DOWNLOAD PDF Jungheinrich Forklift EJE 20/22/25 -R 20/22 Operating Manual 10003712

EJE 20/22/25 -R 20/22 Operating instructions

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10003712 08.01

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Foreword The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter. Each chapter starts with page 1. The page identification consists of a chapter letter and a page number.

For example: Page B 2 is the second page in chapter B. The operating instructions detail different truck models. When operating and servicing the truck, make sure that the instructions apply to your truck model.

Safety instructions and important explanations are indicated by the following graphics: before safety instructions which must be observed to avoid danger to personf Used nel.

m

Used before notices which must be observed to avoid material damage.

A Used before notices and explanations. t Used to indicate standard equipment. o Used to indicate optional equipment.

Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. No guarantee of particular features of the truck should therefore be assumed from the present operating instructions.

Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG

Jungheinrich Aktiengesellschaft Am Stadtrand 35 D-22047 Hamburg - Germany Telephone: +49 (0) 40/6948-0 www.jungheinrich.com

Table of contents A

Correct use and application of the truck

B

Truck description

1 2 3 3.1 3.2 3.3 3.4 4 4.1 4.2

Application ........................................................................................... B 1 Description of assemblies and functions ............................................. B 2 Technical data - standard version ....................................................... B 3 Performance data for standard trucks ................................................. B 3 Dimensions ......................................................................................... B 3 EN standards ...................................................................................... B 5 Conditions for application .................................................................... B 5 Location of instruction labels and identification plates ........................ B 6 Truck identification plate ..................................................................... B 7 Label: order no., inventory no., full service no. ................................... B 7

C

Transportation and commissioning

1 2 3

Transportation by crane ...................................................................... C 1 Commissioning .................................................................................... C 1 Moving an incapacitated truck (emergency operation) ....................... C 2

D

Battery - Servicing, recharging, replacement

1 2 3 4 5 6

Safety regulations governing the handling of lead-acid batteries ........ D 1 Battery types ....................................................................................... D 2 Exposing the battery ........................................................................... D 2 Charging the battery ............................................................................ D 3 Removing and installing the battery .................................................... D 4 Combined instrument (o) ................................................................... D 5

E

Operation

1 2 3 4 4.1 4.2 4.3 4.4 4.5

Safety regulations for the operation of the floor conveyor ................... E 1 Description of controls and indicating instruments .............................. E 2 Putting vehicle in operation ................................................................. E 4 Working with the truck ......................................................................... E 5 Safety regulations for operating mode Drive ....................................... E 5 Driving, steering, braking .................................................................... E 6 Picking up or lowering load units ......................................................... E 9 Safe parking of the truck ..................................................................... E 11 Fault location ....................................................................................... E 12

I1

I2

F

Maintenance of the truck

1 2 3 4 5 5.1 6 6.1 6.2 6.3 6.4 6.5 7 7.1 7.2 7.3 8

Operational safety and protection of the environment ........................ F 1 Safety regulations for repair ................................................................ F 1 Maintenance and service .................................................................... F 3 Maintenance checklist ......................................................................... F 4 Lubrication schedule EJE 20 / 22 / 25 / EJE-R 20 / 22 ...................... F 6 Operating material ............................................................................... F 7 Notes on maintenance ........................................................................ F 8 Preparation of the truck for servicing and maintenance operation ...... F 8 Open the battery hood ........................................................................ F 8 Open the front hood ............................................................................ F 8 Checking the electric fuses ................................................................. F 9 Recommissioning the truck ................................................................. F 10 Decommissioning the fork lift truck ..................................................... F 10 Operations to be performed prior to decommissioning ....................... F 10 Measures to be taken during decommissioning .................................. F 10 Recommissioning the truck ................................................................. F 11 Safety checks to be performed at regular intervals and following any untoward incidents (D: Accident prevention check according to VBG 36) .......................................................................... F 11

A Correct use and application of the truck A included in the scope of delivery for this truck. The guidelines are part of these ope-

rating instructions and must always be heeded. National regulations are fully applicable.

The fork-lift truck described in these operating instructions is a truck that is suitable for lifting and transporting loads.

It must be used, operated and maintained according to the information in these operating instructions. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. admissible load to be picked up is indicated on the identification plate or load diagram label shown on the truck. The fork-lift truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres prevail.

Duties of the user: fined as any natural or legal person who either uses the fork-lift truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is considered the person, who, in accordance with existing contractual agreements between the owner and the user of the fork-lift truck, is charged with the observance of the operating duties.

The user must ensure that the truck is not abused and only used within its design limits and that all danger to life and limb of the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety-related provisions, as well as the operating, servicing and maintenance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions.

m

If these Operating Instruction are not observed the warranty becomes void. The same applies if improper works are carried out at the device by the customer and/or third parties without permission of our Customer Service.

Mounting of attachments: The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after written approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained.

Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary.

A1

B Truck description 1

Application The trucks of the EJE series are of a three-wheeled design equipped with a steered drive wheel and two spring-loaded, swivellable supporting wheels arranged within the enclosed truck envelope. The EJE truck is designed for operation on level ground and is intended for the handling of loads. The EJE can pick up pallets of open ground support, or pallets provided with lateral boards arranged outside the range of the loadbearing wheels, as well as trolleys. The capacity of the truck is shown on the identification plate, or can be seen from the capacity label Qmax.

Truck types, capacities and motor output: Type EJE 20 EJE 22 EJE 25 EJE-R 20 EJE-R 22

Capacity 2000 kg 2200 kg 2500 kg 2000 kg 2200 kg

Motor output 1.3 kW 1.5 kW 1.5 kW 1.3 kW 1.5 kW

B1

2

Assembly groups

ë ê

ïî è

ì

é

í î ï

ç

ïð

ïï

ïð

Item EJE 20 / 22 / 25 Designation EJE-R 20 / 22

B2

1 2

t o

3 4

t t

Key switch Combined instrument (battery discharge monitor and operating hour meter) Master switch (emergency stop) Control shaft with control shaft head

5 6

t t

Safety key Driving regulator

7 8

t t

Battery hood Lifting device

9 10 11

t t t

Front hood Supporting wheel Drive wheel

12

t

Button-creep speed

3

Technical data - standard version

data to VDI 2198.

A Technical Technical data are subject to alteration and extension in scope.

3.1

Performance data for standard trucks Designation Q Capacity C Load centre distance for standard fork length *) Travelling speed with rated load / without load Lifting speed with rated load / without load Max. climbing capacity (5 minutes) with/ without load

EJE 20 EJE-R 20 2000 600

EJE 22 EJE-R 22 2200 600

EJE 25 2500 600

kg mm

6.0 / 6.0

6.0 / 6.0

6.0 / 6.0

km/h

5.1 / 6.7

4.9 / 6.7

4.7 / 6.7

cm/s

10 / 20

9 / 20

8 / 20

%

*) In the case of longer fork versions, the load centre of gravity is at the fork centre.

3.2

Dimensions Designation

EJE 20 EJE 22 EJE 25 EJE-R 20 EJE-R 22

h2

Lift

130

130

130

mm

h

Fork lowered

85

85

85

mm

y

Wheel base, *) load assembly lowered

L XL

1305 -

1340 1410

1340 1410

mm

L

Length of truck (=L2 + l)

L XL

1760 -

1760 1830

1760 1830

mm

L2

Front design length

L XL

610 -

610 680

610 680

mm

l

Standard fork length

1150

1150

1150

mm

B

Width of truck

690

690

690

mm

L XL

1620 -

1620 1690

1620 1690

mm

Wa Turning radius *) at shunt driving (upright control shaft)

L XL

1390 -

1390 1460

1390 1460

mm

Ast Aisle width **) 800 x 1200 longitudinal

L XL

2130 -

2130 2200

2130 2200

mm

Wa Turning radius *

)

*) With load part lowered + 75 mm **) Ast diagonally, acc. to VDI Ast at shunt driving

+196 mm - 230 mm

B3

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Ï

§ Ôî Ô

ß­¬

B4

3.3

EN standards Continuous sound level:

64 dB(A) according to prEN 12053 as stipulated in ISO 4871

continuous sound level is a value averaged according to standard regulations, A The taking the sound pressure level into account when driving, lifting and idling. The sound pressure level is measured at the ear.

Vibration:

0.77 m/s2 according to prEN 13059

swinging acceleration acting on the body in its operating position is, according to A The standard regulations, the linear integrated, weighted acceleration in the vertical plane. It is determined by driving over bumps with a constant speed.

Electromagnetic compatibility (EMC) The manufacturer confirms compliance with the limit values for electromagnetic emission and interference immunity as well as testing of static electricity discharge according to prEN 12895 and the references to other standards contained therein. or electronic components and their arrangement may only be modified after A Electrical written approval by the manufacturer has been obtained.

3.4

Conditions for application Ambient temperature: - during operation 5 C to 40 C

trucks must be specially equipped and approved for continuous use in enA Industrial vironments with temperatures below 5 °C or in cold stores respectively with extreme temperatures or humidity changes.

B5

4

Location of instruction labels and identification plates

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Ȩ¨ Ȩ¨¨ Ȩ¨¨¨¨¨ Ȩ¨¨¨¨¨¨¨

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Ȩ¨¨¨¨ Ȩ¨¨¨¨

Ȩ¨¨¨¨¨¨¨ Ȩ¨¨¨¨¨¨¨¨

µ¹

Ȩ¨¨¨¨¨¨¨¨¨¨¨¨¨¨¨¨¨ Ȩ¨¨¨¨¨¨¨¨¨¨¨¨¨¨¨

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Ȩ¨¨¨¨¨¨¨¨¨¨¨¨¨¨¨¨¨ Ȩ¨¨¨¨¨¨¨¨¨¨¨¨¨¨¨

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Ȩ¨¨¨¨¨¨¨¨¨¨¨¨¨¨¨¨ Ȩ¨¨¨¨¨¨¨¨¨¨¨¨¨¨¨¨¨ ¨¨¨¨¨¨¨¨¨¨ ¨¨¨¨¨¨¨¨

Ȩ¨¨¨¨¨ Ȩ¨¨¨¨

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Item Designation

B6

14 15 16 17

Load capacity Qmax.

Truck identification label Label: order no., inventory no., full service no.

Limit-stop for crane loading

19

UVV control label

ïé

µ¹

µ¹

4.1

Truck identification plate íî

îï

íï

îî

íð

îí

îç

îì

îè

îë îê Item 20 21 22 23 24 25 26

Designation Type Serial no.

Rated capacity in kg Battery: Voltage V Ampere hours Ah Manufacturer Order no.

Load centre distance in mm

îé

Item 27 28 29 30

Designation Drive power in kW Customer no.

Min./max. battery weight in kg Empty weight without battery in kg

31 32

Year of manufacture Manufacturer logo

the event of queries relating to the truck or spare part orders, please state the serial A In no. (21) of the truck.

4.2

Label: order no., inventory no., full service no. íí íì íë Item 33 34 35

Designation Order no.

Inventory no.

Full service no.

full service no. will only be assigned if a servicing agreement has been concluA The ded.

B7

C Transportation and commissioning 1

Transportation by crane

m

Only lifting gear of adequate capacity must be used (for the transport weight, refer to the truck identification label).

gear attachment points (1) are provided at the chassis and at the fork in case A Lifting the truck is to be lifted or transported by crane. to chapter E). ment points (1).

m

The lifting gear must be attached to the attachment points in such a manner that it absolutely cannot slip. If necessary, pull it through the openings! The lifting gear must be fitted in such a way that it will not come into contact with any attachments of the truck when the truck is lifted.

2

Commissioning

m

The truck must only be operated on battery current. Rectified alternate current will damage the electronics. Cables connected to the battery (trailing cable) must be less than 6 meters in length.

In order to prepare the truck for work following delivery or transportation, the following operations must be performed:

type of battery (see chapter D).

the combined instrument matches the

parked, the running surface of the tyres will flatten. The flattening will disappear A When after a short operating time of the truck.

C1

3

Moving an incapacitated truck (emergency operation) In order to be able to move the truck in emergency operation, the electromagnetically operated brake must be released.

The truck can now be moved.

m

After the truck is parked at the correct location, the screws (3) must be turned clockwise again until they stop to reactivate the brakes!

î

í

C2

D Battery - Servicing, recharging, replacement 1

Safety regulations governing the handling of lead-acid batteries The truck must be parked and rendered safe, before any operations on batteries are to be undertaken (refer to chapter E).

Servicing staff: Recharging, servicing and replacing of batteries must only be performed by qualified personnel. The instructions contained in this operating manual, and the instructions as prepared by the battery supplier and as available at the battery recharging station must be observed, when performing the above operations.

Fire protection measures: Smoking and naked flames are not permitted when handling batteries. No inflammable substances or spark-generating materials must be present or stored within a distance of 2 meters of the truck parked for battery recharging. The location must be well ventilated and fire fighting equipment must be kept ready.

Servicing of batteries: The battery cell screw caps must be kept dry and clean. Terminals and cable shoes must be clean, lightly greased with pole grease and must be securely tightened.

Disposal of the battery: Batteries must only be disposed of as stipulated in the national environmental protection regulations or waste disposal provisions. The manu-

m

Before closing the battery hood, make sure that the battery cable cannot be damaged.

contain dissolved acid, which is toxic and caustic. For this reason protective f Batteries clothing and goggles must be worn whenever work is undertaken on batteries. Avoid physical contact with battery acid.

If clothing, skin or eyes have accidentally come into contact with battery acid, liberally flush the affected parts with clean water. Consult a doctor, when skin or eyes have come into contact with battery acid. Spilled battery acid must be immediately neutralized.

m

Only batteries with closed battery trough may be used.

weight and dimensions have considerable influence on the safety of truck f Battery operation. A change of battery equipment is only permitted with approval of the manufacturer.

D1

2

Battery types The vehicle is equipped with different battery types depending on the type. The battery weights can be seen from the battery identification plates. Batteries with non-isolated poles must be covered with a non-slip isolation mat.

m

When replacing or installing batteries, ensure that the battery is correctly secured in the battery compartment of the truck.

The following table shows the standard battery combinations and battery capacities: Chassis model Long version L2 = 610 mm XL version L2 = 680 mm

Truck type EJE 20 / 22 / 25 EJE-R 20 / 22 EJE 22 / 25 EJE-R 22

24V PzS batteries 2 PzS 200 Ah 2 PzS 300 Ah

Depending on the type of battery used, it is also possible to use models with enhanced performance or maintenance-free batteries.

m

Only batteries with closed battery trough may be used.

3

Exposing the battery

D2

4

Charging the battery

battery connector and the socket must only be connected and disconnected with f The the truck switched off. the recharging operation the, tops of the battery cells must be exposed to enf During sure adequate ventilation. No metal objects must be placed on the battery. Prior to starting the recharging operation, check all cable connections and plugged connections for visible damage.

All safety instructions as provided by the battery supplier and battery charger supplier must be strictly observed.

tery charger.

m

Recharge the battery observing the instructions provided by the battery supplier and by the battery charger supplier.

D3

5

Removing and installing the battery

truck must be parked on level ground. To prevent short-circuits, batteries with exf The posed poles or cell connectors must be covered using rubber matting. Place the bat-

tery connector or the battery cable, respectively, in such a way that they will not catch behind any truck protrusions when the battery is withdrawn.

transporting batteries with the aid of a crane, ensure that the crane is of adeA When quate capacity (the battery weight is indicated on the battery identification plate at the

battery trough). The lifting gear must pull in a vertical direction to prevent damage to the battery trough. The lifting gear hooks must be secured to the attachment points (8) in such a way that the lifting gear, when slack, cannot collaps on the battery cells.

Installation is in the reverse order of operations. Check for correct mounting position and correct connection of the battery. completion of the battery refitting operations, check all cable connections and f Upon plugged connections for any visible damage. Before starting the truck, fasten the battery support (7) with the screw (6) and make sure that the battery hood is closed safely with the hood lock !

D4

6

Combined instrument (o) Battery discharge indicator: The charging condition of the battery is indicated in 10% increments by means of ten bars shown on the battery symbol (9).

With progressive depletion of the battery, the illuminated bars will go out from the top downwards.

m

Ì

¸

Ì

¸

Ì

¸

When using maintenance-free batteries, symbol (12) will appear next to the operating hour display. When this setting is not performed, the battery might suffer damage caused by exhaustive discharge. For adjusting the instrument, it is recommended to consult the manufacturer service. appear at a residual battery capacity of: -30 percent in the case of standard batteries and -50 percent in the case of maintenance:free batteries.

Battery recharging is now advisable.

will appear at a residual battery capacity of: -20 percent in the case of standard batteries and -40 percent in the case of maintenancefree batteries.

recharging is now required.

Battery discharge monitor: ed, the lifting function of the truck will be automatically switched off. will only become possible again after the battery has been recharged to at least A Lifting 70 percent.

Hour meter: The hour meter (13) integrated into the battery discharge indicator shows the total operating time of the travelling and lifting movements.

A In the operative condition, the digit after the comma will flash.

D5

E Operation 1

Safety regulations for the operation of the floor conveyor Driving licence: The floor conveyor must only be operated by persons who have been adequately trained and have proved to the persons in charge or their representatives their ability to handle the truck correctly and who have been explicitly entrusted with the operation of the truck.

Rights, obligations and behavioural rules for the driver: The driver must have been informed about his rights and duties, must have been trained in the operation of the truck and must be familiar with these operating instructions. All necessary rights must be granted to him.

If the floor conveyor is to be accompanied by a second person, it is required to wear protective shoes.

Operation through unauthorised persons is prohibited: The driver is responsible for his truck during working time. He must forbid unauthorised persons to drive or operate the truck. Persons may neither be transported nor lifted.

Damages and defects: Damages or defects noted on the truck or on the attachments must immediately be brought to the notice of the person in charge. Trucks that cannot be safely operated (e.g. due to worn tires or defective brakes) must not be used until they have been properly repaired.

Repairs: Without specific training and express authorisation the driver is not allowed to perform any repairs or modifications on the truck. Under no circumstances must the driver change the setting of switches or safety installations, or render them ineffective.

Danger zone: The danger zone is that area in which persons are endangered by driving or lifting movements of the floor conveyor, its load lifting devices (e.g. fork tines or attachments) or the load. Also the area in which the load may fall down or in which a operating device may be lowered or fall down belongs to this area.

persons must be told to leave the danger area. The driver must give a f Unauthorised warning signal, whenever a situation presenting danger to persons might develop.

The truck must immediately be brought to a standstill, if persons, although asked, do not leave the danger area.

Safety devices and warning labels: The safety devices, warning labels and warning notes described in the present operating instructions must always be heeded.

E1

2

Description of controls and indicating instruments Pos. Controls or indicating instrument respectively 1 Key switch

EJE EJE-R Function 20/22/25 20 / 22

2

Combined instrument

o

o

3 4

Control shaft Master switch (Emergency Stop) Button - warning signal (horn) Operating key Lower fork Operating key Raise fork Driving regulator

t t

t t

t

t

Switches the control current on and off. When the key is removed from the key switch, the truck cannot be operated by unauthorised persons.

Indicates the remaining capacity of the battery and the hours of operation that truck has already performed (see chapter D).

Steering and braking the truck.

The circuit is interrupted, all electric functions are switched off.

Trigger warning signal.

t

t

Lowering the fork.

t

t

Raising the fork.

t

t

Collision-guard button

t

t

10 Operating key Lifting Aux. lift, ramp operation 11 Inching speed key

---

t

t

t

Controls the driving direction driving speed.

During marshaling ride, the vehicle drives away from operator and stops Raising of the fork base with simultaneous lowering of the fork tip.

If the drawbar is in vertical position, the brake function can be bypassed by actuating a switch; this allows to move the vehicle in marshaling mode.

5 6 7 8 9

t

t

t = Standard equipment

E2

o = Optional equipment

E3

3

Putting vehicle in operation

starting or operating the truck, or before lifting any loads, the driver has to f Before make sure that nobody is within the danger area.

Checks and actions before routine start-up devices).

e truck (especially tyres and load carrying

Starting up the truck

The truck is now ready for operation. The battery discharge indicator (2) indicates the available battery capacity.

E4

4

Working with the truck

4.1

Safety regulations for operating mode Drive Routes and working areas: Only such lanes and routes that are specially allocated for truck traffic may be used. Unauthorised third parties must stay away from the working area. Loads may only be stored at places specially provided for this purpose.

Driving the vehicle: The driver must choose a driving speed suitable for the local conditions. The truck must be driven at slow speed when negotiating bends or narrow passages, when passing through swing doors and at blind spots. The driver must always keep an adequate braking distance between his truck and the vehicle in front and he must be in control of the floor conveyor at all times. Sudden stopping (except in emergencies), rapid U-turns and overtaking at dangerous or blind spots is not permitted. Leaning or gripping out of the working and operating range is prohibited.

Visibility during driving: The driver must look into the driving direction and have a sufficient overview of the driving route. If load units are transported which are obstructing the driver's view, the floor conveyor is to be driven with the load pointing to the back. If this is not possible, a second person must give suitable warnings.

Driving on slopes: Driving on slopes or descents is only permitted, if they are defined as traffic routes and if the surface is clean and suitable for driving. In addition, these routes must conform to the regulations for safe driving as defined in the technical truck specifications. Loads must always be carried at that end of the truck facing uphill. U-turns, cutting obliquely over slopes or inclines and parking of the truck on slopes or inclines is not permitted. Inclines must only be negotiated at slow speed with the driver ready to brake at any moment.

Driving in lifts or on loading platforms: Lifts and loading platforms must only be used, if they are of adequate load bearing capacity, if suitable for driving on, and if authorised by the user of the truck for truck traffic. 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 together with the truck must only enter the lift after the truck has come safely to a standstill, and must leave the lift before the truck.

Requirements for the load to be transported: Only loads that have been securely fastened according to the regulations may be transported. Never transport loads that have been stacked higher than the top of the fork carrier or the load backrest.

E5

4.2

Driving, steering, braking

attention has to be paid during driving and steering the truck, especially if f Increased movements outside of the truck contour are to be performed.

It is not admissible to stay on the vehicle during driving.

EMERGENCY STOP All electric functions are switched off. The truck is compulsory braked.

Emergency stop When the control shaft is released, the truck is compulsory braked (emergency stop) - the control shaft automatically swivels into the upper braking range (B). the control shaft swivels only slowly into the braking position, it is required to perf Ifform troubleshooting measures. For example, the return spring must be exchanged! ç ì

Driving not drive the truck unless the hoods are closed and locked in the stipulated manf Do ner. When driving through swinging doors, etc., make sure that the doors do not trigger the collision-guard button (9).

the desired driving direction (V or R).

The truck starts to drive into the selected direction.

A The driving speed can be continuously regulated with the driving switch (8).

E6

the truck can only be moved with reduced driving speed, a defect has occurred f Ifwhich is influencing the safety of operation of the truck. It may be that the service brake can only be used after pressing the EMERGENCY-STOP switch (4).

The truck needs to be taken out of service and must be repaired by expert personnel (see chapter F).

Driving on slopes

m

The load must be transported pointing towards the mountain!

If the driving switch is set to zero, the service brake is automatically triggered when the truck starts to roll downhill (the control system detects the unintended movement of the truck). The driving switch can be used to release the service brake and to select the desired driving speed and direction. the roll-off brake was deactivated by the service, only service brake and counterflow f Ifbrake are available.

Shunt driving

f

The truck can be moved with its control shaft (3) in vertical position (e.g. in confined spaces / lifts):

rection (V or R).

The service brake is triggered. The truck changes to the slow-driving mode.

m

The service brake is only activated after releasing the counterflow brake (driving switch (8)).

f Steering

E7

Braking braking effect of the truck is mainly depending on the road surface. This must be f The taken into account by the driver for his driving behavior.

The truck may be braked in three ways:

Braking with the service brake:

f In case of danger, the truck must be braked with the service brake (control shaft (3)).

The drive motor is mechanically braked. the control shaft (3) is released, it swivels into the upper braking range (B). If A When the truck is parked, the service brake is used as parking brake

E8

Dynamic braking (roll-off brake): with the help of the dynamic brake (roll-off brake), depending on the selected setting. the roll-off brake was deactivated by the service, only service brake and counterflow f Ifbrake are available.

Braking with the counterflow brake:

m

If the control system or driving mechanism breaks down, the counterflow brake becomes ineffective.

A The braking effect depends on the position of the driving switch. standard driving operations, only the dynamic brake and that counterflow brake f For are to be used, since these brake types are reduce wear and tear and help to save energy (energy return supply).

4.3

Picking up or lowering load units

a load unit is picked up, the driver has to make sure that it is properly palletised f Before and does not exceed the permitted bearing capacity of the truck.

Do not grab into the hoist frame during lifting and lowering.

It is not permitted to pick up long goods with the truck driving transversally below the good.

Lifting the desired height has been reached.

Lowering (6) and the fork will descend. fork lowering speed cannot be adjuA The sted as it was permanently set before leaving the works.

the maximum possible lifting height A Use when lifting heavy loads.

E9

Aux. lift for ramp operations (EJE-R 20/22 only) fork will be automatically lowered before the fork lift function is changed over to A The the aux. lift function.

The fork base will be automatically lowered before changing over from the aux. lift function to the fork lift function. on an incline.

Picking up a load

pressing the operating key (6) while at the same time continuing to insert the fork into the pallet.

E 10

king range.

third of the required movement into the direction of travel. ving range - the truck will start without rolling back.

Setting down the load: Set down the load and withdraw the fork from the pallet by proceeding in the reverse sequence of operations adopted when picking up the load.

4.4

Safe parking of the truck If the truck is left unattended, even for only short periods of time, it must be rendered safe.

not park the truck on slopes! The lifting device must always be completely lowef Do red.

E 11

4.5

Fault location This chapter helps the operator to locate and fix simple malfunctions or the results of operating errors him- or herself. The order of the work stated in the table must be observed for fault location.

Fault Truck does not move

Possible cause

Remedy

not connected

and reconnect it, if necessary

STOP) pressed

(EMERGENCY STOP)

the battery and recharge, if necessary fuses F1 and 1F1 Load cannot be lifted

measures that are mentioned

A please contact the Customer Service, as more intricate faults can only be rectified by specially trained and qualified service personnel.

E 12

F Maintenance of the truck 1

Operational safety and protection of the environment The checks and maintenance work listed in this chapter have to be performed according to the intervals of the maintenance checklists.

of truck assemblies, especially of the safety installations, are not perf Modifications mitted. On no account must the operational speeds of the truck be changed.

m

Only original spare parts have been passed by our quality assurance service. In order to ensure safe and reliable operation only original spare parts of the manufacturer must be used. Old parts and changed consumption type materials must be disposed of in accordance with the applicable environmental protection regulations. The Oil Change Service of the manufacturer is available for oil changes.

Upon completion of any checks and servicing activities, the operations contained in the section "Recommissioning" must be performed (see chapter F).

2

Safety regulations for repair Servicing and maintenance personnel: Maintenance and repair of the floor conveyors may only be performed by expert personnel of the manufacturer. The Service Organisation of the manufacturer has service engineers available that have been specifically trained for these tasks. We therefore advise to conclude a maintenance Lifting and jacking up: When a fork-lift truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When the truck is to be jacked up, suitable measures must be taken to prevent the truck from slipping or tipping over (use of chocks, wooden blocks). Work underneath raised forks must only be carried out, when the fork is immobilised and supported by a chain of adequate strength.

Cleaning operations: No inflammable liquids must be used when cleaning the industrial truck. Prior to performing cleaning operations all appropriate safety measures must be taken to avoid sparking (e.g. due to short circuits). The battery connector must be disconnected. Electric and electronic components must be cleaned with lowpressure air or suction air and a non-conducting, antistatic brush.

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If the truck is to be cleaned using water or a steam jet, all electric and electronic assemblies have to be carefully covered beforehand, as humidity will cause malfunctions.

Steam-cleaning is not permitted.

F1

Work on the electric system: Work on the electric system of the truck must only be performed by personnel specially trained for such operations. Before commencing any work on the electric system, all measures required to prevent electric shocks have to be taken.

For battery-operated fork-lift trucks, the truck must also be depowered by removing the battery plug.

Welding operations: To prevent any damage to electric or electronic components, these have to be removed from the fork-lift truck before any welding operations are undertaken.

Settings: When repairing or replacing hydraulic, electric or electronic components or assemblies, all truck-specific settings have to be retained.

Tire equipment: The quality of the tires greatly affects the stability and the driving behaviour of the fork-lift truck. Modifications must only be carried out after discussion with the manufacturer. When replacing wheels or tires, it must be ensured that the truck remains level (tires and wheels must always be replaced in pairs, i.e. left and right together).

Lift chains: The lift chains wear rapidly if not lubricated. The intervals stated in the service checklist apply for use in normal environment. For applications in aggravated conditions (dust, temperature), frequent re-lubrication must be performed. The specified chain spray must be used as specified. Applying grease to the outside and heavy external dirt accumulation prevent the lubricant to penetrate into the joints.

Hydraulic hoses: The hoses must be renewed every six years. When replacing hydraulic components, you should also replace the hydraulic hose lines in the corresponding hydraulic system.

F2

3

Maintenance and service Thorough and expert servicing is one of the most important preconditions for safe operation of the fork-lift truck. The neglect of regular servicing intervals can lead to fork-lift failure and constitutes a potential hazard to personnel and operation.

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The indicated servicing intervals are based on single-shift operation under normal operating conditions. For applications in dusty environments, or involving large temperature fluctuations or multiple-shift operation, the servicing intervals must be shortened accordingly.

The following servicing checklist indicates the operations to be performed and the respective intervals to be observed. The following maintenance intervals are defined: W1 = Every 50 operating hours, at least, however, once a week M3 = Every 500 operating hours, at least, however, every 3 months M6 = Every 1000 operating hours, at least, however, every 6 months M12 = Every 2000 operating hours, at least, however, every 12 months

A The W1 maintenance intervals must be carried out by the operator / customer.

In the running-in phase of the truck, the following additional operations have to be carried out: After the first 100 operating hours:

After the first 500 operating hours:

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4

Maintenance checklist

Chassis/ Design: Drive unit:

Wheels: Steering: Brake system:

1.1 1.2 2.1 2.2 2.3 3.1 3.2 4.1 5.1 5.2

5.3 5.4 Lifting device: 6.1 6.2 6.3 Hydr. system: 7.1 7.2 7.3 7.4 7.5 7.6

Maintenance intervals Standard = t W M M M Cold-storage depot = k 1 3 6 12 Check all load bearing elements for damage t Check all bolted connections t Check the transmission for noises and leakage t Check the transmission oil level t Change the gear oil k t Check for wear and damage t Check seating and attachment a) k t Check the steering clearance t Check function and adjustment k t Check the return spring for repositioning function and t damage Check the brake linings for wear t Check the brake linkage and adjust, if necessary k t Check function, wear and tear and adjustment t Visual check of rollers, slide pieces and stops k t Check fork tines and fork carrier for wear and damage k t Check function k t Check all connections for leakage and damage b) k t Check hydraulic cylinders for leakage, k t damage and secure attachment Check hydraulic oil level k t Replace the hydraulic oil and the filter cartridge c) k t Check the pressure relief valves for correct functioning k t

a) First check of the wheel nuts after approx. 100 operating hours for tight fit. Re-tighten if necessary. b) Hydraulic connections to be first checked for leakage after approx. 100 operating hours; tighten, if necessary. c) 1. exchange after 500 hours of operation. maintenance intervals refer to normal service conditions. If you are working unA The der difficult conditions, reduce the intervals, if required.

F4

Electr. system:

Electric motors: Battery:

Maintenance intervals Standard = t W M M M Cold-storage depot = k 1 3 6 12 8.1 Check function t 8.2 Check all cables for secure connection and damage t 8.3 Check the fuses for correct amperage t 8.4 Check switches and trip cams for proper functioning and t seating 8.5 Check contactors and relays, replace wearing parts, t if necessary 8.6 Check functioning of warning devices and safety circuits k t 9.1 Check wear of carbon brushes t 9.2 Check the motor for secure attachment t 9.3 Suck out engine block, check wear of collector k t 10.1 Check acid density, acid level and cell voltage k t 10.2 Check the terminals for secure attachment and apply k t pole grease 10.3 Clean battery connections, check for tight fit k t 10.4 Check the battery cables for damage and replace, t if necessary 11.1 Grease truck according to lubrication schedule k t

Lubrication service: General mea- 12.1 Check electrical system for short to ground surements: 12.2 Check driving speed and braking distance 12.3 Check lifting and lowering speed 12.4 Check safety facilities and switch-off devices t Demon13.1 Perform a trial run under a nominal load t stration: 13.2 Demonstrate the truck to a person charged with inspec- k t tion upon completion of the maintenance of the truck

t t t

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5

Lubrication schedule EJE 20 / 22 / 25 / EJE-R 20 / 22

î

g Slide faces s Grease nipple Filler neck for hydraulic oil b Filler neck Gear oil a Drain plug Gear oil Cold store usage 1) Mixing proportion for application in cold-storage depots 1:1 2) Tandem load wheel

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5.1

Operating material Handling operating material: Consumption type material must always be handled properly. Manufacturer's instructions to be observed.

handling endangers health, life and environment. Operating material must f Improper only be stored in containers conforming to specification. They might be inflammable and must not come into contact with hot components or open fire.

When filling in consumption type materials, use clean containers only. It is prohibited to mix consumption type materials of different grades or qualities, except if mixing is expressively prescribed in these operating instructions. -This instruction may only be ignored, if another mixing ratio is explicitly prescribed in this manual.

Avoid any spilling. Spilled liquid must be removed immediately using a suitable binding agent, and the mixture of consumption type material and binding agent is to be disposed of according to the regulations.

Code

Order-no.

A B C

29 200 670 29 200 680 29 200 810

Supplied quantity 5.0 l 5.0 l 5.0 l

E F

29 201 430 29 200 100

1.0 kg 1.0 kg

Description

Used for:

H-LP 46, DIN 51524 Hydraulic system CLP 100, DIN 51517 Transmission H-LP 10, DIN 51524 Transmission hydraulic system Grease, DIN 51825 Lubrication service Grease, TTF52 Lubrication service

Grease standard values Code Type of Dropping Worked penetration Saponification point C at 25 C E Lithium 185 265 - 295 F --310 - 340

NLG1 Class 2 1

Service temperature C -35/+120 -52/+100

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6

Notes on maintenance

6.1

Preparation of the truck for servicing and maintenance operation All required safety measures must be taken to prevent any accidents in the course of the servicing and maintenance operations. The following preparatory operations must be performed:

ration. work has to be performed under the jacked-up truck, suitable measures must f When be taken to prevent any dropping, tilting or slipping of the truck. When lifting the truck, observed.

6.2

Open the battery hood See chapter D.

6.3

Open the front hood compartment.

A Mounting is performed in reverse order.

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6.4

Checking the electric fuses (refer to section 6.1).

Description

Protection of:

EJE 20 / 22 / 25 EJE-R 20 / 22

F1

Total control fuse

10 A

1F1

Drive motor (in parallel to 1F10)

150 A

1F10

Drive motor (in parallel to 1F1)

40 A

2F1

Pump motor

150 A

6F1

Discharge indicator/operating hour meter

10 A

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6.5

Recommissioning the truck Recommissioning of the truck following the performance of cleaning or maintenance work is permitted only after the following operations have been performed:

7

Decommissioning the fork lift truck If the fork lift truck is to be decommissioned for more than two months, it must be parked in a frost-free and dry location and all measures to be taken before, during and following decommissioning must be performed as detailed below.

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During decommissioning, the fork lift truck must be jacked up, ensuring that the wheels are clear of the ground. Only this measure will ensure that wheels and wheel bearings do not suffer damage.

If the fork lift truck is to be decommissioned for more than 6 months, additional measures must be discussed with the Service Department of the manufacturer.

7.1

Operations to be performed prior to decommissioning

A In addition to this, all instructions given by the battery supplier must be observed.

7.2

Measures to be taken during decommissioning Every 2 months:

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F 10

Battery-operated fork lift trucks: Regular recharging of the battery is very important; otherwise, exhaustive depletion of the battery caused by self-discharging would occur. Owing to sulfatisation, this will result in the destruction of the battery.

7.3

Recommissioning the truck

battery.

fork lift trucks: A Battery-operated If switching troubles are experienced in the electric system, spray the exposed contacts with contact spray and remove any oxide layer on the contacts of the operating controls by repeated operation.

f Perform several brake tests immediately after recommissioning the truck.

8

Safety checks to be performed at regular intervals and following any untoward incidents (D: Accident prevention check according to VBG 36) At least once yearly, or after any untoward incident, the fork lift truck has to be chekked by a qualified inspector. The inspector must assess the condition of the truck from a standpoint purely concerned with safety aspects, uninfluenced by any company or economic circumstances. The inspector must be adequately informed and experienced to be able to assess the condition of the fork lift truck and the effectiveness of the safety installations based on the technical rules and principles governing the inspection of fork lift trucks.

The inspection must comprise a comprehensive check of the technical condition of the fork lift truck with regard to accident prevention aspects. Apart from this, the fork lift truck must be thoroughly inspected for damage possibly caused by incorrect use of the fork lift truck. The inspection results must be recorded in an inspection report which must be kept available for a period spanning at least the next two inspection intervals.

The user has to ensure that all defects are eliminated without delay.

manufacturer has set up a special safety service with specially qualified staff. As A The visual proof that the fork lift truck has passed the safety inspection, a plaque is affixed to it. This plaque indicates in which month of which year the next test will be due.

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