Jungheinrich EJD 220 Operating Instructions Manual
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Jungheinrich EJD 220 Operating Instructions Manual

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EJD 220/220 XL
05.05 -
G
Operating Instructions
50469507
07.08

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Summary of Contents for Jungheinrich EJD 220

  • Page 1 EJD 220/220 XL 05.05 - Operating Instructions 50469507 07.08...
  • Page 2 Used to indicate standard equipment. Used to indicate optional equipment. Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. No guarantee of particular features of the truck should therefore be inferred from the present operating instructions.

  • Page 4: Table Of Contents

    Index Correct Application Truck Description Application ................... B 1 Assemblies and Functional Description ..........B 2 Truck ....................B 3 Load handling ..................B 4 Standard Version Specifications ............B 5 Performance data for standard trucks ..........B 5 Dimensions ..................B 5 EN norms ....................
  • Page 5 Operation Safety Regulations for the Operation of Forklift Trucks ...... E 1 Controls and Displays ................. E 2 Starting up the truck ................E 4 Industrial Truck Operation ..............E 5 Safety regulations for truck operation ..........E 5 Travel, steering, braking ..............E 6 Lifting and depositing loads ..............
  • Page 6 Appendix JH Traction Battery Operating Instructions These operating instructions apply only to Jungheinrich battery models. If using another brand, refer to the manufacturer's operating instructions.

  • Page 8: A Correct Application

    A Correct Application The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are supplied with the truck. The guidelines form part of these operating instructions and must be observed. National regulations apply in full. The truck described in the present operating instructions is an industrial truck designed for lifting and transporting loads.

  • Page 10: B Truck Description

    B Truck Description Application The EJD 220 is a threewheel, electric tiller operated stacker that can be used for lifting and stacking pallets and horizontal transportation. For horizontal transportation, two pallets can be stacked on top of each other. With its compact design and application as both stacker and for horizontal transportation, the truck is especially suited for use in retail environments, workshops, small warehouses and for assisting lorry loading and unloading.

  • Page 11: Assemblies And Functional Description

    Assemblies and Functional Description Item Model Item Model t Key switch t Battery panel o Combination instrument t Lift mechanism t Main switch/Isolator t Battery panel (Emergency Disconnect) t Tiller and tiller handle t Control electronics t Safety button o Battery charger t Controller t Castor wheel t Mast...

  • Page 12: Truck

    The main switch (3) disconnects all electrical function in hazardous situations. Structure: The EJD 220 is a threewheel truck with a steered drive wheel (15) and two sprung, cushioned and pivoting castor wheels (14) within the enclosed truck geometry.

  • Page 13: Load Handling

    Load handling The load handler consists of the lift mechanism and the attached mast (7). Lift mechanism: The lift mechanism and the outriggers are connected to the chassis via the lift cylinder and the lift linkage. The roller cylinders are raised by the lift cylinder while simultaneously moving the load wheel support of the lift linkage.

  • Page 14: Standard Version Specifications

    Standard Version Specifications Technical specification details in accordance with VDI 2198. Technical modifications and additions reserved. Performance data for standard trucks Model Q Capacity 2000 C Load centre distance with standard fork length Travel speed w / w.o. load 6.0 / 6.0 km/h Lift speed w / w.o.

  • Page 15: En Norms

    EN norms Noise emission level: < 70 dB(A) in accordance with EN 12053 as harmonized with ISO 4871. The noise emission level is calculated in accordance with standard procedures and takes into account the noise level when travelling, lifting and when idle. The noise level is measured at the driver’s ear.

  • Page 16: Identification Points And Data Plates

    Identification points and data plates 1,5 V Item Model Test sticker (o) Truck data plate "No passengers” warning "Do not reach through the mast" warning Strap point for crane lifting “Do not step under the load handler” warning Load chart Capacity Attention: Read operating instructions.

  • Page 17: Truck Data Plate

    Truck data plate Item Model Item Model 25 Type 31 Manufacturer 26 Serial no. 32 Min./max. battery weight (kg) 27 Rated capacity (kg) 33 Output (kW) 28 Battery: Voltage (V) 34 Load centre of gravity (mm) 29 Net weight w.o. battery (kg) 35 Year of Manufacture 30 Manufacturer’s logo 36 Option...

  • Page 18: Load Chart

    Load chart The capacity plate (22) indicates the capacity (Q kg) of the truck. The permissible load is shown as a function of the load centre of gravity distance (D -Nr. in mm) and the lift height (H in mm) in Serien-Nr.
  • Page 19 B 10...

  • Page 20: C Transport And Commissioning

    C Transport and Commissioning Lifting by crane Only use lifting gear with sufficient capacity (for truck weight see truck data plate, chapter B). – Park the truck securely (see Chapter E). – Attach the crane slings to the strap point (1) so that the truck cannot slip. Using the truck for the first time Only operate the truck with battery current.

  • Page 21: Operating The Truck Without Its Own Drive System

    Operating the truck without its own drive system To operate the truck in emergency conditions, the electromagnetically applied brake must be released. – Open and lift off the front panel (see chapter F). – Remove the panel. – Screw on 2 off M4x20 bolts (2) to loosen the armature plate..

  • Page 22: D Battery Maintenance, Charging & Replacement

    D Battery Maintenance, Charging & Replacement Safety regulations for handling acid batteries Before any work is carried out on the batteries the truck must be safely parked (see Chapter E). Maintenance personnel: Batteries may only be charged, serviced or replaced by trained personnel.

  • Page 23: Exposing The Battery

    Exposing the Battery – Park the truck securely (see Chapter E). – Turn the main switch (2) "Off". – Lift up the battery panel (1). The battery panel (1) is held up by its own weight. Charging the Battery Alternatively, it can be fitted with an on-board charger. The truck is charged with a stationary charger as standard (without the optional on- board charger).

  • Page 24: Charging The Battery With A Stationary Charger

    Charging the battery with a stationary charger – Park the truck securely (see Chapter E). Only connect and disconnect the battery connector and the socket, and only apply the main switch (2) when the mains and charger are switched off. –...

  • Page 25: Charging The Battery With An On-Board Charger O

    Maintenance-free: 150 -199 Ah Maintenance-free: 200 - 300 Ah Wet cell batteries: 200 - 400 Ah pulse characteristic Wet cell batteries: Jungheinrich 100 - 300 Ah All other switch (6) positions inhibit the charger, and the battery is not charged.
  • Page 26 Setting the charging characteristics Set the characteristics as follows: Connect the battery This allows you to adjust via the charger Turn the setting switch to the If the characteristic curve is right to select the desired valid, the green LED flashes characteristic curve according to the set position.
  • Page 27 Charging continues automatically after a mains failure. Charging can be interrupted by removing the mains connector and continued as partial charging. The mains cable must not be opened. Make sure the battery panel is firmly closed before starting the truck. Charging times The duration of charge depends on the battery capacity.

  • Page 28: Battery Removal And Installation

    Battery removal and installation – Expose the battery (see Section 3). The truck must be parked horizontally. To prevent short circuits, batteries with exposed terminals or connectors must be covered with a rubber mat. Place the battery connector or the battery cable in such a way that they will not get caught on the truck when the battery is removed.
  • Page 29 When replacing a battery always use the same battery type. Installation is in the reverse order of removal. When reinstalling the battery, note the required installation position and make sure the battery is connected correctly. After installing the battery, check all cables and plug connections for visible signs of damage.

  • Page 30: Combination Instrument (O)

    Combination instrument (o) Battery Discharge Indicator: Shows the battery discharge status in 10 % increments through 10 bars on the battery symbol (12). The bars go out from top to bottom as the battery continues to discharge. When using maintenance free batteries the instrument must be set so that that the symbol (T) (15) appears next to the hourmeter display.
  • Page 31 D 10...

  • Page 32: Safety Regulations For The Operation Of Forklift Trucks

    E Operation Safety Regulations for the Operation of Forklift Trucks Driver authorisation The forklift 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.

  • Page 33: Controls And Displays

    Controls and Displays Item Control / Function Display t Switches control current on and off. Key switch Removing the key prevents the truck from being switched on by unauthorised personnel. o Indicates the battery’s residual capacity and Combination instrument number of service hours completed by the truck (see Chapter D).

  • Page 35: Starting Up The Truck

    Starting up the truck Before the truck can be commissioned, operated or a load unit lifted, the driver must ensure that there is nobody within the hazardous area. Checks and operations to be performed before starting daily work – Visually inspect the entire truck (in particular wheels, load handler and mast guard) for obvious damage.

  • Page 36: Industrial Truck Operation

    Industrial Truck Operation 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. Driving conduct: The driver must adapt the travel speed to local conditions.

  • Page 37: Travel, Steering, Braking

    Travel, steering, braking Be extremely careful when driving and steering, especially when operating outside the geometry of the truck. Never carry passengers under any circumstances. When the load handler is raised higher than just off the ground or a load is raised higher than off the ground, the truck must only travel for load collecting and depositing purposes.
  • Page 38 If the truck can only be operated at reduced speed, this indicates a fault affecting the operational safety of the truck. The service brake may only work by applying the EMERGENCY DISCONNECT switch (3). The truck must be decommissioned and repaired by specialist personnel (see chapter F).
  • Page 39 Braking The braking pattern of the truck depends largely on the track conditions. The driver must take this into account when travelling. The truck can brake in three different ways: – With the service brake (tiller (4)) – by plugging (accelerator (8)) –...

  • Page 40: Lifting And Depositing Loads

    Lifting and depositing loads Before collecting a load the driver must make sure that it has been correctly palletised and does not exceed the truck’s capacity. – Drive the truck with forks as far as possible underneath the load. Collect the load, ensuring that it does not protrude excessively (< 50 mm) beyond the fork tines.
  • Page 41 Transporting 2 pallets on top of each other Transport one pallet on the outriggers and a second pallet on the forks. Position the forks under the first pallet and raise with button (10). Now position the outriggers under the second pallet and raise the outriggers with button (7). To transport the truck the forks with the load must be lowered as near as possible to the lower load, however not on top of the lower load.

  • Page 42: Parking The Truck Securely

    Parking the truck securely When you leave the truck it must be securely parked even if you only intend to leave it for a short time. Do not park the truck on a slope. The forks must always be lowered to the floor. –...
  • Page 43 E 12...

  • Page 44: F Truck Maintenance

    F Truck Maintenance Operational Safety and Environmental Protection The servicing and inspection duties contained in this chapter must be performed in accordance with the intervals indicated in the maintenance checklists. Any modification to the forklift truck assemblies, in particular the safety mechanisms, is prohibited.
  • Page 45 Electrical System: Only suitably trained personnel may operate on the truck’s electrical system. Before commencing work on the electrical system, take all precautionary measures to avoid electric shocks. For battery operated trucks, also de-energise the truck by disconnecting the battery. Welding: To avoid damaging electric or electronic components, remove these from the truck before performing welding operations.

  • Page 46: Servicing And Inspection

    The application conditions of an industrial truck have a considerable impact on the wear of the service components. We recommend an application analysis carried out on site by a Jungheinrich customer service adviser to draw up specific service intervals to prevent damage caused by wear.

  • Page 47: Maintenance Checklist

    Maintenance Checklist Maintenance Intervals Standard W A B C Cold store Chassis/ 1.1 Check all load bearing components for damage Superstruc- 1.2 Check screw connections ture: Drive: 2.1 Check transmission for noise and leakage 2.2 Check transmission oil level 2.3 Change transmission oil Wheels: 3.1 Check wheels for wear and damage 3.2 Check suspension and attachment...
  • Page 48 Maintenance Intervals Standard W A B C Cold store Lubrication: 11.1 Lubricate truck in accordance with Lubrication Schedule. General 12.1 Test frame leakage of electrical system Measure- 12.2 Test travel speed and braking distance ments: 12.3 Test lift and lowering speeds 12.4 Test safety devices and cutouts 12.5 Check handling when cornering Demon-...

  • Page 49: Lubrication Schedule

    Lubrication schedule A + C 0,7 l B + C 1,4 l Contact surfaces Grease nipples Hydraulic oil filler plug Transmission oil filler neck Drain plug for gear oil Cold store application 1)Cold store mix ratio 1:1...

  • Page 50: Consumables

    Consumables Handling consumables: Consumables must always be handled correctly. Follow the manufacturer’s instructions. Improper handling is hazardous to health, life and the environment. Consumables must only be stored in appropriate containers. They may be flammable and must therefore not come into contact with hot components or naked flames. Only use clean containers when filling up with consumables.

  • Page 51: Maintenance And Repairs

    Maintenance and Repairs Preparing the truck for maintenance and repairs All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made: – Park the truck securely (see Chapter E). –...

  • Page 52: Check The Hydraulic Oil Level

    Check the hydraulic oil level – Prepare the truck for maintenance and repairs (see Chapter 6.1). – Open the front panel. – Check hydraulic oil level in hydraulic reservoir. There are markings on the hydraulic reservoir. The oil level must be checked when the forks and outrigger lift are lowered.

  • Page 53: Checking Electrical Fuses

    Checking electrical fuses – Prepare the truck for maintenance and repairs – Open the front panel. – Remove the charger (4) from the truck. – Undo the screw (5). – Remove the angle plate (6). – Remove the cover (7) of the electronic system.

  • Page 54: Recommissioning

    Recommissioning The truck may only be restored to service after cleaning or repair work, once the following operations have been performed. – Test horn. – Test main switch operation. – Test brakes. – Lubricate the truck in accordance with the lubrication schedule. Decommissioning the truck If the truck is to be decommissioned for more than two months , e.g.

  • Page 55: Recommissioning

    Carry out a safety check in accordance with national regulations. Junheinrich recommends checks in accordance with FEM Guideline 4.004. Jungheinrich has a special safety department with trained personnel to carry out such checks. The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector.
  • Page 56 Jungheinrich traction battery Table of contents Jungheinrich traction battery ..........2-6 with positive tubular plates type EPzS and EPzB Type plate Jungheinrich traction battery..........7 Instruction for use ............8-12 Aquamatic/BFS III water refilling system Jungheinrich traction battery Maintenance free traction batteries with positive tubular plates type EPzV ....................13-17...

  • Page 57: Jungheinrich Traction Battery

    Jungheinrich traction battery with positive tubular plates type EPzS and EPzB Rating Data 1. Nominal capacity C5: See type plate 2. Nominal voltage: 2,0 V x No of cells 3. Discharge current:: C5/5h 4. Nominal S.G. of electrolyte* Type EPzS:...
  • Page 58 Ignoring the operation instructions, repair with non-original parts or using additives for the electrolyte will render the warranty void. For batteries in classes I and II the instructions for maintaining the appropriate protection class during operation must be complied with (see relevant certificate). 1.
  • Page 59 Battery container lids and the covers of battery compartments must be opened or re- moved. The vent plugs should stay on the cells and remain closed. With the charger switched off connect up the battery, ensuring that the polarity is cor- rect.
  • Page 60 3. Maintenance 3.1 Daily Charge the battery after every discharge. Towards the end of charge the electrolyte level should be checked and if necessary topped up to the specified level with purified water. The electrolyte level must not fall below the anti-surge baffle or the top of the separator or the electrolyte „min“...
  • Page 61 5. Storage If batteries are taken out of service for a lengthy period they should be stored in the fully charged condition in a dry, frost-free room. To ensure the battery is always ready for use a choice of charging methods can be made: 1.

  • Page 62: 7. Type Plate, Jungheinrich Traction Battery

    7. Type plate, Jungheinrich traction battery Baujahr T ype Year of manufacture Serien-Nr. Lieferanten Nr. Serial-Nr. Supplier No. Nennspannung Kapazität Nominal V oltage Capacity Zellenzahl Batteriegewicht min/max Number of Cells Battery mass min/max Hersteller Jungheinrich AG, D-22047 Hamburg, Germany Manufacturer...

  • Page 63: Aquamatic/Bfs Iii Water Refilling System

    Aquamatic/BFS III water refilling system for Jungheinrich traction battery with EPzS and EPzB cells with tubular positive plates Aquamatic plug arrangement for the Operating Instructions Cell series* Aquamatic plug type (length) EPzS EPzB Frötek (yellow) (black) 2/120 – 10/ 600 2/ 42 –...
  • Page 64 Diagrammatic view Equipment for the water refilling system 1. Water tank 2. Level switch 3. Discharge point with ball valve 4. Discharge point with sole- noid valve 5. Charger 6. Sealing coupler 7. Closing nipple 8. Ion exchange cartridge with conductance meter and solenoid valve 9.
  • Page 65 4. Filling (manual/automatic) The batteries should be filled with battery water as soon as possible before the battery charging comes to an end; this ensures that the refilled water quantity is mixed with the electrolyte. In normal operation it is usually sufficient to fill once a week. 5.
  • Page 66 8. Battery hose connections Hose connections for the individual plugs are laid along the existing electric circuit. No changes may be made. 9. Operating temperature The temperature limit for battery operation is set at 55° C. Exceeding this temperature damages the batteries. The battery filling systems may be operated within a tempe- rature range of >...
  • Page 67 10.2.1 Clamping ring tool The clamping ring tool is used to push on a clamping ring to increase the contact pres- sure of the hose connection on the plugs' hose couplings and to loosen it again. 10.3 Filter element For safety reasons a filter element (ident no.: 50307282) can be fitted into the batte- ry's main supply pipe for supplying battery water.

  • Page 68: Jungheinrich Traction Battery

    Jungheinrich traction batterie Maintenance free Jungheinrich traction batterie with positive tubular plates type EPzV and EPzV-BS Rating Data 1. Nominal capacity C5: See type plate 2. Nominal voltage: 2,0 Volt x No of cells 3. Discharge current: C5/5h 4. Rated temperature: 30°...
  • Page 69 Ignoring the operation instructions, repair with non-original parts and non authorised interventions will render the warranty void. For batteries in classes I and II the instructions for maintaining the appropriate protection class during operation must be complied with (see relevant certificate). 1.
  • Page 70 With the charger switched off connect up the battery, ensuring that the polarity is cor- rect (positive to positive, negative to negative). Now switch on the charger. When charging the temperature of the battery rises by about 15° C, so charging should only begin if the battery temperature is below 35°...
  • Page 71 3.2 Weekly Visual inspection after recharging for signs of dirt and mechanical damage. 3.3 Quarterly After the end of the charge and a rest time of 5 h following should be measured and recorded: • the voltages of the battery •...

  • Page 72: 7. Type Plate, Jungheinrich Traction Battery

    Batteries with this sign must be recycled. Batteries which are not returned for the recycling process must be disposed of as hazardous waste! We reserve the right make technical modification. 7. Type plate, Jungheinrich traction battery Baujahr T ype Year of manufacture Serien-Nr.

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Ejd 220 xl

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