Jungheinrich EJD 220 Service Manual

EJD 220																					01.10 -
Operating instructions																								G
51132781
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Declaration of Conformity

Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg

Manufacturer or agent acting in the European Union

Type	Option	Serial no.	Year of
			manufacture
EJD 220

Additional information

On behalf of

Date

GEU 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.

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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: [phone]

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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	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.

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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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3Approved 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.

1.1Truck models and rated capacity

The rated capacity depends on the model. The rated capacity can be derived from the model name.

EJD220

EJD Model name

2 Series

20 Rated capacity x 100 kg

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.

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2 Travel direction definition

The following determinations have been made for travel direction specification:

1

2

3

4

Item	Travel direction

1Left

2Drive direction

3Load direction

4Right

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3 Assemblies and Functional Description

3.1Assembly Overview

8

9

5

6

7

10
12	11

13

14

		15	16	15	17	18		19
Item		Component			Item		Component
5	t	Mast			13	t	Charge display
6	t	Mast protection pane				o	CanDis
	o	Protective grille			14	t	Key switch
		(for cold store operation)
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

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3.2Functional 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.

3.2.1Hourmeter

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.

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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.

4.1Performance data

		EJD 220
Q	Rated capacity	2000	kg
	Capacity for mast lift 1	1000	kg
	Capacity for support arm lift	2000	kg
D	Load centre distance	600	mm
	Travel speed	6.0 / 6.0	km/h
	with / without rated load
	Lift speed	0.14 / 0.25	m/s
	with / without rated load
	Lowering speed	0.40 / 0.40	m/s
	with / without rated load
	Max. gradeability (5 min.)	9 / 15	%
	with / without rated load
	Drive motor,	1.6	kW
	Output S2 60 min
	Lift motor,	2.0	kW
	Output S3 10%

1. Depends on lift height.

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4.2Dimensions

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	2233	mm
	with pallet 1000x12000 traverse 2) 4)
Ast	Aisle width	2243	mm
	with pallet 800x1200 longit. 3) 4)
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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4.3Weights

	Net weight incl. battery M/L	937 / 1032	kg
	Axle loading, laden	1120 / 1825	kg
	front/rear + battery	1160 / 1872
	Axle loading, unladen	665 / 280	kg
	front/rear + battery	732 /300
	Battery weight	220 / 288	kg

4.4Tyre type

	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	1x +2 /2 or 4	mm
	(x = driven)

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4.5EN 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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4.6Conditions 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.

4.7Electrical 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.

5.1Indication Points

X.XXXX.XX.XX

XXXXXXXX

20

	21
22	23
		XXXXkg
	XXXXkg			max
24		1600	100 mm	2000 kg
			max
	Q max	Hmm Q max XXX	Dmm

25

26

27

28

29

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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5.2Data plate

Z The illustration shows the standard version for EU member states. The data plate may differ in other countries.

31	32	33	34	35	36	37
						38
						39
						40
						41
						42

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

Z For queries regarding the truck or ordering spare parts always quote the truck serial number (32).

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