ECE 220/225 Operating instructions 51376929 02.20 06.15 en-GB ECE 220 ECE 225 fiUNGHEINRICH
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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 :
A DANGER!
Indicates an extremely hazardous situation Failure to comply with this instruction will result in severe irreparable injury and even death
A WARNING!
Indicates an extremely hazardous situation Failure to comply with this instruction may result in severe irreparable injury and even death.
A 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.
[±I Used before notices and explanations.
• Indicates standard equipment
0 Indicates optional equipment
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Contents 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 (•) ....................................................................................................................... 12 3.2 Internal Operation in Cold Stores with Cold Store Equipment (0) 13 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...................................................................................................... 22 4 Technical Specifications................................................................................................... 25 4.1 Performance data .............................................................................................................. 25 4.2 Dimensions............................................................................................................................ 27 4.3 Weights.................................................................................................................................... 31 4.4 Tyre type.................................................................................................................................. 31 4.5 EN norms................................................................................................................................ 32 4.6 Specifications according to RED guideline (Radio Equipment Directive) for radio units................................................................................................... 33 4.7 Electrical requirements..................................................................................................... 34 4.8 Power supply of on-board charger (0).................................................................... 35 5 Identification Points and Data Plates........................................................................ 36 5.1 Indication Points ................................................................................................................. 36 5.2 Data plate................................................................................................................................ 38 5.3 Truck capacity plate........................................................................................................... 39 5.4 Wind loads.............................................................................................................................. 39 C Transport and Commissioning........................................................................... 41 1 Lifting by crane..................................................................................................................... 41 2 Transport................................................................................................................................. 43 3 Using the Truck for the First Time............................................................................... 45 D Battery - Servicing, Recharging, Replacement.................................... 47 1 Notes concerning battery types................................................................................... 4 7 2 General safety regulations for batteries................................................................... 48 3 Charge Status Indicator................................................................................................... 48 4 Lead-acid batteries............................................................................................................. 49 cc 4.1 (!) 4.2 I C Safety instructions for handling lead-acid batteries........................................... 49 Battery types......................................................................................................................... 51 (I) 4.3 0 Exposing the battery.......................................................................................................... 52 N 4.4 C'l.i Battery removal and installation................................................................................... 54 0 7
4.5 Charging the battery .......................................................................................................... 58 5 Lithium-Ion Batteries ......................................................................................................... 61 5.1 Notes on lithium-ion batteries 61 5.2 Safety regulations for handling lithium-ion batteries ......................................... . 62 5.3 Lithium-ion battery data plate........................................................................................ 67 5.4 Usage and ambient conditions 69 5.5 Technical Data ...................................................................................................................... 70 5.6 Battery charge status 71 5. 7 Battery types ......................................................................................................................... 72 5.8 Battery removal and installation................................................................................... 73 5.9 Exposing the battery 74 5.10 Charging the battery .......................................................................................................... 75 E Operation 81 1 Safety Regulations for the Operation of Forklift Trucks 81 2 Displays and Controls ....................................................................................................... 83 2.1 Charge Status Indicator and Key Switch ................................................................. 89 2.2 Battery discharge monitor 90 3 Preparing the Truck for Operation 91 3.1 Checks and Operations to Be Performed Before Starting Daily Work 91 3.2 Preparing the truck for operation 92 3.3 Checks and operations to be carried out when the truck is operational.. 93 3.4 Parking the truck securely 94 4 Industrial Truck Operation 96 4.1 Safety regulations for truck operation ....................................................................... 96 4.2 How to act in hazardous situations 99 4.3 Emergency Disconnect 100 4.4 Brakes 102 4.5 Travel 104 4.6 Operator platform ................................................................................................................ 107 4.7 Steering 109 4.8 Second rack level order picking (0) 110 4.9 Load handler raise/lower ................................................................................................. 111 4.1 0 Lifting, transporting and depositing loads ............................................................... 115 5 Troubleshooting 120 5.1 Truck in General .................................................................................................................. 121 5.2 Battery 124 6 Operating the truck without its own drive system. .............................................. . 125 7 Optional equipment. ........................................................................................................... 127 7 .1 Display unit (2 inch display) 127 7 .2 Keyless Access System ................................................................................................... 135 7.3 General Information about the Use of Keyless Access Systems 136 7.4 Commissioning the Keypad and the Transponder Reader 136 7.5 Using the Keypad ................................................................................................................ 139 7.6 Using the Display: ............................................................................................................. 144 7. 7 Operating the transponder reader 149 7.8 ISM access module (0) 154 7.9 Pedestrian mode 155 7.10 easyPILOT 7.11 Floor Spot ............................................................................................................................... 158 192 aJ (!) I C CJ) 0 N c--i 0 8
cc (!) I C (I) 0 N C'l.i 0 F Industrial Truck Maintenance.............................................................................. 195 1 Spare Parts............................................................................................................................ 195 2 Operational Safety and Environmental Protection 195 3 Maintenance Safety Regulations................................................................................ 197 3.1 Working on the electrical system ................................................................................ 198 3.2 Consumables and used parts....................................................................................... 198 3.3 Wheels..................................................................................................................................... 198 3.4 Hydraulic system................................................................................................................. 199 4 Lubricants and Lubrication Schedule........................................................................ 200 4.1 Handling consumables safely....................................................................................... 200 4.2 Lubrication Schedule......................................................................................................... 202 4.3 Consumables........................................................................................................................ 203 5 Maintenance and repairs................................................................................................. 204 5.1 Preparing the truck for maintenance and repairs................................................ 204 5.2 Lifting and jacking up the truck safely....................................................................... 204 5.3 Front panel disassembly and assembly................................................................... 205 5.4 Cleaning................................................................................................................................... 206 5.5 Checking the hydraulic oil level.................................................................................... 209 5.6 Replacing the drive wheel............................................................................................... 210 5.7 Check wheel attachment and wear............................................................................ 210 5.8 Checking electrical fuses................................................................................................ 212 5.9 Restoring the truck to service after maintenance and repairs...................... 213 6 Decommissioning the Industrial Truck...................................................................... 214 6.1 Prior to decommissioning................................................................................................ 214 6.2 Action to be taken during decommissioning.......................................................... 215 6.3 Restoring the truck to service after decommissioning...................................... 215 7 Safety tests to be performed at intervals and after unusual incidents...... 216 8 Final de-commissioning, disposal............................................................................... 216 9 Human vibration measurement.................................................................................... 216 G Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement............................................................................ 217 1 Maintenance Contents ECE 220/225........................................................................ 218 1.1 Owner....................................................................................................................................... 218 1.2 Customer Service............................................................................................................... 222 9
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