Jungheinrich EJD 220 Service Manual
01.10 -
11.14
51132781
EJD 220
Operating instructions G
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Declaration of Conformity
Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg
Manufacturer or agent acting in the European Union
Additional information
On behalf of
Date
G
EU Conformity Declaration
The undersigned hereby declare that the powered industrial truck described below in
detail complies with the European Directives 2006/42/EC (Machinery Directive) and
2004/108/EEC (Electromagnetic Compatibility - EMC) including amendments as well
as the legislative decree to incorporate the directives in national law. The signatories
are in each case individually authorized to compile the technical documents.
Type Option Serial no. Year of
manufacture
EJD 220
G
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Foreword
Notes on the operating instructions
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter and the pages are
numbered continuously.
The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your
truck model.
Our trucks are subject to ongoing development. We reserve the right to alter the
design, equipment and technical features of the system. No guarantee of particular
features of the truck should therefore be assumed from the present operating
instructions.
Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following
graphics:
DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury and even death.
CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury.
NOTE
Indicates a material hazard. Failure to comply with this instruction may result in
material damage.
Z Used before notices and explanations.
t Indicates standard equipment
o Indicates optional equipment
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Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - Germany
Tel: +49 (0) 40/6948-0
www.jungheinrich.com
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Contents
A Correct Use and Application ................................................... 11
1 General.................................................................................................... 11
2 Correct application................................................................................... 11
3 Approved application conditions.............................................................. 12
4 Proprietor responsibilities ........................................................................ 13
5 Adding attachments and/or optional equipment ...................................... 13
B Truck Description .................................................................... 15
1 Application ............................................................................................... 15
1.1 Truck models and rated capacity............................................................. 15
2 Travel direction definition......................................................................... 16
3 Assemblies and Functional Description................................................... 17
3.1 Assembly Overview ................................................................................. 17
3.2 Functional Description ............................................................................. 18
4 Technical Specifications .......................................................................... 21
4.1 Performance data .................................................................................... 21
4.2 Dimensions .............................................................................................. 22
4.3 Weights.................................................................................................... 24
4.4 Tyre type.................................................................................................. 24
4.5 EN norms................................................................................................. 25
4.6 Conditions of use ..................................................................................... 26
4.7 Electrical Requirements........................................................................... 26
5 Identification Points and Data Plates....................................................... 27
5.1 Indication Points ...................................................................................... 27
5.2 Data plate ................................................................................................ 29
5.3 Truck capacity plate................................................................................. 30
5.4 Wind loads ............................................................................................... 31
5.5 Double Decker Mode Capacity Plate....................................................... 32
C Transport and Commissioning ................................................ 33
1 Lifting by crane ........................................................................................ 33
2 Transport ................................................................................................. 35
3 Using the Truck for the First Time ........................................................... 36
D Battery - Servicing, Recharging, Replacement ....................... 37
1 Safety Regulations Governing the Handling of Lead-Acid Batteries ....... 37
2 Battery types............................................................................................ 39
3 Exposing the battery................................................................................ 40
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4 Charging the battery ................................................................................ 41
4.1 Charging the battery with a stationary charger ........................................ 42
4.2 Charging the battery with an on-board charger (o) ................................ 43
5 Battery removal and installation .............................................................. 49
5.1 Lateral battery removal ............................................................................ 50
E Operation ................................................................................ 53
1 Safety Regulations for the Operation of the Forklift Truck....................... 53
2 Displays and Controls.............................................................................. 55
2.1 Battery discharge monitor........................................................................ 58
2.2 Battery discharge indicator ...................................................................... 59
3 Preparing the Truck for Operation ........................................................... 60
3.1 Checks and Operations to Be Performed Before Starting Daily Work .... 60
3.2 Preparing the truck for operation ............................................................. 61
3.3 Checks and operations to be carried out when the truck is operational .. 62
3.4 Parking the truck securely ....................................................................... 63
4 Industrial Truck Operation ....................................................................... 64
4.1 Safety regulations for truck operation ...................................................... 64
4.2 Emergency Disconnect............................................................................ 66
4.3 Automatic braking .................................................................................... 68
4.4 Travel....................................................................................................... 69
4.5 Slow travel ............................................................................................... 72
4.6 Steering ................................................................................................... 72
4.7 Brakes ..................................................................................................... 73
4.8 Load handler raise/lower ......................................................................... 75
4.9 Lifting, transporting and depositing loads ................................................ 78
5 Troubleshooting....................................................................................... 86
5.1 Truck does not start ................................................................................. 87
5.2 Load cannot be lifted ............................................................................... 88
6 Operating the truck without its own drive system .................................... 89
6.1 Release and activate the drive wheel brake ............................................ 89
7 Load handler emergency lowering .......................................................... 91
8 Optional equipment ................................................................................. 92
8.1 Emergency operation with service key GF60 .......................................... 92
8.2 CanCode Keypad (o).............................................................................. 94
8.3 Setting the truck parameters with CanCode ............................................ 113
8.4 Parameters .............................................................................................. 115
8.5 Setting the Battery Parameters with CanCode ........................................ 120
8.6 CanDis Display Instrument (o) ............................................................... 122
8.7 ISM access module (o)........................................................................... 123
F Industrial Truck Maintenance .................................................. 125
1 Operational Safety and Environmental Protection................................... 125
2 Maintenance Safety Regulations............................................................. 126
2.1 Working on the electrical system ............................................................. 127
2.2 Consumables and used parts .................................................................. 127
2.3 Wheels..................................................................................................... 127
2.4 Hydraulic system ..................................................................................... 128
2.5 Lift Chains................................................................................................ 129
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3 Lubricants and Lubrication Schedule ...................................................... 130
3.1 Handling consumables safely .................................................................. 130
3.2 Lubrication Schedule ............................................................................... 132
3.3 Consumables........................................................................................... 133
4 Maintenance and repairs ......................................................................... 134
4.1 Preparing the truck for maintenance and repairs .................................... 134
4.2 Lifting and jacking up the truck safely...................................................... 135
4.3 Cleaning .................................................................................................. 136
4.4 Front cover disassembly.......................................................................... 139
4.5 Drive panel disassembly and assembly .................................................. 139
4.6 Checking the hydraulic oil level ............................................................... 140
4.7 Check the gear oil level ........................................................................... 141
4.8 Tightening the wheel nuts........................................................................ 142
4.9 Checking electrical fuses ......................................................................... 143
4.10 Restoring the truck to service after maintenance and repairs ................. 144
5 Decommissioning the Industrial Truck..................................................... 145
5.1 Prior to decommissioning ........................................................................ 145
5.2 Action to be taken during decommissioning ............................................ 145
5.3 Restoring the truck to service after decommissioning ............................. 146
6 Safety tests to be performed at intervals and after unusual incidents ..... 147
7 Final de-commissioning, disposal............................................................ 147
8 Human vibration measurement ............................................................... 147
9 Servicing and Inspection ......................................................................... 148
10 Maintenance checklist ............................................................................. 149
10.1 Operating company ................................................................................. 149
10.2 Customer Service .................................................................................... 151
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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.
0506.GB
2
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A Correct Use and Application
1 General
The truck must be used, operated and serviced in accordance with the present
instructions. All other types of use are beyond its scope of application and may result
in damage to personnel, the industrial truck or property.
2 Correct application
NOTE
The maximum load and load distance 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 "Lifting, transporting and depositing loads" on
page 78.
– Lifting and lowering loads.
– Transporting lowered loads.
– Do not travel with a raised load (>500 mm).
In double-decker mode the load handler must not be raised higher than 1800 mm.
The bottom load must be heavier than the top.
– Do not carry or lift passengers.
– Do not push or pull load units.
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3 Approved application conditions
– Operation in industrial and commercial environments.
– Permissible temperature range 5°C to 40°C.
– Operation only on secure, level surfaces with sufficient capacity.
– Do not exceed the permissible surface and spot load limits on the travel routes.
– Operation only on routes that are visible and approved by the operating company.
– Negotiating inclines up to a maximum of 15 %.
– Do not travel across or at an angle on inclines. Travel with the load facing uphill.
– Operation in partially public traffic.
WARNING!
Use under extreme conditions
Using the truck under extreme conditions can result in malfunctions and accidents.
XSpecial equipment and authorisation are required if the truck is to be constantly
used in extreme conditions, especially in dusty or corrosive atmospheres.
XThe truck cannot be used in areas at risk of explosion.
XIn adverse weather conditions (thunder, lightning) the industrial truck must not be
operated outside or in endangered areas.
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4 Proprietor responsibilities
For the purposes of the present operating instructions the “operating company” is
defined as any natural or legal person who either uses the industrial truck himself, or
on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is
considered the person who, in accordance with existing contractual agreements
between the owner and user of the industrial truck, is charged with operational duties.
The proprietor must ensure that the industrial truck is used only for the purpose it is
intended for and that danger to life and limb of the user and third parties are excluded.
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 understood these operating instructions.
NOTE
Failure to comply with the operating instructions invalidates the warranty. The same
applies if improper work is carried out on the truck by the customer or third parties
without the permission of the manufacturer.
5 Adding attachments and/or optional equipment
The mounting or installation of additional equipment which affects or enhances the
performance of the industrial truck requires the written permission of the
manufacturer. Local authority approval may also need to be obtained.
Local authority approval however does not constitute the manufacturer’s approval.
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B Truck Description
1 Application
The EJD 220 is a three-wheel, electric tiller-operated pallet truck with a steered drive
wheel and coupling unit
It is designed to be used on level surfaces for lifting, stacking and transporting goods.
For transportation, two pallets can be stacked on top of each other. Open bottom
pallets or roll cages can be lifted.
1.1 Truck models and rated capacity
The rated capacity depends on the model. The rated capacity can be derived from
the model name.
The rated capacity is not generally the same as the permissible capacity. The
capacity can be found on the capacity plate attached to the truck.
EJD220
EJD Model name
2Series
20 Rated capacity x 100 kg
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2 Travel direction definition
The following determinations have been made for travel direction specification:
Item Travel direction
1 Left
2 Drive direction
3 Load direction
4 Right
1
2
3
4
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3 Assemblies and Functional Description
3.1 Assembly Overview
Item Component Item Component
5 t Mast 13 t Charge display
6 t Mast protection pane o CanDis
o Protective grille
(for cold store operation)
14 t Key switch
7 t Battery cover o CanCode
8 t Collision safety switch o ISM Access Module
9 t Travel switch 15 t Support wheel
10 t Slow travel button 16 t Drive wheel
11 t Load handler 17 o On-board charger
12 t Tiller 18 t Battery
19 t Emergency Disconnect switch
t = Standard version o = Option
15
5
7
1918
11
16 17
6
14
13
12
10
8
9
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3.2 Functional Description
Safety mechanisms
An enclosed, smooth truck geometry with rounded edges ensures safe handling of
the truck. The wheels are surrounded by a solid skirt.
The long tiller provides a maximum safety distance to the truck. When it is released
and in hazardous situations, a gas strut forces the tiller up into the brake position. The
collision safety switch in the tiller head responds to body contact, the travel direction
changes and the truck moves away from the operator.
Activating the Emergency Disconnect switch rapidly cuts out all electrical functions in
hazardous situations.
The mast protection pane or grille (o) protect the operator from moving mast parts
and the load.
Emergency Stop safety feature
The Emergency Stop is activated by the traction controller. Each time the truck is
switched on the system performed a self diagnosis. If an error is detected, the truck
automatically brakes to a halt. Control displays in the CanDis display instrument (o)
indicate the Emergency Stop.
CAUTION!
The truck brakes automatically
If the truck detects that signals which are required have not been received, or if it
detects an error, the system reacts by triggering an emergency stop, either by braking
the truck to a halt or until a valid signal status has been reached.
XRemain at a suitable distance from the truck during operation.
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Hydraulic System
Lifting and lowering are activated via the lift and lower buttons. Pressing the lifting
button starts the pump unit, supplying hydraulic oil from the oil reservoir to the lift
cylinder. With the two-stage Duplex mast (ZZ) (o) or three-stage telescopic mast
(DZ) (o) a short, centre-mounted free lift cylinder initially lifts the load handler (free
lift) without changing the overall height of the truck.
Drive system
A fixed AC three-phase motor actuates the drive wheel via a bevel spur gearbox. The
electronic traction controller ensures smooth drive-motor-speed control and hence
smooth starting, powerful acceleration and electrically controlled braking with energy
regeneration. The driver can choose from 3 travel programs depending on the load
and the environment: from high-performance to energy-saving.
Tiller
The driver steers with an ergonomic tiller. All travel and lift operations can be
performed sensitively without having to reach. The tiller has a steer angle of 180°.
Electrical system
The truck has an electronic traction controller. The operating voltage of the truck's
electrical 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 the available
battery capacity. The CanDis display (o) shows information which is important for the
operator such as travel program, service hours, battery capacity and event
messages.
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Mast
The high strength steel sections are narrow, enabling excellent visibility of the load
handler. The lift rails and the load handler run on permanently-lubricated and hence
maintenance-free angled rollers.
Load backrest (
o
)
A load backrest is recommended as an additional protective mechanism to move low
or small item loads above the mast protection frame or grille (o). The load backrest
is mounted on the load handler and protects the operator and truck against falling
loads.
Z The extended mast height (h4) increases according to the load backrest mounted
on the load handler.
WARNING!
Risk of injury from falling loads
Low or small item loads moved above the mast protection pane or grille (o) and
protruding over the load backrest can fall, endangering the operator and truck.
XSecure low or small item loads protruding over the load backrest, e.g. by wrapping
them in film.
3.2.1 Hourmeter
Z Prepare the truck for operation, see "Preparing the truck for operation" on page 61
or see "CanCode Keypad (o)" on page 94.
Service hours are counted while the truck is operational and one of the following
controls is applied:
– Tiller in travel zone "F", see "Travel" on page 69.
– "Slow travel button", see page 72.
– "Lift" button, see page 76.
– "Lower" button, see page 77.
o
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4 Technical Specifications
Z The technical specifications comply with the German "Industrial Truck Data Sheet"
Guidelines.
Technical modifications and additions reserved.
4.1 Performance data
EJD 220
Q Rated capacity 2000 kg
Capacity for mast lift
1
1. Depends on lift height.
1000 kg
Capacity for support arm lift 2000 kg
D Load centre distance 600 mm
Travel speed
with / without rated load
6.0 / 6.0 km/h
Lift speed
with / without rated load
0.14 / 0.25 m/s
Lowering speed
with / without rated load
0.40 / 0.40 m/s
Max. gradeability (5 min.)
with / without rated load
9 / 15 %
Drive motor,
Output S2 60 min
1.6 kW
Lift motor,
Output S3 10%
2.0 kW
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4.2 Dimensions
D
Q
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Model EJD 220
x Load distance 1) 957 mm
y Wheel base 1) 4) 1617 mm
h3 Lift 5) 1660 mm
h5 Initial lift 122 mm
h13 Lowered height 90 mm
h14 Tiller height in the travel position min./max. 711 / 1320 mm
L1 Length 4) 2022 mm
L2 Fork length including fork shank 4) 832 mm
b1/2 Overall width (drive) 726 mm
b5 Width across forks 570 mm
s/e/l Fork dimensions 56 / 185 / 1190 mm
b10 Track width, front 508 mm
b11 Track width, rear 385 mm
m2 Ground clearance, centre wheelbase 20 mm
Ast Aisle width
with pallet 1000x12000 traverse 2) 4)
2233 mm
Ast Aisle width
with pallet 800x1200 longit. 3) 4)
2243 mm
Wa Turning radius 1) 4) 1800 mm
1) Load section lowered + 48 mm
2) Load section lowered + 48 mm; diagonal in accordance with VDI + 369 mm
3) Load section lowered + 48 mm; diagonal in accordance with VDI + 225 mm
4) Battery compartment M version / battery compartment L version = version M + 72
mm
5) Values for standard mast 166ZT
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4.3 Weights
4.4 Tyre type
Net weight incl. battery M/L 937 / 1032 kg
Axle loading, laden
front/rear + battery
1120 / 1825
1160 / 1872
kg
Axle loading, unladen
front/rear + battery
665 / 280
732 /300
kg
Battery weight 220 / 288 kg
Tyre size, drive 230 x 65 mm
Load section tyre size (single / tandem) 85 x 95 / 85 x 75 mm
Castor wheel 100 x 40 mm
Wheels, number front/rear
(x = driven)
1x +2 /2 or 4 mm
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4.5 EN norms
Noise emission level
– EJD 220: 70 dB(A)
in accordance with EN 12053 as harmonised with ISO 4871.
Z The noise emission level is calculated in accordance with standard procedures and
takes into account the noise level when travelling, lifting and when idle. The noise
level is measured at the level of the driver's ear.
Electromagnetic compatibility (EMC)
The manufacturer confirms that the truck adheres to the limits for electromagnetic
emissions 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 components or their arrangement may be
made without the written agreement of the manufacturer.
WARNING!
Medical equipment can be damaged by non-ionised radiation
Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless data
transmission) can affect operators' medical equipment (pacemakers, hearing aids
etc.) and result in malfunctions. Consult a doctor or the manufacturer of the medical
equipment to clarify whether it can be used near the industrial truck.
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4.6 Conditions of use
Ambient temperature
– operating at 5°C to 40°C
Z Special equipment and authorisation 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 with the requirements for the design and
manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety Electrical Requirements", provided the truck is used according to its purpose.
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5 Identification Points and Data Plates
Z Warnings and notices such as capacity charts, strap points and data plates must
be legible at all times. Replace if necessary.
5.1 Indication Points
XXXXXXXX
kg
Q max
XXXX
Q max
Dmm
Hmm
kg
XXXX
1600
XXX
max
2000 kg
max
100 mm
X.XXXX.XX.XX
20
24
26
22
23
29
25
28
27
21
30
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Item Component
20 Warning: “Do not step under the load handler”
21 Attachment points for lifting by crane (with ZZ mast in the middle)
22 Capacity plate
23 Capacity Qmax
24 Warning: "Do not reach through the mast"
25 Serial number
26 Warning: “No passengers”
27 Model name
28 Test plaque
29 Data plate
30 Cold store truck reference
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5.2 Data plate
Z The illustration shows the standard version for EU member states. The data plate
may differ in other countries.
Z For queries regarding the truck or ordering spare parts always quote the truck serial
number (32).
31 32 3433 35
42
38
41
40
39
3736
Item Description Item Description
31 Type 37 Year of manufacture
32 Serial number 38 Load centre (mm)
33 Rated capacity (kg) 39 Output
34 Battery voltage (V) 40 Min./max. battery weight (kg)
35 Net weight w.o. battery (kg) 41 Manufacturer
36 Option 42 Manufacturer’s logo
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