Jungheinrich EJE 225, EJE 220, EJE 220r, EJE 225r, EJE 230 Operating Instructions Manual

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Page 1

EJE 220/225/230/235/220r/225r

05.07

Operating instructions

51040446

04.19

en-GB

EJE 220 EJE 225 EJE 230 EJE 235 EJE 220r EJE 225r

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Declaration of Conformity

Manufacturer

Jungheinrich AG, 22039 Hamburg, Germany

Description

Industrial truck

Type Option Serial no. Year of

manufacture

EJE 220 EJE 225 EJE 230 EJE 235 EJE 220r EJE 225r

On behalf of

Date

EU DECLARATION OF CONFORMITY

The undersigned hereby declare that the powered truck described in detail complies with the current versions of European Directives 2006/42/EG (Machinery Directive) and 2014/30/EU (Electromagnetic Compatibility - EMC). The manufacturer is authorised to compile the technical documentation.

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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.

NOTICE

Indicates a material hazard. Failure to comply with this instruction may result in material damage.

Used before notices and explanations.

Indicates standard equipment

Indicates optional equipment

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Jungheinrich Aktiengesellschaft

Friedrich-Ebert-Damm 129 22047 Hamburg - Germany

Tel: +49 (0) 40/6948-0

www.jungheinrich.com

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A Correct Use and Application 11

1 General 11 2 Correct application 11 3 Approved application conditions 12

3.1 Internal Operation Combined with Brief External or Cold Store

Operation (t) 13

3.2 4 Proprietor responsibilities 14

5 Adding attachments and/or optional equipment 14

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 19 4 Technical Specifications 21

4.1 Performance data 21

4.2 Dimensions 22

4.3 Weights 27

4.4 Tyre type 28

4.5 EN norms 29

4.6 Conditions of use 30

4.7 Electrical Requirements 30 5 Identification Points and Data Plates 31

5.1 Indication Points 31

5.2 Data plate 32

5.3 Truck capacity plate 33

C Transport and Commissioning 35

1 Lifting by crane 35 2 Transport 37 3 Using the Truck for the First Time 38

D Battery - Servicing, Recharging, Replacement 39

1 Safety Regulations Governing the Handling of Lead-Acid Batteries 39 2 Battery types 41 3 Exposing the battery 44 4 Charging the battery 45

4.1 Charging the battery with a stationary charger 46

4.2 5 Battery removal and installation 52

5.1 Changing the battery from the top 53

5.2 Lateral battery removal 56

Internal Operation in Cold Stores with Cold Store Equipment (o) 13

Charging the battery with an on-board charger (o) 46

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E Operation 57

1 Safety Regulations for the Operation of Forklift Trucks 57 2 Displays and Controls 59

2.1 EJE 220r / EJE 225r Tiller 65

2.2 Battery discharge indicator 66

2.3 Battery discharge monitor 66 3 Preparing the Truck for Operation 67

3.1 Checks and Operations to Be Performed Before Starting Daily Work 67

3.2 Preparing the truck for operation 68

3.3 Making the EJE 220r / 225r operational 69

3.4 Checks and operations to be carried out when the truck is operational 70

3.5 Parking the truck securely 71 4 Industrial Truck Operation 73

4.1 Safety regulations for truck operation 73

4.2 Emergency Disconnect 75

4.3 Automatic braking 77

4.4 Travel 78

4.5 Slow travel 80

4.6 Steering 81

4.7 Brakes 81

4.8 Load handler raise/lower 83

4.9 Lifting, transporting and depositing loads 88 5 Troubleshooting 97

5.1 Truck does not start 98

5.2 Load cannot be lifted 99 6 Operating the truck without its own drive system 100

6.1 Release and activate the drive wheel brake 100 7 Optional equipment 103

7.1 Emergency operation with service key GF60 103

7.2 Tiller with buttons on both faces 105

7.3

7.4 Setting the truck parameters with CanCode 125

7.5 Parameters 127

7.6 Setting the Battery Parameters with CanCode 129

7.7

7.8 Display unit (2 inch display) 133

7.9 General Information about the Use of Keyless Access Systems 138

7.10 Using the Display: 139

7.11

Keypad (CanCode) (o) 106

CanDis Display Instrument (o) 131

ISM access module (o) 143

F Industrial Truck Maintenance 145

1 Operational Safety and Environmental Protection 145 2 Maintenance Safety Regulations 146

2.1 Working on the electrical system 147

2.2 Consumables and used parts 147

2.3 Wheels 147

2.4 Hydraulic system 148 3 Lubricants and Lubrication Schedule 150

3.1 Handling consumables safely 150

3.2 Lubrication Schedule 152

3.3 Consumables 153

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4 Maintenance and repairs 154

4.1 Preparing the truck for maintenance and repairs 154

4.2 Lifting and jacking up the truck safely 154

4.3 Cleaning 155

4.4 Front cover disassembly 159

4.5 Drive panel disassembly and assembly 160

4.6 Tightening the wheel nuts 161

4.7 Checking the hydraulic oil level 162

4.8 Check the gear oil level 163

4.9 Checking electrical fuses 164

4.10 Restoring the truck to service after maintenance and repairs 166 5 Decommissioning the Industrial Truck 167

5.1 Prior to decommissioning 167

5.2 Action to be taken during decommissioning 167

5.3 Restoring the truck to service after decommissioning 168 6 Safety tests to be performed at intervals and after unusual incidents 169 7 Final de-commissioning, disposal 169 8 Human vibration measurement 169

G Maintenance, Inspection and Changing of Maintenance

Parts Requiring Replacement 171

1 Maintenance Contents EJE 235 172

1.1 Owner 172

1.2 Customer Service 176 2 Maintenance Contents EJE 220r-225r 182

2.1 Owner 182

2.2 Customer Service 186 3 Maintenance Contents EJE 230 192

3.1 Owner 192

3.2 Customer Service 196 4 Maintenance Contents EJE 220/225 201

4.1 Owner 201

4.2 Customer Service 205

H Traction battery 211

1 Correct Use and Application 211 2 Data plate 211 3 Safety Instructions, Warning Indications and other Notes 212 4 Lead acid batteries with armour plated cells and liquid electrolyte 213

4.1 Description 213

4.2 Operation 215

4.3 Servicing lead-acid batteries with armour plated cells 218 5 PzV and PzV-BS lead-acid batteries with sealed armour plated cells 220

5.1 Description 220

5.2 Operation 221

5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated cells 224

6 Aquamatik water replenishment system 225

6.1 Water replenishment system design 225

6.2 Functional Description 226

6.3 Adding water 226

6.4 Water pressure 226

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6.5 Filling time 227

6.6 Water quality 227

6.7 Battery tubing 227

6.8 Operating temperature 227

6.9 Cleaning measures 227

6.10 Service mobile vehicle 227

7 Electrolyte circulation 228

7.1 Functional Description 228

8 Cleaning batteries 230 9 Storing the battery 232 10 Troubleshooting 232 11 Disposal 232

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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

NOTICE

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 page 88.

The following operations are in accordance with regulations and are permitted: – Lifting and lowering of loads. – Stacking and retrieving loads. – Transporting lowered loads.

The following operations are prohibited: – Carrying and lifting passengers. – Pushing or pulling loads. – Transverse lifting of long loads.

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3 Approved application conditions

The permissible operating conditions change if the truck is equipped with a lithiumion battery (o), see the manufacturer's operating instructions.

– Operation in industrial and commercial environments. – 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 20 %. – Do not travel across or at an angle on inclines. Travel with the load facing uphill. – Operation in partially public traffic.

WARNING!

Use under extreme conditions

Using the truck under extreme conditions can result in malfunctions and accidents.

Special equipment and authorisation are required if the truck is to be constantly

used in extreme conditions, especially in dusty or corrosive atmospheres. The truck cannot be used in areas at risk of explosion.

In adverse weather conditions (thunder, lightning) the industrial truck must not be

operated outside or in endangered areas.

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3.1 Internal Operation Combined with Brief External or Cold Store

Operation (t)

In addition to the permissible application conditions in industrial and commercial environments, the truck may also be used in outdoor environments, cold stores and fresh food areas. Secure parking is only permissible indoors or in a cold store environment.

– Permissible temperature range -10°C to 40°C. – Secure parking is only permissible at +5°C to 40°C. – Maximum air humidity 95% non-condensing. – The application areas can be changed, but in general this should be minimised

due to thawing and possible corrosion. – Thawing is permissible only if the truck can be subsequently dried thoroughly. – Do not charge the battery below +5°C.

3.2

Internal Operation in Cold Stores with Cold Store Equipment (o)

In addition to the permissible operating conditions in industrial and commercial environments, the truck remains primarily in cold stores. The truck should only leave the cold store briefly to hand over a load.

– Permissible temperature range -28°C to +25°C. – Maximum air humidity 95% non-condensing. – Thawing is permissible only if the truck can be subsequently dried thoroughly. – In cold store areas below -10°C the truck must be operated permanently and

should not be parked securely for more than 15 minutes. – Do not charge the battery below +5°C.

NOTICE

Battery damage

As the temperature becomes increasingly cold, the battery can be damaged if the battery charge is low.

If the battery charge is low do not use the truck in areas of -28°C to -5°C.

If the battery charge is low it is preferable not to use the truck in areas of -5°C to

+5°C. Charge the battery, see page 45.

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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.

NOTICE

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 EJE 220/225/230/235/220r/225r is designed to transport goods on level surfaces. It can lift open-bottom pallets or pallets with transverse boards outside area the load-wheel area, as well as roll cages. The capacity is shown on the capacity plate, Qmax.

EJE 220r / 225r

The EJE 220r / 225r with ramp lift is particularly suitable for loading and unloading on ramps. In particular, it can be used for lifting and depositing palletised goods right up to the pitch bend.

1.1 Truck models and rated capacity

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

EJE220

EJE Model name

2 Series

20 Rated capacity x 100 kg

The rated capacity is not generally the same as the maximum capacity. The capacity can be found on the capacity plate attached to the truck.

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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

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3 Assemblies and Functional Description

6910115

78121314

161718

3.1 Assembly Overview

Item

Description Ite

Collision safety switch 14

Travel switch

Slow-travel button

Tiller

Battery panel

Emergency disconnect

Load handler 15

On-board battery charger

24 V / 30 A (including safety switch)

Description

Key switch

Keypad (CanCode)

Key switch (also with second

stage for brake release)

ISM access module

Keypad

Transponder reader

Front panel

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Discharge indicator 16

Two-section drive panel

Display instrument (CanDis) 17

Display unit (2-inch display) 18

Support wheels

Drive wheel

t = Standard equipment o = Optional equipment

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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 pressure spring 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.

Emergency stop safety concept

The emergency stop is activated by the traction controller. Each time the truck is switched on, the system carries out a self-diagnosis. If an error is detected, the truck

automatically brakes to a halt. Indicator lights on the CanDis display instrument (o) or on the display unit (2-inch display) (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.

Remain at a suitable distance from the truck during operation.

Hydraulic system

Pressing the lifting button starts the pump unit, supplying hydraulic oil from the oil reservoir to the lift cylinder. Pressing the lifting button raises the load handler at a constant speed; pressing the lowering button lowers the load handler.

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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 instrument (o) or the display unit (2-inch display) (o) shows the operator key information such as the service hours, battery

capacity and event messages.

3.2.1 Hourmeter

Prepare the truck for operation, see page 68 or see page 106.

Service hours are counted while the truck is operational and one of the following controls is applied: – Tiller in travel zone "F", see page 78. – "Slow travel button", see page 80. – "Lift" button, see page 84. – "Lower" button, see page 85.

On the EJE 220r / 225r the service hours are also counted when one of the following controls is applied: – "Ramp lift raise" button, see page 86. – "Ramp lift lower" button, see page 87.

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4 Technical Specifications

The technical specifications comply with the German "Industrial Truck Data Sheet" Guidelines. Technical modifications and additions reserved.

4.1 Performance data

Model EJE 220 EJE 225 EJE 230 EJE 235

Q Rated capacity 2000 2500 3000 3500 kg

Load centre distance for

standard load handler length *)

Travel speed

with / without rated load

Lift speed

with / without rated load

Lowering speed

with / without rated load

Max. gradeability (5 min rating) with / without rated load

600 600 600 600 mm

6.0 / 6.0 6.0 / 6.0 6.0 / 6.0 6.0 / 6.0 km/h

0.04/0.06 0.03/0.06 0.02/0.06 0.02/0.06 m/s

0.05/0.05 0.05/0.05 0.05/0.05 0.05/0.05 m/s

10 / 20 8 / 20 6 / 20 6 / 20 %

*) For longer load handler lengths the load centre of gravity is at the centre of the load handler

Model EJE 220r EJE 225r

Q Rated capacity 2,000 2500 kg

Load centre distance for

standard load handler length *)

Travel speed

with / without rated load

Lift speed

with / without rated load

Lowering speed

with / without rated load

Max. gradeability (5 min rating) with / without rated load

*) For longer load handler lengths the load centre of gravity is at the centre of the load handler

600 600 mm

6.0 / 6.0 6.0 / 6.0 km/h

0.04/0.06 0.03/0.06 m/s

0.05/0.05 0.05/0.05 m/s

10 / 20 8 / 20 %

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4.2 Dimensions

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Model EJE 220 / 225 /

235

EJE 230

D Load centre distance

for standard load handler length *)

Lift

h13

h14

Load handler lowered

Tiller height in the travel position min./max.

Wheelbase (short, long)

Overall length (short, long)

Chassis length (short / long)

Truck width

Overall width of the load

handler

600

122

805 / 1321 805 / 1321

1353 / 1425 1353 / -

1763 / 1835 1763 / -

613 / 685 613 / -

720

540

m m

b10

b11

s/e/l

Wa**

Ast**

Track width, front

Track width, rear

Load handler dimensions

Ground clearance, centre wheelbase

Load distance

Turning radius (short / long)

Working aisle width for pallets 800x1200 length (short/long)

Aisle width for pallet 1000 x 1200 short (short/long)

Safety distance

508

368

55 / 172 / 1150

911

1538 / 1610 1538 / -

2027***/2099*** 2027 / - ***

1977**** / 2049**** 1977 / - ****

200

m m

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*) For longer load handler lengths the load centre of gravity is at the centre of the load handler

** Load handler raised / lowered +53 mm

***Diagonal in accordance with the German directive "Data Sheets for Industrial Trucks +204 mm

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***Diagonal in accordance with the German directive "Data Sheets for Industrial Trucks +386 mm

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Model EJE 220r EJE 225r

D Load centre distance

for standard load handler length *)

Lift

h13

h14

Load handler lowered

Tiller height in the travel position min. / max.

Wheelbase (short, long)

Overall length (short, long)

Chassis length (short / long)

Truck width

Load handler external

dimensions

600

122

805 / 1321

1353 / 1425

1763 / 1835

613 / 685

720

540

m m

b10

b11

s/e/l

Wa**

Ast**

Track width, front

Track width, rear

Load handler dimensions

Ground clearance, centre of wheelbase

Load distance

Turning radius (short / long)

Aisle width for pallets 800x1200 lengthways (short, long)

Aisle width, pallet 1000x1200 transverse (short, long)

Safety clearance

508

368

55 / 172 / 1150

911

1538 /1610

2027 ***/ 2099***

1977 **** / 2049****

200

m m

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*) For longer load handler lengths the load centre of gravity is at the centre of the load handler.

** Load handler raised / lowered +53 mm

***Diagonal in accordance with the German directive "Data Sheets for Industrial Trucks +204 mm

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***Diagonal in accordance with the German directive "Data Sheets for Industrial Trucks +386 mm

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4.3 Weights

Description EJE 220 EJE 225 EJE 230 EJE 235

Truck weight; m / l 540 / 637 550 / 647 580 550 kg

Axle loading, laden drive axle / load axle; m

Axle loading, unladen drive end/ load end; m

Component EJE 220r EJE 225r

Net weight; 540 550 kg

Axle loading, with load drive axle / load side:

Axle load without load drive side / load side:

876 / 1664 990 / 2060 1154 / 2426 1300 / 2750 kg

423 / 117 427 / 123 457 / 123 427 / 123 kg

876 / 1664 990 / 2060 kg

423 / 117 427 / 123 kg

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4.4 Tyre type

Description EJE 220 EJE 225 EJE 230 EJE 235

Tyre size, drive end ø230 x 70 ø230 x 70 ø230 x 70 ø230 x 70 mm

Tyre size, load end; single / tandem

Additional wheels (dimensions)

ø85x110 /

ø85x85

ø85x110 /

ø85x85

- / ø85x85 - / ø85x85 mm

ø100x40 ø100x40 ø100x40 ø100x40 mm

Wheels, number (drive end / load end (x =

1x +2 / 2 or 4 1x +2 / 4

driven))

Model EJE 220r EJE 225r

Tyre size, drive side ø230 x 70 ø230 x 70 mm

Tyre size, load side; single ø85x110 ø85x110 mm

Additional wheels (dimensions)

ø100x40 ø100x40 mm

Wheels, number drive side / load side (x =

1x +2 / 2 or 4

driven)

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4.5 EN norms

Continuous sound pressure level

– EJE 220/225/230/235/220r/225r: 70 dB(A)

in accordance with EN 12053 as harmonised with ISO 4871.

The continuous sound pressure level is calculated according to standard procedures and takes into account the sound pressure level when travelling, lifting and idling. The sound pressure level is measured at the operator'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.

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

– without cold store equipment: operating at -10°C to 40°C, see page 13 – with cold store equipment: operating at -28°C to +25°C, see page 13

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

232624

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

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Item Component

19 Serial number

20 Capacity Qmax

21 Prohibition plate: “No passengers”

22 Truck data plate

23 Strap point for crane lifting

Cold store (o)

Inspection plaque (o)

26 Model description

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5.2 Data plate

27283029313934

373635

Item Model Item Model

27 Type 34 Load centre distance (mm)

28 Serial number 35 Drive output

29 Rated capacity (kg) 36 Min./max. battery weight (kg)

30 Battery voltage (V) 37 Manufacturer

31 Net weight w/o battery (kg) 38 QR code

32 Option 39 Manufacturer's logo

33 Year of manufacture

For queries regarding the truck or ordering spare parts, always quote the truck serial number (28).

QR code

The QR code contains the serial number and product hierarchy of the truck.

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5.3 Truck capacity plate

The capacity plate (20) gives the maximum load-bearing capacity (Q) of the truck in kg assuming the load on the load handler is evenly distributed.

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C Transport and Commissioning

1 Lifting by crane

WARNING!

All persons involved in loading by crane must be trained

Incorrect crane loading procedures due to untrained personnel can cause the truck to fall. There is a risk of injury to personnel and a risk of material damage to the truck.

Loading must only be performed by specialist personnel trained for this purpose.

The specialist personnel must be instructed in securing loads on road vehicles and handling load securing devices. In each case correct measurements must be taken and appropriate safety measures applied.

WARNING!

Improper loading by crane can result in accidents

Improper use or use of unsuitable lifting gear can cause the truck to crash when being loaded by crane.

Prevent the truck from hitting other objects during lifting, and avoid uncontrolled movements. If necessary, secure the truck with guide ropes.

The truck may be loaded only by people who are trained in using lifting

accessories and lifting gear. Wear personal protective equipment (e.g. safety shoes, safety helmet, hi-vis

jacket, protective gloves) when loading by crane. Do not stand under suspended loads.

Do not walk into or stand in a hazardous area.

Always use lifting gear with sufficient capacity (for truck weight, see truck data

plate). Always attach the crane lifting gear to the prescribed attachment points and

prevent them from slipping. Use the lifting accessories only in the prescribed load direction.

Crane lifting gear must be fastened in such a way that it does not come into

contact with any attachments when lifting.

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CAUTION!

Trucks with side battery removal (o) can only be raised when the battery is not in position: strap points are covered by the battery.

Strap points (23) on the chassis are provided for transporting the truck with crane lifting gear.

Lifting the truck by crane

Requirements

– Park the truck securely, see page 71.

Tools and Material Required

– Lifting gear – Crane lifting gear

Procedure

• Open the battery cover and remove the

battery if necessary.

• Secure the lifting slings to the strap

points (23).

The truck can now be lifted by crane.

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2 Transport

WARNING!

Accidental movement during transport

Improper fastening of the truck and mast during transport can result in serious accidents.

Loading must only be performed by specialist personnel trained for this purpose.

The truck must be securely fastened when transported on a lorry or a trailer.

The lorry or trailer must have fastening rings.

Use wedges to prevent the truck from moving.

Use only fastening belts with sufficient strength.

Use non-slip materials to securing the load aids (pallet, wedges, ...) e. g. non-slip

mats.

Securing the truck for transport

Requirements

– Load the truck. – Truck parked securely, see page 71.

Tools and Material Required

– Lashing straps – Edge protectors – Wooden beam or pallet

Procedure

• Position the wooden beam or pallet

between the front of the transport

vehicle and the load handler to

ensure a positive fit between the front

of the transport vehicle and the load

handler.

• Attach the lashing straps (40) to the

industrial truck and the transport

vehicle and tension sufficiently.

Use edge protectors to protect the truck and the lashing straps.

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The truck can now be transported.

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3 Using the Truck for the First Time

WARNING!

The use of unsuitable energy sources can be hazardous

Rectified AC current will damage the assemblies (controllers, sensors, motors etc.) of the electronic system. Unsuitable cable connections (too long, insufficient wire cross-section) to the battery (tow cables) can overheat, setting the truck and battery on fire.

The truck must only be operated with battery current.

Cable connections to the battery (tow leads) must be less than 6 m long and have

a minimum cross-section of 50 mm².

NOTICE

Do not lift loads if the truck is operated via a tow lead with an external battery.

If the truck is delivered in multiple parts, setup and commissioning must only be performed by trained, authorised personnel.

Procedure

• Check the equipment is complete.

• If necessary, install the battery, see page 52. Do not damage the battery cable.

• Charge the battery, see page 45.

The truck settings must match the battery model (if the customer is charging the

battery).

• Check the hydraulic oil level and top up if necessary (see page 162).

• Start up the truck (see page 68).

Truck is operational.

Wheel flattening

If the truck has been parked for a long period, the wheel surfaces may tend to flatten. This flattening has a negative effect on the safety and stability of the truck. Once the truck has covered a certain distance, the flattening will disappear.

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Page 39

D Battery - Servicing, Recharging,

Replacement

For use of lithium-ion batteries (o), see the manufacturer's operating instructions.

1 Safety Regulations Governing the Handling of Lead-Acid

Batteries

Maintenance personnel

Batteries may only be charged, serviced or replaced by trained personnel. These operating instructions and the manufacturer’s instructions concerning batteries and charging stations must be observed when carrying out the work.

Fire Protection

Do not smoke and avoid naked flames when handling batteries. Wherever an industrial truck is parked for charging there must be no inflammable material or consumables capable of creating sparks within a minimum distance of 2 m from the truck. The room must be ventilated. Fire protection equipment must be available.

CAUTION!

The use of unsuitable fire protection equipment can result in scalding

Extinguishing fires with water can cause a reaction with the battery acid. This can result in scalding from the acid.

Use powder extinguishers.

Never extinguish a burning battery with water.

Battery maintenance

The battery-cell covers must be kept dry and clean. The terminals and cable lugs must be clean, secure and have a light coating of terminal grease.

WARNING!

Short circuits can result in fire

Damaged cables can cause short circuits, setting the truck and battery on fire.

Before closing the battery cover make sure that the battery cables are not

damaged.

Battery disposal

Batteries may only be disposed of in accordance with national environmental protection regulations or disposal laws. The manufacturer’s disposal instructions must be observed.

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Page 40

WARNING!

Batteries can be hazardous

Batteries contain an acid solution which is poisonous and corrosive. Avoid contact with battery acid at all times.

Dispose of used battery acid in accordance with regulations.

Always wear protective clothing and goggles when working with batteries.

Do not let battery acid come into contact with skin, clothing or eyes. If necessary,

rinse with plenty of clean water. In the event of physical damage (e.g. skin or eye contact with battery acid) call for

a doctor immediately. Spilled battery acid should be neutralised immediately with plenty of water.

Only batteries with a sealed battery container may be used.

Follow national guidelines and legislation.

WARNING!

Unsuitable batteries that have not been approved by Jungheinrich for the truck can be hazardous

The design, weight and dimensions of the battery have a considerable effect on the operational safety of the truck, in particular its stability and capacity. The use of unsuitable batteries that have not been approved for the truck by Jungheinrich, can lead to a deterioration of the braking characteristics of the truck during energy recovery, causing considerable damage to the electric controller and resulting in serious danger to the health and safety of individuals.

Only Jungheinrich-approved batteries may be used on the truck.

Battery equipment may only be replaced with the agreement of Jungheinrich.

When replacing/installing the battery make sure the battery is securely located in

the battery compartment of the truck. Do not use batteries that have not been approved by the manufacturer.

Park the truck securely before carrying out any work on the batteries (see page 71).

04.19 en-GB

Page 41

2 Battery types

Depending on the model, the truck will be supplied with different battery types. The following table shows which combinations are included as standard:

EJE 220 / 225

Battery tray

M 24 V - XFC 158 Ah 220 623X211X627

Battery type Weight (kg) Dimensions (mm)

24 V - XFC 158 Ah 180 623X211X627

24 V - 2PzV 160 Ah wf Exide 180 624X212X537

24 V - 2PzW 160 Ah 180 624X212X537

24 V - 2PzV 174 Ah wf Hawker 183 623X211X537

24 V - 2PzS 180 Ah 180 624X212X537

24 V - 2PzM 180 Ah 180 621X209X537

24 V - 2PzV 200 Ah wf Exide 215 621X209X627

24 V - 2PzV 220 Ah wf Hawker 218 623X211X627

24 V - 2PzW 220 Ah 220 624X212X627

24 V - 2PzS 250 Ah 220 624X212X627

24 V - 2PzS 250 Ah 220 621X209X627

24 V - 2PzM 250 Ah 222 621X209X625

24 V - LIB 110 Ah 210 624X207X627

L 24 V - 3PzV 300 Ah wf Exide 290 621X281X627

24 V - XFC 316 Ah 288 624X284X627

24 V - 3PzV 330 Ah wf Hawker 300 623X283X627

24 V - 3PzW 330 Ah 288 624X284X627

24 V - 3PzS 345 Ah Lib. Silver 282 621X284X627

24 V - 3PzS 375 Ah 288 624X284X627

24 V - 3PzS 375 Ah Lib. Silver 288 621X281X627

24 V - 3PzM 375 Ah 299 621X281X627

24 V - LIB 240 Ah SBE 288 624X284X683

24 V - LIB 360 Ah SBE 288 624X284X683

Optionally, the truck can be fitted with a lithium-ion battery, see "Li-Ion battery 24V 240Ah / 360Ah" operating instructions.

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Page 42

EJE 230 / 235

Battery tray

M 24 V - XFC 158 Ah 220 623X211X627

Optionally, the truck can be fitted with a lithium-ion battery, see "Li-Ion battery 24V 240Ah / 360Ah" operating instructions.

Battery type Weight (kg) Dimensions (mm)

24 V - XFC 158 Ah 180 623X211X627

24 V - 2PzV 160 Ah wf Exide 180 624X212X537

24 V - 2PzW 160 Ah 180 624X212X537

24 V - 2PzV 174 Ah wf Hawker 183 623X211X537

24 V - 2PzS 180 Ah 180 624X212X537

24 V - 2PzM 180 Ah 180 621X209X537

24 V - 2PzV 200 Ah wf Exide 215 621X209X627

24 V - 2PzV 220 Ah wf Hawker 218 623X211X627

24 V - 2PzW 220 Ah 220 624X212X627

24 V - 2PzS 250 Ah 220 624X212X627

24 V - 2PzS 250 Ah 220 621X209X627

24 V - 2PzM 250 Ah 222 621X209X625

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Page 43

EJE 220r / 225r

Battery

Battery type Weight (kg) Dimensions (mm)

tray

M 24 V - XFC 158 Ah 220 623X211X627

24 V - XFC 158 Ah 180 623X211X627

24 V - 2PzV 160 Ah wf Exide 180 624X212X537

24 V - 2PzW 160 Ah 180 624X212X537

24 V - 2PzV 174 Ah wf Hawker 183 623X211X537

24 V - 2PzS 180 Ah 180 624X212X537

24 V - 2PzM 180 Ah 180 621X209X537

24 V - 2PzV 200 Ah wf Exide 215 621X209X627

24 V - 2PzV 220 Ah wf Hawker 218 623X211X627

24 V - 2PzW 220 Ah 220 624X212X627

24 V - 2PzS 250 Ah 220 624X212X627

24 V - 2PzS 250 Ah 220 621X209X627

24 V - 2PzM 250 Ah 222 621X209X625

L 24 V - 3PzV 300 Ah wf Exide 290 621X281X627

24 V - XFC 316 Ah 288 624X284X627

24 V - 3PzV 330 Ah wf Hawker 300 623X283X627

24 V - 3PzW 330 Ah 288 624X284X627

24 V - 3PzS 345 Ah Lib. Silver 282 621X284X627

24 V - 3PzS 375 Ah 288 624X284X627

24 V - 3PzS 375 Ah Lib. Silver 288 621X281X627

24 V - 3PzM 375 Ah 299 621X281X627

The battery weights can be taken from the battery data plate. Batteries with non insulated terminals must be covered with a non slip insulating mat.

NOTICE

Battery damage

The battery, charger (charge characteristics) and battery parameters must match each other, otherwise damage may result.

NOTICE

Reduced service life of the battery

To ensure the optimum service life of the battery, the battery manufacturer's latest operating and maintenance instructions must be observed.

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Page 44

3 Exposing the battery

WARNING!

An unsecured truck can cause accidents

Parking the truck on an incline or with a raised load handler is dangerous and is strictly prohibited.

Park the truck on a level surface. In special cases the truck may need to be

secured with wedges. Fully lower the load handler.

Select a place to park where no other people are at risk of injury from the lowered

load handler. If the brakes are not working, place wedges underneath the wheels of the truck to

prevent it from moving.

CAUTION!

A closing battery panel can pose a trapping hazard

If the battery cover is not opened fully, it can suddenly close on its own and cause bruising. The battery cover is only properly opened at an angle greater than 90°. It is then held by gravity.

Open the battery cover as far as the stop.

Requirements

– Park the truck on a level surface. – Park the truck securely, see page 71.

Procedure

• Open the battery panel (9).

• Where necessary remove the insulating

mat from the battery.

The battery is now exposed.

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Page 45

4 Charging the battery

WARNING!

The gases produced during charging can cause explosions

The battery gives off a mixture of oxygen and hydrogen (electrolytic gas) during charging. Gassing is a chemical process. This gas mixture is highly explosive and must not be ignited.

Switch the charging station and truck off first before connecting/disconnecting the

charging cable of the battery charging station to/from the battery connector. The charger must match the battery in terms of voltage, charge capacity and

battery type. Before charging, check all cables and plug connections for visible signs of

damage. Ventilate the room in which the truck is being charged.

The battery cover must be open and the battery cell surfaces must be exposed

during charging to ensure adequate ventilation. Do not smoke and avoid naked flames when handling batteries.

Wherever an industrial truck is parked for charging there must be no inflammable

material or consumables capable of creating sparks within a minimum distance of 2 m from the truck.

Fire-control equipment must be available.

Do not place any metallic objects on the battery.

Always follow the safety regulations of the battery and charger station

manufacturers.

NOTICE

Battery damage

The battery, charger (charge characteristics) and battery parameters must match each other, otherwise damage may result.

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Page 46

4.1 Charging the battery with a stationary charger

Charging the battery

Requirements

– Expose the battery, see

page 44.

Procedure

• Disconnect the battery

connector (41) from the truck

connector.

• Connect the battery

connector (41) to the charging

cable (42) of the stationary

charger.

• Start charging in accordance

with the charger operating

instructions.

The battery is charging.

4.2

Completing battery charging, restoring the truck to operation

NOTICE

If charging has been interrupted, the full battery capacity will not be available.

Requirements

– The battery is fully charged.

Procedure

• Complete charging in accordance with the charger operating instructions.

• Disconnect the battery connector (41) from the charging cable (42) of the

stationary charger.

• Attach the battery connector (41) to the industrial truck.

The truck is now ready for operation.

Charging the battery with an on-board charger (o)

DANGER!

Risk of electric shock and fire

Damaged and unsuitable cables can cause electric shocks and can overheat, resulting in fires.

Always use mains cables with a maximum length of 30 m.

Local regulations must be observed. Unwind the cable reel fully when using it.

Always use original manufacturer’s mains cables.

Insulation safety, acid and caustic ratings must comply with the manufacturer's

mains lead. The charging connector must be dry and clean when used.

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Page 47

NOTICE

Improper use of the on-board charger can cause material damage

The on-board charger consisting of a battery charger and battery controller must not be opened. If faulty, contact the manufacturer’s customer service department.

The charger must only be used for batteries supplied by Jungheinrich or other

approved batteries provided it has been adapted by the manufacturer's customer service department.

Batteries must never be swapped from truck to truck.

Do not connect the battery to two chargers simultaneously.

4.2.1 Setting the charging characteristics (ELG 2430)

The factory setting for trucks without a battery is the 0 position. A battery discharge indicator, a charge/discharge indicator, a CanDis or a bipolar LED can be attached to the connector (44).

04.19 en-GB

CAUTION!

Remove the mains connector before setting the respective charging curve.

Set the charging characteristic

Requirements

– Battery connected.

Procedure

• Turn the setting switch (43) on the charger right to adapt the charging curve to the

battery being used.

• The validity of the new setting is acknowledged by the flashing of the green LED

and the setting takes immediate effect.

The charging characteristic is now set.

Page 48

Flashing sequence / charging curve assignment (ELG 2430)

Flashing sequence Selected charging curves (characteristics)

0 Truck without battery

Wet cell battery: PzS with 100 - 300 Ah Wet cell battery: PzM with 100 - 179 Ah

2 Maintenance-free: PzV with 100 - 149 Ah

3 Maintenance-free: PzV with 150 - 199 Ah

4 Maintenance-free: PzV with 200 - 330 Ah

Wet cell battery: PzS with pulse characteristic 200 400 Ah

Wet cell battery: PzM with pulse characteristic 180 400 Ah Wet cell battery: PzS with pulse characteristic 200 414 Ah

6 Jungheinrich 100 - 300 Ah

NOTICE

All other switch positions (43) block the charger, and the battery is not charged.

For PzM batteries with a capacity of less than 180 Ah set characteristic 1, beyond

180 Ah set characteristic 5. With PzS 200-300 Ah wet cell batteries both characteristic curves 1 and 5 can be

used. Characteristic 5 achieves a faster charge. When the battery is connected this allows you to adjust via the charger: If the

switch position is valid the green LED flashes according to the position set; if the switch position is invalid the red LED flashes.

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Page 49

4.2.2 Charging the battery

Starting to charge with the on-board charger

Mains connection

Mains supply: 230 V / 110 V (+10/-15%) Mains frequency: 50 Hz / 60 Hz

The mains cable of the charger (45) is in the front panel or the battery compartment.

Charging the battery

Requirements

– Park the truck securely, see page 71. – Expose the battery, see page 44. – Correct charging program set on charger.

Procedure

• Remove any insulating mats from the battery.

• The battery connector must remain plugged.

• Attach the mains connector (45) to a mains socket.

• Pull the emergency disconnect switch up.

The flashing LED indicates the charge status or a

fault (for flashing codes see “LED Display” table).

The battery is charged.

When the mains connector (45) is attached to the mains, all the truck’s electrical functions are disconnected (electric immobilizer). The truck cannot be operated.

Completing battery charging, restoring the truck to operation

NOTICE

If charging has been interrupted, the full battery capacity will not be available.

Requirements

– The battery is fully charged.

Procedure

• Remove the mains connector (45) from the mains socket and store it along with

the cable in the storage compartment (47).

• If applicable, place the existing insulating mats back over the battery.

• Close the battery panel securely.

04.19 en-GB

The truck is now ready for operation.

CAUTION!

Damaged mains cables can be hazardous

Do not trap the mains cable when closing the battery panel.

Page 50

Charging times

The duration of charge depends on the battery capacity.

Charging continues automatically after a mains failure. Charging can be interrupted by removing the mains connector and continued as partial charging.

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Page 51

LED display

(46)

Green LED (charge status)

Lit Charging complete, battery full. (Charge interval, float

or compensation charge).

Flashes slowly Charging.

Rapid flash Display at beginning of charge or after setting a new

characteristic curve. Number of flash pulses corresponds to the characteristic curve set.

Red LED (fault)

Lit Overtemperature. Charging is interrupted.

Flashes slowly Safety charging time exceeded. Charging is cancelled.

Mains must be disconnected for charging to restart.

Rapid flash Invalid characteristic curve setting.

Compensation charge

The compensation charge starts automatically when charging is complete.

04.19 en-GB

Partial charging

The charger is designed to automatically adapt to partially charged batteries. This keeps battery wear to a minimum.

Page 52

5 Battery removal and installation

WARNING!

Accident risk during battery removal and installation

Due to the battery weight and acid there is a risk of trapping or scalding when the battery is removed and installed.

Note the "Safety regulations for handling acid batteries" section in this chapter.

Wear safety shoes when removing and installing the battery.

Use only batteries with insulated cells and terminal connectors. If necessary cover

them with a rubber mat. Park the truck on a level surface.

Make sure the crane lifting gear has sufficient capacity to replace the battery.

Use only approved battery replacement devices (battery roller stand, replacement

trolley etc.). Make sure the battery is securely located in the truck's battery compartment.

CAUTION!

Risk of accidents and injury from electrical voltage

When installing and removing the lithium-ion battery, there is a risk of accidents and injury from electrical voltages.

The lithium-ion battery may only be installed and removed by trained experts.

CAUTION!

Trapping hazard

There is a risk of trapping when you close the battery cover.

Make sure there is nothing between the battery cover and the truck when you

close the battery cover.

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Page 53

5.1 Changing the battery from the top

Removing the battery

Requirements

– Park the truck securely, see page 71. – Expose the battery, see page 44.

Tools and Material Required

– Crane lifting gear

Procedure

• Disconnect the battery connector from the

truck connector.

Place the battery cable on the tray so that it cannot be severed when the battery

is pulled out.

• Attach the crane lifting gear to the eyes (47).

The hooks must be fitted in such a way that when the crane lifting gear is

slackened, they do not fall onto the battery cells. The lifting gear must exert a

vertical pull so that the battery container is not compressed.

• Lift the battery slowly out of the battery compartment using crane lifting gear.

The battery has now been removed.

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Page 54

Battery Installation EJE 220 / 225 / 230 / 235

Requirements

– Park the truck securely, see page 71.

Procedure

Assembly is the reverse order. Note the correct assembly position and make sure

the battery is connected correctly.

Place the battery cable on the tray so that it cannot be severed when the battery

is inserted.

• Attach the battery connector to the truck connector.

CAUTION!

Trapping hazard

There is a risk of trapping when you close the battery cover.

Do not reach between the battery cover and chassis. Hold the battery cover only

by the designated recess. Close the battery panel carefully and slowly.

Close the battery panel.

The battery is now installed.

After installing the battery again, check all cables and plug connections for visible signs of damage.

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Page 55

Battery Installation EJE 220r / 225r

Requirements

– Park the truck securely, see page 71.

Procedure

Assembly is the reverse order. Note the correct assembly position and make sure

the battery is connected correctly.

Place the battery cable on the tray so that it cannot be severed when the battery

is inserted.

NOTICE

Avoid damaging the auxiliary hydraulics in the battery compartment

When installing the battery make sure that the auxiliary hydraulics components

(valves, hoses and electrical connecting cables) are not trapped.

• Attach the battery connector to the truck connector.

CAUTION!

Trapping hazard

There is a risk of trapping when you close the battery cover.

Do not reach between the battery cover and chassis. Hold the battery cover only

by the designated recess. Close the battery panel carefully and slowly.

Close the battery panel.

The battery is now installed.

After installing the battery again, check all cables and plug connections for visible signs of damage.

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Page 56

5.2 Lateral battery removal

Lateral battery removal is optional only. And on the EJE 220r / 225r the battery can only be removed from the left-hand side.

CAUTION!

Trapping hazard

Trapping hazard when removing and installing the battery.

When removing and installing the battery do not put your hands between the

battery and the chassis.

Removing the battery

Requirements

– Park the truck securely, see page 71 – Battery exposed, see page 44.

Procedure

• Disconnect the battery connector from the truck connector.

• Turn the battery lock (48) as far as the stop.

• Pull the battery out from the side.

The battery is now removed.

Installation is the reverse order. When reinstalling the battery, note the proper installation position and make sure the battery is connected correctly. Place the battery cable on the tray so that it cannot be severed when the battery is inserted.

– After installing the battery, check all cables and plug connections for visible signs

of damage.

CAUTION!

Trapping hazard

There is a risk of trapping when you close the battery cover.

Do not reach between the battery cover and chassis. Hold

the battery cover only by the designated recess. Close the battery panel carefully and slowly.

04.19 en-GB

Page 57

E Operation

1 Safety Regulations for the Operation of Forklift Trucks

Driver authorisation

The truck may only be used by suitably trained personnel, who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to operate the truck by the proprietor or his representative.

Operator’s rights, responsibilities and rules of conduct

The driver must be informed of his duties and responsibilities and be instructed in the operation of the truck and shall be familiar with the operating instructions. Safety shoes must be worn on pedestrian-operated trucks.

Unauthorised use of truck

The operator is responsible for the truck during the time it is in use. The operator must prevent unauthorised persons from driving or operating the truck. Do not carry passengers or lift other people.

Damage and faults

The supervisor must be informed immediately of any damage or faults to the truck or attachment. Trucks which are unsafe for operation (e.g. wheel or brake problems) must not be used until they have been rectified.

Repairs

The operator must not carry out any repairs or alterations to the truck without authorisation and the necessary training to do so. The operator must never disable or adjust safety mechanisms or switches.

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Page 58

Hazardous area

WARNING!

Risk of accidents/injury in the hazardous area of the truck

A hazardous area is defined as the area in which people are at risk due to travel or lifting operations of the truck, its load handler or the load. This also includes the area within reach of falling loads or lowering/falling operating equipment.

Instruct unauthorised persons to leave the hazardous area.

In case of danger to third parties, give a warning signal in good time.

If unauthorised persons are still within the hazardous area, stop the truck

immediately.

Safety devices, warning signs and warning instructions

Safety devices, warning signs (see page 31) and warning instructions in the present operating instructions must be strictly observed.

WARNING!

Removing or disabling safety devices can cause accidents

Removing or disabling safety devices such as the emergency disconnect switch, key switch, buttons, horn, strobe lights, sensors, panels, etc. can result in accidents and injury.

Report any defects immediately to your supervisor.

Mark defective truck and take it out of service.

Do not return the truck to service until you have identified and rectified the fault.

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Page 59

2 Displays and Controls

65537126525010

13, 54, 55

14, 56

04.19 en-GB

Page 60

ItemControl/display Function

5 Collision safety switch

6 Travel switch

7 Slow-travel button

8 Tiller

10 Emergency disconnect switch

12 Cable connection

On-board battery charger (including safety switch)

t t

Safety function for travel in the drive direction: When the collision safety switch is actuated, the truck travels for approx. 3 seconds in the load direction. The truck then switches off until the travel switch is briefly restored to the neutral position.

Controls the travel direction and the travel speed.

Pressing the slow-travel button reduces the travel speed and acceleration. If the tiller is in the brake zone, pressing this button overrides the brake function and the truck can be operated at slow speed.

Used for steering and braking.

Disconnects the battery supply – All electrical functions are

deactivated and the truck is braked

Charges the battery by inserting the mains connector into a mains socket.

49 Load handler lower button

50 Load handler lower button

51 Load handler raise button

52 Load handler raise button

53 Warning signal button

7 Slow-travel button

o t o t t t

Lowers the load handler.

Raises the load handler.

Activates an audible signal.

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Page 61

65537126525010

13, 54, 55

14, 56

04.19 en-GB

Page 62

ItemControl/display Function

13 Charge/discharge indicator

14 Key switch

Key switch with second

switch stage

54 CanDis

55 Display unit

(2-inch display)

Shows the charge/discharge status of the battery.

– Activates the truck by applying the

control voltage

– Removing the key prevents the

truck from being switched on by unauthorised personnel

Brake release to move the truck when non-operational.

Display instrument for: – Battery charge status – Service hours – Warning messages – Parameter setting

Display for: – Battery charge status – Battery capacity – Service hours – Travel program – Warning indicators – Event messages

Soft keys under the display unit

56 CanCode

ISM Online

Keypad

Replaces the key switch – Entering the appropriate code

activates the truck – Travel program selection – Code setting

Replaces the key switch – Activates the truck via a card/

transponder – Displays readiness for operation – Operational data logging – Data exchange with card/

transponder

Replaces the key switch – Provided only as a supplement to

the display unit – Truck release by entering set-up

and access codes

Transponder reader

Replaces the key switch – Provided only as a supplement to

the display unit – Activates the truck via a card/

transponder

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Page 63

65537126525010

13, 54, 55

14, 56

04.19 en-GB

Page 64

04.19 en-GB

Page 65

2.1 EJE 220r / EJE 225r Tiller

575852

525057

04.19 en-GB

ItemControl/display Function

50 Load handler lower button

52 Load handler raise button

57 Ramp lift lower button

58 Ramp lift raise button

t t t t

Lowers the load handler.

Raises the load handler.

Lowers ramp lift.

Raises ramp lift.

Page 66

2.2 Battery discharge indicator

When the truck has been released via the key switch, CanCode or ISM, the battery charge status is displayed. The LED colours (59) represent the following conditions:

LED colour Charge status

Green 40–100%

Orange 30–40%

Green/orange

flashes at 1 Hz

Red 0–20%

If the LED is red, the load can no longer be lifted. Lifting is only enabled when the battery connected is at least 70% charged.

If the LED flashes red and the truck is not ready for operation, inform the manufacturer's service department. Red flashing is a truck controller code. The flashing sequence indicates the type of fault.

20–30%

2.3 Battery discharge monitor

The standard setting for the battery discharge indicator / discharge monitor is based on standard batteries. When using maintenance-free or special batteries, the display and cut-out points of the battery discharge monitor must be set by manufacturer's service department. If this adjustment is not made, the battery may become damaged due to deep discharge.

NOTICE

Full discharge can damage the battery

Self-discharge can cause the battery to fully discharge. Full discharge shortens the useful life of the battery.

Charge the battery at least every 2 months.

Charge the battery see page 45.

If the residual capacity falls below the required level, lifting is inhibited. An alternating display (59) appears. Lifting is only released when the battery connected is at least 70% charged.

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Page 67

3 Preparing the Truck for Operation

3.1 Checks and Operations to Be Performed Before Starting Daily Work

WARNING!

Risk of accident due to damage to or other defects in the truck and optional features

If damage or other truck or attachment (optional equipment) defects are discovered during the following checks, the truck must be taken out of service until it has been repaired.

Report any defects immediately to your supervisor.

Mark defective truck and take out of service.

Do not return the industrial truck to service until you have identified and rectified

the fault.

Inspection before daily operation

Procedure

• Check the whole of the outside of the truck for signs of damage and leaks. Damaged hoses must be replaced immediately.

• Check the battery attachment and wire connections for damage and make sure they are secure.

• Check the battery connectors are secure.

• Check the load handler for visible signs of damage such as cracks, bent or severe wear.

• Check the drive wheel and load wheels for damage.

• Check that the markings and labels are present, clean and legible, see page 31.

• Make sure the drive panels and covers are secure and check for damage.

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Page 68

3.2 Preparing the truck for operation

13, 54

14, 56

Switching on the truck

Requirements

– Checks and operations to be performed before starting daily work, see page 67.

Procedure

• Pull the emergency disconnect switch (10) to unlock it.

• To switch on the truck:

• Insert the key in the key switch (14) and turn it as far to the right as it will go.

•

Enter the code in CanCode (o) (56).

• Hold the card or transponder in front of the ISM access module and, depending

on the setting, press the green button on the ISM access module (o).

The tiller (8) must be in the upper braking zone "B". If event message "E-0914" is displayed on the CanDis display instrument (o) or on the display unit (2-inch display) (o), move the tiller to the upper brake zone "B", see page 78.

The truck is ready for operation.

t The charge status indicator (13) shows the current battery charge status.

o The CanDis display instrument (54) or the display unit (2-inch display) (o) shows

the current battery charge status and the service hours.

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Page 69

3.3 Making the EJE 220r / 225r operational

13, 54

14, 56

On the EJE 220r / 225r you must check that the load handler is lowered when making the truck operational. If the load handler is not fully lowered, it can tilt slightly when raised.

Switching on the EJE 220r / 225r truck

Requirements

– Checks and operations to be performed before starting daily work, see page 67.

Procedure

• Pull the emergency disconnect switch (10) to unlock it.

• To switch on the truck:

• Insert the key in the key switch (14) and turn it as far to the right as it will go.

•

Enter the code in CanCode (o) (56).

• Hold the card or transponder in front of the ISM access module and, depending

on the setting, press the green button on the ISM access module (o).

• Check that the load handler is fully lowered.

• Lower the load handler if necessary, see page 83.

The truck is ready for operation.

t The charge status indicator (13) shows the current battery charge status.

o The CanDis display instrument (54) or the display unit (2-inch display) (o) shows

the current battery charge status and the service hours.

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3.4 Checks and operations to be carried out when the truck is operational

WARNING!

Risk of accident due to damage to or other defects in the truck and optional features

If damage or other truck or attachment (optional equipment) defects are discovered during the following checks, the truck must be taken out of service until it has been repaired.

Report any defects immediately to your supervisor.

Mark defective truck and take out of service.

Do not return the industrial truck to service until you have identified and rectified

the fault.

Procedure

• Test warning indicators and safety devices:

• Test the emergency disconnect function by pressing the emergency disconnect switch. The main circuit is disconnected and no truck operations can be performed. Now pull the Emergency Disconnect switch to unlock it.

• Test the horn by pressing the "warning signal" button.

• Check braking efficiency, see page 81.

• Test the steering, see page 81.

• Test the hydraulic system, see page 83.

• Test travel operations, see page 78.

• Test the "collision safety switch" by depressing it whilst driving in the drive direction.

• Test the controls and displays and check for damage, see page 59.

• Check tiller return function.

• Check the controls automatically return to the neutral position after use.

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3.5 Parking the truck securely

105060

14, 56

WARNING!

An unsecured truck can cause accidents

Parking the truck on an incline, without the brakes applied or with a raised load or load handler is dangerous and is strictly prohibited.

Park the truck on a level surface. In special cases the truck may need to be

secured with wedges. Fully lower the load handler.

Select a place to park where no other people are at risk of injury from the lowered

load handler. If the brakes are not working, place wedges underneath the wheels of the truck to

prevent it from moving.

EJE 220 / 225 / 230 / 235

Park the truck securely

Procedure

• Park the truck on a level surface.

• Fully lower the load handler (60):

• Press the lower button (50).

• Using the tiller (8) set the drive wheel to the straight ahead position.

• Switch off the truck, to do this:

• Turn the key in the key switch (14)

anti-clockwise as far as it will go. Remove the key from the key switch (14).

• For CanCode (56) press the O key

(o).

• Press the red button on the ISM

access module (o).

• Press the Emergency Disconnect (10).

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The truck is parked.

Page 72

EJE 220r / 225r

105060

14, 56

Parking the truck securely

Procedure

• Park the truck on a level surface.

• Fully lower the load handler (60):

• Press the "lower" button (50) or the "ramp lift lower" button (57).

• Using the tiller (8), turn the drive wheel to "forward travel".

• Switch off the truck, to do this:

• Turn the key in the key switch (14) anti-clockwise as far as it will go. Remove

the key from the key switch (14).

•

For CanCode (56), press the O key (o).

•

Press the red key on the ISM access module (o).

• Press the emergency disconnect switch (10).

The truck is parked.

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4 Industrial Truck Operation

4.1 Safety regulations for truck operation

Travel routes and work areas

Only use lanes and routes specifically designated for truck traffic. Unauthorised third parties must stay away from work areas. Loads must only be stored in places specially designated for this purpose. The truck must only be operated in work areas with sufficient lighting to avoid danger to personnel and materials. Additional equipment is necessary to operate the truck in areas of insufficient lighting.

DANGER!

Do not exceed the permissible surface and point loading on the travel lanes. At blind spots get a second person to assist. The driver must ensure that the loading dock /dock leveller cannot be removed or come loose during loading/unloading.

Travel conduct

The operator must adapt the travel speed to local conditions. The truck must be driven at slow speed when negotiating bends or narrow passageways, when passing through swing doors and at blind spots. The operator must always observe an adequate braking distance between the forklift truck and the vehicle in front and must be in control of the truck at all times. Abrupt stopping (except in emergencies), rapid U turns and overtaking at dangerous or blind spots are not permitted. Do not lean out or reach beyond the working and operating area.

Travel visibility

The operator must look in the direction of travel and must always have a clear view of the route ahead. If the truck is carrying loads that affect visibility, the truck must travel against the load direction. If this is not possible, a second person must walk alongside the truck as a lookout to observe the travel route while maintaining eye contact with the operator. Proceed only at walking pace and with particular care. Stop the truck as soon as you lose eye contact.

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Negotiating slopes and inclines

Negotiating slopes and inclines up to 20 % is only permitted when they are recognised lanes. The slopes and inclines must be clean, have a non-slip surface, and negotiating them safely must be within the technical specifications of the truck. The truck must always be driven with the load facing uphill. The industrial truck must not be turned, operated at an angle or parked on inclines or slopes. Inclines must only be negotiated at slow speed, with the driver ready to brake at any moment.

Negotiating lifts, loading ramps and docks

Lifts may only be negotiated if they have sufficient capacity, are suitable for driving on and authorised for truck traffic by the owner. The driver must satisfy himself of the above before entering these areas. The truck must enter lifts with the load in front and must take up a position which does not allow it to come into contact with the walls of the lift shaft. Persons riding in the lift with the forklift truck must only enter the lift after the truck has come to a rest and must leave the lift before the truck. The driver must ensure that the loading ramp / dock cannot move or come loose during loading / unloading.

Type of loads to be carried

The operator must make sure that the load is in a satisfactory condition. Loads must always be positioned safely and carefully. Use suitable precautions to prevent parts of the load from tipping or falling down. Prevent liquid loads from sloshing out.

WARNING!

Electromagnetic influence can result in accidents

Strong magnets can cause electronic components such as Hall sensors to become damaged, resulting in accidents.

Do not use magnets in the operating area of the truck. Exceptions to this rule are

commercial, weak clamping magnets for attaching notices.

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4.2 Emergency Disconnect

CAUTION!

Applying maximum braking can result in accidents

Applying the Emergency Disconnect switch during travel will cause the truck to decelerate to a halt at maximum force. This may cause the load to slide off the load handler. There is a higher risk of accidents and injury.

Do not use the Emergency Disconnect switch as a service brake.

Use the Emergency Disconnect switch during travel only in emergencies.

CAUTION!

Faulty or non-accessible Emergency Disconnect switches can cause accidents

A faulty or non-accessible Emergency Disconnect switch can cause accidents. In dangerous situations the operator cannot bring the truck to a halt in time by applying the Emergency Disconnect switch.

The operation of the Emergency Disconnect switch must not be affected by any

objects placed in its way. Report any defects on the Emergency Disconnect switch immediately to your

supervisor. Mark defective truck and take out of service.

Do not return the industrial truck to service until you have identified and rectified

the fault.

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Press the Emergency Disconnect switch

Procedure

• Press the Emergency Disconnect (10).

All electrical functions are deactivated. The truck brakes to a halt.

Press the Emergency Disconnect switch on in emergencies.

Releasing the Emergency Disconnect switch

Procedure

• Pull the Emergency Disconnect switch (10) to unlock it.

All electrical functions are enabled and the truck is operational again (provided the truck was operational before the Emergency Disconnect was pressed).

Trucks with CanCode and ISM access module remain switched off.

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4.3 Automatic braking

863

When the tiller is released, it returns automatically to the upper brake zone (B) and the brakes are applied automatically.

WARNING!

Risk of collision due to a defective tiller

Operating the truck with a defective tiller can lead to collisions with persons or objects.

If the tiller returns to the brake position slowly or not at all, the truck must be taken

out of service until the cause of this fault is be rectified. Contact the manufacturer's customer service department.

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4.4 Travel

WARNING!

Collision hazard when operating the truck

Collisions with personnel and equipment can result if the truck is operated with open panels.

Do not operate the truck unless the panels and covers are closed and properly

locked. When travelling through swing doors etc. make sure that the doors do not activate

the collision safety button.

Requirements

– Start up the truck, see page 67.

Procedure

• Set the tiller (8) to the travel zone (F).

• Control the travel direction with the travel switch (6):

• Rotate the travel switch (6) slowly in the load direction (3):

Travel in load direction:

• Rotate the travel switch (6) slowly in the drive direction (2):

Travel in drive direction:

• Control the travel speed with the travel switch (6):

• The further the travel switch (6) is rotated, the greater the travel speed.

• Control the travel speed by rotating the travel switch (6) further or less.

After releasing the travel switch (6), it automatically returns to the neutral position (0), and the truck brakes.

The brakes are released and the truck moves in the selected direction.

Anti-roll back device for slow travel on inclines

If the truck does not have sufficient speed to travel up an incline, it may roll back. Rolling back is detected by the truck's controller and the truck brakes to a halt immediately.

oReduced speed when the load handler is fully loweredI

When the load handler is fully lowered the truck can only travel at reduced speed. The load handler must be raised in order to use the maximum available speed.

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4.4.1 Changing direction during travel

863

CAUTION!

Danger when changing direction during travel

Changing direction during travel causes the truck to decelerate sharply. When the truck changes direction, it can start travelling at high speed in the opposite direction unless the travel switch is released in time.

After setting off in the opposite direction, apply the travel switch gently or not at all.

Do not perform any sudden steering operations.

Always face in the direction of travel.

Maintain an adequate overview of the route you are travelling.

Changing direction during travel

Procedure

• Set the travel switch (6) to the opposite direction while travelling.

The truck decelerates until it starts to travel in the opposite direction.

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4.5 Slow travel

867

CAUTION!

Risk of accident if the service brake is deactivated

Particular care and attention is required by the operator during slow travel. The service brake is deactivated during slow travel and is only reactivated after the "slow travel" button is released.

In hazardous situations brake by immediately releasing the "slow travel" button

and the travel switch. During slow travel you can only brake by coating braking.

The truck can be operated with an upright tiller (8) (e. g. in confined spaces / elevators).

Switch on the slow travel function

Procedure

• Press and hold down the "slow travel" button (7).

• Rotate the travel switch (6) in the required travel direction.

The brake is released. The truck travels at slow speed.

Switching off slow travel

Procedure

• Release the "slow travel" button (7).

If the tiller is in brake zone "B", the brake applies and the truck stops. If the tiller is in brake zone "F" the truck continues at slow travel speed.

• Release the travel switch (6).

Slow travel ends and the truck can now travel again at normal speed.

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4.6 Steering

Procedure

• Move the tiller (8) to the left or right.

The truck is steered in the required direction.

4.7 Brakes

WARNING!

Accident risk while braking

The truck’s braking response depends largely on the floor condition and the type of surface. The truck’s braking distance increases when the ground is wet or dirty.

The operator must be aware of floor conditions and take them into account when

braking. Brake with care to prevent the load from slipping.

CAUTION!

In hazardous situations, move the tiller to the brake position or press the

emergency disconnect switch.

The truck can brake in two ways:

– With the service brake (brake zone B). – By regenerative braking (coasting brake).

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4.7.1 Braking with the service brake

Procedure

• Move the tiller (8) up or down to one of the brake zones (B).

The truck decelerates at the maximum rate until it comes to a halt.

4.7.2 Regenerative braking

4.7.3 Parking brake

The mechanical brake applies automatically when the truck comes to rest.

Procedure

• If the travel switch (6) is set to (0), the truck automatically brakes regeneratively.

The truck brakes to a halt regeneratively via the coasting brake.

When braking regeneratively, energy is returned to the battery, ensuring a longer service time.

The mechanical brake applies automatically when the truck comes to rest.

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4.8 Load handler raise/lower

WARNING!

Accident risk when lifting and lowering

Other people can be injured in the truck's hazardous area. The hazardous area is defined as the area in which people are at risk from the movement of the truck including the load handler, etc. This also includes areas which can be reached by falling loads, operating equipment, etc. Apart from the driver (in the normal operating position) there should be no other people in the truck's hazardous area.

Instruct other people to move out of the hazardous area of the truck. Stop working

with the truck if people do not leave the hazardous area. If people do not leave the hazardous area despite the warning, prevent the truck

from being used by unauthorised people. Only carry loads that have been secured and positioned in accordance with

regulations. Use suitable precautions to prevent parts of the load from tipping or falling down.

Never exceed the maximum loads specified on the capacity plate.

Do not stand on the load handler.

Do not lift other people on the load handler.

Never reach or climb into moving truck parts.

Do not climb onto parts of the building or other trucks.

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4.8.1 Raising the load handler

Requirements

– Prepare the truck for operation, see page 68.

Procedure

Press the “Raise load handler ” button (52) until you reach the desired lift height.

NOTICE

Risk of material damage to the hydraulic unit

When the mechanical end stop of the load has been reached, release the "Raise load handler" button. Otherwise the hydraulic unit could suffer material damage.

The load handler is raised.

Tiller from above

Tiller from below

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Page 85

4.8.2 Lowering the load handler

Requirements

– Prepare the truck for operation, see page 68.

Procedure

• Press the “Lower load handler” button (50) until you reach the desired lift height.

The load handler is lowered.

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Page 86

4.8.3 Raising the ramp lift

EJE 220r / 225r

Requirements

– Prepare the truck for operation, see page 68.

Procedure

• Press the “ramp lift raise” button (58) until you reach the desired lift height.

The load handler is raised to ramp lift.

If the load handler is raised with the "load handler raise" button, it cannot change directly to ramp lift. When the "ramp lift raise" button is applied the load handler is first fully lowered and then raised to ramp lift.

If the load handler is raised with ramp lift, it cannot change directly to normal lift. When the "load handler raise" button is applied, ramp lift is first fully lowered and then the load handler is raised.

Tiller from above

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Tiller from below

4.8.4 Lowering ramp lift

EJE 220r / 225r

Requirements

– Prepare the truck for operation, see page 68.

Procedure

• Press the “ramp lift lower” button (57) until you reach the desired lift height.

The load handler is lowered from ramp lift.

When you release the "ramp lift lower" button (57) or the "load handler lower" button a lag time of 1 to 2 seconds begins. If the "ramp lift raise" button (58) or the "load handler raise" button are pressed during this lag time, the load handler is raised after a delay.

The lag time ensures that the load handler is fully lowered.

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4.9 Lifting, transporting and depositing loads

WARNING!

Unsecured and incorrectly positioned loads can cause accidents.

Before lifting a load unit, the driver must make sure that it has been correctly palletised and does not exceed the truck’s capacity.

Instruct other people to move out of the hazardous area of the truck. Stop working

with the truck if people do not leave the hazardous area. Only carry loads that have been correctly secured and positioned. Use suitable

precautions to prevent parts of the load from tipping over or falling off the truck. Damaged loads must not be transported.

Never exceed the maximum loads specified on the load diagram.

Never stand underneath a raised load handler.

Do not stand on the load handler.

Do not lift other people on the load handler.

Insert the load handler as far as possible underneath the load.

CAUTION!

Do not lift long loads at an angle.

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4.9.1 Raising a load

Requirements

– Load correctly palletised. – Load weight matches the truck's capacity. – Load handler evenly loaded for heavy loads.

Procedure

• Drive the truck carefully up to the pallet.

• Drive the load handler slowly into the pallet until the pallet is against the back of the load handler (see graphic to the right).

The load must not extend by more than 50 mm beyond the load handler tips.

• Raise the load handler until the desired height is reached, (see page 84).

The load is being raised.

NOTICE

Risk of material damage to the hydraulic unit

When the mechanical stops of the load handler have been reached, release the "raise load handler" button. Otherwise the hydraulic unit may suffer material damage.

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4.9.2 Raising the load with ramp lift

EJE 220r / 225r

Requirements

– Load correctly palletised. – Load weight matches the truck's rated capacity. – Load handler evenly laden for heavy loads. – Truck is on a ramp. – Load handler lowered.

Procedure

• Drive the truck slowly up to the pallet.

• Raise ramp lift (see page 86).

• Slowly insert the load handler into the pallet and lower the ramp lift incrementally.

• Insert the load handler into the pallet until the pallet is resting against the back of the load handler.

The load must not extend by more than 50 mm beyond the load handler tips.

• Fully lower the ramp lift.

• Raise the load handler until you reach the desired height, (see page 84).

The load is raised.

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Page 93

4.9.3 Transporting a load

Requirements

– Load raised correctly. – Load is not on the ground. – Perfect ground conditions.

Procedure

• Accelerate and decelerate with care.

• Adapt your travel speed to the conditions of the route and the load you are transporting.

• Travel at a constant speed.

• Be prepared to brake at all times.

• Brake gently in normal circumstances.

• Only stop suddenly in dangerous situations.

• Watch out for other traffic at crossings and passageways.

• Always travel with a lookout at blind spots.

• Do not travel across or at an angle on inclines. Do not turn on slopes and inclines, and always drive with the load facing uphill (see graphic).

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4.9.4 Depositing a load

CAUTION!

Loads must not be set down on transport or escape routes, in front of safety installations or factory equipment that must be accessible at all times.

Requirements

– Storage location suitable for storing the load.

Procedure

• Drive the truck carefully up to the storage location.

• Lowers the load handler.

To avoid damaging the load and the load handler, avoid setting the load down abruptly.

• Lower the load handler so that it is clear of the load (see page 85).

• Carefully drive the load handler out from beneath the pallet.

The load is deposited.

NOTICE

Avoid depositing the load suddenly to avoid damaging the load, load handler and the rack.

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4.9.5 Depositing the load with ramp lift

EJE 220r / 225r

CAUTION!

Loads must not be deposited on travel or escape routes, in front of safety mechanisms or operating equipment that must be accessible at all times.

Requirements

– Storage location suitable for storing the load.

Procedure

• Drive carefully up to the storage location.

• Lower the load handler fully (see page 85).

Avoid lowering the load suddenly to prevent the load and load handler from damage.

• Carefully remove the load handler from the pallet and raise the ramp lift incrementally (see page 86).

• When the load handler has been fully removed from the pallet, lower the ramp lift.

The load has been deposited.

NOTICE

Avoid depositing the load suddenly to avoid damaging the load, load handler and the rack.

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5 Troubleshooting

This chapter enables the operator to localize and rectify basic faults or the results of incorrect operation himself. When trying to locate a fault, proceed in the order shown in the remedy table.

If, after carrying out the following remedial action, the truck cannot be restored to operation or if a fault in the electronics system is displayed with a corresponding error code, contact the manufacturer’s service department. Troubleshooting must only be performed by the manufacturer’s customer service department. The manufacturer has a service department specially trained for these tasks. In order for customer services to react quickly and specifically to the fault, the following information is essential:

- Truck serial number

- Event message from the display unit (if applicable)

- Error description

- Current location of truck.

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5.1 Truck does not start

Possible cause Actions

Battery connector not plugged in Check the battery connector

Emergency disconnect switch pressed Release the emergency disconnect

Key switch in position "O" Set the key switch to position "I"

Battery charge too low Check battery charge and

Faulty fuse Check fuses, see page 164

and connect if necessary

switch, see page 75

charge battery if necessary, see page 45

Incorrect ISM access module transponder used

Use correct transponder

Incorrect code entered in CanCode Enter correct code, see page 108

Tiller not in brake position when the truck is switched on

Swing the tiller into the top or the bottom brake zone

(for CanDis or on the display unit (2-inch display) (o), event message

E-0914 appears)

"Raise load handler" button/"Lower load

Do not actuate the buttons handler" button not in home position when truck switched on (for CanDis or

on the display unit (2-inch display) (o), event message E-2951 appears)

Travel switch not in home position when

Do not actuate the travel switch truck switched on (for CanDis or the

display unit (2-inch display) (o), event message E-1901 appears)

Collision safety switch actuated when

Do not actuate the collision safety switch truck switched on (for CanDis or on the

display unit (2-inch display) (o), event message E-1914 appears)

"Slow travel" button actuated when truck switched on (for CanDis or the display

unit (2-inch display) (o), event message E-1901 appears)

Do not actuate the button

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5.2 Load cannot be lifted

Possible cause Actions

Truck not operational Carry out all actions listed under "Truck

Hydraulic oil level too low Check the hydraulic oil level, see

does not start"

page 162

Battery discharge monitor has switched

Charge the battery, see page 45 off

Faulty fuse Check fuses, see page 164

Excessive load Observe the rated capacity, see data

plate

Tiller not in brake position when the truck is switched on

Swing the tiller into the top or the bottom

brake zone (for CanDis or on the display unit (2-inch

display) (o), event message E-0914 appears)

"Raise load handler" button/"Lower load

Do not actuate the buttons handler" button not in home position when truck switched on (for CanDis or

on the display unit (2-inch display) (o), event message E-2951 appears)

Travel switch not in home position when

Do not actuate the travel switch truck switched on (for CanDis or the

display unit (2-inch display) (o), event message E-1901 appears)

Collision safety switch actuated when truck switched on (for CanDis or on the

display unit (2-inch display) (o), event message E-1914 appears)

"Slow travel" button actuated when truck switched on (for CanDis or the display

unit (2-inch display) (o), event message E-1901 appears)

Do not actuate the collision safety switch

Do not actuate the button

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6 Operating the truck without its own drive system

With the right optional equipment (o) it is possible to switch the truck to emergency operation via the GF60 service key: The brakes are released electrically and the truck can move without its own drive system, see page 103.

6.1 Release and activate the drive wheel brake

WARNING!

Accidental truck movement

When the brakes are de-activated the truck must be parked on a level surface, since the brakes are no longer effective.

Do not release the brake on slopes or inclines.

Do not park the truck with the brake released.

Apply the brake again when you reach your destination.

100

04.19 en-GB