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

Jungheinrich EJE 222 Operating Instructions Manual

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EJE 222 / 225 / 222r / 225r / 230 / 235
Operating instructions
51650155
12.19
06.18
en-GB
EJE 222
EJE 225
EJE 222r
EJE 225r
EJE 230
EJE 235

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Summary of Contents for Jungheinrich EJE 222

  • Page 1 EJE 222 / 225 / 222r / 225r / 230 / 235 06.18 Operating instructions en-GB 51650155 12.19 EJE 222 EJE 225 EJE 222r EJE 225r EJE 230 EJE 235...

  • Page 3: Declaration Of Conformity

    Declaration of Conformity Manufacturer Jungheinrich AG, 22039 Hamburg, Germany Description Industrial truck Type Option Serial no. Year of manufacture EJE 222 EJE 225 EJE 222r EJE 225r EJE 230 EJE 235 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) Permissible operating conditions for trucks with lithium-ion batteries Proprietor responsibilities Adding attachments and/or accessories Removal of components...
  • Page 8 Integrated modular lithium-ion batteries Notes on lithium-ion batteries Safety regulations for handling lithium-ion batteries Battery types Battery data plate Usability as a Function of the Battery Temperature Exposing the battery Charging the battery Operation Safety Regulations for the Operation of Forklift Trucks Displays and Controls Tiller Charge Status Indicator...
  • Page 9 Restoring the truck to service after decommissioning Safety tests to be performed at intervals and after unusual incidents Final de-commissioning, disposal Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement Maintenance Contents EJE 222/ 225/ 225US Owner Customer Service Maintenance Contents EJE 230/235 Owner...

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

  • 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: Permissible Operating Conditions For Trucks With Lithium-Ion Batteries

    Permissible operating conditions for trucks with lithium-ion batteries Replaceable lithium-ion batteries If equipped with a lithium-ion battery (o), the permissible operating conditions change; see the "Lithium-ion battery 24V - 240 Ah / 360 Ah. operating instructions" Integrated modular lithium-ion batteries The battery is not authorised for use in cold stores with temperatures below -10°C.

  • Page 15: 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 EJE 222 / 225 / 222r / 225r / 230 / 235 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 18: 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 19: Assemblies And Functional Description

    Assemblies and Functional Description Assembly Overview Item Designation Item Designation t Travel switch o Mains plug for integrated battery charger t Battery panel t Key switch t Emergency disconnect o Keypad t Load handler o Transponder reader t Charge status indicator o ISM Online access module o Display unit (2-inch display) t Front panel...

  • Page 20: Protective And Safety Equipment

    Protective and safety equipment Truck contour An enclosed, smooth truck perimeter with rounded edges ensures safe handling of the truck. The wheels are surrounded by a solid skirt offering collision protection. The truck contour must not be changed. Contact the manufacturer’s customer service department, if necessary.

  • Page 21: Functional Description

    Functional Description Electrical system The truck has an electronic traction controller. The truck electrical system operates with a rated operating voltage of 24 V. Drive system An AC three-phase motor actuates the drive wheel via a gearbox. The electronic traction controller ensures smooth speed control of the drive motor and hence smooth starting, powerful acceleration and electrically controlled braking with energy recovery.
  • Page 22 positionCONTROL (o) The "positionCONTROL" option enables comfortable approach of predefined entry and lifted heights and free lift heights for up to three definable pallet types with simple actuation of the raise/lower function. "positionCONTROL" can be activated and deactivated with the display unit menu (o). Before angled entry into a pallet, positionCONTROL must be deactivated as pallets can become damaged in the event of accidental lifting with the automatic function.

  • Page 23: Technical Specifications

    Max. gradeability (5 min rating) 6/20 5/20 with/without rated load Engine Data Designation EJE 222 / 225 / 222r / 225r / 230 / 235 Drive motor, operating mode S2 60 min Lift motor, operating mode S3...

  • Page 24: Dimensions

    Dimensions...
  • Page 25 Designation EJE 222 / EJE 225 Lift Load centre distance for standard fork length Load handler lowered Tiller height in travel position min./max. 750/1237 2) 3) 1351/1423 Wheelbase (M/L) 1737/1802 Overall length (M/L) 587/659 Length including fork shank (M/L) Standard fork length...
  • Page 26 Designation EJE 222r / EJE 225r Lift Load centre distance for standard fork length Load handler lowered Tiller height in travel position min./max. 750/1237 2) 3) 1351/1423 Wheelbase (M/L) Overall length (M/L) 1737/1802 587/659 Length including fork shank (M/L) Standard fork length 1150 Fork width Width across forks...
  • Page 27 Designation EJE 230 / EJE 235 Lift Load centre distance for standard fork length Load handler lowered Tiller height in travel position min./max. 750/1237 2) 3) 1351 Wheelbase 1737 Overall length Length including fork shank Standard fork length 1150 Fork width Width across forks Track width, front Track width, rear...

  • Page 28: Weights

    Weights Designation EJE 222 EJE 225 Truck weight M/L 535/613 Axle load, laden 879/1870 970/2072 front/rear (M) Axle load without load 408/127 408/127 front/rear (M) Designation EJE 222r EJE 225r Truck weight M/L 560/640 Axle load, laden 889/1885 980/2087 front/rear (M)

  • Page 29: Norms

    EN norms Continuous sound pressure level – EJE 222 / 225 / 222r / 225r / 230 / 235: 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 WMT 110 13.56 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 Item Description Truck data plate Capacity Q Attachment point for loading by crane "Cold store"...

  • Page 32: Data Plate

    Data plate Item Model Item Model Rated capacity (kg) Load centre distance (mm) Battery voltage (V) Drive output Net weight w.o. battery (kg) Min./max. battery weight (kg) Option Manufacturer Model QR code Serial number Manufacturer's logo Year of manufacture For queries regarding the truck or when ordering spare parts, always quote the truck serial number (32).

  • Page 33: 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 34 Strap points (21) on the chassis are provided for transporting the truck with crane lifting gear. Lifting the truck by crane Requirements – Park the truck securely, see page 79. Tools and Material Required – Lifting gear – Crane lifting gear Procedure •...

  • Page 35: Transport

    Transport WARNING! Uncontrolled movement during transport Improper fastening of the truck and mast during transport can result in serious accidents. uLoading is only to be carried out by specially trained staff. The specialist personnel must be instructed in the securing of loads on road vehicles and in the use of load- securing equipment.

  • Page 36: 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 37: D Battery - Servicing, Recharging, Replacement

    D Battery - Servicing, Recharging, Replacement Replaceable lead-acid and lithium-ion batteries Notes on Battery Technologies Lithium-ion batteries (o) The trucks may be optionally equipped with a lithium-ion battery. All notes and information concerning lithium-ion batteries can be found in the separate "Lithium-ion battery 24 V - 240 Ah / 360 Ah"...
  • Page 38 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 39: Battery Types

    The use of battery types not listed here must be agreed with the manufacturer. The battery weights can be taken from the battery data plate. Batteries with non insulated terminals must be covered with a non slip insulating mat. EJE 222 / 225 Battery tray M Top battery removal/ side battery removal Voltage Battery type Min.

  • Page 40: 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 41: Charging The Battery

    Charging the battery Information on charging the integrated modular lithium-ion batteries see page 62. The following applies for lead-acid batteries: WARNING! The gases produced during charging can cause explosions The battery produces a mixture of nitrogen and hydrogen (electrolytic gas) during charging.
  • Page 42 1.5.1 Charging the battery with a stationary charger Requirements – The truck is parked securely, see page 79. – Battery exposed, see page 40. – The charging program that matches the battery type is set on the battery charger. Procedure •...
  • Page 43 1.5.2 Charging the battery with the integrated charger (o) DANGER! Risk of electric shock and fire Damaged and unsuitable cables can cause electric shocks and can overheat, resulting in fires. uAlways use mains cables with a maximum length of 30 m. Local regulations must be observed.
  • Page 44 1.5.2.2 Charging the battery Starting to charge with the on-board charger Mains connection Mains voltage: 230 V Mains frequency: 50 Hz The mains cable and mains connector (13) of the battery charger are stowed in a storage compartment in the front panel (15). Charge battery Requirements –...
  • Page 45 Procedure If charging has been interrupted, the full battery capacity will not be available. • Remove the mains connector from the socket and store it in the storage compartment with the cable. • If applicable, place the insulating mat back over the battery. •...
  • Page 46 LED display (43) Green LED (charge status) Charging complete, battery full. (Charge interval, float or compensation charge). Slow flash 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.

  • Page 47: 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 48 1.6.1 Changing the battery from the top Removing the battery Requirements – Park the truck securely, see page 79. – Expose the battery, see page 40. Tools and Material Required – Crane lifting gear Procedure • Disconnect the battery connector from the truck connector. Place the battery cable on the tray so that it cannot be severed when the battery is pulled out.
  • Page 49 Installing the battery Requirements – The truck is parked securely – see page 79. – Battery compartment is open – see page 40. – Battery is correctly attached to the crane lifting gear – see page 48. Procedure • Place the battery cable on the battery tray such that it cannot be severed by the battery during insertion.
  • Page 50 1.6.2 Removing the battery from the 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. Lateral battery removal is optional only. And on the EJE 222r / 225r, the battery can only be removed from the right-hand side.
  • Page 51 Installing the battery Requirements – The truck is parked securely, see page 79. – Battery compartment is freely accessible. Procedure • Place the battery cable on the tray so that it cannot be severed when the battery is inserted. • Ensure that the battery is installed and connected correctly •...

  • Page 52: Integrated Modular Lithium-Ion Batteries

    The truck is optionally fitted with an integrated modular lithium-ion battery. All notes and information concerning lithium-ion batteries can be found in these operating instructions. The Jungheinrich lithium-ion batteries are maintenance-free batteries with rechargeable high-performance energy cells. The batteries' daily operating time can be extended through intermediate charges.

  • Page 53: Safety Regulations For Handling Lithium-Ion Batteries

    Safety regulations for handling lithium-ion 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. 2.2.1 Correct application No hazards are anticipated if the equipment is used correctly.
  • Page 54 Buy-back terms and type of recycling are to be agreed with the manufacturer. 2.2.4 Shipping information The Jungheinrich lithium-ion battery is a hazardous material. The applicable ADR regulations must be observed during transport. ADR = Accord européen relatif au transport international des marchandises Dangereuses par Route If in doubt, contact the manufacturer's customer service department.
  • Page 55 The lithium-ion battery is wear-free. The components are designed to be maintenance-free, and therefore no maintenance intervals are defined for this battery. The battery is continually monitored by the battery management system. 2.2.6 Dangers and information relating to fire in the vicinity of the lithium-ion battery The lithium ion battery may be damaged by a fire in the vicinity of the lithium ion battery.
  • Page 56 2.2.7 Touch voltage hazard WARNING! Hazardous contact voltages only arise in the event of a technical or physical defect. The batteries are normally charged. There is still some residual voltage in a discharged battery. This must be considered as a hazardous contact voltage. With this kind of defect the battery must not be touched and must not come into contact with metal objects see page 53.
  • Page 57 2.2.8 Hazard and Safety Instruction Phrases Hazard and safety instruction phrases are codified hazard and safety instruction phrases for hazardous materials used as part of the globally harmonised system for the grading and identification of chemicals. The following H phrases describe the hazards arising from the battery cells and their contents.

  • Page 58: Battery Types

    Disposal (P500 range) Obtain information on recycling or reuse from the manufacturer or P502 supplier. Battery types Depending on the version, the truck is equipped with different battery types. The following table shows the different battery types. Battery type Rated voltage Number of cells Capacity Lithium ion...

  • Page 59: Battery Data Plate

    Battery data plate The integrated modular lithium-ion battery is an inherent component of the truck and must not be changed by the operator or owner. For this reason, the data plate of the battery is not directly visible. Item Model Item Model Battery type Battery weight (±...
  • Page 60 2.4.1 Safety and warning information Used lithium-ion batteries must be treated as hazardous waste. Lithium-ion batteries marked with the recycling symbol and the sign showing a crossed-out waste bin must not be disposed of with ordinary household waste. Buy-back terms and type of recycling are to be agreed with the manufacturer in accordance with the Battery Directive 2006/66/EG.

  • Page 61: Usability As A Function Of The Battery Temperature

    Usability as a Function of the Battery Temperature Lithium-ion battery Usability temperature Travel and hydraulic functions: -10°C to +55°C 1, 2 – The usable battery capacity and power is reduced at low temperatures. Charging of the lithium-ion battery: – In the event of high temperatures (≥ 50°C), the 0°C to +55°C charging time of the lithium-ion battery is extended due to a reduction in the charge...

  • Page 62: Charging The Battery

    Charging the battery 2.7.1 Safety instructions for charging lithium-ion batteries Only charge the lithium-ion battery with the manufacturer's stationary battery charger SLH 300i. Observe the battery charger operating instructions. WARNING! Warning: hazardous electrical voltage! The charger is an electric component conducting voltages and currents that are hazardous to people.
  • Page 63 NOTICE Intermediate charging of the lithium-ion battery Intermediate charging of the lithium-ion battery is possible, i.e. a battery that is not fully discharged can be charged or partially charged at any time. uThe lithium-ion battery should be fully charged before use. uTo ensure reliable operation of the lithium-ion battery, it must be fully charged at least every 4 weeks with frequent intermediate charging.
  • Page 64 2.7.2 Activating the lithium-ion battery If the lithium-ion battery is not used for several hours, it switches to energy-saving mode to protect against deep discharge. The lithium-ion battery can be reactivated by connecting it to the stationary battery charger, see page 65. 2.7.3 Compensation charging The lithium-ion battery can be partially charged (compensation charging) each time...
  • Page 65 2.7.6 Charging the battery with a stationary charger Only charge the lithium-ion battery with the manufacturer's stationary battery charger SLH 300i. Observe the battery charger operating instructions. Charging the battery Requirements – The truck is parked securely, see page 79. –...
  • Page 66 WARNING! There is a danger of sparks if charging is improperly interrupted Owing to the high charge currents, there is a risk of spark discharge if the charge connector is removed while charging is active. There is a risk of injury and of damage to the electrical contacts.

  • Page 67: 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 68: Displays And Controls

    Displays and Controls 08 09 I D E N T ? Item Control/display Function t Used to brake the truck with maximum force and Emergency disconnect switch to interrupt the truck functions in an emergency. Activating the emergency disconnect switch disables all electrical functions in hazardous situations.
  • Page 69 Item Control/display Function 2-inch display unit with o Display for: soft keys – Battery charge status – Battery capacity – Service hours – Travel program – Warning indicators – Event messages Selection of – Travel program – Options Replaces the key switch –...

  • Page 70: Tiller

    Tiller EJE 222 / 225 / 230 / 235...
  • Page 71 Item Control/display Function Travel switch t Controls travel direction and travel speed. t Safety feature, drive direction travel only: Collision safety switch When applied the truck travels for approx. 3 seconds in the load direction. The parking brake then applies. The truck remains switched off until the travel switch is set to neutral.
  • Page 72 EJE 222r / 225r...
  • Page 73 Item Control/display Function Travel switch t Controls travel direction and travel speed. t Safety feature, drive direction travel only: Collision safety switch When applied the truck travels for approx. 3 seconds in the load direction. The parking brake then applies. The truck remains switched off until the travel switch is set to neutral.

  • Page 74: Charge Status Indicator

    Charge Status Indicator After the truck has been started, the charge status of the battery is shown. The LED (80) colours represent the following conditions: LED colour Charge status Green 40 - 100% Orange 30 - 40 % Green/orange 20 - 30 % flashes 1 Hz 0 - 20 % If the LED is lit red, load can no longer be lifted.

  • Page 75: Starting Up The Truck

    Starting up the truck Checks and operations to be performed before starting daily operation WARNING! Any damage and other defects to the truck can result in accidents. If damage or other truck defects are discovered during the following checks, the truck must be taken out of service until it has been repaired.

  • Page 76: Preparing The Truck For Operation

    Preparing the truck for operation On the EJE 222r / 225r, you should check that the load handler is lowered when establishing operational readiness – see page 93. If the load handler is not fully lowered, it can tilt slightly when raised. I D E N T ?
  • Page 77 Switching on the truck Requirements – Checks and operations before starting daily work performed, see page 75. Procedure • Pull the emergency disconnect switch (7) to unlock it. • Switch on the truck; to do this • Insert the key in the key switch (14) and turn it as far to the right as it will go. •...

  • Page 78: 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 79: 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 89.
  • Page 80 Parking the truck securely Procedure • Park the truck on a level surface. • Fully lower the load handler (8), see page 93. • Using the tiller (12), turn the drive wheel to the straight-ahead position. • Switch off the truck; to do this: •...

  • Page 81: Industrial Truck Operation

    Industrial Truck Operation Safety regulations for truck operation Travel routes and work areas Only use lanes and routes specifically designated for traffic. Unauthorised third parties must stay away from work areas. The load may only be stored in the designated locations. The truck must only be operated in work areas with sufficient lighting to avoid danger to personnel and materials.
  • Page 82 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 83: 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 84 Pressing the emergency disconnect switch Procedure • Press the emergency disconnect switch (7). All electrical functions are deactivated. The truck brakes to a halt. Press the Emergency Disconnect switch on in emergencies. Do not use the emergency disconnect switch as a service brake; otherwise, wear of the drive wheel will increase significantly.

  • Page 85: 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 86: Travel

    Travel Trucks can be equipped with an optional foot protection tiller. In this case, the travel speed is reduced in the upper range (o) of the travel zone F, see page 21. Requirements – Truck prepared for operation, see page 75 Procedure •...

  • Page 87: Changing Direction During Travel

    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 88: Slow Travel

    Slow travel CAUTION! The driver must be particularly careful when applying the “slow travel” button (75). The brake is only activated when the "slow travel" button is released. uIn hazardous situations, brake by immediately releasing the slow travel button (75) or the travel switch (5).

  • Page 89: Steering

    Steering Procedure • Move the tiller (12) to the left or right. The truck is steered in the required direction. Brakes CAUTION! uIn hazardous situations, swing the tiller to the brake position or press the emergency disconnect switch. Braking types The brake pattern of the truck depends largely on the travel-lane conditions.
  • Page 90 Regenerative braking Procedure • If the travel switch is set to 0, the truck automatically brakes regeneratively. The truck brakes to a halt regeneratively via the coasting brake. The brake is then applied. When braking regeneratively, energy is returned to the battery, ensuring a longer service time.

  • Page 91: Raising Or Lowering The Load Handler

    Raising or Lowering the Load Handler 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 92 4.9.3 Raising the ramp lift EJE 222r / 225r Requirements – Truck operational, see page 76. Procedure • Press the “ramp lift raise” button (79) 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 93: Lifting, Transporting And Depositing Loads

    4.10 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 94 4.10.1 Raising a load Picking up the load units Requirements – Load unit correctly palletised. – Load weight matches the truck's capacity. – Fork arms evenly loaded for heavy loads. Procedure • Drive the truck carefully up to the pallet. •...
  • Page 95 4.10.2 Raising the load with ramp lift EJE 222r / 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 97 4.10.3 Transporting a load Transporting Load Units Requirements – Load raised correctly. – Good 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 98 4.10.4 Depositing a load Depositing load units NOTICE 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 – Warehouse location suitable for storing the load. Procedure •...
  • Page 99 4.10.5 Depositing the load with ramp lift EJE 222r / 225r...
  • Page 100 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 • Drive carefully up to the storage location. •...
  • Page 101 4.10.6 Lifting or lowering the load handler with the automatic lifting/lowering function - positionCONTROL (o) WARNING! Risk of accidents while lifting with the automatic lifting function Damage can occur from the use of the automatic lifting function in the hazardous area of the truck, since this function cannot be cancelled by releasing a control.
  • Page 102 Requirements – Truck operational, see page 76. Raising the load handler Procedure • Briefly press the "Raise load handler" button (77). The load handler is raised continuously up to the free lift height. Lowering the load handler Procedure • Briefly press the "Lower load handler" button (78). The load handler is lowered continuously down to the lifted height or the lowering limit.

  • Page 103: 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 104: Lithium-Ion Battery Fault

    Lithium-ion battery fault If any faults are found in the battery or the Jungheinrich charger, contact the manufacturer's customer service department immediately. The operating company must not carry out any remedial work on its own. Independent attempts to tamper with or repair the battery may invalidate the warranty.

  • Page 105: Operating The Truck Without Its Own Drive System

    Operating the truck without its own drive system WARNING! Accidental truck movement When the brakes are deactivated, the truck must be parked on a level surface, as the brakes are no longer effective. uDo not install or remove the brake on slopes or inclines. uThe brake may only be installed or removed by the manufacturer's customer service department.

  • Page 106: Optional Equipment

    Optional equipment 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 109. Battery type Displays the set battery type or set battery (characteristics) characteristic curve 1 = Maintenance-free gel/dry-cell battery...
  • Page 107 7.1.1 Information field Any event messages are shown in the left section of the information line (82). The right section of the information line shows the truck speed in km/h or mph. 7.1.2 Button allocation of the display unit (o) 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.
  • Page 108 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 109: Symbol Meaning

    7.1.3 Symbols in the display Any number of pictograms can be displayed in the pictogram field (84). 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 110 Symbol Meaning Colour Function Support arm lift Yellow Illuminates if the "lower support arms" lowering limit button is pressed when the lowering limit of the support arm lift has been reached. Charging Green Battery charge display (on-board charger only): – Flashing: Charging in progress –...

  • Page 111: 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. I D E N T ? Item Description Display unit (EasyAccess Softkey): –...

  • Page 112: 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 113 7.4.1 Activating the keypad Procedure • Release emergency disconnect switch, see page 83. • Enter the default code 1-2-3-4 using the keys below the display unit (68). The truck is switched on. • Press the key below the "Settings" symbol (90). •...
  • Page 114 7.4.2 Activating the transponder reader Procedure • Release emergency disconnect switch, see page 83. • Enter the default code 1-2-3-4 using the keys below the display unit (68). The truck is switched on. • Press the key below the "Settings" symbol (90).

  • Page 115: Using The Display

    Using the Display: 7.5.1 Switch on the truck with the access code. Procedure • Release emergency disconnect switch, see page 83. • Enter the access code with the buttons below the display (68). The truck is switched on. 7.5.2 Switching off the truck Procedure •...
  • Page 116 7.5.3 Changing the Set-up Code Requirements – The truck is switched on, see page 120. Procedure • Press the key below the "Settings" symbol (90). • Press the key below the "Change set- up code" symbol (91). • Enter the set-up code using the keys below the display unit (68).
  • Page 117 7.5.4 Adding a new access code Requirements – The truck is switched on, see page 120. Procedure • Press the key below the "Settings" symbol (90). • Press the key below the "Edit access code" symbol (96). The set-up code is requested. •...
  • Page 118 7.5.5 Deleting an access code Requirements – The truck is switched on, see page 120. Procedure • Press the key below the "Settings" symbol (90). • Press the key below the "Edit access code" symbol (96). The set-up code is requested. •...
  • Page 119 7.5.6 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 120: Using The Keypad

    Using the Keypad 7.6.1 Switch on the truck with the access code. Procedure • Release the emergency disconnect switch, see page 83. • Enter the access code with the keypad (71). The truck is switched on. Procedure • Press the key under the "Switch off" symbol (95) in the display unit. •...
  • Page 121 7.6.3 Changing the Set-up Code Requirements – The truck is switched on, see page 120. Procedure • Press the key below the "Settings" symbol (90). • Press the key below the "Change set- up code" symbol (91). • Enter the set-up code using the keypad (71).
  • Page 122 7.6.4 Adding a new access code Requirements – The truck is switched on, see page 120. Procedure • Press the key below the "Settings" symbol (90). • Press the key below the "Edit access code" symbol (96). The set-up code is requested. •...
  • Page 123 7.6.5 Deleting an access code Requirements – The truck is switched on, see page 120. Procedure • Press the key below the "Settings" symbol (90). • Press the key below the "Edit access code" symbol (96). The set-up code is requested. •...
  • Page 124 7.6.6 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 125: Operating The Transponder Reader

    Operating the transponder reader NOTICE Take care not to damage the transponder. If the transponder is damaged, the truck cannot be switched on. 7.7.1 Switching on the truck with the transponder Procedure • Release the Emergency Disconnect switch, see page 83. •...
  • Page 126 7.7.3 Changing the Set-up Transponder Requirements – The truck is switched on, see page 125. Procedure • Press the key below the "Settings" symbol (90). • Press the key below the "Change set-up code" symbol (91). • Place the set-up transponder on the transponder reader (69).
  • Page 127 7.7.4 Adding a new transponder Requirements – The truck is switched on, see page 125. Procedure • Press the key below the "Settings" symbol (90). • Press below "Edit transponder" symbol (96). The set-up transponder is requested. • Place the set-up transponder on the transponder reader (69).
  • Page 128 7.7.5 Deleting transponders Requirements – The truck is switched on, see page 125. Procedure • Press the key below the "Settings" symbol (90). • Press the key below the "Edit transponder" symbol (96). set-up transponder requested. • Place the set-up transponder on the transponder reader (69).
  • Page 129 7.7.6 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 130: Access Module (Ism Online)

    Access module (ISM Online) *If equipped with ISM Online access module, see "ISM Online access module" operating instructions. Parameters The default settings can be changed by the manufacturer's customer service department. For supplied batteries, the correct battery parameter is set ex works.

  • Page 131: F Industrial Truck Maintenance

    (www.jungheinrich.de/spare-parts-search) by entering the serial number. The serial number can be found on the data plate, see page 32. 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 151).
  • Page 132 Exception: Operating companies should only make changes or have changes made to powered industrial trucks if the manufacturer is no longer operating in the field and there is no successor to the business; operating companies must however: – Ensure that the changes to be made are planned, tested and performed by a specialist engineer in industrial trucks taking safety into account.

  • Page 133: Maintenance Safety Regulations

    Maintenance Safety Regulations Maintenance personnel The truck should only be serviced and repaired by the manufacturer's specialist customer service personnel who have been trained to do this. We therefore recommend that you enter into a maintenance contract with the manufacturer’s local sales office.

  • Page 134: Consumables And Used Parts

    Consumables and used parts CAUTION! Consumables and used parts are an environmental hazard Used parts and consumables must be disposed of in accordance with the applicable environmental-protection regulations. Oil changes should be carried out by the manufacturer's customer service department, whose staff are specially trained for this task.
  • Page 135 NOTICE Testing and replacing hydraulic hoses Hydraulic hoses can become brittle through age and must be checked at regular intervals. The operating conditions of the truck have a considerable impact on the ageing of the hydraulic hoses. uHydraulic hoses must be checked at least 1x per year and replaced if necessary. uIf the operating conditions become more arduous, the inspection intervals must be reduced accordingly.

  • Page 136: 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 marked containers.
  • Page 137 CAUTION! Consumables and used parts are an environmental hazard Used parts and consumables must be disposed of in accordance with the applicable environmental-protection regulations. Oil changes should be carried out by the manufacturer's customer service department, whose staff are specially trained for this task.

  • Page 138: Lubrication Schedule

    Lubrication Schedule The truck is equipped with lubrication-free bushes. As such, no lubrication is required as part of maintenance. k Cold store application Hydraulic-oil filler plug b Transmission oil filling...

  • Page 139: Consumables

    1:1 ratio. *The trucks are factory-equipped with a special hydraulic oil (the Jungheinrich hydraulic oil with a blue colouration) and the cold store hydraulic oil (red colouration). The Jungheinrich hydraulic oil is available only from the Jungheinrich service department. The Jungheinrich hydraulic...

  • Page 140: Maintenance And Repairs

    Maintenance and repairs Preparing the truck for maintenance and repairs Procedure • Park the truck securely, see page 79. • Disconnect the battery to prevent the truck from being switched on accidentally. 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.

  • Page 141: Front Panel Disassembly And Assembly

    Front panel disassembly and assembly Removing the covers Requirements – Truck prepared for maintenance and repair work, see page 140. Tools and Material Required – Allen key, size 13 (7 Nm) Procedure • Remove the M8 hex. bolt with width across flats 13 (7 Nm) (101) from the front panel (15).

  • Page 142: Cleaning

    Cleaning 5.4.1 Cleaning the truck The truck may only be cleaned in the designated locations, which adhere to the stipulations of the country of use. 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.
  • Page 143 5.4.2 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 144: Check Wheel Attachment And Wear

    Check wheel attachment and wear Replace the wheels if the wear limit (106) has been reached. The drive wheel must only be replaced by authorised service personnel. The wheel nuts on the drive wheel must be re-tightened in accordance with the maintenance intervals indicated in the maintenance checklist, see page 151.

  • Page 145: Checking The Hydraulic Oil Level

    Checking the hydraulic oil level Checking the oil level Requirements – Lower the load handler. – Prepare the truck for maintenance and repairs, see page 140. Procedure • Disassemble the front panel, see page 141. • Check the oil level in the hydraulic reservoir (108). With the load handler lowered, the hydraulic oil level in the hydraulic reservoir must be at roughly the "8"...

  • Page 146: Checking Electrical Fuses

    Checking electrical fuses Checking fuses Requirements – Truck prepared for maintenance and repair work, see page 140. – Front panel removed, see page 141. Procedure • Check the fuse ratings against the table and their condition, and replace if necessary. The fuses have been checked.

  • Page 147: Restoring The Truck To Service After Maintenance And Repairs

    Restoring the truck to service after maintenance and repairs Procedure • Thoroughly clean the truck – see page 142. • Lubricate the truck according to the lubrication diagram, see page 138. • On trucks with lead-acid batteries: Clean the battery, grease the terminals and connect the battery.

  • Page 148: 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 149 NOTICE Full discharge can damage the battery Self-discharge can cause the battery to fully discharge. Full discharge shortens the useful life of the battery. uCharge the battery at least every 2 months. Charge the battery see page 41.

  • Page 150: Restoring The Truck To Service After Decommissioning

    Restoring the truck to service after decommissioning Procedure • Thoroughly clean the truck – see page 138. • Lubricate the truck according to the lubrication diagram, see page 41. • On trucks with lead-acid batteries: Clean the battery, grease the terminals and connect the battery.

  • Page 151: 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 152: Maintenance Contents Eje 222/ 225/ 225Us

    Maintenance Contents EJE 222/ 225/ 225US Issued on: 2019-12-12 08:00 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 Hydraulic operations Correct the hydraulic oil level. Steering Test the tiller return function.
  • Page 153 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 154 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 155 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 On-board charger 35A 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...

  • Page 156: Customer Service

    Customer Service In accordance with the EJE 222/ 225/ 225US service interval, to be performed every 1000 service hours, but at least once a year. 1.2.1 Maintenance contents 1.2.1.1 Standard equipment Brakes Test the brake with the tiller in the maximum vertical and horizontal positions.
  • Page 157 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 158 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 159 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 160 On-board charger 35A Battery charger The mains plug and mains cable for damage The function of the fan and for damage The secure seating of the cables and electrical connections and for damage Hinged frame Chassis/structure The function and attachment of the folding frame and its stop and for damage Lead-acid battery, international Power supply The secure seating of the battery, battery cables and cell connectors and for damage...
  • Page 161 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 Hydraulic oil filter 2000 Transmission oil 10000 1.2.3.2 Optional equipment...

  • Page 162: Maintenance Contents Eje

    Maintenance Contents EJE 230/235 Issued on: 2019-12-12 08:00 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 Hydraulic operations Correct the hydraulic oil level. Steering Test the tiller return function.
  • Page 163 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 164 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 165 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 On-board charger 35A 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...

  • Page 166: Customer Service

    Customer Service In accordance with the EJE 230/235 service interval, to be performed every 1000 service hours, but at least once a year. 2.2.1 Maintenance contents 2.2.1.1 Standard equipment Brakes Test the brake with the tiller in the maximum vertical and horizontal positions. Electrical system Test the contactors and/or relays.
  • Page 167 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. 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 168 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 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 169 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 170 On-board charger 35A Battery charger The mains plug and mains cable for damage The function of the fan and for damage The secure seating of the cables and electrical connections and for damage Hinged frame Chassis/structure The function and attachment of the folding frame and its stop and for damage Lead-acid battery, international Power supply The secure seating of the battery, battery cables and cell connectors and for damage...
  • Page 171 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 Hydraulic oil filter 2000 Transmission oil 10000 2.2.3.2 Optional equipment...

This manual is also suitable for:

Eje 225Eje 222rEje 225rEje 230Eje 235

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