Jungheinrich EJE 222 Operating Instructions Manual
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Jungheinrich EJE 222 Operating Instructions Manual

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EJE 220/222/225/230/220r/222r
10.03 -
G
Operating instructions
50425892
06.06

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Summary of Contents for Jungheinrich EJE 222

  • Page 1 EJE 220/222/225/230/220r/222r 10.03 - Operating instructions 50425892 06.06...
  • 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

    Table of contents Correct use and application of the truck Truck description Application ................... B 1 Assembly groups ................. B 2 Technical data - standard version ............B 3 Performance data for standard trucks ..........B 3 Dimensions ..................B 3 EN standards ..................
  • Page 5 Operation Safety Regulations for the Operation of Forklift Trucks ...... E 1 Description of controls and indicating instruments ......E 2 Putting vehicle in operation ..............E 4 Using the industrial truck ..............E 5 Safety regulations for truck operation ..........E 5 Driving, steering, braking ..............
  • 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 Use And Application Of The Truck

    A Correct use and application of the truck The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are included in the scope of delivery for this truck. The guidelines are part of these oper- ating instructions and must always be heeded. National regulations are fully applica- ble.

  • Page 10: B Truck Description

    Qmax. Truck types, capacities and motor output: Type Capacity Motor output EJE 220 2000 kg 1.3 kW EJE 222 2,200 kg 1.5 kW EJE 225 2,500 kg 1.5 kW EJE 230 3,000 kg 1.5 kW...

  • Page 11: Assembly Groups

    Assembly groups Item EJE 220/222/225/ Designation 230/220r/222r Key switch Discharge indicator Display instrument (CANDIS) CANCODE keypad Master switch (emergency stop) Control shaft with control shaft head Safety key Driving regulator Battery hood Lifting device Front hood Supporting wheel Drive wheel Button-creep speed...

  • Page 12: Technical Data - Standard Version

    Technical data - standard version Technical data to VDI 2198. Technical data are subject to alteration and extension in scope. Performance data for standard trucks Model EJE 220 EJE 222 EJE 225 EJE 230 EJE 220r EJE 222r Q Capacity 2000...
  • Page 13 EJE 220/222/225/220r/222r...
  • Page 14 EJE 230...

  • Page 15: En Standards

    EN standards Continuous sound level: 64 dB(A) according to EN 12053 as stipulated in ISO 4871 The continuous sound level is a value averaged according to standard regulations, taking the sound pressure level into account when driving, lifting and idling. The sound pressure level is measured at the ear.

  • Page 16: Location Of Instruction Labels And Identification Plates

    Location of instruction labels and identification plates xx00 Ihr Kundendienst-Partner Item Designation Prohibition sign “Do not ride on truck” Load capacity Qmax. Truck identification label Label: order no., inventory no., full service no. Limit-stop for crane loading UVV control label...

  • Page 17: Truck Identification Plate

    Truck identification plate Item Designation Item Designation Type Manufacturer Serial no. Min./max. battery weight in kg Rated capacity in kg Drive power in kW System Voltage V Load centre distance in mm Empty weight without battery in kg Year of manufacture Manufacturer logo Option In the event of queries relating to the truck or spare part orders, please state the serial...

  • Page 18: C Transportation And Commissioning

    C Transportation and commissioning Transportation by crane Only lifting gear of adequate capacity must be used (for the transport weight, refer to the truck identification label). Lifting gear attachment points (1) are provided at the chassis and at the fork in case the truck is to be lifted or transported by crane.

  • Page 19: Moving An Incapacitated Truck (Emergency Operation)

    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. – Open and remove the front hood (2) (see chapter F). – Screw on 2 off M4x20 bolts (3) to loosen the armature plate. The truck can now be moved.

  • Page 20: D Battery - Servicing, Recharging, Replacement

    D Battery - Servicing, recharging, replacement 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 per- formed by qualified personnel.

  • Page 21: Battery Types

    = 610 mm EJE 220 / 222 / 225 2 PzS 200 Ah EJE 220r / 222r XL - version L = 680 mm EJE 222 / 225 2 PzS 300 Ah EJE 222r Long version L = 770 mm EJE 230...

  • Page 22: Charging The Battery

    Charging the battery – Park the truck and render it safe (refer to chapter E). The battery connector and the socket must only be connected and disconnected with the truck switched off. – Expose the battery (refer to section 3). During the recharging operation the, tops of the battery cells must be exposed to en- sure adequate ventilation.

  • Page 23: Removing And Installing The Battery

    Removing and installing the battery – Expose the battery (see section 3). The truck must be parked on level ground. To prevent short-circuits, batteries with ex- 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.

  • Page 24: Combined Instrument (O)

    Combined instrument (o) Battery discharge indicator: charging condition of the battery is indi- cated in 10% increments by means of ten bars shown on the battery symbol (9). With progressive depletion of the bat- tery, the illuminated bars will go out from the top downwards.

  • Page 26: 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 27: Description Of Controls And Indicating Instruments

    Description of controls and indicating instruments Item Control / EJE 220 / EJE 220r Function Display 222 / 225 / 222r / 230 Key switch Switches current on and off. Removing the key prevents the truck from being switched on by unauthorised personnel.

  • Page 29: Putting Vehicle In Operation

    Putting vehicle in operation Before starting or operating the truck, or before lifting any loads, the driver has to make sure that nobody is within the danger area. Checks and actions before routine start-up – Visual inspection for damages of the whole truck (especially tyres and load carrying devices).

  • Page 30: Using The Industrial Truck

    Using the industrial truck Safety regulations for truck operation Travel routes and work areas: Only use lanes and routes specifically designated for truck traffic. Unauthorised persons 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 31: Driving, Steering, Braking

    Driving, steering, braking Increased attention has to be paid during driving and steering the truck, especially if movements outside of the truck contour are to be performed. It is not admissible to stay on the vehicle during driving. EMERGENCY STOP –...
  • Page 32 If the truck can only be moved with reduced driving speed, a defect has occurred which 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 (5). The truck needs to be taken out of service and must be repaired by expert personnel (see chapter F).
  • Page 33 Braking The braking effect of the truck is mainly depending on the road surface. This must be taken into account by the driver for his driving behavior. The truck may be braked in three ways: – Using the service brake (control shaft (4)), –...

  • Page 34: Picking Up Or Lowering Load Units

    Dynamic braking (roll-off brake): – After releasing the driving switch (9) - driving switch set to zero - the truck is braked with the help of the dynamic brake (roll-off brake), depending on the selected set- ting. If the roll-off brake was deactivated by the service, only service brake and counterflow brake are available.
  • Page 35 Aux. lift for ramp operations (EJE-R 220/222 only) The fork will be automatically lowered before the fork lift function is changed over to the aux. lift function. The fork base will be automatically lowered before changing over from the aux. lift function to the fork lift function.

  • Page 36: Safe Parking Of The Truck

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

  • Page 37: Cancode Keypad

    CANCODE keypad The keypad consists of 10 digit keys, a Set key and a o-key. Activation of the travel programs is indicated through green LEDs on keys 1, 2 and 3. The o key indicates operational status through a red/green LED. It contains the following functions: –...
  • Page 38 Commissioning The LED (11) goes red when you connect the battery and if necessary switch on the key switch. When you enter the correct operator code (factory setting 2-5-8-0) the LED (12) turns green. If the wrong code is entered LED (12) flashes red for two seconds. The correct code can then be entered.

  • Page 39: Travel Programs

    Travel programs Press the digit keys 1, 2, and 3 to select any of three travel programs. The activated program is indicated by the green LEDs (14), (15), (16) in the corresponding key. The travel programs differ with respect to travel speed, acceleration and deceleration force.

  • Page 40: Parameter Settings

    Parameter Settings To change the truck setting you must enter the master code. The factory setting for the master code is 7-2-9-5. When starting the truck for the first time, change the master code (see Section 5.1). Safety instructions for trucks with a display instrument (CANDIS (o)) –...
  • Page 41 Setting procedure for trucks with and without display instrument (CANDIS (o)): – Enter the three digit parameter number, confirm with the Set key (13). – The display instrument (CANDIS (o)) continues to display the operating hours. If the display changes, cancel the setting procedure with the o key (17) and restart from the beginning.
  • Page 42 Function Setting Standard Comments range setting Procedure Code Lock 002 Change user code 0000 - 9999 (LED 14 flashes) Enter current code 00000 - 99999 Confirm (Set) 000000 - 999999 (LED 15 flashes) Enter a new code Confirm (Set) (LED 16 flashes) Repeat code entry Confirm...
  • Page 43 Function Setting Standard Comments range setting Procedure Code Lock 021 Travel program 1* 0 or 1 0 = Travel program release not released 1 = travel program released 022 Travel program 2* 0 or 1 0 = Travel program release not released 1 = travel program released...
  • Page 44 Travel parameters For trucks without a display instrument (CANDIS (o)) the code lock parameters can only be set by the manufacturer's service department. The following example shows the parameter setting for the acceleration of travel program 1 (parameter 101). Acceleration example Display instrument LED (17) LED (14)
  • Page 45 Travel programs Function Setting Standard Comments range setting Travel program 1 101 Acceleration 0 - 9 (0.2 – 2.0 m/s 0.8 m/s 102 Coasting brake 0 - 9 (0.2 – 1.1 m/s (0.5 m/s 104 Maximum speed in drive 0 - 9 depending on direction via controller travel switch...

  • Page 46: Discharge Monitor Function

    Function Setting Standard Comments range setting Travel program 3 301 Acceleration 0 - 9 (0.2 – 2.0 m/s (2.0 m/s 302 Coasting brake 0 - 9 (0.2 – 2.0 m/s 1.1 m/s 304 Maximum speed in tiller 0 - 9 depending on direction via travel switch travel switch...
  • Page 47 Display instrument (CANDIS) The instrument indicates: – Residual battery charge ((LED bars (19)), – Service hours (LCD display (21)). In addition, service messages for the electronic components parameter changes are displayed. Discharge status display Setting limits for the additional “Warning” (18) and “Stop” (20) displays will depend on the battery type.

  • Page 48: Operating Hours Display

    Discharge monitor function When the discharge monitor function is enabled, lifting is cut out when the discharge limit is reached (the Stop LED is lit). Travel and lowering are still possible. For wet batteries the residual capacity is 20%, for maintenance-free batteries it is 40%. The batteries should be recharged when they reach 30% (for wet batteries) or 50% (for maintenance-free batteries).

  • Page 49: Fault Location

    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 ob- served for fault location. Fault Possible cause Remedy Truck does not –...

  • Page 50: F Maintenance Of The Truck

    F Maintenance of the truck Operational safety and protection of the environment The checks and maintenance work listed in this chapter have to be performed accord- ing to the intervals of the maintenance checklists. Modifications of truck assemblies, especially of the safety installations, are not per- mitted.
  • Page 51 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.

  • Page 52: Maintenance And Service

    The application conditions of an industrial truck have a considerable impact on the wear of the service components. We recommend that a Jungheinrich customer service adviser carries out an applica- tion analysis on site to establish specific service intervals to prevent damage caused by wear.

  • Page 53: Maintenance Checklist Eje 220 / 222 / 225 / 230 / Eje 220R / 222R

    Maintenance checklist EJE 220 / 222 / 225 / 230 / EJE 220r / 222r. Maintenance intervals = t W A B C Standard Cold-storage depot Chassis/ 1.1 Check all load bearing elements for damage Design: 1.2 Check all bolted connections Drive unit: 2.1 Check the transmission for noises and leakage 2.2 Check the transmission oil level...
  • Page 54 Maintenance intervals = t W A B C Standard Cold-storage depot = k Electr. 8.1 Check function system: 8.2 Check all cables for secure connection and damage 8.3 Check the fuses for correct amperage 8.4 Check switches and trip cams for proper functioning and seating 8.5 Check contactors and relays, replace wearing parts, if necessary...

  • Page 55: Lubrication Chart Eje 220 / 222 / 225 / 230 / Eje 220R / 222R

    Lubrication chart EJE 220 / 222 / 225 / 230 / EJE 220r / 222r 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) For twin load wheel...

  • Page 56: Operating Material

    Operating material Handling operating material: Consumption type material must always be handled properly. Manufacturer's instructions to be observed. Improper handling endangers health, life and environment. Operating material must only be stored in containers conforming to specification. They might be inflammable and must not come into contact with hot components or open fire.

  • Page 57: Notes On Maintenance

    Notes on maintenance 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: – Park the truck and render it safe (refer to chapter E). –...

  • Page 58: Checking The Electric Fuses

    Checking the electric fuses – Preparation of the truck for servicing and maintenance operations (refer to section 6.1). – Open the front hood (see section 6.3). – Referring to the table, check all fuses for correct rating and replace, where required. Description Protection of: EJE 220 / 222 / 225 / 230 EJE 220r / 222r...

  • Page 59: Recommissioning The Truck

    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: – Check the horn for proper functioning. – Check the master switch for correct functioning. –...

  • Page 60: Recommissioning The Truck

    Recommissioning the truck – Thoroughly clean the fork lift truck. – Lubricate the fork lift truck according to the lubrication chart (refer to chapter F). – Clean the battery. Grease the pole screws using pole grease and reconnect the battery. –...
  • Page 61 F 12...
  • Page 62 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 63: 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 64 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 65 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 66 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 67 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 68: 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 69: 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 70 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 71 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 72 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 73 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 74: 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 75 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 76 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 77 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 78: 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.

This manual is also suitable for:

Eje 220Eje 230Eje 220rEje 222rEje 225

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