25
26
22
21
Q
max
2000
kg
*
)
*)
23
23
23
1106.G B
B 8
4.1 Truck identification plate
Z
In the event of queries relating to the truck or spare part orders, please state the serial No. (28) of the truck.
Item Designation Item Designation
27 Type 33 Manufacturer
28 Serial No. 34 Min./max. battery weight in kg
29 Rated capacity in kg 35 Drive power in kW
30 Battery: Voltage V 36 Load centre distance in mm
31 Empty weight without battery in kg 37 Year of manufacture
32 Manufacturer logo 38 Option
33
32
34
31
35
30
36
29
37
28
38
27
C 1
1106.G B
C Transportation and commissioning
1 Transportation by crane
F
Only lifting gear of adequate ca- pacity must be used (for the transport weight, refer to the truck identification label).
Z
Lifting gear attachment points are provided on the chassis (1) and the fork (2) in case the truck is to be lifted or transported by crane.
– Park the truck and render it
safe (refer to chapter E). – Open front hood (5) and put
away (refer to chapter F). – Secure the lifting gear to the
attachment points (1) and (2).
M
The lifting gear must be at- tached to the attachment points in such a manner that it abso- lutely cannot slip and cannot come into contact with any at- tachments of the truck when the truck is lifted.
2 Commissioning
M
The truck must only be operated on battery current. Rectified alternate current will damage the electronics. Cables connected to the battery (trailing cables) must be less than 6 meters in length.
In order to prepare the truck for work following delivery or transportation, the following operations must be performed:
– Check the truck for completeness and satisfactory condition of the equipment. – If necessary, install the battery. Do not damage the battery cable
(refer to chapter D). – Charge the battery (refer to chapter D). – Commission the truck as detailed in chapter E.
Z
When the truck is parked for extended periods, the running surface of the tyres may flatten. The flattening will disappear after a short operating time of the truck.
2
1
1106.G B
C 2
3 Operating the truck without its own drive system
F
This operating mode is not permitted when negotiating inclines and gradients.
If the truck has to be moved after a failure has rendered it immobile, proceed as follows:
– Set the isolator “OFF”. – Set the key switch “OFF” (“0”) and remove the key. – Prevent the truck from rolling away. – Open the battery panel (see chapter D). – Open the front panel (5) and put it to one side (see chapter F). – Screw on 2 off M4x20 bolts (3) to loosen the armature plate.
The brake is now released and the truck can move.
F
Remove the screws again once you have parked the truck at its destination. Braking is now restored again.
– Refit the front panel (5).
5
4
3
D 1
0404.GB
D Battery - Servicing, recharging, replace-
ment
1 Safety regulations governing the handling of lead-acid batteries
The truck must be parked and rendered safe before any operations on batteries are undertaken (refer to chapter E).
Servicing staff: Recharging, servicing and replacing of batteries must only be per- formed by qualified personnel. The instructions contained in this operating manual, and the instructions of the manufacturer of the battery and of the battery recharging station, must be observed when performing the above operations.
Fire protection measures: Smoking and naked flames are not permitted when han- dling batteries. No inflammable substances or spark-generating materials must be present or stored within a distance of 2 meters of the truck parked for battery recharg- ing. The location must be well ventilated and fire fighting equipment must be kept ready.
Servicing of batteries: The battery cell screw caps must be kept dry and clean. Ter- minals and cable shoes must be clean, lightly greased with pole grease and must be securely tightened. Batteries with bare terminal posts must be covered using a non- skid insulating mat.
Disposal of the battery: Batteries must only be disposed of as stipulated in the na- tional environmental protection regulations or waste disposal provisions. The manu- facturer’s specifications for the disposal must be heeded.
M
Before closing the battery hood, make sure that the battery cable cannot be dam- aged.
F
Batteries contain dissolved acid which is toxic and caustic. For this reason, protective clothing and goggles must be worn whenever work is undertaken on batteries. Avoid physical contact with battery acid. If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush the affected parts with clean water. Consult a doctor when skin or eyes come into con- tact with battery acid. Spilled battery acid must be immediately neutralized.
M
Only batteries with closed tray may be used.
F
Battery weight and dimensions have considerable influence on operational safety of the truck. Changing the battery equipment is not permitted without prior approval by the manufacturer.
0404.GB
D 2
2Battery types
Depending on the use, the truck is equipped with different types of batteries. The table below shows the capacity of the batteries and also the combinations used as standard equipment:
1)
XL version only
For the battery weight, refer to the battery identification plate.
Depending on the type of battery used, it is also possible to use models with en- hanced performance or maintenance-free batteries.
F
When changing/replacing the battery you must make sure that the battery is safely fastened in the battery compartment of the truck.
3 Exposing the battery
F
Park the truck and render it safe (refer to chapter E).
– Pull lever (1) upward and at the same time swivel up the control shaft. – Release the lever (1) again. – Fold up the battery hood latch (2), lift the locking mechanism and open the battery
cover (3).
F
All covers and connections must be restored to the normal operating condition before the truck is started up for work.
24 V PzS battery 3 PzS 420 Ah L
24 V PzS battery performance-enhanced 3 PzS 450 Ah HX
24 V PzS battery 4 PzS 560 Ah L
1)
24 V PzS battery performance-enhanced 4 PzS 600 Ah HX
1)
1
23
D 3
0404.GB
4 Charging the battery
F
To charge the battery, the truck must be parked in a closed and properly ventilated room.
– Expose the battery (refer to section 3).
M
The battery connector (4) and the charging cable (7) must only be connected or dis- connected with the truck and the battery charger switched off. The master switch (6) must also only be actuated with the truck and the battery charger switched off.
F
During the recharging operation, the tops of the battery cells must be exposed to en- sure adequate ventilation. No metal objects must be placed on the battery. Prior to starting the recharging operation, check all cable connections and plugged connec- tions for visible damage. All safety instructions as provided by the battery supplier and battery charger supplier must be strictly observed.
– Pull out the battery plug (4) from the holder (5). – Remove any insulating mats from the battery. – Connect the charging cable (7) of the battery charger to the battery connector (4)
and switch on the charger.
M
Recharge the battery observing the instructions provided by the battery supplier and by the battery charger supplier.
7
54 6
0404.GB
D 4
5 Removing and installing the battery
F
The truck must be parked on level ground. To prevent short-circuits, batteries with ex- posed poles or cell connectors must be covered using a rubber mat. Place the battery connector or the battery cable, respectively, in such a way that they will not catch be- hind any truck protrusions when the battery is withdrawn.
M
When transporting batteries with the aid of a crane, ensure that the crane is of ade- quate capacity (the battery weight is indicated on the battery identification plate at the battery trough). The lifting gear must pull in a vertical direction to prevent damage to the battery trough. Attach the hooks to the attachment points (8) in such a way that the lifting gear, when slack, cannot collapse on the battery cells.
– Expose the battery (refer to section 3). – Pull out the battery plug (4) from the holder (5). – Fold back the battery locking mechanism (9). – Pull the battery (10) laterally onto the battery exchange trolley or lift the battery
carefully and slowly out of the truck using lifting gear.
F
Observe the operating instructions of the manufacturer of the battery exchange trol- ley!
Installation is in the reverse order of operations. When reinstalling the battery, heed the required installation position and make sure the battery is connected correctly.
F
After reinstallation of the battery, visually check all leads and connectors for damage. Ensure that the battery is firmly secured in the truck to prevent any damage caused by sudden movements of the truck. After each replacement it must be ensured that the battery is secured against sliding, by flipping over the battery locking mechanism (9) into the recess. The battery hood must be securely locked.
5
9
4
10
8
8
E 1
1106.G B
E Operation
1 Safety regulations governing the operation of the fork lift truck
Driving permission: The fork lift truck must only be operated by persons who have
been trained in the operation of trucks, who have demonstrated to the user or his rep- resentative their capability of moving and handling loads, and who have expressly been charged by the user or his representative with the operation of the truck.
Rights, duties and conduct of the driver: The driver must be: informed of his rights and duties; trained in the operation of the fork lift truck; and familiar with the contents of these operating instructions. All necessary rights must be granted to him. If the fork lift truck can be used in the pedestrian-controlled mode, the driver must wear safety boots when operating the truck.
Prohibition of unauthorised use: The driver is responsible for the fork lift truck dur- ing working time. He must forbid unauthorised persons to drive or operate the fork lift truck. The transport or lifting of persons is forbidden.
Damage and defects: Damage or defects noted on the fork lift truck or on the attach- ments must immediately be brought to the notice of the person in charge. fork lift trucks that cannot be safely operated (e.g. due to worn tyres or defective brakes) must not be used until they have been properly repaired.
Repairs: Without specific training and express authorisation, the driver is not allowed to perform any repairs or modifications on the fork lift truck. Under no circumstances must the driver change the setting of switches or safety installations or render them ineffective.
Danger area: A “danger area” is considered to be the area within which persons are endangered by the travelling or lifting movements of the fork lift truck or its load lifting devices (e.g. fork or attachments), or by the loads being transported. This also in- cludes the area within reach of falling loads or falling / lowering truck attachments.
F
Unauthorised persons must be asked to leave the danger area. The driver must give a warning signal whenever a situation presenting danger to persons might develop. The fork lift truck must immediately be brought to a standstill if persons, although asked, do not leave the danger area.
Safety devices and warning labels: The safety devices, warning labels and warning notes described in the present operating instructions must always be heeded.
1106.G B
E 2
2 Description of the operating controls and indicators
Item Operating control or indicator Function
1 Master switch
(emergency stop)
t The circuit is interrupted, all electrical func-
tions are switched off and the truck is auto- matically braked.
2 Operating key “Horn” t Gives an audible warning signal. 3 Operating key “Lowering” t Lowers the lifting device. 4 Operating key “Lifting” t Lifts the lifting device. 5 Brake key t The truck is braked at the maximum possi-
ble deceleration rate until it stands still.
6 Controller t Controls the direction of travel as well as
the travelling speed.
7 Control shaft t Is used to steer the truck. 8Jet Pilot o Is used to steer the truck.
9 Key “Pedestrian operation
forward”
o Travel is started in pedestrian-controlled
operation in forward direction (V) (slow travel).
10 Stop button o The electrical functions are switched off
and the truck is automatically decelerated.
11 Key “Pedestrian operation
backward” (not for “inching function in drive direction on- ly” option)
o Travel is started in pedestrian-controlled
operation in reverse direction (R) (slow travel).
t = Standard equipment o = Optional equipment
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