Jungheinrich Forklift EJE 220 EJE 225 EJE 230 EJE 235 EJE 220r EJE 225r Operating Instructions Manua

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

05.07

Operating instructions

en-GB

51040446 04.19 EJE 220 EJE 225 EJE 230 EJE 235 EJE 220r EJE 225r

fiUNGHEINRICH

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Contents

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A

Correct Use and Application................................................................................

11

1 2 3 3.1

11 11 12

3.2 4 5

General....................................................................................................................................

Correct application .............................................................................................................

Approved application conditions..................................................................................

Internal Operation Combined with Brief External or Cold Store Operation (•) .......................................................................................................................

Internal Operation in Cold Stores with Cold Store Equipment (0) ............

Proprietor responsibilities................................................................................................

Adding attachments and/or optional equipment..................................................

13 13 14 14

B

Truck Description..........................................................................................................

15

1 1.1 2 3 3.1 3.2 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 5 5.1 5.2 5.3

Application..............................................................................................................................

Truck models and rated capacity................................................................................

Travel direction definition................................................................................................

Assemblies and Functional Description...................................................................

Assembly Overview...........................................................................................................

Functional Description......................................................................................................

Technical Specifications...................................................................................................

Performance data ..............................................................................................................

Dimensions............................................................................................................................

Weights....................................................................................................................................

Tyre type..................................................................................................................................

EN norms................................................................................................................................

Conditions of use................................................................................................................

Electrical Requirements...................................................................................................

Identification Points and Data Plates........................................................................

Indication Points .................................................................................................................

Data plate................................................................................................................................

Truck capacity plate...........................................................................................................

15 15 16 17 17 19 21 21 22 27 28 29 30 30 31 31 32 33

C

Transport and Commissioning...........................................................................

35

1 2 3

Lifting by crane.....................................................................................................................

Transport.................................................................................................................................

Using the Truck for the First Time...............................................................................

35 37 38

D

Battery - Servicing, Recharging, Replacement....................................

39

1 2 3 4 4.1 4.2 5 5.1 5.2

Safety Regulations Governing the Handling of Lead-Acid Batteries.........

Battery types.........................................................................................................................

Exposing the battery..........................................................................................................

Charging the battery..........................................................................................................

Charging the battery with a stationary charger....................................................

Charging the battery with an on-board charger (0) ..........................................

Battery removal and installation...................................................................................

Changing the battery from the top..............................................................................

Lateral battery removal....................................................................................................

39 41 44 45 46 46 52 53 56

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E

Operation ...........................................................................................................................

57

1 2 2.1 2.2 2.3 3 3.1 3.2 3.3 3.4 3.5 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 5 5.1 5.2 6 6.1 7 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11

Safety Regulations for the Operation of Forklift Trucks ...................................

Displays and Controls .......................................................................................................

EJE 220r / EJE 225r Tiller ..............................................................................................

Battery discharge indicator.............................................................................................

Battery discharge monitor...............................................................................................

Preparing the Truck for Operation ..............................................................................

Checks and Operations to Be Performed Before Starting Daily Work .... .

Preparing the truck for operation .................................................................................

Making the EJE 220r / 225r operational ..................................................................

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

Parking the truck securely ..............................................................................................

Industrial Truck Operation ..............................................................................................

Safety regulations for truck operation .......................................................................

Emergency Disconnect ....................................................................................................

Automatic braking ...............................................................................................................

Travel ........................................................................................................................................

Slow travel ..............................................................................................................................

Steering ....................................................................................................................................

Brakes.......................................................................................................................................

Load handler raise/lower .................................................................................................

Lifting, transporting and depositing loads ...............................................................

Troubleshooting ...................................................................................................................

Truck does not start ...........................................................................................................

Load cannot be lifted .........................................................................................................

Operating the truck without its own drive system. ...............................................

Release and activate the drive wheel brake..........................................................

Optional equipment. ...........................................................................................................

Emergency operation with service key GF60 .......................................................

Tiller with buttons on both faces ..................................................................................

Keypad (CanCode) (0) ...................................................................................................

Setting the truck parameters with CanCode..........................................................

Parameters.............................................................................................................................

Setting the Battery Parameters with CanCode ....................................................

CanDis Display Instrument (0) ....................................................................................

Display unit (2 inch display) ...........................................................................................

General Information about the Use of Keyless Access Systems ............... .

Using the Display: .............................................................................................................

ISM access module (0) ...................................................................................................

57 59 65 66 66 67 67

F

Industrial Truck Maintenance.............................................................................. 145

1 2 2.1 2.2 2.3 2.4 3 3.1 3.2 3.3

Operational Safety and Environmental Protection .............................................

Maintenance Safety Regulations ................................................................................

Working on the electrical system ................................................................................

Consumables and used parts .......................................................................................

Wheels .....................................................................................................................................

Hydraulic system .................................................................................................................

Lubricants and Lubrication Schedule ........................................................................

Handling consumables safely .......................................................................................

Lubrication Schedule.........................................................................................................

Consumables ........................................................................................................................

8

68 69 70 71 73 73 75 77 78 80 81 81

83 88 97

98 99 100 100 103 103 105 106 125 127 129 131 133

138 139

143

145 146 147 147 147

148 150 150 152 153

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4

4.1 4.2 4.3 4.4

4.5 4.6 4.7

4.8 4.9 4.10 5 5.1 5.2 5.3 6 7 8

Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement............................................................................ 171

1 1.1 1.2 2 2.1

4.1 4.2

Maintenance Contents EJE 235..................................................................................

Owner.......................................................................................................................................

Customer Service...............................................................................................................

Maintenance Contents EJE 220r-225r.....................................................................

Owner.......................................................................................................................................

Customer Service...............................................................................................................

Maintenance Contents EJE 230..................................................................................

Owner.......................................................................................................................................

Customer Service...............................................................................................................

Maintenance Contents EJE 220/225.........................................................................

Owner.......................................................................................................................................

Customer Service...............................................................................................................

H

Traction battery............................................................................................................... 211

1 2 3 4

Correct Use and Application..........................................................................................

Data plate................................................................................................................................

Safety Instructions, Warning Indications and other Notes..............................

Lead acid batteries with armour plated cells and liquid electrolyte...........

Description.............................................................................................................................

Operation ................................................................................................................................

Servicing lead-acid batteries with armour plated cells ....................................

PzV and PzV-BS lead-acid batteries with sealed armour plated cells ....

Description .............................................................................................................................

Operation ................................................................................................................................

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

Aquamatik water replenishment system..................................................................

Water replenishment system design.........................................................................

Functional Description......................................................................................................

Adding water.........................................................................................................................

Water pressure.....................................................................................................................

2.2 3.2 4

4.1 4.2 4.3 5 5.1 5.2 5.3

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154 154 154 155 159 160 161 162 163 164 166 167 167 167 168 169 169 169

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3 3.1

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Maintenance and repairs.................................................................................................

Preparing the truck for maintenance and repairs................................................

Lifting and jacking up the truck safely.......................................................................

Cleaning...................................................................................................................................

Front cover disassembly.................................................................................................

Drive panel disassembly and assembly...................................................................

Tightening the wheel nuts...............................................................................................

Checking the hydraulic oil level....................................................................................

Check the gear oil level....................................................................................................

Checking electrical fuses................................................................................................

Restoring the truck to service after maintenance and repairs......................

Decommissioning the Industrial Truck......................................................................

Prior to decommissioning................................................................................................

Action to be taken during decommissioning..........................................................

Restoring the truck to service after decommissioning......................................

Safety tests to be performed at intervals and after unusual incidents......

Final de-commissioning, disposal...............................................................................

Human vibration measurement....................................................................................

6 6.1 6.2 6.3 6.4

172 172 176 182 182 186 192 192 196 201 201 205

211 211 212 213 213 215 218 220 220 221 224 225 225 226 226 226

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9

6.5 6.6 6.7 6.8 6.9 6.10 7 7.1 8 9 10 11

Filling time...............................................................................................................................

Water quality..........................................................................................................................

Battery tubing........................................................................................................................

Operating temperature.....................................................................................................

Cleaning measures............................................................................................................

Service mobile vehicle......................................................................................................

Electrolyte circulation........................................................................................................

Functional Description......................................................................................................

Cleaning batteries...............................................................................................................

Storing the battery..............................................................................................................

Troubleshooting...................................................................................................................

Disposal...................................................................................................................................

227 227 227 227 227 227 228 228 230 232 232 232

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CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL