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EJE 222

Jungheinrich EJE 222, EJE 220, EJE 230, EJE 220r, EJE 222r Operating Instructions Manual

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Operating instructions
50425892
EJE 220/222/225/230/220r/222r
G
10.03 -
06.06
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
0606.GB
Table of contents
A Correct use and application of the truck
B Truck description
1 Application ........................................................................................... B 1
2 Assembly groups ................................................................................. B 2
3 Technical data - standard version ....................................................... B 3
3.1 Performance data for standard trucks ................................................. B 3
3.2 Dimensions ......................................................................................... B 3
3.3 EN standards ...................................................................................... B 6
3.4 Conditions for application .................................................................... B 6
4 Location of instruction labels and identification plates ........................ B 7
4.1 Truck identification plate ..................................................................... B 8
4.2 Label: order no., inventory no., full service no. ................................... B 8
C Transportation and commissioning
1 Transportation by crane ...................................................................... C 1
2 Commissioning .................................................................................... C 1
3 Moving an incapacitated truck (emergency operation) ....................... 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
6 Combined instrument (o) ................................................................... D 5
0606.GB
I 2
E Operation
1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1
2 Description of controls and indicating instruments .............................. E 2
3 Putting vehicle in operation ................................................................. E 4
4 Using the industrial truck ..................................................................... E 5
4.1 Safety regulations for truck operation ................................................. E 5
4.2 Driving, steering, braking .................................................................... E 6
4.3 Picking up or lowering load units ......................................................... E 9
4.4 Safe parking of the truck ..................................................................... E 11
5 CANCODE keypad ............................................................................. E 12
5.1 Code Lock ........................................................................................... E 12
5.2 Travel programs .................................................................................. E 14
5.3 Parameters .......................................................................................... E 14
5.4 Parameter Settings ............................................................................. E 15
5.5 Travel parameters ............................................................................... E 19
6 Display instrument (CANDIS) .............................................................. E 22
6.1 Discharge monitor function ................................................................. E 23
6.2 Operating hours display ...................................................................... E 23
6.3 Power up test ...................................................................................... E 23
6.4 Fault location ....................................................................................... E 24
F Maintenance of the truck
1 Operational safety and protection of the environment ........................ F 1
2 Safety regulations for repair ................................................................ F 1
3 Maintenance and service .................................................................... F 3
4 Maintenance checklist EJE 220 / 222 / 225 / 230 / EJE 220r / 222r. .. F 4
5 Lubrication chart EJE 220 / 222 / 225 / 230 / EJE 220r / 222r ........... F 6
5.1 Operating material ............................................................................... F 7
6 Notes on maintenance ........................................................................ F 8
6.1 Preparation of the truck for servicing and maintenance operation ...... F 8
6.2 Open the battery hood ........................................................................ F 8
6.3 Open the front hood ............................................................................ F 8
6.4 Checking the electric fuses ................................................................. F 9
6.5 Recommissioning the truck ................................................................. F 10
7 Decommissioning the fork lift truck ..................................................... F 10
7.1 Operations to be performed prior to decommissioning ....................... F 10
7.2 Measures to be taken during decommissioning .................................. F 10
7.3 Recommissioning the truck ................................................................. F 11
8 Safety checks to be performed at regular intervals and following
any untoward incidents (D: Accident prevention check according
to BGV D27) ........................................................................................ F 11
9 Final de-commissioning, disposal ....................................................... F 11
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
0600.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.
0600.GB
A 2
B 1
0606.GB
B Truck description
1 Application
The trucks of the EJE series are of a three-wheeled design equipped with a steered drive wheel and two spring-loaded, swivellable supporting wheels arranged within the enclosed truck envelope. The EJE truck is designed for operation on level ground and is intended for the handling of loads. The EJE can pick up pallets of open ground sup- port, or pallets provided with lateral boards arranged outside the range of the load- bearing wheels, as well as trolleys. The capacity of the truck is shown on the identifi- cation plate, or can be seen from the capacity label Qmax.
Truck types, capacities and motor output:
Type Capacity Motor output EJE 220 2000 kg 1.3 kW EJE 222 2,200 kg 1.5 kW EJE 225 2,500 kg 1.5 kW EJE 230 3,000 kg 1.5 kW
EJE 220r 2,000 kg 1.3 kW EJE 222r 2,200 kg 1.5 kW
0606.GB
B 2
2 Assembly groups
Item EJE 220/222/225/
230/220r/222r
Designation
1 t Key switch 2 t Discharge indicator
o Display instrument (CANDIS) 3 o CANCODE keypad 4 t Master switch (emergency stop) 5 t Control shaft with control shaft head 6 t Safety key 7 t Driving regulator 8 t Battery hood 9 t Lifting device
10 t Front hood 11 t Supporting wheel 12 t Drive wheel 13 t Button-creep speed
1
3
2
4
5
6
8
10
1211 11
9
13
7
B 3
0606.GB
3 Technical data - standard version
Z
Technical data to VDI 2198. Technical data are subject to alteration and extension in scope.
3.1 Performance data for standard trucks
*)In the case of longer fork versions, the load centre of gravity is at the fork centre.
3.2 Dimensions
*)Load section lowered + 75 mm (EJE 230 + 100 mm)
**) Ast diagonally, acc. to VDI +196 mm
Ast at shunt driving - 230 mm
Model EJE 220
EJE 220r
EJE 222
EJE 222r
EJE 225 EJE 230
Q Capacity 2000 2200 2500 3000 kg
C Load centre distance for
standard fork length *)
600 600 600 600 mm
Travel speed with rated load / w.o. load
6.0 / 6.0 6.0 / 6.0 6.0 / 6.0 5.0 / 6.0 km/h
Lift speed (lift) with rated load / w.o. load
5.1 / 6.7 4.9 / 6.7 4.7 / 6.7 4.2 / 6.1 cm/s
Max. gradeability (5 min) w / w.o. load
10 / 20 9 / 20 8 / 20 5 / 20 %
Model EJE 220
EJE 220r
EJE 222
EJE 222r
EJE 225 EJE 230
h2Lift 130 130 130 130 mm
h Load fork lowered 85 85 85 90 mm
y Wheel base *
)
L
XL
1340
-
1340 1410
1340 1410
1570 1640
mm
L Truck length (= L2 + l) L
XL
1760
-
1760 1830
1760 1830
1920 1990
mm
L
2
Headlength L
XL
610
-
610 680
610 680
770 840
mm
l Standard fork length 1150 1150 1150 1150 mm
b
1
Truck width 690 690 690 790 mm
Wa Turning radius *
)
L
XL
1620
-
1620 1690
1620 1690
2000 2080
mm
Wa Turning radius*)
in shunt mode (tiller vertical)
L
XL
1390
-
1390 1460
1390 1460
1770 1850
mm
Ast Aisle width **
)
800 x 1200 longit.
L
XL
2130
-
2130 2200
2130 2200
2250 2320
mm
0606.GB
B 4
EJE 220/222/225/220r/222r
hh
2
b
1
Ast
Wa
850
y
L
2
l
L
1305
C
Q
B 5
0606.GB
EJE 230
1270
L
2
L
h
h
2
0606.GB
B 6
3.3 EN standards
Continuous sound level: 64 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: 0.77 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 5 °C to 40 °C
Z
Industrial trucks must be specially equipped and approved for continuous use in en- vironments with temperatures below 5 °C or in cold stores respectively with extreme temperatures or humidity changes.
B 7
0606.GB
4 Location of instruction labels and identification plates
Item Designation
14 Prohibition sign “Do not ride on truck” 15 Load capacity Qmax. 16 Truck identification label 17 Label: order no., inventory no., full service no. 18 Limit-stop for crane loading 19 UVV control label
15
16
17
18
Qmax xx00kg
19
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
1996
Ihr Kundendienst-Partner
14
0606.GB
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. (21) of the truck.
4.2 Label: order no., inventory no., full service no.
The full service no. will only be assigned if a servicing agreement has been conclud- ed.
Item Designation Item Designation
20 Type 26 Manufacturer 21 Serial no. 27 Min./max. battery weight in kg 22 Rated capacity in kg 28 Drive power in kW 23 System Voltage V 29 Load centre distance in mm 24 Empty weight without battery in kg 30 Year of manufacture 25 Manufacturer logo 31 Option
Item Designation
32 Order no. 33 Inventory no. 34 Full service no.
26
25
2724
2823
2922
3021
3120
32
33
34
C 1
0606.GB
C Transportation and commissioning
1 Transportation by crane
M
Only lifting gear of adequate capacity must be used (for the transport weight, refer to the truck identification label).
Z
Lifting gear attachment points (1) are provided at the chassis and at the fork in case the truck is to be lifted or transported by crane.
– Park the truck and render it safe (refer
to chapter E).
– Secure the lifting gear to the attach-
ment points (1).
M
The lifting gear must be attached to the attachment points in such a manner that it absolutely cannot slip. If necessary, pull it through the openings! The lifting gear must be fitted in such a way that it will not 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 cable) 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. – Charge battery (refer to chapter D). – If necessary, check whether the setting of the combined instrument matches the
type of battery (see chapter D).
– Commission the truck as detailed in chapter E.
Z
When parked, the running surface of the tyres will flatten. The flattening will disappear after a short operating time of the truck.
0606.GB
C 2
3 Moving an incapacitated truck (emergency operation)
In order to be able to move the truck in emergency operation, the electromagnetically operated brake must be released.
– Open and remove the front hood (2) (see chapter F). – Screw on 2 off M4x20 bolts (3) to loosen the armature plate.
The truck can now be moved.
M
Remove the screws again when you have parked the truck. Braking is now restored again.
3
2
D 1
0606.GB
D Battery - Servicing, recharging,
replacement
1 Safety regulations governing the handling of lead-acid batteries
The truck must be parked and rendered safe, before any operations on batteries are to be 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 as prepared by the battery supplier and as available at 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.
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 have accidentally come into contact with battery acid, liberally flush the affected parts with clean water. Consult a doctor, when skin or eyes have come into contact with battery acid. Spilled battery acid must be immediately neutral- ized.
M
Only batteries with closed battery trough may be used.
F
Battery weight and dimensions have considerable influence on the safety of truck op- eration. A change of battery equipment is only permitted with approval of the manu- facturer.
0606.GB
D 2
2Battery types
The vehicle is equipped with different battery types depending on the type. The bat- tery weights can be seen from the battery identification plates. Batteries with non-iso- lated poles must be covered with a non-slip isolation mat.
M
When replacing or installing batteries, ensure that the battery is correctly secured in the battery compartment of the truck.
The following table shows the standard battery combinations and battery capacities:
Depending on the type of battery used, it is also possible to use models with en- hanced performance or maintenance-free batteries.
M
Only batteries with closed battery trough may be used.
3 Exposing the battery
– Park the truck and render it safe (refer to chapter E). – Press the main switch (1) to “OFF”. – Lift up and swing forward the battery hood (2) using the handle (3).
Chassis version Truck type 24 V PzS battery
Long version L2 = 610 mm EJE 220 / 222 / 225
EJE 220r / 222r
2 PzS 200 Ah
XL - version L2 = 680 mm EJE 222 / 225
EJE 222r
2 PzS 300 Ah
Long version L2 = 770 mm EJE 230 2 EPzS 230 Ah
XL - version L2 = 840 mm EJE 230 3 EPzS 345 Ah
D 3
0606.GB
4 Charging the battery
– Park the truck and render it safe (refer to chapter E).
F
The battery connector and the socket must only be connected and disconnected with the truck switched off.
– Expose the battery (refer to section 3).
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.
– Disconnect the battery connector (4). – If present, remove any insulating mats from the batteries. – Connect the charging cable (5) to the battery connector (4) and switch on the bat-
tery charger.
M
Recharge the battery observing the instructions provided by the battery supplier and by the battery charger supplier.
0606.GB
D 4
5 Removing and installing the battery
– Expose the battery (see section 3).
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 rubber matting. Place the bat- tery connector or the battery cable, respectively, in such a way that they will not catch behind any truck protrusions when the battery is withdrawn.
Z
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. The lifting gear hooks must be secured to the attachment points (8) in such a way that the lifting gear, when slack, cannot collaps on the battery cells.
– Loosen the screw (6) of the battery support (7). – Lift and pull out the battery support. – Disconnect the battery. – Fix the lifting gear to the attachment points (8) and lift out the battery.
Installation is in the reverse order of operations. Check for correct mounting position and correct connection of the battery.
F
Upon completion of the battery refitting operations, check all cable connections and plugged connections for any visible damage. Before starting the truck, fasten the bat- tery support (7) with the screw (6) and make sure that the battery hood is closed safe- ly with the hood lock !
D 5
0606.GB
6 Combined instrument (o)
Battery discharge indicator: The
charging condition of the battery is indi- cated in 10% increments by means of ten bars shown on the battery symbol (9).
With progressive depletion of the bat- tery, the illuminated bars will go out from the top downwards.
M
When using maintenance-free batteries, the instrument must be set so that the “T” symbol (12) will appear next to the oper- ating hour display. When this setting is not performed, the battery might suffer damage caused by exhaustive dis- charge. For adjusting the instrument, it is recommended to consult the manufac- turer service.
An advance “CAUTION” symbol (10) will appear at a residual battery capacity of:
-30 percent in the case of standard batteries and
-50 percent in the case of maintenance:free batteries.
Battery recharging is now advisable.
The advance “CAUTION” symbol will go out and a flashing “STOP” symbol (11) will appear at a residual battery capacity of:
-20 percent in the case of standard bat-
teries and
-40 percent in the case of maintenance-
free batteries.
After a period of 5 minutes the “STOP” symbol will remain permanently alight. Battery recharging is now required.
Battery discharge monitor: As soon as the “STOP” symbol is permanently dis- played, the lifting function of the truck will be automatically switched off.
Z
Lifting will only become possible again after the battery has been recharged to at least 70 percent.
Hour meter: The hour meter (13) integrated into the battery discharge indicator shows the total operating time of the travelling and lifting movements.
Z
In the operative condition, the digit after the comma will flash.
h
h
h
STOP
T
T
T
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