Page 1 EJE 220/225/230/235/220r/225r 05.07 Operating instructions en-GB 51040446 04.19 EJE 220 EJE 225 EJE 230 EJE 235 EJE 220r EJE 225r...
Page 3 Declaration of Conformity Manufacturer Jungheinrich AG, 22039 Hamburg, Germany Description Industrial truck Type Option Serial no. Year of manufacture EJE 220 EJE 225 EJE 230 EJE 235 EJE 220r EJE 225r On behalf of Date EU DECLARATION OF CONFORMITY The undersigned hereby declare that the powered truck described in detail complies with the current versions of European Directives 2006/42/EG (Machinery Directive) and 2014/30/EU (Electromagnetic Compatibility - EMC).
Page 5 Foreword Notes on the operating instructions The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter and the pages are numbered continuously.
Page 6 Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG. Jungheinrich Aktiengesellschaft Friedrich-Ebert-Damm 129 22047 Hamburg - Germany Tel: +49 (0) 40/6948-0 www.jungheinrich.com...
Page 7: Table Of Contents
Contents Correct Use and Application General Correct application Approved application conditions Internal Operation Combined with Brief External or Cold Store Operation (t) Internal Operation in Cold Stores with Cold Store Equipment (o) Proprietor responsibilities Adding attachments and/or optional equipment Truck Description Application Truck models and rated capacity Travel direction definition...
Page 8 Operation Safety Regulations for the Operation of Forklift Trucks Displays and Controls EJE 220r / EJE 225r Tiller Battery discharge indicator Battery discharge monitor Preparing the Truck for Operation Checks and Operations to Be Performed Before Starting Daily Work Preparing the truck for operation Making the EJE 220r / 225r operational Checks and operations to be carried out when the truck is operational Parking the truck securely...
Page 9 Maintenance and repairs Preparing the truck for maintenance and repairs Lifting and jacking up the truck safely Cleaning Front cover disassembly Drive panel disassembly and assembly Tightening the wheel nuts Checking the hydraulic oil level Check the gear oil level Checking electrical fuses 4.10 Restoring the truck to service after maintenance and repairs Decommissioning the Industrial Truck...
Page 10 Filling time Water quality Battery tubing Operating temperature Cleaning measures 6.10 Service mobile vehicle Electrolyte circulation Functional Description Cleaning batteries Storing the battery Troubleshooting Disposal...
Page 11: A Correct Use And Application
A Correct Use and Application General The truck must be used, operated and serviced in accordance with the present instructions. All other types of use are beyond its scope of application and may result in damage to personnel, the industrial truck or property. Correct application NOTICE The maximum load and load distance are indicated on the capacity plate and must...
Page 12: Approved Application Conditions
Approved application conditions The permissible operating conditions change if the truck is equipped with a lithium- ion battery (o), see the manufacturer's operating instructions. – Operation in industrial and commercial environments. – Operation only on secure, level surfaces with sufficient capacity. –...
Page 13: Internal Operation Combined With Brief External Or Cold Store Operation (T)
Internal Operation Combined with Brief External or Cold Store Operation (t) In addition to the permissible application conditions in industrial and commercial environments, the truck may also be used in outdoor environments, cold stores and fresh food areas. Secure parking is only permissible indoors or in a cold store environment.
Page 14: Proprietor Responsibilities
Proprietor responsibilities For the purposes of the present operating instructions the “operating company” is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties.
Page 15: B Truck Description
B Truck Description Application The EJE 220/225/230/235/220r/225r is designed to transport goods on level surfaces. It can lift open-bottom pallets or pallets with transverse boards outside area the load-wheel area, as well as roll cages. The capacity is shown on the capacity plate, Qmax.
Page 16: Travel Direction Definition
Travel direction definition The following determinations have been made for travel direction specification: Item Travel direction Left Drive direction Load direction Right...
Page 17: Assemblies And Functional Description
Assemblies and Functional Description Assembly Overview Description Description Item t Collision safety switch t Key switch t Travel switch o Keypad (CanCode) t Slow-travel button o Key switch (also with second stage for brake release) t Tiller o ISM access module t Battery panel o Keypad t Emergency disconnect...
Page 18 t Discharge indicator t Two-section drive panel o Display instrument (CanDis) t Support wheels o Display unit (2-inch display) t Drive wheel t = Standard equipment o = Optional equipment...
Page 19: Functional Description
Functional Description Safety mechanisms An enclosed, smooth truck geometry with rounded edges ensures safe handling of the truck. The wheels are surrounded by a solid skirt. The long tiller provides a maximum safety distance to the truck. When it is released and in hazardous situations a gas pressure spring forces the tiller up into the brake position.
Page 20 Drive system A fixed AC three-phase motor actuates the drive wheel via a bevel spur gearbox. The electronic traction controller ensures smooth drive-motor-speed control and hence smooth starting, powerful acceleration and electrically controlled braking with energy regeneration. The driver can choose from 3 travel programs depending on the load and the environment: from high-performance to energy-saving.
Page 21: Technical Specifications
Technical Specifications The technical specifications comply with the German "Industrial Truck Data Sheet" Guidelines. Technical modifications and additions reserved. Performance data Model EJE 220 EJE 225 EJE 230 EJE 235 Q Rated capacity 2000 2500 3000 3500 Load centre distance for...
Page 22: Dimensions
Dimensions...
Page 23 Model EJE 220 / 225 / EJE 230 Load centre distance for standard load handler length *) Lift Load handler lowered Tiller height in the travel 805 / 1321 805 / 1321 position min./max. Wheelbase (short, long) 1353 / 1425 1353 / - Overall length (short, long) 1763 / 1835...
Page 24 ***Diagonal in accordance with the German directive "Data Sheets for Industrial Trucks +386 mm...
Page 25 Model EJE 220r EJE 225r Load centre distance for standard load handler length *) Lift Load handler lowered Tiller height in the travel 805 / 1321 position min. / max. Wheelbase (short, long) 1353 / 1425 Overall length (short, long) 1763 / 1835 Chassis length (short / long) 613 / 685...
Page 26 ***Diagonal in accordance with the German directive "Data Sheets for Industrial Trucks +386 mm...
Page 27: Weights
Weights Description EJE 220 EJE 225 EJE 230 EJE 235 Truck weight; m / l 540 / 637 550 / 647 Axle loading, laden drive axle / 876 / 1664 990 / 2060 1154 / 2426 1300 / 2750 kg load axle;...
Page 28: Tyre Type
Tyre type Description EJE 220 EJE 225 EJE 230 EJE 235 Tyre size, drive end ø230 x 70 ø230 x 70 ø230 x 70 ø230 x 70 mm Tyre size, load end; ø85x110 / ø85x110 / - / ø85x85 - / ø85x85 mm single / tandem ø85x85...
Page 29: En Norms
EN norms Continuous sound pressure level – EJE 220/225/230/235/220r/225r: 70 dB(A) in accordance with EN 12053 as harmonised with ISO 4871. The continuous sound pressure level is calculated according to standard procedures and takes into account the sound pressure level when travelling, lifting and idling. The sound pressure level is measured at the operator's ear.
Page 30: Conditions Of Use
Conditions of use Ambient temperature – without cold store equipment: operating at -10°C to 40°C, see page 13 – with cold store equipment: operating at -28°C to +25°C, see page 13 Special equipment and authorisation are required if the truck is to be used continually in conditions of extreme temperature or condensing air humidity fluctuations.
Page 31: Identification Points And Data Plates
Identification Points and Data Plates Warnings and notices such as capacity charts, strap points and data plates must be legible at all times. Replace if necessary. Indication Points Item Component Serial number Capacity Qmax Prohibition plate: “No passengers” Truck data plate Strap point for crane lifting Cold store (o) Inspection plaque (o)
Page 32: Data Plate
Data plate Item Model Item Model Type Load centre distance (mm) Serial number Drive output Rated capacity (kg) Min./max. battery weight (kg) Battery voltage (V) Manufacturer Net weight w/o battery (kg) QR code Option Manufacturer's logo Year of manufacture For queries regarding the truck or ordering spare parts, always quote the truck serial number (28).
Page 33: Truck Capacity Plate
Truck capacity plate The capacity plate (20) gives the maximum load-bearing capacity (Q) of the truck in kg assuming the load on the load handler is evenly distributed.
Page 35: C Transport And Commissioning
C Transport and Commissioning Lifting by crane WARNING! All persons involved in loading by crane must be trained Incorrect crane loading procedures due to untrained personnel can cause the truck to fall. There is a risk of injury to personnel and a risk of material damage to the truck.
Page 36 CAUTION! u Trucks with side battery removal (o) can only be raised when the battery is not in position: strap points are covered by the battery. Strap points (23) on the chassis are provided for transporting the truck with crane lifting gear.
Page 37: Transport
Transport WARNING! Accidental movement during transport Improper fastening of the truck and mast during transport can result in serious accidents. uLoading must only be performed by specialist personnel trained for this purpose. The specialist personnel must be instructed in securing loads on road vehicles and handling load securing devices.
Page 38: Using The Truck For The First Time
Using the Truck for the First Time WARNING! The use of unsuitable energy sources can be hazardous Rectified AC current will damage the assemblies (controllers, sensors, motors etc.) of the electronic system. Unsuitable cable connections (too long, insufficient wire cross-section) to the battery (tow cables) can overheat, setting the truck and battery on fire.
Page 39: D Battery - Servicing, Recharging, Replacement
D Battery - Servicing, Recharging, Replacement For use of lithium-ion batteries (o), see the manufacturer's operating instructions. Safety Regulations Governing the Handling of Lead-Acid Batteries Maintenance personnel Batteries may only be charged, serviced or replaced by trained personnel. These operating instructions and the manufacturer’s instructions concerning batteries and charging stations must be observed when carrying out the work.
Page 40 The use of unsuitable batteries that have not been approved for the truck by Jungheinrich, can lead to a deterioration of the braking characteristics of the truck during energy recovery, causing considerable damage to the electric controller and resulting in serious danger to the health and safety of individuals.
Page 41: Battery Types
Battery types Depending on the model, the truck will be supplied with different battery types. The following table shows which combinations are included as standard: EJE 220 / 225 Battery Battery type Weight (kg) Dimensions (mm) tray 24 V - XFC 158 Ah 623X211X627 24 V - XFC 158 Ah 623X211X627...
Page 42 EJE 230 / 235 Battery Battery type Weight (kg) Dimensions (mm) tray 24 V - XFC 158 Ah 623X211X627 24 V - XFC 158 Ah 623X211X627 24 V - 2PzV 160 Ah wf Exide 624X212X537 24 V - 2PzW 160 Ah 624X212X537 24 V - 2PzV 174 Ah wf Hawker 623X211X537...
Page 43 EJE 220r / 225r Battery Battery type Weight (kg) Dimensions (mm) tray 24 V - XFC 158 Ah 623X211X627 24 V - XFC 158 Ah 623X211X627 24 V - 2PzV 160 Ah wf Exide 624X212X537 24 V - 2PzW 160 Ah 624X212X537 24 V - 2PzV 174 Ah wf Hawker 623X211X537...
Page 44: Exposing The Battery
Exposing the battery WARNING! An unsecured truck can cause accidents Parking the truck on an incline or with a raised load handler is dangerous and is strictly prohibited. uPark the truck on a level surface. In special cases the truck may need to be secured with wedges.
Page 45: Charging The Battery
Charging the battery WARNING! The gases produced during charging can cause explosions The battery gives off a mixture of oxygen and hydrogen (electrolytic gas) during charging. Gassing is a chemical process. This gas mixture is highly explosive and must not be ignited. uSwitch the charging station and truck off first before connecting/disconnecting the charging cable of the battery charging station to/from the battery connector.
Page 46: Charging The Battery With A Stationary Charger
Charging the battery with a stationary charger Charging the battery Requirements – Expose battery, page 44. Procedure • Disconnect battery connector (41) from the truck connector. • Connect battery connector (41) to the charging cable (42) of the stationary charger. •...
Page 47 The on-board charger consisting of a battery charger and battery controller must not be opened. If faulty, contact the manufacturer’s customer service department. uThe charger must only be used for batteries supplied by Jungheinrich or other approved batteries provided it has been adapted by the manufacturer's customer service department.
Page 48 400 Ah Wet cell battery: PzS with pulse characteristic 200 - 414 Ah Jungheinrich 100 - 300 Ah NOTICE uAll other switch positions (43) block the charger, and the battery is not charged. uFor PzM batteries with a capacity of less than 180 Ah set characteristic 1, beyond 180 Ah set characteristic 5.
Page 49 4.2.2 Charging the battery Starting to charge with the on-board charger Mains connection Mains supply: 230 V / 110 V (+10/-15%) Mains frequency: 50 Hz / 60 Hz The mains cable of the charger (45) is in the front panel or the battery compartment. Charging the battery Requirements –...
Page 50 Charging times The duration of charge depends on the battery capacity. Charging continues automatically after a mains failure. Charging can be interrupted by removing the mains connector and continued as partial charging.
Page 51 LED display (46) Green LED (charge status) Charging complete, battery full. (Charge interval, float or compensation charge). Flashes slowly Charging. Rapid flash Display at beginning of charge or after setting a new characteristic curve. Number of flash pulses corresponds to the characteristic curve set. Red LED (fault) Overtemperature.
Page 52: Battery Removal And Installation
Battery removal and installation WARNING! Accident risk during battery removal and installation Due to the battery weight and acid there is a risk of trapping or scalding when the battery is removed and installed. uNote the "Safety regulations for handling acid batteries" section in this chapter. uWear safety shoes when removing and installing the battery.
Page 53: Changing The Battery From The Top
Changing the battery from the top Removing the battery Requirements – Park the truck securely, see page 71. – Expose the battery, see page 44. Tools and Material Required – Crane lifting gear Procedure • Disconnect the battery connector from the truck connector.
Page 54 Battery Installation EJE 220 / 225 / 230 / 235 Requirements – Park the truck securely, see page 71. Procedure Assembly is the reverse order. Note the correct assembly position and make sure the battery is connected correctly. Place the battery cable on the tray so that it cannot be severed when the battery is inserted.
Page 55 Battery Installation EJE 220r / 225r Requirements – Park the truck securely, see page 71. Procedure Assembly is the reverse order. Note the correct assembly position and make sure the battery is connected correctly. Place the battery cable on the tray so that it cannot be severed when the battery is inserted.
Page 56: Lateral Battery Removal
Lateral battery removal Lateral battery removal is optional only. And on the EJE 220r / 225r the battery can only be removed from the left-hand side. CAUTION! Trapping hazard Trapping hazard when removing and installing the battery. uWhen removing and installing the battery do not put your hands between the battery and the chassis.
Page 57: E Operation
E Operation Safety Regulations for the Operation of Forklift Trucks Driver authorisation The 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 58 Hazardous area WARNING! Risk of accidents/injury in the hazardous area of the truck A hazardous area is defined as the area in which people are at risk due to travel or lifting operations of the truck, its load handler or the load. This also includes the area within reach of falling loads or lowering/falling operating equipment.
Page 59: Displays And Controls
Displays and Controls 13, 54, 55 14, 56...
Page 60 Control/display Function Collision safety switch Safety function for travel in the drive direction: When the collision safety switch is actuated, the truck travels for approx. 3 seconds in the load direction. The truck then switches off until the travel switch is briefly restored to the neutral position.
Page 61 13, 54, 55 14, 56...
Page 62 Control/display Function 13 Charge/discharge indicator Shows the charge/discharge status of the battery. 14 Key switch – Activates the truck by applying the control voltage – Removing the key prevents the truck from being switched on by unauthorised personnel Key switch with second Brake release to move the truck when switch stage non-operational.
Page 63 13, 54, 55 14, 56...
Page 65: Eje 220R / Eje 225R Tiller
EJE 220r / EJE 225r Tiller Control/display Function 50 Load handler lower button Lowers the load handler. 52 Load handler raise button Raises the load handler. 57 Ramp lift lower button Lowers ramp lift. 58 Ramp lift raise button Raises ramp lift.
Page 66: Battery Discharge Indicator
Battery discharge indicator When the truck has been released via the key switch, CanCode or ISM, the battery charge status is displayed. The LED colours (59) represent the following conditions: LED colour Charge status Green 40–100% Orange 30–40% Green/orange 20–30% flashes at 1 Hz 0–20% If the LED is red, the load can no longer be lifted.
Page 67: Preparing The Truck For Operation
Preparing the Truck for Operation Checks and Operations to Be Performed Before Starting Daily Work WARNING! Risk of accident due to damage to or other defects in the truck and optional features If damage or other truck or attachment (optional equipment) defects are discovered during the following checks, the truck must be taken out of service until it has been repaired.
Page 68: Preparing The Truck For Operation
Preparing the truck for operation Switching on the truck Requirements – Checks and operations to be performed before starting daily work, see page 67. Procedure • Pull the emergency disconnect switch (10) to unlock it. • To switch on the truck: •...
Page 69: Making The Eje 220R / 225R Operational
Making the EJE 220r / 225r operational On the EJE 220r / 225r you must check that the load handler is lowered when making the truck operational. If the load handler is not fully lowered, it can tilt slightly when raised. Switching on the EJE 220r / 225r truck Requirements –...
Page 70: Checks And Operations To Be Carried Out When The Truck Is Operational
Checks and operations to be carried out when the truck is operational WARNING! Risk of accident due to damage to or other defects in the truck and optional features If damage or other truck or attachment (optional equipment) defects are discovered during the following checks, the truck must be taken out of service until it has been repaired.
Page 71: Parking The Truck Securely
Parking the truck securely WARNING! An unsecured truck can cause accidents Parking the truck on an incline, without the brakes applied or with a raised load or load handler is dangerous and is strictly prohibited. uPark the truck on a level surface. In special cases the truck may need to be secured with wedges.
Page 72 EJE 220r / 225r Parking the truck securely Procedure • Park the truck on a level surface. • Fully lower the load handler (60): • Press the "lower" button (50) or the "ramp lift lower" button (57). • Using the tiller (8), turn the drive wheel to "forward travel". •...
Page 73: 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. The truck must only be operated in work areas with sufficient lighting to avoid danger to personnel and materials.
Page 74 Negotiating slopes and inclines Negotiating slopes and inclines up to 20 % is only permitted when they are recognised lanes. The slopes and inclines must be clean, have a non-slip surface, and negotiating them safely must be within the technical specifications of the truck. The truck must always be driven with the load facing uphill.
Page 75: Emergency Disconnect
Emergency Disconnect CAUTION! Applying maximum braking can result in accidents Applying the Emergency Disconnect switch during travel will cause the truck to decelerate to a halt at maximum force. This may cause the load to slide off the load handler. There is a higher risk of accidents and injury. uDo not use the Emergency Disconnect switch as a service brake.
Page 76 Press the Emergency Disconnect switch Procedure • Press the Emergency Disconnect (10). All electrical functions are deactivated. The truck brakes to a halt. Press the Emergency Disconnect switch on in emergencies. Releasing the Emergency Disconnect switch Procedure • Pull the Emergency Disconnect switch (10) to unlock it. All electrical functions are enabled and the truck is operational again (provided the truck was operational before the Emergency Disconnect was pressed).
Page 77: Automatic Braking
Automatic braking When the tiller is released, it returns automatically to the upper brake zone (B) and the brakes are applied automatically. WARNING! Risk of collision due to a defective tiller Operating the truck with a defective tiller can lead to collisions with persons or objects.
Page 78: Travel
Travel WARNING! Collision hazard when operating the truck Collisions with personnel and equipment can result if the truck is operated with open panels. uDo not operate the truck unless the panels and covers are closed and properly locked. uWhen travelling through swing doors etc. make sure that the doors do not activate the collision safety button.
Page 79 4.4.1 Changing direction during travel CAUTION! Danger when changing direction during travel Changing direction during travel causes the truck to decelerate sharply. When the truck changes direction, it can start travelling at high speed in the opposite direction unless the travel switch is released in time. uAfter setting off in the opposite direction, apply the travel switch gently or not at all.
Page 80: Slow Travel
Slow travel CAUTION! Risk of accident if the service brake is deactivated Particular care and attention is required by the operator during slow travel. The service brake is deactivated during slow travel and is only reactivated after the "slow travel" button is released. uIn hazardous situations brake by immediately releasing the "slow travel"...
Page 81: Steering
Steering Procedure • Move the tiller (8) to the left or right. The truck is steered in the required direction. Brakes WARNING! Accident risk while braking The truck’s braking response depends largely on the floor condition and the type of surface.
Page 82 4.7.1 Braking with the service brake Procedure • Move the tiller (8) up or down to one of the brake zones (B). The truck decelerates at the maximum rate until it comes to a halt. The mechanical brake applies automatically when the truck comes to rest. 4.7.2 Regenerative braking Procedure...
Page 83: Load Handler Raise/Lower
Load handler raise/lower WARNING! Accident risk when lifting and lowering Other people can be injured in the truck's hazardous area. The hazardous area is defined as the area in which people are at risk from the movement of the truck including the load handler, etc. This also includes areas which can be reached by falling loads, operating equipment, etc.
Page 84 4.8.1 Raising the load handler Requirements – Prepare the truck for operation, see page 68. Procedure Press the “Raise load handler ” button (52) until you reach the desired lift height. NOTICE Risk of material damage to the hydraulic unit When the mechanical end stop of the load has been reached, release the "Raise load handler"...
Page 85 4.8.2 Lowering the load handler Requirements – Prepare the truck for operation, see page 68. Procedure • Press the “Lower load handler” button (50) until you reach the desired lift height. The load handler is lowered.
Page 86 4.8.3 Raising the ramp lift EJE 220r / 225r Requirements – Prepare the truck for operation, see page 68. Procedure • Press the “ramp lift raise” button (58) until you reach the desired lift height. The load handler is raised to ramp lift. If the load handler is raised with the "load handler raise"...
Page 87 Tiller from below 4.8.4 Lowering ramp lift EJE 220r / 225r Requirements – Prepare the truck for operation, see page 68. Procedure • Press the “ramp lift lower” button (57) until you reach the desired lift height. The load handler is lowered from ramp lift. When you release the "ramp lift lower"...
Page 88: Lifting, Transporting And Depositing Loads
Lifting, transporting and depositing loads WARNING! Unsecured and incorrectly positioned loads can cause accidents. Before lifting a load unit, the driver must make sure that it has been correctly palletised and does not exceed the truck’s capacity. uInstruct other people to move out of the hazardous area of the truck. Stop working with the truck if people do not leave the hazardous area.
Page 89 4.9.1 Raising a load Requirements – Load correctly palletised. – Load weight matches the truck's capacity. – Load handler evenly loaded for heavy loads. Procedure • Drive the truck carefully up to the pallet. • Drive the load handler slowly into the pallet until the pallet is against the back of the load handler (see graphic to the right).
Page 90 4.9.2 Raising the load with ramp lift EJE 220r / 225r Requirements – Load correctly palletised. – Load weight matches the truck's rated capacity. – Load handler evenly laden for heavy loads. – Truck is on a ramp. – Load handler lowered. Procedure •...
Page 93 4.9.3 Transporting a load Requirements – Load raised correctly. – Load is not on the ground. – Perfect ground conditions. Procedure • Accelerate and decelerate with care. • Adapt your travel speed to the conditions of the route and the load you are transporting.
Page 94 4.9.4 Depositing a load CAUTION! Loads must not be set down on transport or escape routes, in front of safety installations or factory equipment that must be accessible at all times. Requirements – Storage location suitable for storing the load. Procedure •...
Page 95 4.9.5 Depositing the load with ramp lift EJE 220r / 225r CAUTION! Loads must not be deposited on travel or escape routes, in front of safety mechanisms or operating equipment that must be accessible at all times. Requirements – Storage location suitable for storing the load. Procedure •...
Page 97: Troubleshooting
Troubleshooting This chapter enables the operator to localize and rectify basic faults or the results of incorrect operation himself. When trying to locate a fault, proceed in the order shown in the remedy table. If, after carrying out the following remedial action, the truck cannot be restored to operation or if a fault in the electronics system is displayed with a corresponding error code, contact the manufacturer’s service department.
Page 98: Truck Does Not Start
Truck does not start Possible cause Actions Battery connector not plugged in Check the battery connector and connect if necessary Emergency disconnect switch pressed Release the emergency disconnect switch, see page 75 Key switch in position "O" Set the key switch to position "I" Battery charge too low Check battery charge and charge battery if necessary, see page 45...
Page 99: Load Cannot Be Lifted
Load cannot be lifted Possible cause Actions Truck not operational Carry out all actions listed under "Truck does not start" Hydraulic oil level too low Check the hydraulic oil level, see page 162 Battery discharge monitor has switched Charge the battery, see page 45 Faulty fuse Check fuses, see page 164 Excessive load...
Page 100: Operating The Truck Without Its Own Drive System
Operating the truck without its own drive system With the right optional equipment (o) it is possible to switch the truck to emergency operation via the GF60 service key: The brakes are released electrically and the truck can move without its own drive system, see page 103. Release and activate the drive wheel brake WARNING! Accidental truck movement...
Page 101 Release the brake Tools and Material Required – Two M5x45 screws – Spanner Procedure • Switch off the truck, to do this: • Turn the key in the key switch (14) anti-clockwise as far as it will go. Remove the key from the key switch (14). •...
Page 102 CAUTION! Open covers can cause injury and accidents uThe covers (side panels, drive compartment cover etc.) must be closed during operation. Refit the right-hand drive panel (63), see page 160. • Install the front panel (15), see page 159. The brake has been reactivated. The brake is now be applied without current. WARNING! Only return the truck to service when you have identified and rectified the fault.
Page 103: Optional Equipment
Optional equipment Emergency operation with service key GF60 WARNING! Accidental truck movement When the brakes are de-activated the truck must be parked on a level surface, since the brakes are no longer effective. uDo not release the brake on slopes or inclines. uDo not park the truck with the brake released.
Page 104 Parking the truck Procedure • Turn the service key to the 0 position and remove the key. After switching back from level 2 to level 1, the lock bar returns to its original position. The brake is now activated again. WARNING! Only return the truck to service when you have identified and rectified the fault.
Page 105: Tiller With Buttons On Both Faces
Tiller with buttons on both faces EJE 220 / 225 / 230 / 235 Tiller from above Tiller from below Item Control Load handler lower button Load handler raise button Load handler lower button Load handler raise button...
Page 106: Keypad (Cancode) (O)
Keypad (CanCode) (o) 7.3.1 Code lock The code lock allows a user or group of users to assign an individual user code. Travel programs can also be assigned to the individual user codes. The user code is configured with a master code and is described in the following sections in this chapter.
Page 107 The keypad consists of 10 digit keys, a Set key (67) and a o key (69). Digit keys The digit keys are used to enter the user or master code and select the travel program. The green LEDs of the digit keys 1, 2 and 3 (64, 65, 66) show the travel program setting.
Page 108 7.3.2 Preparing the truck for operation with the keypad (CanCode) Preparing the truck for operation by entering a valid operator code Procedure • Pull the Emergency Disconnect to unlock it, see page 75. The LED (68) lights up red. • Enter the operator code with the digit keys. When you have entered a valid operator code the LED (68) lights up green, the travel program selected is indicated by the corresponding LEDs (64,65,66) and the truck is switched on.
Page 109 7.3.4 Changing the master code To change the length of the master code you must follow the procedure in "Choose length of the new master code (4-6 digit) and add user codes", see page 118. If there are still user codes stored in the code lock, the master code to be changed must be the same length as the saved user codes.
Page 110 Error displays changing the master code For the following events the LED (68) flashes red: Cause Remedy – Switch off the truck, see page 108. – Choose a different master code, see page 109. – New master code is already –...
Page 111 7.3.5 Add operator code Requirements – To prepare the truck for operation, see page 108. Procedure • Press the O key (69). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (68) flashes green.
Page 112 Error displays adding a user code For the following events the LED (68) flashes red: Cause Remedy – The user code entered is – Switch off the truck, see page 108. not the same length as the – Repeat the entry, making sure that the master master code code is the same length as the user code.
Page 113 7.3.6 Change operator code Requirements – To prepare the truck for operation, see page 108. Procedure • Press the O key (69). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (68) flashes green.
Page 114 Error displays changing a user code For the following events the LED (68) flashes red: Cause Remedy – The user code entered is – Switch off the truck, see page 108. not the same length as the – Repeat the entry, making sure that the master master code code is the same length as the user code.
Page 115 7.3.7 Delete individual user codes Requirements – To prepare the truck for operation, see page 108. Procedure • Press the O key (69). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (68) flashes green.
Page 116 Error displays deleting individual user codes For the following events the LED (68) flashes red: Cause Remedy – The user code entered is – Switch off the truck, see page 108. not the same length as the – Repeat the entry, making sure that the master master code code is the same length as the user code.
Page 117 7.3.8 Delete all user codes, Requirements – To prepare the truck for operation, see page 108. Procedure • Press the O key (69). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (68) flashes green.
Page 118 7.3.9 Choose length of the new master code (4-6 digit) and add user codes The master code is factory set to a four-digit entry: If necessary, the four-digit master code can be changed to a five or six-digit entry. Before the master code length can be changed, all user codes must be deleted.
Page 119 7.3.10 Setting the automatic truck cutout (timeframe) Requirements – To prepare the truck for operation, see page 108. Procedure • Press the O key (69). • Enter the valid master code with the digit keys. When you enter the correct master code the LED (68) flashes green.
Page 120 Error displays setting the automatic cutout period of the truck For the following events the LED (68) flashes red: Cause Remedy – Switch off the truck, see page 108. – Cutout time entered is out of – Enter the time again while making sure it is range within range.
Page 121 7.3.11 Assigning the travel program The travel programs are fixed to the user code and can be released or blocked with a configuration code. The configuration code can also be used to assign a starting travel program to each user code. The starting travel program is the travel program that is activated when the truck is switched on and is displayed by the (64,65,66) LEDs.
Page 122 Specifying a configuration code: Setting Description – Travel program 1 is blocked for the user code selected 1st digit – Travel program 1 is enabled for the user code selected – Travel program 2 is blocked for the user code selected 2nd digit –...
Page 123 Adapting the travel program configuration to the user code Procedure • Press the O key (69). • Enter the valid master code with the digit keys. When you enter the valid master code the green LED (68) flashes green. • Enter the parameters 0-2-4 with the digit keys. •...
Page 124 Error displays configuring the travel programs For the following events the LED (68) flashes red: Cause Remedy – Blocked travel program – Switch off the truck, see page 108. defined as start travel – Try again, making sure the configuration code is program entered correctly.
Page 125: Setting The Truck Parameters With Cancode
Setting the truck parameters with CanCode CAUTION! Incorrect input Without CanDis, only CanCode internal parameters can be changed. Traction controller parameters can be changed only with CanDis; without CanDis, the settings must be configured by the manufacturer's service department. CAUTION! Altering settings for the travel and hydraulic functions can result in accidents Increasing the settings for travel and hydraulic functions can result in accidents.
Page 126 To continue setting, reconfirm with the Set key (67). Saving travel parameters Requirements – Enter all parameters. Procedure • Run "SaveParameters" by pressing 1-2-3-Set. • Confirm with the O key (69).
Page 127: Parameters
Parameters Travel program 1 Function Setting range Standard Comments setting 0256 Acceleration 0 - 9 (0.2 - 2.0 m/s (0.6 m/s 0260 Coasting brake 0 - 9 (0.2 - 1.1 m/s (0.8 m/s 0264 Maximum speed in drive 0 - 9 depending on direction using travel (0.5 - 6.0 km/h)
Page 128 Battery parameters Function Range Standard Comments setting 1377 Battery type 0 - 9 0 = Normal (wet) 1 = High performance (wet) 2 = Dry (maintenance- free) 9 = XFC (Special battery) 1389 Discharge monitor 0 /1 0 = Not active function 1 = Active...
Page 129: Setting The Battery Parameters With Cancode
Setting the Battery Parameters with CanCode WARNING! Altering parameters can cause accidents uAltering the settings can cause accidents. uThis requires greater attention on the part of the operator The following example shows the parameter setting for the battery type (parameter 1377) to "dry - maintenance-free".
Page 130 The parameter is now saved. Testing an altered parameter Requirements – The parameter is now saved. Procedure • Press the O key (69). • Enter the master code. • Enter the four-digit parameter number "1377" and confirm with the Set key. •...
Page 131: Candis Display Instrument (O)
CanDis Display Instrument (o) The instrument indicates: Battery charge display (on board charger only) LED bars for battery charge status "Warning" symbol (yellow), Battery charge recommended "Stop" symbol (red); lift cut-off, Battery charge essential No symbol when battery type set to normal or enhanced performance wet cell battery "T"...
Page 132 7.7.1 Discharge monitor function The discharge limit has been reached when the "Stop" symbol (73) lights up. When the discharge monitor function is activated lifting operations are disabled. Travel and lowering are still possible. Lifting is only enabled again when the battery is 70% charged.
Page 133: Display Unit (2 Inch Display)
Display unit (2 inch display) Item Control or Function display element Battery capacity display Battery discharge status Information line Displays event messages and optional information such as speed or remaining time. Power display Shows the available power in the travel program selected.
Page 134 7.8.1 Information field Any event messages are shown in the left section of the information line (76). The right section of the information line shows the truck speed in km/h or mph. The manufacturer's customer service department can change the information line from kg and km/h units to lbs and mph units and vice versa.
Page 135 7.8.2 Button allocation of the display Functions and operator menus that can be operated via the icons and keys of the display unit depend on the operating situation as well as the scope and settings of the truck. Key allocation in main menu Symbol Meaning Menu change:...
Page 136 7.8.3 Symbols in the display Any number of pictograms can be displayed in the pictogram field (78). Which pictograms are shown in the pictogram field depends on the operating and truck status. Symbol Meaning Colour Function Operator platform Yellow Operator platform not occupied when Deadman switch travel switch actuated (trucks without pedestrian mode optional equipment...
Page 137 Symbol Meaning Colour Function Lithium-ion battery Yellow Lithium-ion battery low temperature low temperature detected – Discharge currents and energy recovery are reduced at low temperatures. Lithium-ion battery below permissible temperature range – The truck switches off via the battery contactor. –...
Page 138: General Information About The Use Of Keyless Access Systems
General Information about the Use of Keyless Access Systems The default code is to be found on a sticker. When using for the first time, change the set-up code and remove the sticker! – Default code: 1-2-3-4 – Factory set-up code: 2-4-1-2 When allocating the codes, ensure the rider trucks are given a different code than pedestrian trucks.
Page 139: Using The Display
7.10 Using the Display: 7.10.1 Switch on the truck with the access code. Procedure • Release the emergency disconnect switch, see page 75. • Enter the access code with the buttons below the display (55). The truck is switched on. 7.10.2 Switching off the truck Procedure...
Page 140 7.10.3 Changing the Set-up Code Requirements – The truck is switched on, see page 139. Procedure • Press the key below the "Settings" symbol (85). • Press the key below the "Change set- up code" symbol (86). • Enter the set-up code using the keys below the display unit (55).
Page 141 7.10.4 Adding a new access code Requirements – The truck is switched on, see page 139. Procedure • Press the key below the "Settings" symbol (85). • Press the key below the "Edit access code" symbol (90). The set-up code is requested. •...
Page 142 7.10.5 Deleting an access code Requirements – The truck is switched on, see page 139. Procedure • Press the key below the "Settings" symbol (85). • Press the key below the "Edit access code" symbol (90). The set-up code is requested. •...
Page 143: Ism Access Module (O)
7.10.6 Displaying the Log-in Process The use of the last different access codes is displayed during the log-in process. The last log-in is displayed first. If multiple access codes are logged as being displayable simultaneously, the display area can be moved by scrolling forward or back. Requirements –...
Page 145: Industrial Truck Maintenance
F Industrial Truck Maintenance Operational Safety and Environmental Protection The inspections and maintenance tasks listed in chapter "Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement" must be performed according to the defined service intervals (see page 171). The manufacturer recommends the replacement of the maintenance parts also listed in chapter "Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement"...
Page 146: Maintenance Safety Regulations
Maintenance Safety Regulations Maintenance and repair personnel The manufacturer has a customer service department specially trained for these tasks. A maintenance contract with the manufacturer will support trouble-free operation. Truck maintenance, repair work and changing of parts requiring replacement must only be carried out by specialist personnel.
Page 147: Working On The Electrical System
Working on the electrical system WARNING! Electrical current can cause accidents Make sure the electrical system is voltage-free before starting work on it. The capacitors in the controller must be completely discharged. The capacitors are completely discharged after approximately 10 minutes. Before starting maintenance on the electrical system: uOnly suitably trained electricians may operate on the truck's electrical system.
Page 148: Hydraulic System
Hydraulic system WARNING! Leaky hydraulic systems can result in accidents Hydraulic oil can escape from leaky and faulty hydraulic systems. uReport any defects immediately to your supervisor. uMark defective truck and take out of service. uDo not return the industrial truck to service until you have identified and rectified the fault.
Page 149 NOTICE Testing and replacing hydraulic hoses Hydraulic hoses can become brittle through age and must be checked at regular intervals. The application conditions of the industrial truck have a considerable impact on the ageing of the hydraulic hoses. uCheck the hydraulic hoses at least annually and replace if necessary. uIf the operating conditions become more arduous the inspection intervals must be reduced accordingly.
Page 150: Lubricants And Lubrication Schedule
Lubricants and Lubrication Schedule Handling consumables safely Handling consumables Consumables must always be handled correctly. Follow the manufacturer’s instructions. WARNING! Improper handling is hazardous to health, life and the environment Consumables can be flammable. uKeep consumables away from hot components and naked flames. uAlways keep consumables in prescribed containers.
Page 151 WARNING! Improper handling of oils can be hazardous Oils (chain spray / hydraulic oil) are flammable and poisonous. uDispose of used oils in accordance with regulations. Store used oil safely until it can be disposed of in accordance with regulations. uDo not spill oil.
Page 152: Lubrication Schedule
Lubrication Schedule 0,9 l 0,55 l Cold-store application g Running surfaces Mixing ratio 1:1 a Transmission-oil drain plug Grease nipple b Transmission-oil filler neck Gear-oil overflow and dipstick Hydraulic-oil filler plug...
Page 153: Consumables
The Jungheinrich hydraulic oil may be mixed with one of the named alternative hydraulic oils. For cold store operations the Jungheinrich hydraulic oil and the cold store hydraulic oil must be mixed in a 1:1 ratio.
Page 154: 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: Procedure • Park the truck securely, see page 71. •...
Page 155: Cleaning
Raising and jacking up the truck securely Requirements – Prepare the truck for maintenance and repairs (see page 154). Tools and Material Required – Jack – 4 hard wooden blocks Procedure • Apply the jacks in turn: • On the right-hand side of the drive chassis •...
Page 156 CAUTION! Fire hazard Do not use flammable liquids to clean the industrial truck. uDisconnect the battery before starting cleaning work. uCarry out all necessary safety measures to prevent sparking before cleaning (e.g. by short-circuiting). CAUTION! Risk of component damage when cleaning the truck Cleaning with a pressure washer can result in malfunctions due to humidity.
Page 157 Cleaning the truck Requirements – Prepare the truck for maintenance and repairs (see page 154). Tools and Material Required – Water-based solvents – Sponge or cloth Procedure • Clean the surface of the truck with water-based solvents and water. Use a sponge or cloth to clean.
Page 158 4.3.2 Cleaning the electrical system assemblies CAUTION! Risk of electrical system damage Cleaning the assemblies (controllers, sensors, motors etc.) of the electronic system with water can damage the electrical system. uDo not clean the electrical system with water. uClean the electrical system with weak suction or compressed air (use a compressor with a water trap) and not a conductive, anti-static brush.
Page 159: Front Cover Disassembly
Front cover disassembly Front cover disassembly Requirements – Prepare the truck for maintenance and repairs, see page 154. Tools and Material Required – Allen key size 8 Procedure • Remove the screws (95) with the Allen key. • Lift and remove the front panel (15).
Page 160: Drive Panel Disassembly And Assembly
Drive panel disassembly and assembly The drive panel consists of two halves (63 and 97). Drive panel disassembly Tools and Material Required – Allen key Procedure • Turn the tiller to the right limit position. • Remove 2 screws (96). •...
Page 161: Tightening The Wheel Nuts
Tightening the wheel nuts The wheel nuts on the drive wheel must be retightened in accordance with the maintenance intervals indicated in the maintenance checklist, see page 171. Tightening the wheel nuts Requirements – Prepare the truck for maintenance and repairs, see page 154. Tools and Material Required –...
Page 162: Checking The Hydraulic Oil Level
Checking the hydraulic oil level Checking hydraulic level replenishing Requirements – Fully lower the load handler. – Prepare the truck for maintenance and repairs, see page 154. Procedure • Remove the front panel, see page 159. • Check level hydraulic reservoir (103).
Page 163: Check The Gear Oil Level
Check the gear oil level Check the transmission oil level Requirements – Park the truck securely, see page 71. Tools and Material Required – Oil sump Procedure • Place the oil drain tray underneath the transmission (105). • Remove the front panel (15), see page 159. •...
Page 164: Checking Electrical Fuses
Checking electrical fuses Checking fuses Requirements – Truck prepared for maintenance and repairs, see page 154. – Front panel removed, see page 159. Procedure • Check the fuse ratings against the table and replace if necessary. The fuses have been checked. EJE 220 / 225 / 230 / 235 107 108 109 Item...
Page 165 EJE 220r / 225r 107 108 109 Item Component To protect Rating Solenoid / magnetic brake control fuse 10 A Travel / lift electronics control fuse Discharge indicator control fuse Travel / lift fuse 200 A 9F17 EJE 220r / 225r auxiliary hydraulics fuse...
Page 166: Restoring The Truck To Service After Maintenance And Repairs
4.10 Restoring the truck to service after maintenance and repairs Procedure • Thoroughly clean the truck, see page 155. • Lubricate the truck according to the lubrication schedule, see page 152. • Clean the battery, grease the terminal screws and connect the battery. •...
Page 167: Decommissioning The Industrial Truck
Decommissioning the Industrial Truck If the truck is to be out of service for more than a month, it must be stored in a frost- free and dry room. All necessary measures must be taken before, during and after decommissioning as described hereafter. When the truck is out of service it must be jacked up so that all the wheels are clear of the ground.
Page 168: Restoring The Truck To Service After Decommissioning
Restoring the truck to service after decommissioning Procedure • Thoroughly clean the truck, see page 155. • Lubricate the truck according to the lubrication schedule, see page 152. • Clean the battery, grease the terminal screws and connect the battery. •...
Page 169: Safety Tests To Be Performed At Intervals And After Unusual Incidents
Safety tests to be performed at intervals and after unusual incidents The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector. The manufacturer offers a safety inspection service which is performed by personnel specifically trained for this purpose.
Page 171: Maintenance, Inspection And Changing Of Maintenance Parts Requiring Replacement
G Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement WARNING! Lack of maintenance can result in accidents Failure to perform regular maintenance and inspections can lead to truck failure and poses a potential hazard to personnel and equipment. uThorough and expert maintenance and inspections are among the most important requirements for the safe operation of the industrial truck.
Page 172: Maintenance Contents Eje
Maintenance Contents EJE 235 Issued on: 2019-04-24 12:00 Owner To be performed every 50 service hours, but at least once a week. 1.1.1 Maintenance contents 1.1.1.1 Standard equipment Brakes Test the function of the brakes Hydraulic operations Correct the hydraulic oil level. Steering Test the tiller return function.
Page 173 1.1.1.2 Optional equipment Lead-acid battery, international Power supply Correct the battery acid level using demineralised water. Lead-acid battery Power supply Correct the battery acid level using demineralised water.
Page 174 1.1.2 Inspection contents 1.1.2.1 Standard equipment The following points must be checked: Electrical system Warning and safety devices are in accordance with the operating instructions Function of display and controls The function of the emergency disconnect and for damage Power supply Battery and battery components for damage The function and secure seating of the battery connector and for damage Travel...
Page 175 1.1.2.2 Optional equipment The following points must be checked: Standard on-board charger Battery charger The mains plug and mains cable for damage Lead-acid battery, international Power supply Battery and battery components for damage Battery cable connections are secure Lead-acid battery Power supply Battery cable connections are secure...
Page 176: Customer Service
Customer Service 1.2.1 Maintenance contents In accordance with the EJE 235 service interval, to be performed every 1000 service hours, but at least once a year. 1.2.1.1 Standard equipment Brakes Test the brake with the tiller in the maximum vertical and horizontal positions. Measure the air gap of the magnetic brake.
Page 177 1.2.1.2 Optional equipment Standard on-board charger Battery charger Test the immobiliser on trucks with on-board chargers. Carry out a potential measurement on the chassis while charging is in progress. Data radio System components Clean the scanner and terminal. Other inspections Agreed services Note: Tests on other options and special parts such as radio data and access modules (ISM) must be recorded in the test report.
Page 178 1.2.2 Inspection contents The following points must be checked: 1.2.2.1 Standard equipment Electrical system Cables and engine are secure and for damage Warning and safety devices are in accordance with the operating instructions Function of display and controls The function of the emergency disconnect and for damage Contactors and/or relays for wear and damage The electric wiring for damage (insulation damage, connections) and the fuse ratings Power supply...
Page 179 1.2.2.2 Optional equipment Standard on-board charger Battery charger The mains plug and mains cable for damage The secure seating of the cables and electrical connections and for damage Electrolyte circulation Power supply The function of the hose connections and pump Aquamatik Power supply The function of the Aquamatik plug, hose connections and float and for leaks...
Page 180 Lead-acid battery, international Power supply The secure seating of the battery, battery cables and cell connectors and for damage The presence of safety labels are present and for damage Lead-acid battery Power supply The secure seating of the battery, battery cables and cell connectors and for damage...
Page 181 1.2.3 Maintenance parts The manufacturer recommends the replacement of the following maintenance parts at the specified intervals. 1.2.3.1 Standard equipment maintenance part service hours months Hydraulic oil 2000 Hydraulic system - breather filter 2000 Transmission oil 10000 1.2.3.2 Optional equipment Cold-store application maintenance part service hours...
Page 182: Maintenance Contents Eje 220R-225R
Maintenance Contents EJE 220r-225r Issued on: 2019-04-24 12:00 Owner To be performed every 50 service hours, but at least once a week. 2.1.1 Maintenance contents 2.1.1.1 Standard equipment Brakes Test the function of the brakes Hydraulic operations Correct the hydraulic oil level. Steering Test the tiller return function.
Page 183 2.1.1.2 Optional equipment Lead-acid battery, international Power supply Correct the battery acid level using demineralised water. Lead-acid battery Power supply Correct the battery acid level using demineralised water.
Page 184 2.1.2 Inspection contents 2.1.2.1 Standard equipment The following points must be checked: Electrical system Warning and safety devices are in accordance with the operating instructions Function of display and controls The function of the emergency disconnect and for damage Power supply Battery and battery components for damage The function and secure seating of the battery connector and for damage Travel...
Page 185 2.1.2.2 Optional equipment The following points must be checked: Standard on-board charger Battery charger The mains plug and mains cable for damage Lead-acid battery, international Power supply Battery and battery components for damage Battery cable connections are secure Lead-acid battery Power supply Battery cable connections are secure...
Page 186: Customer Service
Customer Service 2.2.1 Maintenance contents In accordance with the EJE 220r-225r service interval, to be performed every 1000 service hours, but at least once a year. 2.2.1.1 Standard equipment Brakes Test the function of the brakes Measure the air gap of the magnetic brake. Electrical system Adjust the microswitches.
Page 187 2.2.1.2 Optional equipment Standard on-board charger Battery charger Test the immobiliser on trucks with on-board chargers. Carry out a potential measurement on the chassis while charging is in progress. Lead-acid battery, international Power supply Clean and grease the battery terminals. Clean the battery.
Page 188 2.2.2 Inspection contents The following points must be checked: 2.2.2.1 Standard equipment Electrical system Cables and engine are secure and for damage Warning and safety devices are in accordance with the operating instructions Function of display and controls Microswitches for function and damage The function of the emergency disconnect and for damage Contactors and/or relays for wear and damage Carbon brushes for wear...
Page 189 2.2.2.2 Optional equipment Standard on-board charger Battery charger The mains plug and mains cable for damage The secure seating of the cables and electrical connections and for damage Electrolyte circulation Power supply The function of the hose connections and pump Aquamatik Power supply The function of the Aquamatik plug, hose connections and float and for leaks...
Page 190 Lead-acid battery, international Power supply The secure seating of the battery, battery cables and cell connectors and for damage The presence of safety labels are present and for damage Lead-acid battery Power supply The secure seating of the battery, battery cables and cell connectors and for damage...
Page 191 2.2.3 Maintenance parts The manufacturer recommends the replacement of the following maintenance parts at the specified intervals. 2.2.3.1 Standard equipment maintenance part service hours months Hydraulic oil 2000 Hydraulic system - breather filter 2000 Transmission oil 10000 2.2.3.2 Optional equipment Cold-store application maintenance part service hours...
Page 192: Maintenance Contents Eje
Maintenance Contents EJE 230 Issued on: 2019-04-24 12:00 Owner To be performed every 50 service hours, but at least once a week. 3.1.1 Maintenance contents 3.1.1.1 Standard equipment Brakes Test the function of the brakes Hydraulic operations Correct the hydraulic oil level. Steering Test the tiller return function.
Page 193 3.1.1.2 Optional equipment Lead-acid battery, international Power supply Correct the battery acid level using demineralised water. Lead-acid battery Power supply Correct the battery acid level using demineralised water.
Page 194 3.1.2 Inspection contents 3.1.2.1 Standard equipment The following points must be checked: Electrical system Warning and safety devices are in accordance with the operating instructions Function of display and controls The function of the emergency disconnect and for damage Power supply Battery and battery components for damage The function and secure seating of the battery connector and for damage Travel...
Page 195 3.1.2.2 Optional equipment The following points must be checked: Standard on-board charger Battery charger The mains plug and mains cable for damage Lead-acid battery, international Power supply Battery and battery components for damage Battery cable connections are secure Lead-acid battery Power supply Battery cable connections are secure...
Page 196: Customer Service
Customer Service 3.2.1 Maintenance contents In accordance with the EJE 230 service interval, to be performed every 1000 service hours, but at least once a year. 3.2.1.1 Standard equipment Brakes Test the function of the brakes Measure the air gap of the magnetic brake. Electrical system Adjust the microswitches.
Page 197 3.2.1.2 Optional equipment Standard on-board charger Battery charger Test the immobiliser on trucks with on-board chargers. Carry out a potential measurement on the chassis while charging is in progress. Lead-acid battery, international Power supply Clean and grease the battery terminals. Clean the battery.
Page 198 3.2.2 Inspection contents The following points must be checked: 3.2.2.1 Standard equipment Electrical system Cables and engine are secure and for damage Warning and safety devices are in accordance with the operating instructions Function of display and controls Microswitches for function and damage The function of the emergency disconnect and for damage Contactors and/or relays for wear and damage Carbon brushes for wear...
Page 199 3.2.2.2 Optional equipment Standard on-board charger Battery charger The mains plug and mains cable for damage The secure seating of the cables and electrical connections and for damage Electrolyte circulation Power supply The function of the hose connections and pump Aquamatik Power supply The function of the Aquamatik plug, hose connections and float and for leaks...
Page 200 3.2.3 Maintenance parts The manufacturer recommends the replacement of the following maintenance parts at the specified intervals. 3.2.3.1 Standard equipment maintenance part service hours months Hydraulic oil 2000 Hydraulic system - breather filter 2000 Transmission oil 10000 3.2.3.2 Optional equipment Cold-store application maintenance part service hours...
Page 201: Owner
Maintenance Contents EJE 220/225 Issued on: 2019-04-24 12:00 Owner To be performed every 50 service hours, but at least once a week. 4.1.1 Maintenance contents 4.1.1.1 Standard equipment Hydraulic operations Correct the hydraulic oil level. Steering Test the tiller return function.
Page 202 4.1.1.2 Optional equipment Lead-acid battery, international Power supply Correct the battery acid level using demineralised water. Lead-acid battery Power supply Correct the battery acid level using demineralised water.
Page 203 4.1.2 Inspection contents 4.1.2.1 Standard equipment The following points must be checked: Electrical system Warning and safety devices are in accordance with the operating instructions Function of display and controls The function of the emergency disconnect and for damage Power supply Battery and battery components for damage The function and secure seating of the battery connector and for damage Travel...
Page 204 4.1.2.2 Optional equipment The following points must be checked: Standard on-board charger Battery charger The mains plug and mains cable for damage Lead-acid battery, international Power supply Battery and battery components for damage Battery cable connections are secure Lead-acid battery Power supply Battery cable connections are secure...
Page 205: Customer Service
Customer Service 4.2.1 Maintenance contents In accordance with the EJE 220/225 service interval, to be performed every 1000 service hours, but at least once a year. 4.2.1.1 Standard equipment Brakes Test the brake with the tiller in the maximum vertical and horizontal positions. Measure the air gap of the magnetic brake.
Page 206 4.2.1.2 Optional equipment Standard on-board charger Battery charger Test the immobiliser on trucks with on-board chargers. Carry out a potential measurement on the chassis while charging is in progress. Data radio System components Clean the scanner and terminal. Other inspections Agreed services Note: Tests on other options and special parts such as radio data and access modules (ISM) must be recorded in the test report.
Page 207 4.2.2 Inspection contents The following points must be checked: 4.2.2.1 Standard equipment Electrical system Cables and engine are secure and for damage Warning and safety devices are in accordance with the operating instructions Function of display and controls The function of the emergency disconnect and for damage Contactors and/or relays for wear and damage The electric wiring for damage (insulation damage, connections) and the fuse ratings Power supply...
Page 208 4.2.2.2 Optional equipment Standard on-board charger Battery charger The mains plug and mains cable for damage The secure seating of the cables and electrical connections and for damage Electrolyte circulation Power supply The function of the hose connections and pump Aquamatik Power supply The function of the Aquamatik plug, hose connections and float and for leaks...
Page 209 Lead-acid battery, international Power supply The secure seating of the battery, battery cables and cell connectors and for damage The presence of safety labels are present and for damage Lead-acid battery Power supply The secure seating of the battery, battery cables and cell connectors and for damage...
Page 210 4.2.3 Maintenance parts The manufacturer recommends the replacement of the following maintenance parts at the specified intervals. 4.2.3.1 Standard equipment maintenance part service hours months Hydraulic oil 2000 Hydraulic system - breather filter 2000 Transmission oil 1000 4.2.3.2 Optional equipment Cold-store application maintenance part service hours...
Page 211: H Traction Battery
H Traction battery Correct Use and Application Failure to observe the operating instructions, carrying out repairs with non-original spare parts, tampering with the battery or using electrolyte additives will invalidate the warranty. Observe the instructions for maintaining the safety rating during operation for batteries in accordance with Ex I and Ex II (see relevant certification).
Page 212: Safety Instructions, Warning Indications And Other Notes
Safety Instructions, Warning Indications and other Notes Used batteries must be treated as hazardous waste. These batteries are marked with the recycling symbol and the sign showing a crossed-out rubbish bin, and should not be disposed of with ordinary household waste. Buy-back terms and type of recycling are to be agreed with the manufacturer as described in §...
Page 213: Lead Acid Batteries With Armour Plated Cells And Liquid Electrolyte
Lead acid batteries with armour plated cells and liquid electrolyte Description Jungheinrich traction batteries are lead acid batteries with armour plated cells and liquid electrolyte. The names of the traction batteries are PzS, PzB, PzS Lib and PzM. Name Explanation –...
Page 214 4.1.1 Battery nominal data Product Traction battery Nominal voltage 2.0 V x number of cells Rated capacity C5 See data plate Discharge current C5/5h 1.29 kg/l Nominal electrolyte density 30 °C Nominal temperature System rated electrolyte level up to "Max" electrolyte level marking 55 °C Limit temperature 2) Reached within the first 10 cycles.
Page 215: Operation
Operation 4.2.1 Commissioning unfilled batteries The operations required must be carried out by the manufacturer's customer service department or a customer service organisation authorised by the manufacturer. 4.2.2 Commissioning filled and charged batteries Battery cell cross section Top view of a battery cell Checks and operations to be performed before starting daily work Procedure •...
Page 216 4.2.3 Discharging the battery To achieve an optimum useful life avoid operational discharge of more than 80% of nominal capacity (full discharge). This corresponds to a minimum electrolyte density of 1.13 kg/l at the end of the discharge. Fully or partially discharged batteries must be re-charged immediately and not left unattended.
Page 217 The electrolyte temperature rises by approx. 10°C during charging. Charging should therefore only begin when the electrolyte temperature is below 45°C. The electrolyte temperature of batteries must be at least +10°C before charging. Otherwise the battery will not charge correctly. Below 10°C the battery is insufficiently charged with standard charging systems.
Page 218: Servicing Lead-Acid Batteries With Armour Plated Cells
Servicing lead-acid batteries with armour plated cells 4.3.1 Quality of Water for Adding Electrolyte The quality of the water used to add electrolyte must correspond to purified or distilled water. Purified water can be produced through distillation or ion exchangers and is then suitable for the production of electrolyte.
Page 219 4.3.3 Weekly – After re-charging, carry out a visual inspection for dirt and physical damage. – If the battery is charged regularly according to the IU characteristic, carry out a compensation charge. 4.3.4 Monthly – Towards the end of the charging process measure and record the voltages of all the cells with the charger switched on.
Page 220: Pzv And Pzv-Bs Lead-Acid Batteries With Sealed Armour Plated Cells
PzV and PzV-BS lead-acid batteries with sealed armour plated cells Description PzV batteries are sealed batteries with fixed electrolytes, to which no water can be added over the entire lifespan of the battery. Relief valves are used as plugs which are destroyed when opened.
Page 221: Operation
Operation 5.2.1 Commissioning Checks and operations to be performed before starting daily work Procedure • Make sure the battery is in physically good condition. • Make sure the terminals are correct (positive to positive and negative to negative) and check that contacts on the battery terminal conducting system are secure. •...
Page 222 NOTICE Charging the battery incorrectly can result in material damage. Incorrect battery charging can result in overloading of the electric wires and contacts, hazardous gas formation and electrolyte leakage from the battery cell. uAlways charge the battery with DC current. uAll DIN 41773 charging procedures are permitted in the format approved by the manufacturer.
Page 223 Charging the battery Requirements – Electrolyte temperature between +15°C and +35°C Procedure • Open or take off the tray lid or covers from the battery compartment. • Connect the battery to the switched off charger, ensuring the terminals are connect (positive to positive and negative to negative). •...
Page 224: Servicing Pzv And Pzv-Bs Lead-Acid Batteries With Sealed Armour Plated Cells
Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated cells Do not add water! 5.3.1 Daily – Charge the battery after each discharge. 5.3.2 Weekly – Visually inspect for dirt and physical damage. 5.3.3 Every three months – Measure and record the overall voltage. –...
Page 225: Aquamatik Water Replenishment System
Aquamatik water replenishment system Water replenishment system design > 3 m Water container Tap connection with ball cock Flow indicator Shut-off cock Locking coupling Battery lock connector...
Page 226: Functional Description
Functional Description The Aquamatik water replenishment system is used to adjust the rated electrolyte level automatically on traction batteries for industrial trucks. The battery cells are interconnected through hoses and are attached to the water supply (e.g. water container) through a plug connection. When the shut-off cock is opened all the cells are filled with water.
Page 227: Filling Time
Filling time The filling time for a battery depends on the electrolyte level, the ambient temperature and the filling pressure. Filling ends automatically. The water supply line must be disconnected from the battery when the water has been filled. Water quality The quality of the water used to fill up electrolyte must correspond to purified or distilled water.
Page 228: Electrolyte Circulation
Electrolyte circulation Functional Description Electrolyte circulation ensures the supply of air during charging to mix the electrolyte, thereby preventing any acid layer, shortening the charge time (charge factor approx. 1.07) and reducing the formation of gas during charging. The charger must be suitable for the battery and electrolyte circulation.
Page 229 NOTICE If an installed electrolyte circulation system is seldom used or not used at all, or if the battery is subjected to severe temperature fluctuations, the electrolyte may flow back into the hose system. uAttach a separate coupling system to the air inlet line, such as: locking coupling to the battery side and through-coupling to the air supply side.
Page 230: Cleaning Batteries
Cleaning batteries Batteries and trays must be cleaned in order to – Maintain cell insulation and protect cells from ground or external conductive parts. – Avoid damage from corrosion and stray currents. – Avoid excessive and varying automatic discharge of the individual cells or block batteries due to stray currents.
Page 231 Cleaning the battery with a high pressure cleaner Requirements – Cell connectors tight, plugged in securely – Cell plugs closed Procedure • Follow the high pressure cleaner's user instructions. • Do not use any cleaning additives. • Observe the permissible cleaning device temperature setting of 140°C. This generally ensures that the temperature does not exceed 60°C at a distance of 30cm behind the outlet nozzle.
Page 232: Storing The Battery
Storing the battery NOTICE The battery should not be stored for longer than 3 months without charging as otherwise it will no longer be functional. If the battery is to be taken out of service for a long period, it should be stored fully charged in a dry room protected from frost.

This manual is also suitable for:

Eje 220 Eje 220r Eje 225r Eje 230 Eje 235

Jungheinrich EJE 225 Operating Instructions Manual

A Correct Use and Application

B Truck Description

C Transport and Commissioning

D Battery - Servicing, Recharging, Replacement

E Operation

Industrial Truck Maintenance

Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement

H Traction Battery

Quick Links

Troubleshooting

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Jungheinrich EJE 225

Summary of Contents for Jungheinrich EJE 225

This manual is also suitable for:

Table of Contents