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

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EJD 220
Operating instructions
51132781
04.19
01.10
en-GB
EJD 220

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Summary of Contents for Jungheinrich EJD 220

  • Page 1 EJD 220 01.10 Operating instructions en-GB 51132781 04.19 EJD 220...
  • Page 3 Declaration of Conformity Manufacturer Jungheinrich AG, 22039 Hamburg, Germany Description Industrial truck Type Option Serial no. Year of manufacture EJD 220 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 Battery removal and installation Lateral battery removal Operation Safety Regulations for the Operation of Forklift Trucks Displays and Controls Battery discharge monitor Battery discharge indicator Preparing the Truck for Operation Checks and Operations to Be Performed Before Starting Daily Work Preparing the truck for operation Checks and operations to be carried out when the truck is operational Parking the truck securely...
  • Page 9 Action to be taken during decommissioning Restoring the truck to service after decommissioning Safety tests to be performed at intervals and after unusual incidents Final de-commissioning, disposal Human vibration measurement Maintenance and Inspection Maintenance Contents EJD 220 Owner Customer Service...
  • Page 11 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 13: 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 14: Approved Application Conditions

    Approved application conditions – Operation in industrial and commercial environments. – Operation only on secure, level surfaces with sufficient capacity. – Do not exceed the permissible surface and spot load limits on the travel routes. – Operation only on routes that are visible and approved by the operating company. –...

  • Page 15: 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 16: 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 17: B Truck Description

    B Truck Description Application The EJD 220 is a three-wheel, electric tiller-operated pallet truck with a steered drive wheel and coupling unit It is designed to be used on level surfaces for lifting, stacking and transporting goods. For transportation, two pallets can be stacked on top of each other. Open bottom pallets or roll cages can be lifted.

  • Page 19: 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 20: Assemblies And Functional Description

    Assemblies and Functional Description Assembly Overview...
  • Page 21 Item Description Item Description t Mast 14 t Key switch t Protective screen panel o CanCode o Protective grille o ISM access module (for cold-store application) o Keypad t Battery panel o Transponder reader t Collision safety switch 15 t Support wheel t Travel switch 16 t Drive wheel 10 t Slow-travel button...

  • Page 22: 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 strut forces the tiller up into the brake position.
  • Page 23 Hydraulic System Lifting and lowering are activated via the lift and lower buttons. Pressing the lifting button starts the pump unit, supplying hydraulic oil from the oil reservoir to the lift cylinder. With the two-stage Duplex mast (ZZ) (o) or three-stage telescopic mast (DZ) (o) a short, centre-mounted free lift cylinder initially lifts the load handler (free lift) without changing the overall height of the truck.
  • Page 24 Mast The high strength steel sections are narrow, enabling excellent visibility of the load handler. The lift rails and the load handler run on permanently-lubricated and hence maintenance-free angled rollers. Load backrest (o) A load backrest is recommended as an additional protective mechanism to move low or small item loads above the mast protection frame or grille (o).

  • Page 25: Technical Specifications

    Technical Specifications The technical specifications comply with the German "Industrial Truck Data Sheet" Guidelines. Technical modifications and additions reserved. Performance data EJD 220 Q Rated capacity 2000 1000 Capacity for mast lift Capacity for support arm lift 2000 D Load centre distance Travel speed 6.0 / 6.0...

  • Page 26: Dimensions

    Dimensions...
  • Page 27 Model EJD 220 Load distance 1) Wheel base 1) 4) 1617 Lift 5) 1660 Initial lift h13 Lowered height h14 Tiller height in the travel position min./max. 711 / 1320 Length 4) 2022 Fork length including fork shank 4) b1/2 Overall width (drive)

  • Page 28: Weights

    Weights Net weight incl. battery M/L 937 / 1032 Axle loading, laden 1120 / 1825 front/rear + battery 1160 / 1872 Axle loading, unladen 665 / 280 front/rear + battery 732 /300 Battery weight 220 / 288 Tyre type Tyre size, drive 230 x 65 Load section tyre size (single / tandem) 85 x 95 / 85 x 75...

  • Page 29: En Norms

    EN norms Continuous sound pressure level – EJD 220: ≤ 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.

  • Page 30: Specifications According To Red Guideline (Radio Equipment Directive) For Radio Units

    Specifications according to RED guideline (Radio Equipment Directive) for radio units The table contains any components installed according to the European Directive 2014/53/EU. The table shows the affected frequency range and the emitted transmission power for each component. Component Frequency range Transmission power Radio module (ISM Online) 433,05 - 434,79 MHz...

  • 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...
  • Page 32 Item Description Prohibition plate: "Do not step under the load handler" Attachment points for loading by crane (with ZZ mast in the middle) Capacity plate Capacity plate for stacking, transport and double-deck operations Prohibition plate: "Do not reach through the mast" Serial number Prohibition plate: "No passengers"...

  • Page 33: Data Plate

    Data plate The illustration shows the standard version for EU member states. The data plate may differ in other countries. Item Description Item Description Type Year of manufacture Serial number Load centre distance (mm) Rated capacity (kg) Nominal power Battery voltage (V) Min./max.

  • Page 34: Truck Capacity Plate

    Truck capacity plate The capacity plate (22) indicates the maximum capacity Q (in kg) for a given load centre distance D (in mm) and corresponding lift height H (in mm) for the truck when raising a load. Example of how to calculate the maximum capacity: The maximum capacity is Q1 at a load centre G within the load centre distance D1 and a lift height up to HH1.
  • Page 35 Load centre distance The load centre distance D of the load handler is specified as the horizontal distance from the front face and the vertical distance from the upper edge of the load handler. The capacity plate for standard load handlers specifies valid load centre distances of 500 mm, 600 mm and 700 mm.
  • Page 36 5.3.1 Example of Use of Capacity Plate (575 mm) 1150 mm SERIAL NO. 3600 3200 1050 1050 2900 1200 1200 Example load (palletised): – several cardboard boxes of the same size and same weight – Load height: 800 mm – Load length: 1150 mm –...

  • Page 37: Wind Loads

    Wind loads Wind forces can affect the stability of a truck when lifting, lowering and transporting loads with large surface areas. Light loads must be especially secured when they are subjected to wind forces. This will prevent the load from sliding or falling. Stop the truck in both cases.

  • Page 38: Capacity Plate For Stacking, Transport And Double-Deck Operations

    Capacity Plate for Stacking, Transport and Double-Deck Operations CAUTION! Risk to operational stability In order not to jeopardize the operational stability, pay attention to the weight when transporting two pallets so that the truck does not tip over. uIn order not to jeopardize the operational stability, the heavier pallet should always be transported underneath.

  • Page 39: 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 40 Lifting the truck by crane Requirements – Park the truck securely, see page 70. – Remove any mast guards. Tools and Material Required – Lifting gear – Crane lifting gear Procedure • Secure the lifting slings to the strap points (21). The truck can now be lifted by crane.

  • Page 41: 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 42: 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 43: D Battery - Servicing, Recharging, Replacement

    D Battery - Servicing, Recharging, Replacement 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. Fire Protection Do not smoke and avoid naked flames when handling batteries.
  • Page 44 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 45: 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: Battery type Capacity (Ah) Min. weight Max. dimensions (kg) (mm) 24 V battery XFC 158 624X212X628 24 V battery 2 PzV 200...

  • Page 46: 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 47: 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 48: Charging The Battery With A Stationary Charger

    Charging the battery with a stationary charger Charging the battery Requirements – Expose the battery, see page 44. Procedure • Disconnect the battery connector (46) from the truck connector. • Connect the battery connector (46) to the charging cable (47) of the stationary charger.

  • Page 49: Charging The Battery With An On-Board Charger (O)

    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 50 4.2.1 Setting the charging characteristics (ELG 2430) The factory setting for trucks without a battery is the 0 position. A battery discharge indicator, a charge/discharge indicator, a CanDis or a bipolar LED can be attached to the connector (49). CAUTION! uRemove the mains connector before setting the respective charging curve.
  • Page 51 Wet cell battery: PzM with pulse characteristic 180 - 400 Ah Wet cell battery: PzS with pulse characteristic 200 - 414 Ah Jungheinrich 100 - 300 Ah NOTICE uAll other switch positions (48) block the battery charger, and the battery is not charged.
  • Page 52 4.2.2 Setting the charging characteristics (ELH 2415 / 2425 / 2435) The charging characteristics are set via parameter 1388 of the truck software. The setting is made by the manufacturer's customer service department.
  • Page 53 Flashing sequence/charging curve assignment (ELH 2415/2425/2435) Flashing Charging curves (characteristics) sequence 2415 2425 2435 Truck without battery PzS 100 - 300 Ah PzM to 179 Ah Pulse characteristic PzS 200 - 400 Ah PzM 180 - 400Ah PzV 100 - 150 Ah PzV 151 - 200 Ah PzV 201 - 300 Ah PzV 301 - 330 Ah...
  • Page 54 4.2.3 Charging the battery Starting to charge with the on-board charger – ELG mains connection Mains supply: 230 V / 110 V (+10/-15%) Mains frequency: 50 Hz / 60 Hz The mains cable and mains connector (51) of the charger are contained in the battery compartment with their storage compartment (50) .
  • Page 55 Completing battery charging, restoring the truck to operation NOTICE If charging has been interrupted, the full battery capacity will not be available. Requirements – The battery is fully charged. Procedure • Remove the mains connector (51) from the mains socket and store it along with the cable in the storage compartment (50).
  • Page 56 LED display (52) 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 57: 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 58: Lateral Battery Removal

    Lateral battery removal 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. Removing the battery Requirements – Truck parked securely, see page 70 –...

  • Page 61: 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 62 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 63: Displays And Controls

    Displays and Controls 13, 62 14, 64...
  • Page 64 Item Control/display EJD 220 Function Slow-travel button Pressing the slow-travel button reduces the travel speed and acceleration. If the tiller is in the brake zone, pressing this button overrides the brake function and the truck can be operated at slow speed.
  • Page 65 Item Control/display EJD 220 Function Support-arm lowering Lowers the support arms at a button constant speed. Fork lowering button Lowers the forks. The lowering speed can be infinitely controlled by the stroke of the button (8 mm). Warning signal button Issues a warning signal.
  • Page 66 Item Control/display EJD 220 Function Keypad Replaces the key switch – Provided only as a supplement to the display unit – Truck release by entering set-up and access codes Transponder reader Replaces the key switch – Provided only as a supplement to the display unit –...

  • Page 67: Battery Discharge Monitor

    Battery discharge monitor The standard setting for the battery discharge indicator / discharge monitor is based on standard batteries. When using maintenance-free or special batteries, the display and cut-out points of the battery discharge monitor must be set by manufacturer's service department.

  • Page 68: 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 (66) 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 69: Preparing The Truck For Operation

    Preparing the Truck for Operation Checks and Operations to Be Performed Before Starting Daily Work WARNING! Damage and other truck or attachment (optional equipment) defects can result in accidents. 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 70: 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 (18) to unlock it. • To switch on the truck: •...

  • Page 71: 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 72: Parking The Truck Securely

    Parking the truck securely WARNING! An unsecured truck can cause accidents Do not leave an unsecured truck. uPark the truck securely when leaving it. uException: If the operator intends to remain in the immediate vicinity and is leaving the truck for only a short while, the applied parking brake is sufficient to hold the truck, see page 81.

  • 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 15% 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 (18). 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 (18) 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 oReduced speed when the load handler is fully loweredI When the load handler is fully lowered the truck can only travel at reduced speed. The load handler must be raised in order to use the maximum available speed.
  • Page 80 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 81: 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 82: Brakes

    Brakes WARNING! Accident risk while braking The truck’s braking response depends largely on the floor condition and the type of surface. The truck’s braking distance increases when the ground is wet or dirty. uThe operator must be aware of floor conditions and take them into account when braking.
  • Page 83 4.7.3 Inversion braking Procedure • Set the travel switch (9) to the opposite direction while travelling, see page 78. The truck brakes regeneratively until it starts to move in the opposite direction. 4.7.4 Parking brake The mechanical brake applies automatically when the truck comes to rest.

  • Page 84: 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 85 4.8.1 Raising the load handler Requirements – Prepare the truck for operation, see page 68. Procedure Press the "Raise load handler" button (56) until you reach the desired lift height. NOTICE Risk of material damage to the hydraulic unit. Once you have reached the mechanical limit position of the load handler do not press the "raise load handler"...
  • Page 86 Use as an elevated work table The raised load handler can be used as an elevated work table when the truck is switched off, see page 94. 4.8.2 Lowering the load handler Requirements – Prepare the truck for operation, see page 68. Procedure •...

  • Page 87: Lifting, Transporting And Depositing Loads

    Lifting, transporting and depositing loads WARNING! Risk of accident when the centre of gravity of the load is outside of the load centre distance If the centre of gravity G of a raised load lies outside the load centre distance D specified for the load handler in the horizontal or vertical planes, under unfavourable conditions the raised load and also the truck can tip over while working.
  • Page 88 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 Transporting a load Requirements – Load picked up correctly. – Mast lowered for proper transport (approx. 150 - 500 mm above the ground). Do not travel with a raised load (>500 mm). In double decker mode: Load handler lowered as far as possible but without touching the lower load, see page 92.
  • Page 91 4.9.3 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 92 4.9.4 Lifting two palletised loads CAUTION! Risk to operational stability In order not to jeopardize the operational stability, pay attention to the weight when transporting two pallets so that the truck does not tip over. uIn order not to jeopardize the operational stability, the heavier pallet should always be transported underneath.
  • Page 93 The additional pallet stop allows double pallets to be stacked without the subsequent need to align the pallets on top of each other.
  • Page 94 4.9.5 Transporting two palletised loads above each other CAUTION! Risk to operational stability In order not to jeopardize the operational stability, pay attention to the weight when transporting two pallets so that the truck does not tip over. uIn order not to jeopardize the operational stability, the heavier pallet should always be transported underneath.
  • Page 95 4.9.6 Lowering two palletised loads in turn CAUTION! Loads must not be deposited on travel or escape routes, in front of safety mechanisms or plant equipment that must be accessible at all times. Requirements – Storage location suitable for storing the load. Procedure •...

  • Page 96: Use As A Lift Work Table

    4.10 Use as a Lift Work Table The load handler can remain in a raised position to be used as a lift work table when the truck is switched off, provided the operator is close to the truck. Immediate vicinity of the truck is when the operator is able to respond to malfunctions or attempts to use the truck by unauthorised persons immediately.

  • 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 73 Key switch in position "O" Set the key switch to position "I" Battery charge too low Check battery charge and charge the battery if necessary...
  • Page 99 Possible cause Actions Tiller not in brake position when truck Set the tiller to the top or bottom brake zone, see page 76 switched on (for CanDis (o) or the display unit (2-inch display) (o), event message E0914 appears) Travel switch actuated for more than Follow the operating sequence: 0.5 seconds with the tiller folded up, 1st Swivel the tiller into the travel zone (F)

  • Page 100: 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 175 Battery discharge monitor has Charge the battery, see page 45 switched off Faulty fuse Check the fuses, see page 179...

  • Page 101: 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 102. Release and activate the drive wheel brake WARNING! Accidental truck movement...
  • Page 102 Activating the brake Procedure • Use wedges to prevent the truck from moving. • Remove the two M5x16 screws (69) from the brake (70). CAUTION! Open covers can cause injury and accidents uThe covers (battery cover, side panels, drive compartment cover etc.) must be closed during operation.

  • Page 103: Load Handler Emergency Lowering

    Load handler emergency lowering WARNING! Load handler emergency lowering uInstruct other people to move out of the hazardous area of the truck during emergency lowering. uNever step or stand underneath a raised load handler. uOnly operate the emergency lowering valve when standing next to the truck. uWhen the load handler is in the racking, emergency lowering is not permitted.

  • Page 104: 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 105 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 106: Cancode Keypad (O)

    CanCode Keypad (o) 8.2.1 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 (76) and a o key (78). 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 (73, 74, 75) show the travel program setting.
  • Page 108 8.2.2 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 73. The LED (77) lights up red. • Enter the operator code with the digit keys. When you have entered a valid operator code the LED (77) lights up green, the travel program selected is indicated by the corresponding LEDs (73,74,75) and the truck is switched on.
  • Page 109 8.2.4 Changing the Set-up 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 116. 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 (77) flashes red: Cause Remedy – Switch off the truck, see page 106. – Choose a different master code, see page 107. – New master code is already –...
  • Page 111 8.2.5 Add operator code Requirements – To prepare the truck for operation, see page 106. Procedure • Press the O key (78). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (77) flashes green.
  • Page 112 Error displays adding a user code For the following events the LED (77) flashes red: Cause Remedy – The user code entered is – Switch off the truck, see page 106. 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 8.2.6 Change operator code Requirements – To prepare the truck for operation, see page 106. Procedure • Press the O key (78). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (77) flashes green.
  • Page 114 Error displays changing a user code For the following events the LED (77) flashes red: Cause Remedy – The user code entered is – Switch off the truck, see page 106. 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 8.2.7 Delete individual user codes Requirements – To prepare the truck for operation, see page 106. Procedure • Press the O key (78). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (77) flashes green.
  • Page 116 Error displays deleting individual user codes For the following events the LED (77) flashes red: Cause Remedy – The user code entered is – Switch off the truck, see page 106. 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 8.2.8 Delete all user codes, Requirements – To prepare the truck for operation, see page 106. Procedure • Press the O key (78). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (77) flashes green.
  • Page 118 8.2.9 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 8.2.10 Setting the automatic truck cutout (timeframe) Requirements – To prepare the truck for operation, see page 106. Procedure • Press the O key (78). • Enter the valid master code with the digit keys. When you enter the correct master code the LED (77) flashes green.
  • Page 120 This setting can be changed if required.
  • Page 121 8.2.11 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 (73,74,75) 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 (78). • Enter the valid master code with the digit keys. When you enter the valid master code the green LED (77) 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 (77) flashes red: Cause Remedy – Blocked travel program – Switch off the truck, see page 106. 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! Faulty entry Without CanDis only CanCode internal parameters can be changed. Traction controller parameters can only be changed with CanDis, without CanDis the settings must be performed by the manufacturer's service department. CAUTION! Altering settings for the travel, steering and hydraulic functions can result in accidents Increasing or decreasing the settings for travel, steering and hydraulic functions can...
  • Page 126 The truck is now in travel mode and can be checked. To continue setting, confirm with the Set key (76) again. Saving travel parameters Requirements – Enter all parameters. Procedure • Run "SaveParameters" by pressing 1-2-3-Set. • Confirm with the O key (78).

  • Page 127: Parameters

    Parameters Travel program 1 Function Setting Standard Comments range setting 0256 Acceleration 20 - 200 (0.2 - 2.0 m/s (0.4 m/s 0260 Coasting brake 20 - 330 (0.2 - 3.3 m/s (0.5 m/s 0262 Reversing brake 20 - 160 (0.20 – -1.60 (0.7 m/s 0264 Maximum speed in drive 5 - 60...
  • Page 128 Travel program 3 Function Setting Standard Comments range setting 0288 Acceleration 20 - 200 (0.2 - 2.0 m/s (1.0 m/s 0292 Coasting brake 20 - 330 (0.2 - 3.3 m/s (0.8 m/s 0296 Maximum speed in tiller 5 - 60 Depending on travel direction via travel (0.5 - 6.0 km/h)
  • Page 129 Battery parameters Function Setting Standard Comments range setting 1377 Battery type 0 - 9 0 = PzS (wet cell battery) 1 = EPzS (high performance) 2 = EPzV (maintenance- free gel/dry battery) 3 = US "Flat Plate" battery 4 = US "Pallet Pro" battery 5 = US "Tubular Plate"...
  • Page 130 Hydraulic function lock settings 3 , 4 Function Range Standard Comments setting 2338 Lift Lower 0 - 15 0 = Lifting and lowering always released 1 = Lifting only with authorisation 2 = Lifting only when stationary 3 = Lifting only with authorisation and only when stationary 4 = Lowering only when stationary 5 = Lifting and lowering only with...
  • Page 131 5 , 6 Function Range Standard Comments setting 2338 Lift Lower 0 - 15 13 = Lifting and lowering only with authorisation, lowering only when stationary 14 = Lifting and lowering only when stationary, lowering only with authorisation 15 = Lifting and lowering only with authorisation and only when stationary 5) With authorisation = with tiller in travel range (F) or with "slow travel"...

  • Page 132: 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 133 The parameter is now saved. Testing an altered parameter Requirements – The parameter is now saved. Procedure • Press the O key (78). • Enter the master code. • Enter the four-digit parameter number "1377" and confirm with the Set key. •...

  • Page 134: 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 135 8.6.1 Discharge monitor function The discharge limit has been reached when the "Stop" symbol (82) 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 136: Display Unit (2 Inch Display)

    Display unit (2 inch display) Item Control or Function display Information line Display of event messages, speed and remaining run time Battery capacity display Battery discharge status Symbol field Displays the symbols, see page 137. Battery type Displays the set battery type or set battery (characteristics) characteristic curve 1 = Maintenance-free gel/dry-cell battery...
  • Page 137 8.7.1 Button allocation of the display Key allocation in main menu Symbol Meaning Travel program down: To switch the travel program down Travel program up: To switch the travel program up Settings (o): To change to the menu to administer the codes or transponders Switch off (o): Allows the truck to be switched off Switch off is only available in the display if the truck is switched on with...
  • Page 138 Key allocation in menu for managing codes or transponders (o) Symbol Meaning Change Set-Up Code: To change the set-up code and to activate the keypad or the transponder reader. Edit access code / transponder: To add or delete access codes and transponders. Up selection: To select access codes or transponders.
  • Page 139 8.7.2 Symbols in the display Any number of pictograms can be displayed in the pictogram field (87). Which pictograms are shown in the pictogram field depends on the operating and truck status. Symbol Meaning Colour Function Stop notice Functions deactivated due to truck malfunction Warning yellow...
  • Page 140 Symbol Meaning Colour Function Support arm lift yellow Illuminates if "Lift support arms" button lifting limit pressed if the support arm lift lifting limit has been reached. Support arm lift yellow Illuminates if "Lower support arms" button lowering limit pressed if the support arm lift lowering limit has been reached.

  • Page 141: Keyless Access System

    Keyless Access System The keyless access systems serve as a replacement for the key switch to release the truck. The keyless access system allows an individual code to be allocated to each operator or group of operators. Item Description Display unit (EasyAccess Softkey): –...

  • Page 142: 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 143 8.10.1 Activating the keypad Procedure • Release the emergency disconnect switch, see page 73. • Enter the default code 1-2-3-4 using the keys below the display unit (63). The truck is switched on. • Press the key below the "Settings" symbol (94).
  • Page 144 8.10.2 Activating the transponder reader Procedure • Release the emergency disconnect switch, see page 73. • Enter the default code 1-2-3-4 using the keys below the display unit (63). The truck is switched on. • Press the key below the "Settings" symbol (94).

  • Page 145: Using The Display

    8.11 Using the Display: 8.11.1 Switch on the truck with the access code. Procedure • Release the emergency disconnect switch, see page 73. • Enter the access code with the buttons below the display (63). The truck is switched on. 8.11.2 Switching off the truck Procedure...
  • Page 146 8.11.3 Changing the Set-up Code Requirements – The truck is switched on, see page 148. Procedure • Press the key below the "Settings" symbol (94). • Press the key below the "Change set- up code" symbol (95). • Enter the set-up code using the keys below the display unit (63).
  • Page 147 8.11.4 Adding a new access code Requirements – The truck is switched on, see page 148. Procedure • Press the key below the "Settings" symbol (94). • Press the key below the "Edit access code" symbol (100). The set-up code is requested. •...
  • Page 148 8.11.5 Deleting an access code Requirements – The truck is switched on, see page 148. Procedure • Press the key below the "Settings" symbol (94). • Press the key below the "Edit access code" symbol (100). The set-up code is requested. •...
  • Page 149 8.11.6 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 150: Using The Keypad

    8.12 Using the Keypad 8.12.1 Switch on the truck with the access code. Procedure • Release the emergency disconnect switch, see page 73. • Enter the access code with the keypad (65). The truck is switched on. Procedure • Press the key under the "Switch off" symbol (99) in the display unit. •...
  • Page 151 8.12.3 Changing the Set-up Code Requirements – The truck is switched on, see page 148. Procedure • Press the key below the "Settings" symbol (94). • Press the key below the "Change set- up code" symbol (95). • Enter the set-up code using the keypad (65).
  • Page 152 8.12.4 Adding a new access code Requirements – The truck is switched on, see page 148. Procedure • Press the key below the "Settings" symbol (94). • Press the key below the "Edit access code" symbol (100). The set-up code is requested. •...
  • Page 153 8.12.5 Deleting an access code Requirements – The truck is switched on, see page 148. Procedure • Press the key below the "Settings" symbol (94). • Press the key below the "Edit access code" symbol (100). The set-up code is requested. •...
  • Page 154 8.12.6 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 155: Operating The Transponder Reader

    8.13 Operating the transponder reader NOTICE Take care not to damage the transponder. If the transponder is damaged, the truck cannot be switched on. 8.13.1 Switching on the truck with the transponder Procedure • Release the Emergency Disconnect switch, see page 73. •...
  • Page 156 8.13.3 Changing the Set-up Transponder Requirements – The truck is switched on, see page 153. Procedure • Press the key below the "Settings" symbol (94). • Press the key below the "Change set-up code" symbol (95). • Place the set-up transponder on the transponder reader (93).
  • Page 157 8.13.4 Adding a new transponder Requirements – The truck is switched on, see page 153. Procedure • Press the key below the "Settings" symbol (94). • Press below "Edit transponder" symbol (100). The set-up transponder is requested. • Place the set-up transponder on the transponder reader (93).
  • Page 158 8.13.5 Deleting transponders Requirements – The truck is switched on, see page 153. Procedure • Press the key below the "Settings" symbol (94). • Press the key below the "Edit transponder" symbol (100). set-up transponder requested. • Place the set-up transponder on the transponder reader (93).

  • Page 159: Ism Access Module (O)

    8.13.6 Displaying the Log-in Process The use of the last different transponders is displayed during the log-in process. The last log-in is displayed first. If multiple transponders are logged as being displayable simultaneously, the display area can be moved by scrolling forward or back. Requirements –...

  • Page 161: Industrial Truck Maintenance

    F Industrial Truck Maintenance Operational Safety and Environmental Protection The inspections and maintenance tasks listed in chapter "Maintenance and Inspection" must be performed according to the defined service intervals (see page 185). The manufacturer recommends the replacement of the maintenance parts also listed in chapter "Maintenance and Inspection"...

  • Page 162: 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 163: Working On The Electrical System

    Working on the electrical system WARNING! Electrical current can cause accidents Ensure the electrical system is de-energised before starting work. The capacitors in the control must be completely discharged. The capacitors are fully discharged approx. 10 minutes after disconnecting the electrical system from the battery. Before starting maintenance on the electrical system: uOnly suitably trained electricians may work on the truck's electrical system.

  • Page 164: 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 165: Lift Chains

    Lift Chains WARNING! Risk of accident from non-lubricated and incorrectly cleaned lift chains Lift chains are safety-critical parts. Lift chains must not show signs of serious contamination. Lift chains and pivot pins must always be clean and sufficiently lubricated. uThe lift chains are cleaned by wiping or brushing. Significant contamination can be softened by a paraffin derivative such as petroleum.

  • Page 166: 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 167 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 168: Lubrication Schedule

    Lubrication Schedule 0,55 l g Contact surfaces k Cold Store Application a Transmission oil drain plug Grease nipple Hydraulic oil drain plug Hydraulic oil filler neck b Transmission oil filler neck Transmission oil overflow and dipstick Compound ratio for cold store usage 1:1...

  • Page 169: 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 170: 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 70. •...

  • Page 171: Lifting And Jacking Up The Truck Safely

    Lifting and jacking up the truck safely WARNING! Lifting and jacking up the truck safely In order to raise the truck, the lifting gear must only be secured to the points specially provided for this purpose. You may only work under a raised load handler if it has been secured with a sufficiently strong chain or the fastening bolt.

  • Page 172: Cleaning

    Cleaning 4.3.1 Cleaning the truck 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 173 Cleaning the truck Requirements – Prepare the truck for maintenance and repairs (see page 168). 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 174 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 175: Front Cover Disassembly

    Front cover disassembly Front cover disassembly Requirements – Prepare the truck for maintenance and repairs, see page 168. Tools and Material Required – Allen key size 8 Procedure • Remove the screws (105) with the Allen key. • Lift and remove the front panel (67).

  • Page 176: Drive Panel Disassembly And Assembly

    Drive panel disassembly and assembly The drive panel consists of two halves (68 and 106). Drive panel disassembly Tools and Material Required – Allen key Procedure • Turn the tiller to the right limit position. • Remove 2 screws (107). •...

  • Page 177: Checking The Hydraulic Oil Level

    Checking the hydraulic oil level Check oil level Requirements – Lower the load handler. – Prepare the truck for maintenance and repairs, see page 168. Procedure • Lift off the front panel, see page 173 • Check the oil level in the hydraulic reservoir. There are markings on the hydraulic reservoir.

  • Page 178: Check The Gear Oil Level

    Check the gear oil level Check the gear oil level Requirements – Park the truck securely, see page 70. Tools and Material Required – Oil sump Procedure • Place the oil sump underneath the transmission • Remove the front panel (67), see page 173. •...

  • Page 179: Check Wheel Attachment And Wear

    Check wheel attachment and wear Replace the wheels if the wear limit (108) has been reached. The wheel nuts on the drive wheel must be retightened in accordance with the maintenance intervals indicated in the maintenance checklist, see page 185. Tightening the wheel nuts Requirements –...

  • Page 181: Checking Electrical Fuses

    – Front panel removed, see page 173. Procedure • Check the fuse ratings against the table and replace if necessary. The fuses have been checked. Item Designation To protect EJD 220 Discharge indicator control fuse Electronic system control fuse Solenoid/magnetic brake control fuse Travel/lift fuse 200 A 8) Some values have been reduced from 10 A to 4 A in series trucks built in 2016.

  • Page 182: 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 170. • Lubricate the truck according to the lubrication diagram, see page 166. • Clean the battery, grease the terminals and connect the battery. •...

  • Page 183: 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 184: Restoring The Truck To Service After Decommissioning

    Restoring the truck to service after decommissioning Procedure • Thoroughly clean the truck, see page 170. • Lubricate the truck according to the lubrication schedule, see page 166. • Clean the battery, grease the terminal screws and connect the battery. •...

  • Page 185: 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 187: G Maintenance And Inspection

    G Maintenance and Inspection 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 188: Maintenance Contents Ejd

    Maintenance Contents EJD 220 Issued on: 2019-04-26 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 Lubricate the load chains.
  • Page 189 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 190 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 191 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 192: Customer Service

    Customer Service 1.2.1 Maintenance contents In accordance with the EJD 220 service interval, to be performed every 1000 service hours, but at least once a year. 1.2.1.1 Standard equipment Brakes Measure the air gap of the magnetic brake. Electrical system Test the contactors and/or relays.
  • Page 193 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. Lead-acid battery, international Power supply Clean and grease the battery terminals.
  • Page 194 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 195 Hydraulic operations Mast rollers and their running surfaces for wear and damage The function of the hydraulic system The forks or load handler for wear and damage Tie/plunger rods are uniformly adjusted and for wear and damage Steering Lateral play of the tiller The steering components for play and damage...
  • Page 196 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 197 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 199 Foreword Notes to the operating instructions The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the traction battery. The information is presented in a precise and clear manner. The chapters are arranged by letter and the pages are numbered continuously.
  • Page 200 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 201 Contents Traction battery ............... Correct Use and Application..............Data plate ....................Safety Instructions, Warning Indications and other Notes ....... Lead acid batteries with armour plated cells and liquid electrolyte..Description....................Operation....................Servicing lead-acid batteries with armour plated cells......PzV and PzV-BS lead-acid batteries with sealed armour plated cells..Description....................

  • Page 203: A Traction Battery

    A Traction battery Correct Use and Application This appendix does not apply to trucks with lithium-ion batteries. Further documentation for lithium-ion batteries can be obtained from the supplied documents. 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.
  • Page 204 Safety instructions and warning information...

  • Page 205: 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 206: 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 207 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 Nominal electrolyte density 1.29 kg/l Nominal temperature 30 °C System rated electrolyte level up to "Max" electrolyte level marking Limit temperature 55 °C 1.

  • Page 208: 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 209 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 210 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 211: 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. 4.3.2 Daily Battery cell cross section Top view of a battery cell...
  • Page 212 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 213: 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 214: 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 215 NOTE 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. Always charge the battery with DC current. All DIN 41773 charging procedures are permitted in the format approved by the manufacturer.
  • Page 216 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 217: 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 218: 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 219: 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 220: 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 221: 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 222 NOTE 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. Attach 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 223: 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 224 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 225: Storing The Battery

    Storing the battery NOTE 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.

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