EJE 220/225/230/235/220r/225r 05.

07

Operating instructions en-GB

51040446
04.19

EJE 220
EJE 225
EJE 230
EJE 235
EJE 220r
EJE 225r
2
 Declaration of Conformity

Manufacturer

Jungheinrich AG, 22039 Hamburg, Germany

Description

Industrial truck

Type Option Serial no. Year of

manufacture
EJE 220
EJE 225
EJE 230
EJE 235
EJE 220r
EJE 225r

On behalf of

Date

EU DECLARATION OF CONFORMITY

The undersigned hereby declare that the powered truck described in detail complies
with the current versions of European Directives 2006/42/EG (Machinery Directive)
and 2014/30/EU (Electromagnetic Compatibility - EMC). The manufacturer is
authorised to compile the technical documentation.
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4
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 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.

The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your
truck model.

Our trucks are subject to ongoing development. We reserve the right to alter the
design, equipment and technical features of the system. No guarantee of particular
features of the truck should therefore be assumed from the present operating
instructions.
Safety notices and text mark-ups

Safety instructions and important explanations are indicated by the following

graphics:

DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death.

WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury and even death.

CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury.
NOTICE
Indicates a material hazard. Failure to comply with this instruction may result in
material damage.

Z Used before notices and explanations.

t Indicates standard equipment

o Indicates optional equipment
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 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

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 Contents
.
A Correct Use and Application 11
.
1 General 11
2 Correct application 11
3 Approved application conditions 12
3.1 Internal Operation Combined with Brief External or Cold Store
Operation (t) 13
3.2 Internal Operation in Cold Stores with Cold Store Equipment (o) 13
4 Proprietor responsibilities 14
5 Adding attachments and/or optional equipment 14
.
B Truck Description 15
.
1 Application 15
1.1 Truck models and rated capacity 15
2 Travel direction definition 16
3 Assemblies and Functional Description 17
3.1 Assembly Overview 17
3.2 Functional Description 19
4 Technical Specifications 21
4.1 Performance data 21
4.2 Dimensions 22
4.3 Weights 27
4.4 Tyre type 28
4.5 EN norms 29
4.6 Conditions of use 30
4.7 Electrical Requirements 30
5 Identification Points and Data Plates 31
5.1 Indication Points 31
5.2 Data plate 32
5.3 Truck capacity plate 33
.
C Transport and Commissioning 35
.
1 Lifting by crane 35
2 Transport 37
3 Using the Truck for the First Time 38
.
D Battery - Servicing, Recharging, Replacement 39
.
1 Safety Regulations Governing the Handling of Lead-Acid Batteries 39
2 Battery types 41
3 Exposing the battery 44
4 Charging the battery 45
4.1 Charging the battery with a stationary charger 46
4.2 Charging the battery with an on-board charger (o) 46
5 Battery removal and installation 52
5.1 Changing the battery from the top 53
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5.2 Lateral battery removal 56

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.
E Operation 57
.
1 Safety Regulations for the Operation of Forklift Trucks 57
2 Displays and Controls 59
2.1 EJE 220r / EJE 225r Tiller 65
2.2 Battery discharge indicator 66
2.3 Battery discharge monitor 66
3 Preparing the Truck for Operation 67
3.1 Checks and Operations to Be Performed Before Starting Daily Work 67
3.2 Preparing the truck for operation 68
3.3 Making the EJE 220r / 225r operational 69
3.4 Checks and operations to be carried out when the truck is operational 70
3.5 Parking the truck securely 71
4 Industrial Truck Operation 73
4.1 Safety regulations for truck operation 73
4.2 Emergency Disconnect 75
4.3 Automatic braking 77
4.4 Travel 78
4.5 Slow travel 80
4.6 Steering 81
4.7 Brakes 81
4.8 Load handler raise/lower 83
4.9 Lifting, transporting and depositing loads 88
5 Troubleshooting 97
5.1 Truck does not start 98
5.2 Load cannot be lifted 99
6 Operating the truck without its own drive system 100
6.1 Release and activate the drive wheel brake 100
7 Optional equipment 103
7.1 Emergency operation with service key GF60 103
7.2 Tiller with buttons on both faces 105
7.3 Keypad (CanCode) (o) 106
7.4 Setting the truck parameters with CanCode 125
7.5 Parameters 127
7.6 Setting the Battery Parameters with CanCode 129
7.7 CanDis Display Instrument (o) 131
7.8 Display unit (2 inch display) 133
7.9 General Information about the Use of Keyless Access Systems 138
7.10 Using the Display: 139
7.11 ISM access module (o) 143
.
F Industrial Truck Maintenance 145
.
1 Operational Safety and Environmental Protection 145
2 Maintenance Safety Regulations 146
2.1 Working on the electrical system 147
2.2 Consumables and used parts 147
2.3 Wheels 147
2.4 Hydraulic system 148
3 Lubricants and Lubrication Schedule 150
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3.1 Handling consumables safely 150

3.2 Lubrication Schedule 152
3.3 Consumables 153

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 4 Maintenance and repairs 154
4.1 Preparing the truck for maintenance and repairs 154
4.2 Lifting and jacking up the truck safely 154
4.3 Cleaning 155
4.4 Front cover disassembly 159
4.5 Drive panel disassembly and assembly 160
4.6 Tightening the wheel nuts 161
4.7 Checking the hydraulic oil level 162
4.8 Check the gear oil level 163
4.9 Checking electrical fuses 164
4.10 Restoring the truck to service after maintenance and repairs 166
5 Decommissioning the Industrial Truck 167
5.1 Prior to decommissioning 167
5.2 Action to be taken during decommissioning 167
5.3 Restoring the truck to service after decommissioning 168
6 Safety tests to be performed at intervals and after unusual incidents 169
7 Final de-commissioning, disposal 169
8 Human vibration measurement 169
.
G Maintenance, Inspection and Changing of Maintenance
Parts Requiring Replacement 171
.
1 Maintenance Contents EJE 235 172
1.1 Owner 172
1.2 Customer Service 176
2 Maintenance Contents EJE 220r-225r 182
2.1 Owner 182
2.2 Customer Service 186
3 Maintenance Contents EJE 230 192
3.1 Owner 192
3.2 Customer Service 196
4 Maintenance Contents EJE 220/225 201
4.1 Owner 201
4.2 Customer Service 205
.
H Traction battery 211
.
1 Correct Use and Application 211
2 Data plate 211
3 Safety Instructions, Warning Indications and other Notes 212
4 Lead acid batteries with armour plated cells and liquid electrolyte 213
4.1 Description 213
4.2 Operation 215
4.3 Servicing lead-acid batteries with armour plated cells 218
5 PzV and PzV-BS lead-acid batteries with sealed armour plated cells 220
5.1 Description 220
5.2 Operation 221
5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour
plated cells 224
6 Aquamatik water replenishment system 225
6.1 Water replenishment system design 225
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6.2 Functional Description 226

6.3 Adding water 226
6.4 Water pressure 226

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6.5 Filling time 227
6.6 Water quality 227
6.7 Battery tubing 227
6.8 Operating temperature 227
6.9 Cleaning measures 227
6.10 Service mobile vehicle 227
7 Electrolyte circulation 228
7.1 Functional Description 228
8 Cleaning batteries 230
9 Storing the battery 232
10 Troubleshooting 232
11 Disposal 232

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 A Correct Use and Application
1 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.

2 Correct application
NOTICE
The maximum load and load distance are indicated on the capacity plate and must
not be exceeded.
The load must rest on the load handler or be lifted by an attachment approved by the
manufacturer.
The load must be fully raised, see page 88.

The following operations are in accordance with regulations and are permitted:
– Lifting and lowering of loads.
– Stacking and retrieving loads.
– Transporting lowered loads.
The following operations are prohibited:
– Carrying and lifting passengers.
– Pushing or pulling loads.
– Transverse lifting of long loads.
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3 Approved application conditions

Z The permissible operating conditions change if the truck is equipped with a lithium-
ion battery (o), see the manufacturer's operating instructions.

– Operation in industrial and commercial environments.

– Operation only on secure, level surfaces with sufficient capacity.
– 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.
– Negotiating inclines up to a maximum of 20 %.
– Do not travel across or at an angle on inclines. Travel with the load facing uphill.
– Operation in partially public traffic.

WARNING!
Use under extreme conditions
Using the truck under extreme conditions can result in malfunctions and accidents.
uSpecial equipment and authorisation are required if the truck is to be constantly
used in extreme conditions, especially in dusty or corrosive atmospheres.
uThe truck cannot be used in areas at risk of explosion.
uIn adverse weather conditions (thunder, lightning) the industrial truck must not be
operated outside or in endangered areas.

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 3.1 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.
– Permissible temperature range -10°C to 40°C.
– Secure parking is only permissible at +5°C to 40°C.
– Maximum air humidity 95% non-condensing.
– The application areas can be changed, but in general this should be minimised
due to thawing and possible corrosion.
– Thawing is permissible only if the truck can be subsequently dried thoroughly.
– Do not charge the battery below +5°C.

3.2 Internal Operation in Cold Stores with Cold Store Equipment (o)
In addition to the permissible operating conditions in industrial and commercial
environments, the truck remains primarily in cold stores. The truck should only leave
the cold store briefly to hand over a load.
– Permissible temperature range -28°C to +25°C.
– Maximum air humidity 95% non-condensing.
– Thawing is permissible only if the truck can be subsequently dried thoroughly.
– In cold store areas below -10°C the truck must be operated permanently and
should not be parked securely for more than 15 minutes.
– Do not charge the battery below +5°C.

NOTICE
Battery damage
As the temperature becomes increasingly cold, the battery can be damaged if the
battery charge is low.
uIf the battery charge is low do not use the truck in areas of -28°C to -5°C.
uIf the battery charge is low it is preferable not to use the truck in areas of -5°C to
+5°C.
uCharge the battery, see page 45.
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4 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.
The proprietor must ensure that the industrial truck is used only for the purpose it is
intended for and that danger to life and limb of the user and third parties are
excluded. Furthermore, accident prevention regulations, safety regulations and
operating, servicing and repair guidelines must be followed. The operating company
must ensure that all users have read and understood these operating instructions.

NOTICE
Failure to comply with the operating instructions invalidates the warranty. The same
applies if improper work is carried out on the truck by the customer or third parties
without the permission of the manufacturer.

5 Adding attachments and/or optional equipment

The mounting or installation of additional equipment which affects or enhances the
performance of the industrial truck requires the written permission of the
manufacturer. Local authority approval may also need to be obtained.
Local authority approval however does not constitute the manufacturer’s approval.

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 B Truck Description
1 Application
The EJE 220/225/230/235/220r/225r is designed to transport goods on level
surfaces. It can lift open-bottom pallets or pallets with transverse boards outside
area the load-wheel area, as well as roll cages. The capacity is shown on the
capacity plate, Qmax.
EJE 220r / 225r

The EJE 220r / 225r with ramp lift is particularly suitable for loading and unloading
on ramps. In particular, it can be used for lifting and depositing palletised goods right
up to the pitch bend.

1.1 Truck models and rated capacity

The rated capacity depends on the model. The rated capacity can be derived from
the model name.
EJE220
EJE Model name
2 Series
20 Rated capacity x 100 kg

The rated capacity is not generally the same as the maximum capacity. The capacity
can be found on the capacity plate attached to the truck.
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2 Travel direction definition
The following determinations have been made for travel direction specification:

2 3

Item Travel direction

1 Left
2 Drive direction
3 Load direction
4 Right

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 3 Assemblies and Functional Description

3.1 Assembly Overview

5 6

8 9
10 11
12

13

14

15

16

17 18 17

Description Ite Description

Item
m
5 t Collision safety switch 14 t Key switch
6 t Travel switch o Keypad (CanCode)
7 t Slow-travel button o Key switch (also with second
stage for brake release)
8 t Tiller o ISM access module
9 t Battery panel o Keypad
10 t Emergency disconnect o Transponder reader
11 t Load handler 15 t Front panel
12 o On-board battery charger
24 V / 30 A
(including safety switch)
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 13 t Discharge indicator 16 t Two-section drive panel
o Display instrument (CanDis) 17 t Support wheels
o Display unit (2-inch display) 18 t Drive wheel
t = Standard equipment o = Optional equipment

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 3.2 Functional Description

Safety mechanisms

An enclosed, smooth truck geometry with rounded edges ensures safe handling of
the truck. The wheels are surrounded by a solid skirt.

The long tiller provides a maximum safety distance to the truck. When it is released
and in hazardous situations a gas pressure spring forces the tiller up into the brake
position. The collision safety switch in the tiller head responds to body contact, the
travel direction changes and the truck moves away from the operator.

Activating the Emergency Disconnect switch rapidly cuts out all electrical functions in
hazardous situations.
Emergency stop safety concept

The emergency stop is activated by the traction controller. Each time the truck is
switched on, the system carries out a self-diagnosis. If an error is detected, the truck
automatically brakes to a halt. Indicator lights on the CanDis display instrument (o)
or on the display unit (2-inch display) (o) indicate the emergency stop.

CAUTION!
The truck brakes automatically
If the truck detects that signals which are required have not been received, or if it
detects an error, the system reacts by triggering an emergency stop, either by
braking the truck to a halt or until a valid signal status has been reached.
uRemain at a suitable distance from the truck during operation.

Hydraulic system

Pressing the lifting button starts the pump unit, supplying hydraulic oil from the oil
reservoir to the lift cylinder. Pressing the lifting button raises the load handler at a
constant speed; pressing the lowering button lowers the load handler.
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 Drive system

A fixed AC three-phase motor actuates the drive wheel via a bevel spur gearbox.
The electronic traction controller ensures smooth drive-motor-speed control and
hence smooth starting, powerful acceleration and electrically controlled braking with
energy regeneration. The driver can choose from 3 travel programs depending on
the load and the environment: from high-performance to energy-saving.
Tiller

The driver steers with an ergonomic tiller. All travel and lift operations can be
performed sensitively without having to reach. The tiller has a steer angle of 180°.
Electrical system

The truck has an electronic traction controller. The operating voltage of the truck's
electrical system is 24 volts.
Controls and displays

Ergonomic controls ensure fatigue-free operation for sensitive application of the

travel and hydraulic operations. The battery discharge indicator shows the available
battery capacity. The CanDis display instrument (o) or the display unit (2-inch
display) (o) shows the operator key information such as the service hours, battery
capacity and event messages.

3.2.1 Hourmeter

Z Prepare the truck for operation, see page 68 or see page 106.

Service hours are counted while the truck is operational and one of the following
controls is applied:
– Tiller in travel zone "F", see page 78.
– "Slow travel button", see page 80.
– "Lift" button, see page 84.
– "Lower" button, see page 85.
On the EJE 220r / 225r the service hours are also counted when one of the following
controls is applied:
– "Ramp lift raise" button, see page 86.
– "Ramp lift lower" button, see page 87.
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 4 Technical Specifications

Z The technical specifications comply with the German "Industrial Truck Data Sheet"
Guidelines.
Technical modifications and additions reserved.

4.1 Performance data

Model EJE 220 EJE 225 EJE 230 EJE 235
Q Rated capacity 2000 2500 3000 3500 kg
Load centre distance for
D standard load handler 600 600 600 600 mm
length *)
Travel speed
6.0 / 6.0 6.0 / 6.0 6.0 / 6.0 6.0 / 6.0 km/h
with / without rated load
Lift speed
0.04/0.06 0.03/0.06 0.02/0.06 0.02/0.06 m/s
with / without rated load
Lowering speed
0.05/0.05 0.05/0.05 0.05/0.05 0.05/0.05 m/s
with / without rated load
Max. gradeability (5 min
rating) 10 / 20 8 / 20 6 / 20 6 / 20 %
with / without rated load

*) For longer load handler lengths the load centre of gravity is at the centre of the
load handler

Model EJE 220r EJE 225r

Q Rated capacity 2,000 2500 kg
Load centre distance for
c standard load handler 600 600 mm
length *)
Travel speed
6.0 / 6.0 6.0 / 6.0 km/h
with / without rated load
Lift speed
0.04/0.06 0.03/0.06 m/s
with / without rated load
Lowering speed
0.05/0.05 0.05/0.05 m/s
with / without rated load
Max. gradeability (5 min
rating) 10 / 20 8 / 20 %
with / without rated load

*) For longer load handler lengths the load centre of gravity is at the centre of the
load handler
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4.2 Dimensions

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 Model EJE 220 / 225 / EJE 230
235
D Load centre distance
for standard load handler 600
length *)
Lift m
h3 122
m
Load handler lowered m
h13 85
m
Tiller height in the travel m
h14 805 / 1321 805 / 1321
position min./max. m
Wheelbase (short, long) m
Y* 1353 / 1425 1353 / -
m
Overall length (short, long) m
l1 1763 / 1835 1763 / -
m
Chassis length (short / long) m
l2 613 / 685 613 / -
m
Truck width m
b1 720
m
Overall width of the load m
b5 540
handler m
Track width, front m
b10 508
m
Track width, rear m
b11 368
m
Load handler dimensions m
s/e/l 55 / 172 / 1150
m
Ground clearance, centre m
m2 30
wheelbase m
Load distance m
x 911
m
Turning radius (short / long) m
Wa** 1538 / 1610 1538 / -
m
Working aisle width for
m
Ast** pallets 800x1200 length 2027***/2099*** 2027 / - ***
m
(short/long)
Aisle width for pallet 1000 x m
Ast** 1977**** / 2049**** 1977 / - ****
1200 short (short/long) m
Safety distance m
a 200
m

*) For longer load handler lengths the load centre of gravity is at the centre of the
load handler
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** Load handler raised / lowered +53 mm

***Diagonal in accordance with the German directive "Data Sheets for Industrial
Trucks +204 mm

23
 ***Diagonal in accordance with the German directive "Data Sheets for Industrial
Trucks +386 mm

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 Model EJE 220r EJE 225r
D Load centre distance
for standard load handler 600
length *)
Lift m
h3 122
m
Load handler lowered m
h13 85
m
Tiller height in the travel m
h14 805 / 1321
position min. / max. m
Wheelbase (short, long) m
Y* 1353 / 1425
m
Overall length (short, long) m
l1 1763 / 1835
m
Chassis length (short / long) m
l2 613 / 685
m
Truck width m
b1 720
m
Load handler external m
b5 540
dimensions m
Track width, front m
b10 508
m
Track width, rear m
b11 368
m
Load handler dimensions m
s/e/l 55 / 172 / 1150
m
Ground clearance, centre of m
m2 30
wheelbase m
Load distance m
x 911
m
Turning radius (short / long) m
Wa** 1538 /1610
m
Aisle width for pallets
m
Ast** 800x1200 lengthways (short, 2027 ***/ 2099***
m
long)
Aisle width, pallet 1000x1200 m
Ast** 1977 **** / 2049****
transverse (short, long) m
Safety clearance m
a 200
m

*) For longer load handler lengths the load centre of gravity is at the centre of the
load handler.

** Load handler raised / lowered +53 mm

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***Diagonal in accordance with the German directive "Data Sheets for Industrial
Trucks +204 mm

25
 ***Diagonal in accordance with the German directive "Data Sheets for Industrial
Trucks +386 mm

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 4.3 Weights
Description EJE 220 EJE 225 EJE 230 EJE 235
Truck weight; m / l 540 / 637 550 / 647 580 550 kg
Axle loading, laden
drive axle / 876 / 1664 990 / 2060 1154 / 2426 1300 / 2750 kg
load axle; m
Axle loading, unladen
drive end/ 423 / 117 427 / 123 457 / 123 427 / 123 kg
load end; m

Component EJE 220r EJE 225r

Net weight; 540 550 kg
Axle loading, with load
drive axle / 876 / 1664 990 / 2060 kg
load side:
Axle load without load
drive side / 423 / 117 427 / 123 kg
load side:
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4.4 Tyre type
Description EJE 220 EJE 225 EJE 230 EJE 235
Tyre size, drive end ø230 x 70 ø230 x 70 ø230 x 70 ø230 x 70 mm
Tyre size, load end; ø85x110 / ø85x110 /
- / ø85x85 - / ø85x85 mm
single / tandem ø85x85 ø85x85
Additional wheels
ø100x40 ø100x40 ø100x40 ø100x40 mm
(dimensions)
Wheels, number (drive
end / load end (x = 1x +2 / 2 or 4 1x +2 / 4
driven))

Model EJE 220r EJE 225r

Tyre size, drive side ø230 x 70 ø230 x 70 mm
Tyre size, load side; single ø85x110 ø85x110 mm
Additional wheels
ø100x40 ø100x40 mm
(dimensions)
Wheels, number drive
side / load side (x = 1x +2 / 2 or 4
driven)

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 4.5 EN norms
Continuous sound pressure level

– EJE 220/225/230/235/220r/225r: 70 dB(A)

in accordance with EN 12053 as harmonised with ISO 4871.

Z The continuous sound pressure level is calculated according to standard procedures

and takes into account the sound pressure level when travelling, lifting and idling.
The sound pressure level is measured at the operator's ear.

Electromagnetic compatibility (EMC)

The manufacturer confirms that the truck adheres to the limits for electromagnetic
emissions and resistance as well as the static electricity discharge test in
accordance with EN 12895 as well as the standardised instructions contained
therein.

Z No changes to electric or electronic components or their arrangement may be made

without the written agreement of the manufacturer.

WARNING!
Medical equipment can be damaged by non-ionised radiation
Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless data
transmission) can affect operators' medical equipment (pacemakers, hearing aids
etc.) and result in malfunctions. Consult a doctor or the manufacturer of the medical
equipment to clarify whether it can be used near the industrial truck.
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4.6 Conditions of use

Ambient temperature

– without cold store equipment: operating at -10°C to 40°C, see page 13

– with cold store equipment: operating at -28°C to +25°C, see page 13

Z Special equipment and authorisation are required if the truck is to be used

continually in conditions of extreme temperature or condensing air humidity
fluctuations.

4.7 Electrical Requirements

The manufacturer certifies compliance with the requirements for the design and
manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety -
Electrical Requirements", provided the truck is used according to its purpose.

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 5 Identification Points and Data Plates

Z Warnings and notices such as capacity charts, strap points and data plates must be
legible at all times. Replace if necessary.

5.1 Indication Points

19

20 21

22

23

24

25

26

Item Component
19 Serial number
20 Capacity Qmax
21 Prohibition plate: “No passengers”
22 Truck data plate
23 Strap point for crane lifting
24 Cold store (o)
25 Inspection plaque (o)
26 Model description
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5.2 Data plate
27 28 29 30 31 32

33

34

35

36

37

38

39

Item Model Item Model

27 Type 34 Load centre distance (mm)
28 Serial number 35 Drive output
29 Rated capacity (kg) 36 Min./max. battery weight (kg)
30 Battery voltage (V) 37 Manufacturer
31 Net weight w/o battery (kg) 38 QR code
32 Option 39 Manufacturer's logo
33 Year of manufacture

Z For queries regarding the truck or ordering spare parts, always quote the truck serial
number (28).

QR code

The QR code contains the serial number and product hierarchy of the
truck.
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 5.3 Truck capacity plate

20

The capacity plate (20) gives the maximum load-bearing capacity (Q) of the truck in
kg assuming the load on the load handler is evenly distributed.
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34
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 C Transport and Commissioning
1 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.
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. In each case correct measurements must be
taken and appropriate safety measures applied.

WARNING!
Improper loading by crane can result in accidents
Improper use or use of unsuitable lifting gear can cause the truck to crash when
being loaded by crane.
Prevent the truck from hitting other objects during lifting, and avoid uncontrolled
movements. If necessary, secure the truck with guide ropes.
uThe truck may be loaded only by people who are trained in using lifting
accessories and lifting gear.
uWear personal protective equipment (e.g. safety shoes, safety helmet, hi-vis
jacket, protective gloves) when loading by crane.
uDo not stand under suspended loads.
uDo not walk into or stand in a hazardous area.
uAlways use lifting gear with sufficient capacity (for truck weight, see truck data
plate).
uAlways attach the crane lifting gear to the prescribed attachment points and
prevent them from slipping.
uUse the lifting accessories only in the prescribed load direction.
uCrane lifting gear must be fastened in such a way that it does not come into
contact with any attachments when lifting.
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 CAUTION!
u Trucks with side battery removal (o) can only be raised when the battery is not in
position: strap points are covered by the battery.

Z Strap points (23) on the chassis are provided for transporting the truck with crane
lifting gear.

23
Lifting the truck by crane 23

Requirements
– Park the truck securely, see page 71.
Tools and Material Required
– Lifting gear
– Crane lifting gear
Procedure
• Open the battery cover and remove the
battery if necessary.
• Secure the lifting slings to the strap
points (23).

The truck can now be lifted by crane.

04.19 en-GB

36
 2 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. In each case correct measurements must be
taken and appropriate safety measures applied.
uThe truck must be securely fastened when transported on a lorry or a trailer.
uThe lorry or trailer must have fastening rings.
uUse wedges to prevent the truck from moving.
uUse only fastening belts with sufficient strength.
uUse non-slip materials to securing the load aids (pallet, wedges, ...) e. g. non-slip
mats.

Securing the truck for transport

Requirements
– Load the truck.
– Truck parked securely, see page 71.
Tools and Material Required
– Lashing straps
– Edge protectors
– Wooden beam or pallet
Procedure
• Position the wooden beam or pallet
between the front of the transport
vehicle and the load handler to
ensure a positive fit between the front
of the transport vehicle and the load 40
handler.
• Attach the lashing straps (40) to the
industrial truck and the transport
vehicle and tension sufficiently.

Z Use edge protectors to protect the truck and the lashing straps.

The truck can now be transported.

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37
3 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.
uThe truck must only be operated with battery current.
uCable connections to the battery (tow leads) must be less than 6 m long and have
a minimum cross-section of 50 mm².
NOTICE
Do not lift loads if the truck is operated via a tow lead with an external battery.

If the truck is delivered in multiple parts, setup and commissioning must only be
performed by trained, authorised personnel.
Procedure
• Check the equipment is complete.
• If necessary, install the battery, see page 52. Do not damage the battery cable.
• Charge the battery, see page 45.

Z The truck settings must match the battery model (if the customer is charging the
battery).
• Check the hydraulic oil level and top up if necessary (see page 162).
• Start up the truck (see page 68).
Truck is operational.

Wheel flattening

If the truck has been parked for a long period, the wheel surfaces may tend to
flatten. This flattening has a negative effect on the safety and stability of the truck.
Once the truck has covered a certain distance, the flattening will disappear.
04.19 en-GB

38
 D Battery - Servicing, Recharging,
Replacement
Z For use of lithium-ion batteries (o), see the manufacturer's operating instructions.

1 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. Wherever an
industrial truck is parked for charging there must be no inflammable material or
consumables capable of creating sparks within a minimum distance of 2 m from the
truck. The room must be ventilated. Fire protection equipment must be available.

CAUTION!
The use of unsuitable fire protection equipment can result in scalding
Extinguishing fires with water can cause a reaction with the battery acid. This can
result in scalding from the acid.
uUse powder extinguishers.
uNever extinguish a burning battery with water.

Battery maintenance

The battery-cell covers must be kept dry and clean. The terminals and cable lugs
must be clean, secure and have a light coating of terminal grease.

WARNING!
Short circuits can result in fire
Damaged cables can cause short circuits, setting the truck and battery on fire.
uBefore closing the battery cover make sure that the battery cables are not
damaged.

Battery disposal

Batteries may only be disposed of in accordance with national environmental

protection regulations or disposal laws. The manufacturer’s disposal instructions
must be observed.
04.19 en-GB

39
 WARNING!
Batteries can be hazardous
Batteries contain an acid solution which is poisonous and corrosive. Avoid contact
with battery acid at all times.
uDispose of used battery acid in accordance with regulations.
uAlways wear protective clothing and goggles when working with batteries.
uDo not let battery acid come into contact with skin, clothing or eyes. If necessary,
rinse with plenty of clean water.
uIn the event of physical damage (e.g. skin or eye contact with battery acid) call for
a doctor immediately.
uSpilled battery acid should be neutralised immediately with plenty of water.
uOnly batteries with a sealed battery container may be used.
uFollow national guidelines and legislation.

WARNING!
Unsuitable batteries that have not been approved by Jungheinrich for the
truck can be hazardous
The design, weight and dimensions of the battery have a considerable effect on the
operational safety of the truck, in particular its stability and capacity. 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.
uOnly Jungheinrich-approved batteries may be used on the truck.
uBattery equipment may only be replaced with the agreement of Jungheinrich.
uWhen replacing/installing the battery make sure the battery is securely located in
the battery compartment of the truck.
uDo not use batteries that have not been approved by the manufacturer.

Park the truck securely before carrying out any work on the batteries (see page 71).

04.19 en-GB

40
 2 Battery types
Depending on the model, the truck will be supplied with different battery types. The
following table shows which combinations are included as standard:
EJE 220 / 225

Battery Battery type Weight (kg) Dimensions (mm)

tray
M 24 V - XFC 158 Ah 220 623X211X627
24 V - XFC 158 Ah 180 623X211X627
24 V - 2PzV 160 Ah wf Exide 180 624X212X537
24 V - 2PzW 160 Ah 180 624X212X537
24 V - 2PzV 174 Ah wf Hawker 183 623X211X537
24 V - 2PzS 180 Ah 180 624X212X537
24 V - 2PzM 180 Ah 180 621X209X537
24 V - 2PzV 200 Ah wf Exide 215 621X209X627
24 V - 2PzV 220 Ah wf Hawker 218 623X211X627
24 V - 2PzW 220 Ah 220 624X212X627
24 V - 2PzS 250 Ah 220 624X212X627
24 V - 2PzS 250 Ah 220 621X209X627
24 V - 2PzM 250 Ah 222 621X209X625
24 V - LIB 110 Ah 210 624X207X627
L 24 V - 3PzV 300 Ah wf Exide 290 621X281X627
24 V - XFC 316 Ah 288 624X284X627
24 V - 3PzV 330 Ah wf Hawker 300 623X283X627
24 V - 3PzW 330 Ah 288 624X284X627
24 V - 3PzS 345 Ah Lib. Silver 282 621X284X627
24 V - 3PzS 375 Ah 288 624X284X627
24 V - 3PzS 375 Ah Lib. Silver 288 621X281X627
24 V - 3PzM 375 Ah 299 621X281X627
24 V - LIB 240 Ah SBE 288 624X284X683
24 V - LIB 360 Ah SBE 288 624X284X683

Z Optionally, the truck can be fitted with a lithium-ion battery, see "Li-Ion battery 24V -
240Ah / 360Ah" operating instructions.
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41
 EJE 230 / 235

Battery Battery type Weight (kg) Dimensions (mm)

tray
M 24 V - XFC 158 Ah 220 623X211X627
24 V - XFC 158 Ah 180 623X211X627
24 V - 2PzV 160 Ah wf Exide 180 624X212X537
24 V - 2PzW 160 Ah 180 624X212X537
24 V - 2PzV 174 Ah wf Hawker 183 623X211X537
24 V - 2PzS 180 Ah 180 624X212X537
24 V - 2PzM 180 Ah 180 621X209X537
24 V - 2PzV 200 Ah wf Exide 215 621X209X627
24 V - 2PzV 220 Ah wf Hawker 218 623X211X627
24 V - 2PzW 220 Ah 220 624X212X627
24 V - 2PzS 250 Ah 220 624X212X627
24 V - 2PzS 250 Ah 220 621X209X627
24 V - 2PzM 250 Ah 222 621X209X625

Z Optionally, the truck can be fitted with a lithium-ion battery, see "Li-Ion battery 24V -
240Ah / 360Ah" operating instructions.

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42
 EJE 220r / 225r

Battery Battery type Weight (kg) Dimensions (mm)

tray
M 24 V - XFC 158 Ah 220 623X211X627
24 V - XFC 158 Ah 180 623X211X627
24 V - 2PzV 160 Ah wf Exide 180 624X212X537
24 V - 2PzW 160 Ah 180 624X212X537
24 V - 2PzV 174 Ah wf Hawker 183 623X211X537
24 V - 2PzS 180 Ah 180 624X212X537
24 V - 2PzM 180 Ah 180 621X209X537
24 V - 2PzV 200 Ah wf Exide 215 621X209X627
24 V - 2PzV 220 Ah wf Hawker 218 623X211X627
24 V - 2PzW 220 Ah 220 624X212X627
24 V - 2PzS 250 Ah 220 624X212X627
24 V - 2PzS 250 Ah 220 621X209X627
24 V - 2PzM 250 Ah 222 621X209X625
L 24 V - 3PzV 300 Ah wf Exide 290 621X281X627
24 V - XFC 316 Ah 288 624X284X627
24 V - 3PzV 330 Ah wf Hawker 300 623X283X627
24 V - 3PzW 330 Ah 288 624X284X627
24 V - 3PzS 345 Ah Lib. Silver 282 621X284X627
24 V - 3PzS 375 Ah 288 624X284X627
24 V - 3PzS 375 Ah Lib. Silver 288 621X281X627
24 V - 3PzM 375 Ah 299 621X281X627

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.

NOTICE
Battery damage
The battery, charger (charge characteristics) and battery parameters must match
each other, otherwise damage may result.
NOTICE
Reduced service life of the battery
To ensure the optimum service life of the battery, the battery manufacturer's latest
operating and maintenance instructions must be observed.
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43
3 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.
uFully lower the load handler.
uSelect a place to park where no other people are at risk of injury from the lowered
load handler.
uIf the brakes are not working, place wedges underneath the wheels of the truck to
prevent it from moving.

CAUTION!
A closing battery panel can pose a trapping hazard
If the battery cover is not opened fully, it can suddenly close on its own and cause
bruising. The battery cover is only properly opened at an angle greater than 90°. It is
then held by gravity.
uOpen the battery cover as far as the stop.

Requirements 9
– Park the truck on a level surface.
– Park the truck securely, see page 71.
Procedure
• Open the battery panel (9).
• Where necessary remove the insulating
mat from the battery.

The battery is now exposed.

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44
 4 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.
uThe charger must match the battery in terms of voltage, charge capacity and
battery type.
uBefore charging, check all cables and plug connections for visible signs of
damage.
uVentilate the room in which the truck is being charged.
uThe battery cover must be open and the battery cell surfaces must be exposed
during charging to ensure adequate ventilation.
uDo not smoke and avoid naked flames when handling batteries.
uWherever an industrial truck is parked for charging there must be no inflammable
material or consumables capable of creating sparks within a minimum distance of
2 m from the truck.
uFire-control equipment must be available.
uDo not place any metallic objects on the battery.
uAlways follow the safety regulations of the battery and charger station
manufacturers.
NOTICE
Battery damage
The battery, charger (charge characteristics) and battery parameters must match
each other, otherwise damage may result.
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45
4.1 Charging the battery with a stationary charger

Charging the battery

Requirements
– Expose the battery, see
page 44.
Procedure
• Disconnect the battery
connector (41) from the truck
connector.
• Connect the battery
41
connector (41) to the charging
42
cable (42) of the stationary
charger.
• Start charging in accordance
with the charger operating
instructions.

The battery is charging.

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
• Complete charging in accordance with the charger operating instructions.
• Disconnect the battery connector (41) from the charging cable (42) of the
stationary charger.
• Attach the battery connector (41) to the industrial truck.

The truck is now ready for operation.

4.2 Charging the battery with an on-board 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.
uUnwind the cable reel fully when using it.
uAlways use original manufacturer’s mains cables.
uInsulation safety, acid and caustic ratings must comply with the manufacturer's
04.19 en-GB

mains lead.
uThe charging connector must be dry and clean when used.

46
 NOTICE
Improper use of the on-board charger can cause material damage
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.
uBatteries must never be swapped from truck to truck.
uDo not connect the battery to two chargers simultaneously.

4.2.1 Setting the charging characteristics (ELG 2430)

Z 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 (44).

43 44

CAUTION!
uRemove the mains connector before setting the respective charging curve.
Set the charging characteristic

Requirements
– Battery connected.
Procedure
• Turn the setting switch (43) on the charger right to adapt the charging curve to the
battery being used.
• The validity of the new setting is acknowledged by the flashing of the green LED
and the setting takes immediate effect.

The charging characteristic is now set.

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47
 Flashing sequence / charging curve assignment (ELG 2430)
Flashing sequence Selected charging curves (characteristics)
0 Truck without battery
Wet cell battery: PzS with 100 - 300 Ah
1
Wet cell battery: PzM with 100 - 179 Ah
2 Maintenance-free: PzV with 100 - 149 Ah
3 Maintenance-free: PzV with 150 - 199 Ah
4 Maintenance-free: PzV with 200 - 330 Ah
Wet cell battery: PzS with pulse characteristic 200 -
400 Ah
Wet cell battery: PzM with pulse characteristic 180 -
5
400 Ah
Wet cell battery: PzS with pulse characteristic 200 -
414 Ah
6 Jungheinrich 100 - 300 Ah

NOTICE
uAll other switch positions (43) block the charger, and the battery is not charged.
uFor PzM batteries with a capacity of less than 180 Ah set characteristic 1, beyond
180 Ah set characteristic 5.
uWith PzS 200-300 Ah wet cell batteries both characteristic curves 1 and 5 can be
used. Characteristic 5 achieves a faster charge.
uWhen the battery is connected this allows you to adjust via the charger: If the
switch position is valid the green LED flashes according to the position set; if the
switch position is invalid the red LED flashes.

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48
 4.2.2 Charging the battery

Starting to charge with the on-board charger

Mains connection
45
Mains supply: 230 V / 110 V (+10/-15%)
Mains frequency: 50 Hz / 60 Hz

The mains cable of the charger (45) is in the front

panel or the battery compartment.
Charging the battery

Requirements
– Park the truck securely, see page 71.
– Expose the battery, see page 44.
– Correct charging program set on charger.
Procedure
• Remove any insulating mats from the battery.
• The battery connector must remain plugged.
• Attach the mains connector (45) to a mains socket.
• Pull the emergency disconnect switch up.
The flashing LED indicates the charge status or a
fault (for flashing codes see “LED Display” table).

The battery is charged.

Z When the mains connector (45) is attached to the

mains, all the truck’s electrical functions are
disconnected (electric immobilizer). The truck cannot
be operated.
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 (45) from the mains socket and store it along with
the cable in the storage compartment (47).
• If applicable, place the existing insulating mats back over the battery.
• Close the battery panel securely.

The truck is now ready for operation.

CAUTION!
04.19 en-GB

Damaged mains cables can be hazardous

uDo not trap the mains cable when closing the battery panel.

49
 Charging times

The duration of charge depends on the battery capacity.

Z Charging continues automatically after a mains failure. Charging can be interrupted

by removing the mains connector and continued as partial charging.

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50
 46

LED display (46)

Green LED (charge status)

Lit 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)

Lit Overtemperature. Charging is interrupted.
Flashes slowly Safety charging time exceeded. Charging is cancelled.
Mains must be disconnected for charging to restart.
Rapid flash Invalid characteristic curve setting.

Compensation charge

The compensation charge starts automatically when charging is complete.

Partial charging

The charger is designed to automatically adapt to partially charged batteries. This

keeps battery wear to a minimum.
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51
5 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.
uUse only batteries with insulated cells and terminal connectors. If necessary cover
them with a rubber mat.
uPark the truck on a level surface.
uMake sure the crane lifting gear has sufficient capacity to replace the battery.
uUse only approved battery replacement devices (battery roller stand, replacement
trolley etc.).
uMake sure the battery is securely located in the truck's battery compartment.

CAUTION!
Risk of accidents and injury from electrical voltage
When installing and removing the lithium-ion battery, there is a risk of accidents and
injury from electrical voltages.
uThe lithium-ion battery may only be installed and removed by trained experts.

CAUTION!
Trapping hazard
There is a risk of trapping when you close the battery cover.
uMake sure there is nothing between the battery cover and the truck when you
close the battery cover.

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52
 5.1 Changing the battery from the top

Removing the battery 47

Requirements
– Park the truck securely, see page 71.
– Expose the battery, see page 44.
Tools and Material Required
– Crane lifting gear
Procedure
• Disconnect the battery connector from the
truck connector.

Z Place the battery cable on the tray so that it cannot be severed when the battery
is pulled out.
• Attach the crane lifting gear to the eyes (47).

Z The hooks must be fitted in such a way that when the crane lifting gear is
slackened, they do not fall onto the battery cells. The lifting gear must exert a
vertical pull so that the battery container is not compressed.
• Lift the battery slowly out of the battery compartment using crane lifting gear.

The battery has now been removed.

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53
 Battery Installation EJE 220 / 225 / 230 / 235

Requirements
– Park the truck securely, see page 71.
Procedure

Z Assembly is the reverse order. Note the correct assembly position and make sure
the battery is connected correctly.

Z Place the battery cable on the tray so that it cannot be severed when the battery
is inserted.
• Attach the battery connector to the truck connector.
CAUTION!
Trapping hazard
There is a risk of trapping when you close the battery cover.
uDo not reach between the battery cover and chassis. Hold the battery cover only
by the designated recess.
uClose the battery panel carefully and slowly.

Close the battery panel.

The battery is now installed.

Z After installing the battery again, check all cables and plug connections for visible
signs of damage.

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54
 Battery Installation EJE 220r / 225r

Requirements
– Park the truck securely, see page 71.
Procedure

Z Assembly is the reverse order. Note the correct assembly position and make sure
the battery is connected correctly.

Z Place the battery cable on the tray so that it cannot be severed when the battery
is inserted.
NOTICE
Avoid damaging the auxiliary hydraulics in the battery compartment
uWhen installing the battery make sure that the auxiliary hydraulics components
(valves, hoses and electrical connecting cables) are not trapped.
• Attach the battery connector to the truck connector.
CAUTION!
Trapping hazard
There is a risk of trapping when you close the battery cover.
uDo not reach between the battery cover and chassis. Hold the battery cover only
by the designated recess.
uClose the battery panel carefully and slowly.

Close the battery panel.

The battery is now installed.

Z After installing the battery again, check all cables and plug connections for visible
signs of damage.
04.19 en-GB

55
5.2 Lateral battery removal

Z Lateral battery removal is optional only. And on the EJE 220r / 225r the battery can
only be removed from the left-hand side.

CAUTION!
Trapping hazard
Trapping hazard when removing and installing the battery.
uWhen removing and installing the battery do not put your hands between the
battery and the chassis.

Removing the battery 48

Requirements
– Park the truck securely, see page 71
– Battery exposed, see page 44.
Procedure
• Disconnect the battery connector from the truck connector.
• Turn the battery lock (48) as far as the stop.
• Pull the battery out from the side.

The battery is now removed.

Z Installation is the reverse order. When reinstalling the battery, note the proper
installation position and make sure the battery is connected correctly. Place the
battery cable on the tray so that it cannot be severed when the battery is inserted.

– After installing the battery, check all cables and plug connections for visible signs
of damage.

48
CAUTION!
Trapping hazard
There is a risk of trapping when you close the battery cover.
uDo not reach between the battery cover and chassis. Hold
the battery cover only by the designated recess.
uClose the battery panel carefully and slowly.
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56
 E Operation
1 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.
Operator’s rights, responsibilities and rules of conduct

The driver must be informed of his duties and responsibilities and be instructed in
the operation of the truck and shall be familiar with the operating instructions. Safety
shoes must be worn on pedestrian-operated trucks.
Unauthorised use of truck

The operator is responsible for the truck during the time it is in use. The operator
must prevent unauthorised persons from driving or operating the truck. Do not carry
passengers or lift other people.
Damage and faults

The supervisor must be informed immediately of any damage or faults to the truck or
attachment. Trucks which are unsafe for operation (e.g. wheel or brake problems)
must not be used until they have been rectified.
Repairs

The operator must not carry out any repairs or alterations to the truck without
authorisation and the necessary training to do so. The operator must never disable
or adjust safety mechanisms or switches.
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57
 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.
uInstruct unauthorised persons to leave the hazardous area.
uIn case of danger to third parties, give a warning signal in good time.
uIf unauthorised persons are still within the hazardous area, stop the truck
immediately.

Safety devices, warning signs and warning instructions

Safety devices, warning signs (see page 31) and warning instructions in the present
operating instructions must be strictly observed.

WARNING!
Removing or disabling safety devices can cause accidents
Removing or disabling safety devices such as the emergency disconnect switch, key
switch, buttons, horn, strobe lights, sensors, panels, etc. can result in accidents and
injury.
uReport any defects immediately to your supervisor.
uMark defective truck and take it out of service.
uDo not return the truck to service until you have identified and rectified the fault.

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58
 2 Displays and Controls

49
50
51 52
6 5 53 6

12 10

13, 54, 55

14, 56
04.19 en-GB

59
 Ite Control/display Function
m
5 Collision safety switch t Safety function for travel in the drive
direction: When the collision safety
switch is actuated, the truck travels for
approx. 3 seconds in the load
direction. The truck then switches off
until the travel switch is briefly
restored to the neutral position.
6 Travel switch t Controls the travel direction and the
travel speed.
7 Slow-travel button t 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.
8 Tiller t Used for steering and braking.
10 Emergency disconnect switch t Disconnects the battery supply
– All electrical functions are
deactivated and the truck is braked
12 Cable connection o Charges the battery by inserting the
On-board battery charger mains connector into a mains socket.
(including safety switch)
49 Load handler lower button o Lowers the load handler.
50 Load handler lower button t Lowers the load handler.
51 Load handler raise button o Raises the load handler.
52 Load handler raise button t Raises the load handler.
53 Warning signal button t Activates an audible signal.
7 Slow-travel button t 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.
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60
 49
50
51 52
6 5 53 6

12 10

13, 54, 55

14, 56
04.19 en-GB

61
 Ite Control/display Function
m
13 Charge/discharge indicator t Shows the charge/discharge status of
the battery.
14 Key switch t – Activates the truck by applying the
control voltage
– Removing the key prevents the
truck from being switched on by
unauthorised personnel
Key switch with second o Brake release to move the truck when
switch stage non-operational.
54 CanDis o Display instrument for:
– Battery charge status
– Service hours
– Warning messages
– Parameter setting
55 Display unit o Display for:
(2-inch display) – Battery charge status
– Battery capacity
– Service hours
– Travel program
– Warning indicators
– Event messages
Soft keys under the display
unit

56 CanCode o Replaces the key switch

– Entering the appropriate code
activates the truck
– Travel program selection
– Code setting
ISM Online o Replaces the key switch
– Activates the truck via a card/
transponder
– Displays readiness for operation
– Operational data logging
– Data exchange with card/
transponder
Keypad o Replaces the key switch
– Provided only as a supplement to
the display unit
– Truck release by entering set-up
and access codes
Transponder reader o Replaces the key switch
– Provided only as a supplement to
the display unit
04.19 en-GB

– Activates the truck via a card/

transponder

62
 49
50
51 52
6 5 53 6

12 10

13, 54, 55

14, 56
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63
64
04.19 en-GB
 2.1 EJE 220r / EJE 225r Tiller

57 58 52 50

58 57 50 52

Ite Control/display Function

m
50 Load handler lower button t Lowers the load handler.
52 Load handler raise button t Raises the load handler.
57 Ramp lift lower button t Lowers ramp lift.
58 Ramp lift raise button t Raises ramp lift.
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2.2 Battery discharge indicator

When the truck has been released via the key

switch, CanCode or ISM, the battery charge status 59
is displayed. The LED colours (59) represent the
following conditions:

LED colour Charge status

Green 40–100%
Orange 30–40%
Green/orange
20–30%
flashes at 1 Hz
Red 0–20%

Z If the LED is red, the load can no longer be lifted. Lifting is only enabled when the
battery connected is at least 70% charged.
If the LED flashes red and the truck is not ready for operation, inform the
manufacturer's service department. Red flashing is a truck controller code. The
flashing sequence indicates the type of fault.

2.3 Battery discharge monitor

Z 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. If this adjustment is not made, the battery may become
damaged due to deep discharge.
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.

Z Charge the battery see page 45.

If the residual capacity falls below the required level, lifting is inhibited. An alternating
display (59) appears. Lifting is only released when the battery connected is at least
70% charged.
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66
 3 Preparing the Truck for Operation

3.1 Checks and Operations to Be Performed Before Starting Daily

Work
WARNING!
Risk of accident due to damage to or other defects in the truck and optional
features
If damage or other truck or attachment (optional equipment) defects are discovered
during the following checks, the truck must be taken out of service until it has been
repaired.
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.
Inspection before daily operation

Procedure
• Check the whole of the outside of the truck for signs of damage and leaks.
Damaged hoses must be replaced immediately.
• Check the battery attachment and wire connections for damage and make sure
they are secure.
• Check the battery connectors are secure.
• Check the load handler for visible signs of damage such as cracks, bent or severe
wear.
• Check the drive wheel and load wheels for damage.
• Check that the markings and labels are present, clean and legible, see page 31.
• Make sure the drive panels and covers are secure and check for damage.
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3.2 Preparing the truck for operation
Switching on the truck

Requirements
– Checks and operations to be performed before starting daily work, see page 67.
Procedure
• Pull the emergency disconnect switch (10) to unlock it.
• To switch on the truck:
• Insert the key in the key switch (14) and turn it as far to the right as it will go.
• Enter the code in CanCode (o) (56).
• Hold the card or transponder in front of the ISM access module and, depending
on the setting, press the green button on the ISM access module (o).

Z The tiller (8) must be in the upper braking zone "B". If event message "E-0914" is
displayed on the CanDis display instrument (o) or on the display unit (2-inch
display) (o), move the tiller to the upper brake zone "B", see page 78.

The truck is ready for operation.

t The charge status indicator (13) shows the current battery charge status.

o The CanDis display instrument (54) or the display unit (2-inch display) (o) shows
the current battery charge status and the service hours.

14, 56 13, 54 10
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68
 3.3 Making the EJE 220r / 225r operational

Z On the EJE 220r / 225r you must check that the load handler is lowered when
making the truck operational. If the load handler is not fully lowered, it can tilt slightly
when raised.
Switching on the EJE 220r / 225r truck

Requirements
– Checks and operations to be performed before starting daily work, see page 67.
Procedure
• Pull the emergency disconnect switch (10) to unlock it.
• To switch on the truck:
• Insert the key in the key switch (14) and turn it as far to the right as it will go.
• Enter the code in CanCode (o) (56).
• Hold the card or transponder in front of the ISM access module and, depending
on the setting, press the green button on the ISM access module (o).

Z The tiller (8) must be in the upper braking zone "B". If event message "E-0914" is
displayed on the CanDis display instrument (o) or on the display unit (2-inch
display) (o), move the tiller to the upper brake zone "B", see page 78.
• Check that the load handler is fully lowered.
• Lower the load handler if necessary, see page 83.

The truck is ready for operation.

t The charge status indicator (13) shows the current battery charge status.

o The CanDis display instrument (54) or the display unit (2-inch display) (o) shows
the current battery charge status and the service hours.

8
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69
3.4 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.
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.
Procedure
• Test warning indicators and safety devices:
• Test the emergency disconnect function by pressing the emergency disconnect
switch. The main circuit is disconnected and no truck operations can be
performed. Now pull the Emergency Disconnect switch to unlock it.
• Test the horn by pressing the "warning signal" button.
• Check braking efficiency, see page 81.
• Test the steering, see page 81.
• Test the hydraulic system, see page 83.
• Test travel operations, see page 78.
• Test the "collision safety switch" by depressing it whilst driving in the drive
direction.
• Test the controls and displays and check for damage, see page 59.
• Check tiller return function.
• Check the controls automatically return to the neutral position after use.

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 3.5 Parking the truck securely
WARNING!
An unsecured truck can cause accidents
Parking the truck on an incline, without the brakes applied or with a raised load or
load handler is dangerous and is strictly prohibited.
uPark the truck on a level surface. In special cases the truck may need to be
secured with wedges.
uFully lower the load handler.
uSelect a place to park where no other people are at risk of injury from the lowered
load handler.
uIf the brakes are not working, place wedges underneath the wheels of the truck to
prevent it from moving.

8
EJE 220 / 225 / 230 / 235

Park the truck securely 50

Procedure
• Park the truck on a level surface.
• Fully lower the load handler (60):
• Press the lower button (50).
• Using the tiller (8) set the drive wheel
to the straight ahead position.
• Switch off the truck, to do this:
• Turn the key in the key switch (14)
anti-clockwise as far as it will go.
Remove the key from the key
switch (14).
• For CanCode (56) press the O key
(o).
• Press the red button on the ISM
access module (o).
• Press the Emergency Disconnect 60 14, 56 10
(10).

The truck is parked.

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71
 EJE 220r / 225r

Parking the truck securely

Procedure
• Park the truck on a level surface.
• Fully lower the load handler (60):
• Press the "lower" button (50) or the "ramp lift lower" button (57).
• Using the tiller (8), turn the drive wheel to "forward travel".
• Switch off the truck, to do this:
• Turn the key in the key switch (14) anti-clockwise as far as it will go. Remove
the key from the key switch (14).
• For CanCode (56), press the O key (o).
• Press the red key on the ISM access module (o).
• Press the emergency disconnect switch (10).

The truck is parked.

50

57

60 14, 56 10
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72
 4 Industrial Truck Operation

4.1 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. Additional equipment is necessary to operate the truck in
areas of insufficient lighting.

DANGER!
Do not exceed the permissible surface and point loading on the travel lanes.
At blind spots get a second person to assist.
The driver must ensure that the loading dock /dock leveller cannot be removed or
come loose during loading/unloading.

Travel conduct

The operator must adapt the travel speed to local conditions. The truck must be
driven at slow speed when negotiating bends or narrow passageways, when passing
through swing doors and at blind spots. The operator must always observe an
adequate braking distance between the forklift truck and the vehicle in front and
must be in control of the truck at all times. Abrupt stopping (except in emergencies),
rapid U turns and overtaking at dangerous or blind spots are not permitted. Do not
lean out or reach beyond the working and operating area.
Travel visibility

The operator must look in the direction of travel and must always have a clear view
of the route ahead. If the truck is carrying loads that affect visibility, the truck must
travel against the load direction. If this is not possible, a second person must walk
alongside the truck as a lookout to observe the travel route while maintaining eye
contact with the operator. Proceed only at walking pace and with particular care.
Stop the truck as soon as you lose eye contact.
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73
 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. The industrial truck must
not be turned, operated at an angle or parked on inclines or slopes. Inclines must
only be negotiated at slow speed, with the driver ready to brake at any moment.
Negotiating lifts, loading ramps and docks

Lifts may only be negotiated if they have sufficient capacity, are suitable for driving
on and authorised for truck traffic by the owner. The driver must satisfy himself of the
above before entering these areas. The truck must enter lifts with the load in front
and must take up a position which does not allow it to come into contact with the
walls of the lift shaft. Persons riding in the lift with the forklift truck must only enter
the lift after the truck has come to a rest and must leave the lift before the truck. The
driver must ensure that the loading ramp / dock cannot move or come loose during
loading / unloading.
Type of loads to be carried

The operator must make sure that the load is in a satisfactory condition. Loads must
always be positioned safely and carefully. Use suitable precautions to prevent parts
of the load from tipping or falling down. Prevent liquid loads from sloshing out.

WARNING!
Electromagnetic influence can result in accidents
Strong magnets can cause electronic components such as Hall sensors to become
damaged, resulting in accidents.
uDo not use magnets in the operating area of the truck. Exceptions to this rule are
commercial, weak clamping magnets for attaching notices.

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74
 4.2 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.
uUse the Emergency Disconnect switch during travel only in emergencies.

CAUTION!
Faulty or non-accessible Emergency Disconnect switches can cause
accidents
A faulty or non-accessible Emergency Disconnect switch can cause accidents. In
dangerous situations the operator cannot bring the truck to a halt in time by applying
the Emergency Disconnect switch.
uThe operation of the Emergency Disconnect switch must not be affected by any
objects placed in its way.
uReport any defects on the Emergency Disconnect switch 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.
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75
 Press the Emergency Disconnect switch

Procedure
• Press the Emergency Disconnect (10).

All electrical functions are deactivated. The truck brakes to a halt.

Z Press the Emergency Disconnect switch on in emergencies.

Releasing the Emergency Disconnect switch

Procedure
• Pull the Emergency Disconnect switch (10) to unlock it.

All electrical functions are enabled and the truck is operational again (provided the
truck was operational before the Emergency Disconnect was pressed).

Z Trucks with CanCode and ISM access module remain switched off.

10

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76
 4.3 Automatic braking

Z 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.
uIf the tiller returns to the brake position slowly or not at all, the truck must be taken
out of service until the cause of this fault is be rectified.
uContact the manufacturer's customer service department.

6 8

2 3
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77
4.4 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.
Requirements
– Start up the truck, see page 67.
Procedure
• Set the tiller (8) to the travel zone (F).
• Control the travel direction with the travel switch (6):
• Rotate the travel switch (6) slowly in the load direction (3):
Travel in load direction:
• Rotate the travel switch (6) slowly in the drive direction (2):
Travel in drive direction:
• Control the travel speed with the travel switch (6):
• The further the travel switch (6) is rotated, the greater the travel speed.
• Control the travel speed by rotating the travel switch (6) further or less.
Z After releasing the travel switch (6), it automatically returns to the neutral position
(0), and the truck brakes.

The brakes are released and the truck moves in the selected direction.

Anti-roll back device for slow travel on inclines

If the truck does not have sufficient speed to travel up an incline, it may roll back.
Rolling back is detected by the truck's controller and the truck brakes to a halt
immediately.

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.
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78
 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.
uDo not perform any sudden steering operations.
uAlways face in the direction of travel.
uMaintain an adequate overview of the route you are travelling.
Changing direction during travel

Procedure
• Set the travel switch (6) to the opposite direction while travelling.

The truck decelerates until it starts to travel in the opposite direction.

6 8

2 3
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79
4.5 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" button
and the travel switch.
uDuring slow travel you can only brake by coating braking.

Z The truck can be operated with an upright tiller (8) (e. g. in confined spaces /
elevators).
Switch on the slow travel function

Procedure
• Press and hold down the "slow travel" button (7).
• Rotate the travel switch (6) in the required travel direction.

The brake is released. The truck travels at slow speed.

Switching off slow travel 6

Procedure 7
• Release the "slow travel" button (7).
If the tiller is in brake zone "B", the brake
applies and the truck stops.
If the tiller is in brake zone "F" the truck
8
continues at slow travel speed.

• Release the travel switch (6).

Slow travel ends and the truck can now travel again at normal speed.

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 4.6 Steering
Procedure
• Move the tiller (8) to the left or right.

The truck is steered in the required direction.

4.7 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.
uBrake with care to prevent the load from slipping.

CAUTION!
uIn hazardous situations, move the tiller to the brake position or press the
emergency disconnect switch.

The truck can brake in two ways:

– With the service brake (brake zone B).
– By regenerative braking (coasting brake).

6 8
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81
4.7.1 Braking with the service brake
6 8

Procedure
• Move the tiller (8) up or down to one of the brake zones (B).
The truck decelerates at the maximum rate until it comes to a halt.

Z The mechanical brake applies automatically when the truck comes to rest.

4.7.2 Regenerative braking

Procedure
• If the travel switch (6) is set to (0), the truck automatically brakes regeneratively.
The truck brakes to a halt regeneratively via the coasting brake.

Z When braking regeneratively, energy is returned to the battery, ensuring a longer

service time.

4.7.3 Parking brake

Z The mechanical brake applies automatically when the truck comes to rest.
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 4.8 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.
Apart from the driver (in the normal operating position) there should be no other
people in the truck's hazardous area.
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.
uIf people do not leave the hazardous area despite the warning, prevent the truck
from being used by unauthorised people.
uOnly carry loads that have been secured and positioned in accordance with
regulations. Use suitable precautions to prevent parts of the load from tipping or
falling down.
uNever exceed the maximum loads specified on the capacity plate.
uDo not stand on the load handler.
uDo not lift other people on the load handler.
uNever reach or climb into moving truck parts.
uDo not climb onto parts of the building or other trucks.
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4.8.1 Raising the load handler
Requirements
– Prepare the truck for operation, see page 68.

Procedure
Press the “Raise load handler ” button (52) until you reach the desired lift height.
NOTICE
Risk of material damage to the hydraulic unit
When the mechanical end stop of the load has been reached, release the "Raise
load handler" button. Otherwise the hydraulic unit could suffer material damage.

The load handler is raised.

Tiller from above

52 50

Tiller from below

50 52

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84
 4.8.2 Lowering the load handler
Requirements
– Prepare the truck for operation, see page 68.

Procedure
• Press the “Lower load handler” button (50) until you reach the desired lift height.

The load handler is lowered.

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85
4.8.3 Raising the ramp lift

EJE 220r / 225r

Requirements
– Prepare the truck for operation, see page 68.

Procedure
• Press the “ramp lift raise” button (58) until you reach the desired lift height.

The load handler is raised to ramp lift.

Z If the load handler is raised with the "load handler raise" button, it cannot change
directly to ramp lift. When the "ramp lift raise" button is applied the load handler is
first fully lowered and then raised to ramp lift.

Z If the load handler is raised with ramp lift, it cannot change directly to normal lift.
When the "load handler raise" button is applied, ramp lift is first fully lowered and
then the load handler is raised.

Tiller from above

57 58
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86
 Tiller from below

58 57

4.8.4 Lowering ramp lift

EJE 220r / 225r

Requirements
– Prepare the truck for operation, see page 68.

Procedure
• Press the “ramp lift lower” button (57) until you reach the desired lift height.

The load handler is lowered from ramp lift.

Z When you release the "ramp lift lower" button (57) or the "load handler lower" button
a lag time of 1 to 2 seconds begins. If the "ramp lift raise" button (58) or the "load
handler raise" button are pressed during this lag time, the load handler is raised after
a delay.
The lag time ensures that the load handler is fully lowered.
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4.9 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.
uOnly carry loads that have been correctly secured and positioned. Use suitable
precautions to prevent parts of the load from tipping over or falling off the truck.
uDamaged loads must not be transported.
uNever exceed the maximum loads specified on the load diagram.
uNever stand underneath a raised load handler.
uDo not stand on the load handler.
uDo not lift other people on the load handler.
uInsert the load handler as far as possible underneath the load.

CAUTION!
uDo not lift long loads at an angle.

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 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).

Z The load must not extend by more than 50 mm

beyond the load handler tips.
• Raise the load handler until the desired height is
reached, (see page 84).

The load is being raised.

NOTICE
Risk of material damage to the hydraulic unit
When the mechanical stops of the load handler have been reached, release the
"raise load handler" button. Otherwise the hydraulic unit may suffer material damage.
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4.9.2 Raising the load with ramp lift

EJE 220r / 225r

Requirements
– Load correctly palletised.
– Load weight matches the truck's rated capacity.
– Load handler evenly laden for heavy loads.
– Truck is on a ramp.
– Load handler lowered.
Procedure
• Drive the truck slowly up to the pallet.
• Raise ramp lift (see page 86).
• Slowly insert the load handler into the pallet and lower the ramp lift incrementally.
• Insert the load handler into the pallet until the pallet is resting against the back of
the load handler.

Z The load must not extend by more than 50 mm beyond the load handler tips.
• Fully lower the ramp lift.
• Raise the load handler until you reach the desired height, (see page 84).

The load is raised.

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 04.19 en-GB

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92
04.19 en-GB
 4.9.3 Transporting a load
Requirements
– Load raised correctly.
– Load is not on the ground.
– Perfect ground conditions.
Procedure
• Accelerate and decelerate with care.
• Adapt your travel speed to the conditions of the route and the load you are
transporting.
• Travel at a constant speed.
• Be prepared to brake at all times.
• Brake gently in normal circumstances.
• Only stop suddenly in dangerous situations.
• Watch out for other traffic at crossings and passageways.
• Always travel with a lookout at blind spots.
• Do not travel across or at an angle on inclines. Do not turn on slopes and inclines,
and always drive with the load facing uphill (see graphic).
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4.9.4 Depositing a load

CAUTION!
Loads must not be set down on transport or escape routes, in front of safety
installations or factory equipment that must be accessible at all times.
Requirements
– Storage location suitable for storing the load.
Procedure
• Drive the truck carefully up to the storage location.
• Lowers the load handler.

Z To avoid damaging the load and the load handler, avoid setting the load down
abruptly.
• Lower the load handler so that it is clear of the load (see page 85).
• Carefully drive the load handler out from beneath the pallet.

The load is deposited.

NOTICE
Avoid depositing the load suddenly to avoid damaging the load, load handler and the
rack.

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 4.9.5 Depositing the load with ramp lift

EJE 220r / 225r

CAUTION!
Loads must not be deposited on travel or escape routes, in front of safety
mechanisms or operating equipment that must be accessible at all times.
Requirements
– Storage location suitable for storing the load.
Procedure
• Drive carefully up to the storage location.
• Lower the load handler fully (see page 85).

Z Avoid lowering the load suddenly to prevent the load and load handler from
damage.
• Carefully remove the load handler from the pallet and raise the ramp lift
incrementally (see page 86).
• When the load handler has been fully removed from the pallet, lower the ramp lift.

The load has been deposited.

NOTICE
Avoid depositing the load suddenly to avoid damaging the load, load handler and the
rack.
04.19 en-GB

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96
04.19 en-GB
 5 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.

Z 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.
Troubleshooting must only be performed by the manufacturer’s customer service
department. The manufacturer has a service department specially trained for these
tasks.
In order for customer services to react quickly and specifically to the fault, the
following information is essential:
- Truck serial number
- Event message from the display unit (if applicable)
- Error description
- Current location of truck.
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5.1 Truck does not start
Possible cause Actions
Battery connector not plugged in Check the battery connector
and connect if necessary
Emergency disconnect switch pressed Release the emergency disconnect
switch, see page 75
Key switch in position "O" Set the key switch to position "I"
Battery charge too low Check battery charge and
charge battery if necessary, see page 45
Faulty fuse Check fuses, see page 164
Incorrect ISM access module
Use correct transponder
transponder used
Incorrect code entered in CanCode Enter correct code, see page 108
Tiller not in brake position when the truck Swing the tiller into the top or the bottom
is switched on brake zone
(for CanDis or on the display unit (2-inch
display) (o), event message
E-0914 appears)
"Raise load handler" button/"Lower load Do not actuate the buttons
handler" button not in home position
when truck switched on (for CanDis or
on the display unit (2-inch display) (o),
event message E-2951 appears)
Travel switch not in home position when Do not actuate the travel switch
truck switched on (for CanDis or the
display unit (2-inch display) (o), event
message E-1901 appears)
Collision safety switch actuated when Do not actuate the collision safety switch
truck switched on (for CanDis or on the
display unit (2-inch display) (o), event
message E-1914 appears)
"Slow travel" button actuated when truck Do not actuate the button
switched on (for CanDis or the display
unit (2-inch display) (o), event message
E-1901 appears)
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98
 5.2 Load cannot be lifted
Possible cause Actions
Truck not operational Carry out all actions listed under "Truck
does not start"
Hydraulic oil level too low Check the hydraulic oil level, see
page 162
Battery discharge monitor has switched Charge the battery, see page 45
off
Faulty fuse Check fuses, see page 164
Excessive load Observe the rated capacity, see data
plate
Tiller not in brake position when the truck Swing the tiller into the top or the bottom
is switched on brake zone
(for CanDis or on the display unit (2-inch
display) (o), event message
E-0914 appears)
"Raise load handler" button/"Lower load Do not actuate the buttons
handler" button not in home position
when truck switched on (for CanDis or
on the display unit (2-inch display) (o),
event message E-2951 appears)
Travel switch not in home position when Do not actuate the travel switch
truck switched on (for CanDis or the
display unit (2-inch display) (o), event
message E-1901 appears)
Collision safety switch actuated when Do not actuate the collision safety switch
truck switched on (for CanDis or on the
display unit (2-inch display) (o), event
message E-1914 appears)
"Slow travel" button actuated when truck Do not actuate the button
switched on (for CanDis or the display
unit (2-inch display) (o), event message
E-1901 appears)
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99
6 Operating the truck without its own drive system

Z With the right optional equipment (o) it is possible to switch the truck to emergency
operation via the GF60 service key: The brakes are released electrically and the
truck can move without its own drive system, see page 103.

6.1 Release and activate the drive wheel brake

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.
uApply the brake again when you reach your destination.

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100
 Release the brake

Tools and Material Required

– Two M5x45 screws
– Spanner
Procedure
• Switch off the truck, to do this:
• Turn the key in the key switch (14) anti-clockwise as far as it will go. Remove
the key from the key switch (14).
• Press button O on CanCode (56).
• Press the red button on the ISM access module(o).
• Press the emergency disconnect switch (10).
• Remove the front panel (15), see page 159.
• Remove the right-hand drive panel (63), see page 160.
• Use wedges to prevent the truck from moving.
• Insert two M5x45 screws (61) as far as they will go in the brake (62) and lift up the
anchor plate.
Z The two M5x45 screws (61) are used to tension (unlock) the compression springs
which activate the parking brake, so that the truck does not brake when de-
energised.
• Remove the wedges.

The brake is now released. The truck can be moved.

61

62 63 14,56 15 10

Activating the brake

Procedure
• Use wedges to prevent the truck from moving.
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• Remove the two M5x45 screws (61) from the brake (62).

101
 CAUTION!
Open covers can cause injury and accidents
uThe covers (side panels, drive compartment cover etc.) must be closed during
operation.

Refit the right-hand drive panel (63), see page 160.

• Install the front panel (15), see page 159.
The brake has been reactivated. The brake is now be applied without current.

WARNING!
Only return the truck to service when you have identified and rectified the fault.

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102
 7 Optional equipment

7.1 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.
uApply the brake again when you reach your destination.

Z The service key GF60 must not remain on the truck during normal operation. The
service key should only be used by an authorised person (e.g. warehouse manager).

GF 60
Operating the truck without its own drive system.

Requirements
– Truck prevented from rolling away.
– Charged battery in truck.
Tools and Material Required
– Service key GF60 with lock bar
Procedure
• Insert the service key GF60 in the key switch.

Z The service key GF60 with lock bar can only be inserted and turned on one side.
If inserted in the wrong direction the key will not turn.
• Turn service key to position 1.
• Move the lock bar on the head of the key.
• Turn service key to position 2.

The truck can be moved without its own drive system.

CAUTION!
Risk of accident when the brake is released
The operator must pay special care and attention when moving the truck with the
brake released. The truck can be braked by the following measures:
uTurning the service key to position 1.
uPressing the emergency disconnect switch.
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103
 Parking the truck

Procedure
• Turn the service key to the 0 position and remove the key.

Z 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.

GF 30
Z The GF30 key (without lock bar) is for normal operation.
The key can be inserted in both directions and can only be turned to
position 1 in the key switch.

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104
 7.2 Tiller with buttons on both faces

EJE 220 / 225 / 230 / 235

Tiller from above

49 51 52 50

Tiller from below

51 49 50 52

Item Control
50 t Load handler lower button
52 t Load handler raise button
49 o Load handler lower button
51 o Load handler raise button
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105
7.3 Keypad (CanCode) (o)

7.3.1 Code lock

The code lock allows a user or group of users to assign an individual user code.
Travel programs can also be assigned to the individual user codes. The user code is
configured with a master code and is described in the following sections in this
chapter.

When you have entered the valid user code the truck will be operational. The truck
will be able to perform travel, steering and hydraulic operations.

When you have entered the valid master code, the truck will be switched on. Travel
operations are, however, inhibited. The truck will be able to perform hydraulic
operations. The code lock is in programming mode. When you enter one of the
following parameters, the settings in the code lock can be changed.

Parameter Description
– Change master code
0-0-0
(see page 109)
– Add user codes
0-0-1
(see page 111)
– Change a user code
0-0-2
(see page 113)
– Delete a user code
0-0-3
(see page 115)
– Delete all user codes
0-0-4
(see page 117)
– Switch on the truck automatically
0-1-0
(see page 119)
– Assign travel programs to the user codes
0-2-4
(see page 121)

Trucks in as-supplied condition have the code indicated on a sticker. When using the
truck for the first time, change the master and user codes and remove the sticker.
– Default user code: 2-5-8-0
– Default master code: 7-2-9-5

WARNING!
Lack of usage restrictions can result in accidents
If the same codes are used to operate different trucks, there is no restriction of
usage for the operators or operator groups.
uWhen allocating the codes, ensure rider trucks are given a different code from
pedestrian trucks.
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106
 64 65 66
The keypad consists of 10 digit keys, a Set key (67)
and a o key (69).
Digit keys

The digit keys are used to enter the user or master

code and select the travel program.

The green LEDs of the digit keys 1, 2 and 3 (64, 65,

66) show the travel program setting.

o key
67 68 69
Pressing the o key switches the truck off and sets it
to "non operational" status.

The o key indicates the follow operating conditions via a red / green LED (68):
– Code lock function (commissioning the truck).
– Error display configuring the user code.
– Adjusting the travel program depending on the setting and truck.
– Setting and changing parameters.
SET key

When you change the parameters the SET key (67) acts as a confirmation key.
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107
7.3.2 Preparing the truck for operation with the keypad (CanCode)
Preparing the truck for operation by entering a valid operator code

Procedure
• Pull the Emergency Disconnect to unlock it, see page 75.
The LED (68) lights up red.

• Enter the operator code with the digit keys.

When you have entered a valid operator code the LED (68) lights up green, the
travel program selected is indicated by the corresponding LEDs (64,65,66) and
the truck is switched on.

Z If the LED (68) flashes red this means the wrong code has been entered. Enter
the code again.
The Set key (67) has no function in operating mode.

7.3.3 Switching off the truck with the keypad (CanCode)

Switching off the truck

Procedure
• Press the O key (69).

The truck is switched off and the LED (68) is lit red.

Z The truck can cut out automatically after a specified time. If no travel, steering or
hydraulic operations are performed within a set time, the truck switches off
automatically. When you enter a valid code again the truck will be operational. The
code lock parameter responsible for automatic cutout must be set, see page 119.

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108
 7.3.4 Changing the master code

Z To change the length of the master code you must follow the procedure in "Choose
length of the new master code (4-6 digit) and add user codes", see page 118. If
there are still user codes stored in the code lock, the master code to be changed
must be the same length as the saved user codes.

64 65 66
Requirements
– To prepare the truck for operation, see page 108.
Procedure
• Press the O key (69).
• Enter the valid master code with the digit keys.
When you enter the valid master code the LED
(68) flashes green.

• Enter the parameters 0-0-0 with the digit keys.

• Confirm with the SET key (67).
67 68 69
The LEDs (64,68) flash green.

• Enter the valid master code again with the digit keys.
• Confirm with the SET key (67).
The LEDs (65,68) flash green.

• Enter the valid master code with the digit keys.

Z The new master code must be different from existing user codes.
• Confirm with the SET key (67).
The LEDs (66,68) flash green.

• Enter the new master code again with the digit keys.
• Confirm with the SET key (67).
Wait until the LED (68) flashes green. The setting is saved.

• Press the O key (69).

The truck is switched off and the LED (68) is lit red.

• Check the new master code:

• Switch on the truck with the new master code, see page 108
When you enter the valid master code the LED (68) flashes green.

• Press the O key (69).

The truck is switched off and the LED (68) is lit red.
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109
 Error displays changing the master code

For the following events the LED (68) flashes red:

Cause Remedy
– Switch off the truck, see page 108.
– Choose a different master code, see page 109.
– New master code is already – Change the user code so that the required
occupied by a user code master code can be used, see page 113.
– Delete the user code so that the required
master code can be used, see page 115.
– The master codes to be – Switch off the truck, see page 108.
changed do not match – Enter the master code again, see page 109.
– The master code entered is – Switch off the truck, see page 108.
not the same length as the – Repeat the entry, making sure that the length of
user code the master code matches that of the user code.

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110
 7.3.5 Add operator code

64 65 66
Requirements
– To prepare the truck for operation, see page 108.
Procedure
• Press the O key (69).
• Enter the valid master code with the digit keys.
When you enter the valid master code the LED
(68) flashes green.

• Enter the parameters 0-0-1 with the digit keys.

• Confirm with the SET key (67).
The LEDs (65,68) flash green. 67 68 69

• Enter the new user code with the digit keys.

Z The length (4-6 digit) of the new user code must be the same as that of the
previously entered master code. The new user code must also be different from
the existing master code.
• Confirm with the SET key (67).
The LEDs (66,68) flash green.

• Enter the new user code again with the digit keys.
• Confirm with the SET key (67).
Wait until the LED (68) flashes green. The setting is saved.

• Press the O key (69).

The truck is switched off and the LED (68) is lit red.

• Check the new user code:

• Switch on the truck with the new user code, see page 108
After entering the valid user code the LED (68) lights up green, the travel
program setting is shown by the illumination of the corresponding LEDs
(64,65,66) and the truck is switched on.

• Press the O key (69).

The truck is switched off and the LED (68) is lit red.
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111
 Error displays adding a user code

For the following events the LED (68) flashes red:

Cause Remedy
– The user code entered is – Switch off the truck, see page 108.
not the same length as the – Repeat the entry, making sure that the master
master code code is the same length as the user code.
– New user code is already – Switch off the truck, see page 108.
occupied by a master code – Choose a different user code, see page 111.
– The newly entered user – Switch off the truck, see page 108.
codes do not match – Add the user code again, see page 111.
– Switch off the truck, see page 108.
– Code log full. – Delete individual user codes, see page 115.
– Delete all user codes, see page 117.

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112
 7.3.6 Change operator code

64 65 66
Requirements
– To prepare the truck for operation, see page 108.
Procedure
• Press the O key (69).
• Enter the valid master code with the digit keys.
When you enter the valid master code the LED
(68) flashes green.

• Enter the parameters 0-0-2 with the digit keys.

• Confirm with the SET key (67).
The LEDs (64,68) flash green. 67 68 69

• Enter the user code to be changed with the digit keys.

• Confirm with the SET key (67).
The LEDs (65,68) flash green.

• Enter the new user code with the digit keys.

Z The length (4-6 digit) of the new user code must be the same as that of the
previously entered master code. The new user code must also be different from
the existing master code.
• Confirm with the SET key (67).
The LEDs (66,68) flash green.

• Enter the new user code again with the digit keys.
• Confirm with the SET key (67).
Wait until the LED (68) flashes green. The setting is saved.

• Press the O key (69).

The truck is switched off and the LED (68) is lit red.

• Check the new user code:

• Switch on the truck with the new user code, see page 108
After entering the valid user code the LED (68) lights up green, the travel
program setting is shown by the illumination of the corresponding LEDs
(64,65,66) and the truck is switched on.

• Press the O key (69).

The truck is switched off and the LED (68) is lit red.
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113
 Error displays changing a user code

For the following events the LED (68) flashes red:

Cause Remedy
– The user code entered is – Switch off the truck, see page 108.
not the same length as the – Repeat the entry, making sure that the master
master code code is the same length as the user code.
– Operator code to be – Switch off the truck, see page 108.
changed does not exist. – Check the user code entered.
– The user codes to be – Switch off the truck, see page 108.
changed do not match – Change the user code again, see page 113.
– Tried to change the operator
– Switch off the truck, see page 108.
code to another user code
– Choose a different user code, see page 113.
that already exists.

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114
 7.3.7 Delete individual user codes

64 65 66
Requirements
– To prepare the truck for operation, see page 108.
Procedure
• Press the O key (69).
• Enter the valid master code with the digit keys.
When you enter the valid master code the LED
(68) flashes green.

• Enter the parameters 0-0-3 with the digit keys.

• Confirm with the SET key (67).
67 68 69
The LEDs (65,68) flash green.

• Enter the user code to be deleted with the digit keys.

• Confirm with the SET key (67).
The LEDs (66,68) flash green.

• Enter the user code to be deleted again with the digit keys.
• Confirm with the SET key (67).
Wait until the LED (68) flashes green. The user code is now deleted.

• Press the O key (69).

The truck is switched off and the LED (68) is lit red.

• Check that the user code has been deleted:

• Switch the truck on with the user code to be deleted, see page 108
After entering the user code the LED (68) flashes red and the truck remains
switched off.

• Press the O key (69).

The truck remains switched off and the LED (68) is lit red.
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115
 Error displays deleting individual user codes

For the following events the LED (68) flashes red:

Cause Remedy
– The user code entered is – Switch off the truck, see page 108.
not the same length as the – Repeat the entry, making sure that the master
master code code is the same length as the user code.
– Tried to delete an operator – Switch off the truck, see page 108.
code that does not exist. – Check the user code entered.
– The user codes to be – Switch off the truck, see page 108.
changed do not match – Delete the user code again, see page 115.

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116
 7.3.8 Delete all user codes,

64 65 66
Requirements
– To prepare the truck for operation, see page 108.
Procedure
• Press the O key (69).
• Enter the valid master code with the digit keys.
When you enter the valid master code the LED
(68) flashes green.

• Enter the parameters 0-0-4 with the digit keys.

• Confirm with the SET key (67).
The LEDs (66,68) flash green. 67 68 69

• Enter the code 3-2-6-5 with the digit keys.

• Confirm with the SET key (67).
Wait until the LED (68) flashes green. All user codes are deleted.

• Press the O key (69).

The truck is switched off and the LED (68) is lit red.

• Check that the user codes have been deleted:

• Switch on the truck with a previous user code, see page 108.
After entering the user code the LED (68) flashes red and the truck remains
switched off.

• Press the O key (69).

The truck remains switched off and the LED (68) is lit red.
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117
7.3.9 Choose length of the new master code (4-6 digit) and add user codes

Z 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. The length of the user code (4-6 digit)
is always determined by the length of the master code.

64 65 66
Requirements
– To prepare the truck for operation, see page 108.
Procedure
• Delete all user codes, see page 117.
• Enter the new master code (4-6 digit), see
page 109.
• Add user codes again, see page 111.

The length of the new master code is now changed

and user codes have been added.
67 68 69

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118
 7.3.10 Setting the automatic truck cutout (timeframe)

64 65 66
Requirements
– To prepare the truck for operation, see page 108.
Procedure
• Press the O key (69).
• Enter the valid master code with the digit keys.
When you enter the correct master code the LED
(68) flashes green.

• Enter the 0-1-0 parameter with the digit keys.

• Confirm with the SET key (67).
67 68 69
Wait until the LED (68) flashes green.

• Set the truck automatic cutout (time period) with the digit keys:
• 00:
Automatic truck cutout is deactivated.
• 01 - 30:
Set time period (in minutes) after which the truck automatically cuts out
(minimum cutout time is 1 minute,
maximum cutout time is 30 minutes).
• 31:
After 10 seconds the truck cuts out automatically.
• Confirm with the SET key (67).
Wait until the LED (68) flashes green. The setting is saved.

• Press the O key (69).

The truck is switched off and the LED (68) lights up red.

• Checking the truck's automatic cutout:

• Switch on the truck with a valid operator code, see page 108.
When you have entered a valid operator code the LED (68) lights up green, the
travel program selected is indicated by the corresponding LEDs (64,65,66) and
the truck is switched on.

• Do not perform any travel, steering or hydraulic operations with the truck.
• Wait until the truck automatically cuts out at the end of the time period.
The truck is switched off and the LED (68) lights up red.
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119
 Error displays setting the automatic cutout period of the truck

For the following events the LED (68) flashes red:

Cause Remedy
– Switch off the truck, see page 108.
– Cutout time entered is out of
– Enter the time again while making sure it is
range
within range.

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120
 7.3.11 Assigning the travel program
The travel programs are fixed to the user code and can be released or blocked with
a configuration code. The configuration code can also be used to assign a starting
travel program to each user code.

Z The starting travel program is the travel program that is activated when the truck is
switched on and is displayed by the (64,65,66) LEDs.
LED (64) lit = travel program 1 activated
LED (65) lit = travel program 2 activated
LED (66) lit = travel program 3 activated

The configuration code is four-digit and is comprised as follows:

– 1st digit: Specifies the authorisation for travel program 1:
– 2nd digit: Specifies the authorisation for travel program 2:
– 3rd digit: Specifies the authorisation for travel program 3:
– 4. digit: Specifying the starting travel program
When you add or change a user code all travel programs are enabled, the starting
travel program is travel program 2.
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121
 Specifying a configuration code:

Setting Description
– Travel program 1 is blocked for the user code
0
selected
1st digit
– Travel program 1 is enabled for the user code
1
selected
– Travel program 2 is blocked for the user code
0
selected
2nd digit
– Travel program 2 is enabled for the user code
1
selected
– Travel program 3 is blocked for the user code
0
selected
3rd digit
– Travel program 3 is enabled for the user code
1
selected
– When the truck has been switched on with the
0
selected user code, no travel program is activated
– When the truck has been switched on with the
1
selected user code, travel program 1 is activated
4th digit
– When the truck has been switched on with the
2
selected user code, travel program 2 is activated
– When the truck has been switched on with the
3
selected user code, travel program 3 is activated

Z The default setting for the travel program configuration code is:
1-1-1-2.
Meaning:
Travel programs 1, 2 and 3 are enabled.
When the truck has been switched on with the selected user code, travel program 2
is activated

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122
 Adapting the travel program configuration to the
user code
64 65 66
Procedure
• Press the O key (69).
• Enter the valid master code with the digit keys.
When you enter the valid master code the green
LED (68) flashes green.

• Enter the parameters 0-2-4 with the digit keys.

• Confirm with the SET key (67).
The LEDs (64,68) flash green.

• Enter the valid user code with the digit keys. 67 68 69

• Confirm with the SET key (67).
The LEDs (65,68) flash green.

• Enter the configuration code (4 digit) for the travel programs.

• Confirm with the SET key (67).
The LEDs (66,68) flash green.

• Enter the configuration code (4 digit) for the travel programs again using the digit
keys.
• Confirm with the SET key (67).
Wait until the LED (68) flashes green. The travel programs are now assigned to
the user code.

• Press the O key (69).

The truck is switched off and the LED (68) is lit red.

• Checking the travel program configuration to the user code:

• Switch on the truck with the configured user code, see page 108
After entering the valid user code the LED (68) lights up green, the travel
program setting is shown by the illumination of the corresponding LEDs
(64,65,66) and the truck is switched on.

• Press the O key (69).

The truck is switched off and the LED (68) is lit red.

• If necessary, repeat the procedure for other user codes.

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123
 Error displays configuring the travel programs

For the following events the LED (68) flashes red:

Cause Remedy
– Blocked travel program – Switch off the truck, see page 108.
defined as start travel – Try again, making sure the configuration code is
program entered correctly.

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124
 7.4 Setting the truck parameters with CanCode
CAUTION!
Incorrect input
Without CanDis, only CanCode internal parameters can be changed. Traction
controller parameters can be changed only with CanDis; without CanDis, the settings
must be configured by the manufacturer's service department.

CAUTION!
Altering settings for the travel and hydraulic functions can result in accidents
Increasing the settings for travel and hydraulic functions can result in accidents.
uCarry out a test run in a secure environment.
uThis requires greater attention on the part of the operator.

Parameter-setting example

The following example shows the parameter setting for the acceleration of travel
program 1 (parameter 0256).

Acceleration example

Procedure
• Enter four-digit parameter number "0256" and confirm with the Set key (67).
• Enter subindex (enter "2") and confirm with the Set key (67).

Z The parameter and sub index are displayed alternately with the current reading
(0256-2<->0000-3).
• Enter the parameter according to the parameter list and confirm with the Set key
(67).

Z The LED (68) of the O key (69) switches briefly to continuous light and starts
flashing again after 2 seconds.

Z If the entry is incorrect, the LED (68) of the O key (69) flashes in red. Enter the
parameter number again to repeat the setting.

Z The parameter and sub index are displayed alternately with the current reading
(0256-2<->0000-5).

The travel parameter is now set.

Repeat the procedure to enter further parameters as soon as the LED (68) of the O
key (69) flashes.

Z Travel is disabled while the parameters are being entered.

Checking the setting in programming mode

Procedure
• Select the travel program to be worked on after entering the parameter value, and
04.19 en-GB

confirm with the Set key (67).

The truck is now in travel mode and can be checked.

125
Z To continue setting, reconfirm with the Set key (67).
Saving travel parameters

Requirements
– Enter all parameters.
Procedure
• Run "SaveParameters" by pressing 1-2-3-Set.
• Confirm with the O key (69).

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126
 7.5 Parameters

Travel program 1

No. Function Setting range Standard Comments

setting
0256 Acceleration 0-9 2
(0.2 - 2.0 m/s2) (0.6 m/s2)
0260 Coasting brake 0-9 6
(0.2 - 1.1 m/s2) (0.8 m/s2)
0264 Maximum speed in drive
0-9 6 depending on
direction using travel
(0.5 - 6.0 km/h) (4.8 km/h) travel switch
switch
0268 Maximum speed in load
0-9 6 depending on
direction using travel
(0.5 - 6.0 km/h) (4.8 km/h) travel switch
switch

Travel program 2

No. Function Setting range Standard Comments

setting
0272 Acceleration 0-9 5
(0.2 - 2.0 m/s2) (1.2 m/s2)
0276 Coasting brake 0-9 6
(0.2 - 1.1 m/s2) (0.8 m/s2)
0280 Maximum speed in drive
0-9 9 depending on
direction using travel
(0.5 - 6.0 km/h) (6.0 km/h) travel switch
switch
0284 Maximum speed in load
0-9 9 depending on
direction using travel
(0.5 - 6.0 km/h) (6.0 km/h) travel switch
switch

Travel program 3

No. Function Setting range Standard Comments

setting
0288 Acceleration 0-9 9
(0.2 - 2.0 m/s2) (2.0 m/s2)
0292 Coasting brake 0-9 9
(0.2 - 1.1 m/s2) (1.1 m/s2)
0296 Maximum speed in drive
0-9 9 depending on
direction using travel
(0.5 - 6.0 km/h) (6.0 km/h) travel switch
switch
0300 Maximum speed in load
0-9 9 depending on
direction using travel
(0.5 - 6.0 km/h) (6.0 km/h) travel switch
switch
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127
 Battery parameters

No. Function Range Standard Comments

setting
1377 Battery type 0-9 1 0 = Normal (wet)
1 = High performance
(wet)
2 = Dry (maintenance-
free)
9 = XFC
(Special battery)
1389 Discharge monitor 0 /1 1 0 = Not active
function 1 = Active

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128
 7.6 Setting the Battery Parameters with CanCode

WARNING!
Altering parameters can cause accidents 64 65 66

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".
Requirements
– CanCode and CanDis are available.
67 68 69
Procedure
• Press the O key (69).
• Enter the master code.
• Enter the four-digit parameter number "1377" and
confirm with the Set key.
• Enter sub index "2" and confirm with the Set key.
The parameter with subindex are displayed
alternately with the current reading. E.g. (1377-2<-
>0000-1--corresponds to battery type „high-
performance (wet)”.
• Enter parameter "2" according to the parameter list
and confirm with the Set key.
The LED of the O key switches briefly to
continuous light and starts flashing again after
approx. 2 seconds.
If the entry is incorrect, the LED of the O key turns
red. Enter the parameter number again to repeat
the setting.
The parameter and subindex are displayed
alternately with the current reading (1377-2<-
>0000-2).

The "dry maintenance-free" battery type is set.

Z Travel is disabled while the parameters are being

entered.
Storing the parameter

Requirements
– The parameter is now entered.
Procedure
04.19 en-GB

• Run "SaveParameters" by pressing 1-2-3-Set.

• Press the O key.

129
 The parameter is now saved.

Testing an altered parameter

Requirements
– The parameter is now saved.
Procedure
• Press the O key (69).
• Enter the master code.
• Enter the four-digit parameter number "1377" and confirm with the Set key.
• Enter sub index "2" and confirm with the Set key.
The parameter with subindex are displayed alternately with the current reading.
E.g. (1377-2<->0000-2--corresponds to the "dry - maintenance-free" battery type.
• Press the O key.

The parameter has now been checked.

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130
 7.7 CanDis Display Instrument (o)

The instrument indicates:

Battery charge display (on board charger

70
only) 70 71
71 LED bars for battery charge status
72 73
"Warning" symbol (yellow),
72
Battery charge recommended 74 75
"Stop" symbol (red); lift cut-off,
73
Battery charge essential
No symbol when battery type set to normal
or enhanced performance wet cell battery
"T" symbol appears permanently during
74 operation when battery type set to
maintenance-free
"T" symbol flashes during operation when
battery type set to special, such as XFC
6 digit LCD:
– Service hours
75
– Parameter entry and changes
– Event messages

Charge status display

The charge status is shown through eight LED bars.

Eight lit LED bars correspond to a fully charged battery. One lit LED bar corresponds
to an almost discharged battery.

When the "Attention" symbol (72) starts to flash, it is advisable to charge the battery.

If the "Attention" symbol (72) is lit steadily, the battery must be charged.

If the "Stop" symbol (73) is lit steadily, the battery must be charged immediately. If
activated, the discharge monitor function is applied in this case, see page 132.

Z The point at which the "Attention" (72) and "Stop" (73) symbols start to light up
differs depending on the battery type.
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131
7.7.1 Discharge monitor function

The discharge limit has been reached when the "Stop"

symbol (73) lights up. When the discharge monitor
function is activated lifting operations are disabled.
Travel and lowering are still possible. 70 71

Lifting is only enabled again when the battery is 70% 72 73

charged.
74 75

7.7.2 Service hour display

The service hour display range is between 0.0 and 99,999.0 hours. The display (75)
has background lighting.

Z For maintenance-free batteries a "T" (74) symbol is shown in the display.

Z For special batteries the "T" (74) symbol flashes in the service hour display.

7.7.3 Event Messages

The service hours display is also used to display event messages. The event
messages overwrite the service hour display. Event message start with an ”E” for
Event and a four-digit error number.
The event message is displayed as long as the fault persists. If there are several
event messages they are displayed consecutively. Most event messages result in
the Emergency Stop being activated.

Z Remedies, see page 97.

7.7.4 Power up test

Once the truck has become operational the following displays appear:
– Display unit software version is flashed briefly
– Service hours
– Battery charge status
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132
 7.8 Display unit (2 inch display)

76

77
59
78 79
80

81

82

83

Item Control or Function

display element
59 Battery capacity display Battery discharge status
76 Information line Displays event messages and optional
information such as speed or remaining time.
77 Power display Shows the available power in the travel
program selected.
78 Symbol field Displays the symbols, see page 136.
79 Battery type Displays the set battery type or set battery
1
(characteristics) characteristic curve
1 = Maintenance-free gel/dry-cell battery
2 = Special battery, for example XFC
80 Travel program Shows the travel program selected.
81 Service hours Shows the truck service hours, see page 20.
82 Button allocation see page 135
83 Buttons Selection buttons for the functions shown
above them.
04.19 en-GB

1) If the setting is for normal or high-performance wet-cell batteries or batteries for special options, no battery type is shown.

133
7.8.1 Information field
Any event messages are shown in the left section of the information line (76).

The right section of the information line shows the truck speed in km/h or mph.

Z The manufacturer's customer service department can change the information line
from kg and km/h units to lbs and mph units and vice versa.

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134
 7.8.2 Button allocation of the display
Functions and operator menus that can be operated via the icons and keys of the
display unit depend on the operating situation as well as the scope and settings of
the truck.
Key allocation in main menu

Symbol Meaning
Menu change:
Changes to the next operator menu

Travel program up (t):

Changes the travel program in rider mode
(No symbol) (o):
Uses the pre-set travel program in rider mode
The default setting can be changed by the manufacturer's customer
service department.
Shut-down (o):
Allows the truck to be switched off
Switch off is only available on the display if the truck is switched on with
an access code.
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135
7.8.3 Symbols in the display
Any number of pictograms can be displayed in the pictogram field (78). Which
pictograms are shown in the pictogram field depends on the operating and truck
status.

Symbol Meaning Colour Function

Operator platform Yellow Operator platform not occupied when
Deadman switch travel switch actuated (trucks without
pedestrian mode optional equipment
only)
Stop notice red Truck malfunction detected.
– Lifting, lowering and travel functions
deactivated.

Warning yellow Operating error

red Truck malfunction detected
– Lifting, lowering and/or travel functions
reduced
Battery indicator, Yellow Battery capacity ≤30% for wet-cell
low residual batteries and lithium-ion batteries,
capacity battery capacity ≤50% for maintenance-
free batteries
– Charge the battery soon.
Red Battery capacity ≤20% for wet-cell
batteries and lithium-ion batteries,
battery capacity ≤40% for maintenance-
free batteries
– Charge the battery immediately.
Charging Green Battery charge display (on-board battery
charger only):
– Flashing:
Charging in progress
– Steady light:
Charging complete
Red Charging interrupted
Overtemperature yellow Overtemperature detected
– Lifting, lowering and travel functions
reduced
Red Overtemperature detected
– Lifting, lowering and travel functions
deactivated
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136
 Symbol Meaning Colour Function
Lithium-ion battery Yellow Lithium-ion battery low temperature
low temperature detected
(o) – Discharge currents and energy
recovery are reduced at low
temperatures.
Lithium-ion battery below permissible
temperature range
– The truck switches off via the battery
contactor.
– The display unit switches off.
Side arm Yellow Illuminates if both side arms are not
folded in or both are not folded out.

Lift deactivated Yellow Illuminates if the lifting functions are shut

off due to insufficient battery capacity.

Tiller position Yellow Lights up on power-up with tiller in travel

zone.
Illuminates with travel switch operated
and tiller in braking zone.
Support arm lift Yellow Illuminates if the "lift support arms"
lifting limit button is pressed when the lifting limit of
the support arm lift has been reached.

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.

Slow travel Green Symbol illuminates when the "slow

travel" button is pressed (travel speed
reduction).
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137
7.9 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

Z When allocating the codes, ensure the rider trucks are given a different code than
pedestrian trucks.

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138
 7.10 Using the Display:

7.10.1 Switch on the truck with the access code.

55

Procedure
• Release the emergency disconnect switch, see page 75.
• Enter the access code with the buttons below the display (55).

The truck is switched on.

7.10.2 Switching off the truck

Procedure
• Press the key under the "Switch off" symbol (84) in the
display unit. 84
• Press the Emergency Disconnect switch, see page 75.

The truck is switched off.

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139
7.10.3 Changing the Set-up Code

Requirements
– The truck is switched on, see 85
page 139.
Procedure
86
• Press the key below the "Settings"
symbol (85).
• Press the key below the "Change set-
up code" symbol (86).
• Enter the set-up code using the keys
below the display unit (55).
The set-up code entered is shown as 55
filled-in circles.

• Press the key below the "Delete"

symbol (87).
The set-up code is deleted.
87
• Enter the new set-up code using the
keys below the display unit (55).

Z The new set-up code must be different

from existing access codes. 88

• Press the key below the "Confirm"

symbol (88).
The new set-up code is displayed.

Z If the new set-up code has been

entered incorrectly, delete it and add a
set-up code again.

To return to the main menu, press the

key below the "Back" symbol (89).

The set-up code has been changed. 89 04.19 en-GB

140
 7.10.4 Adding a new access code

Requirements
– The truck is switched on, see
page 139.
85
Procedure
• Press the key below the "Settings"
symbol (85).
• Press the key below the "Edit access
90
code" symbol (90).
The set-up code is requested.

• Enter the set-up code using the keys

below the display unit (55).
All the access codes are displayed.
55
• Press the key below the "Add"
symbol (91).
• Enter the new access code using the
keys below the display unit (55).

Z The new access code must be

different from existing access codes.
• Press the key below the "Confirm"
symbol (88).
The new access code is displayed.

Z If the new access code has been 91

entered incorrectly, delete it, see
page 142, and add an access code
again. 88
89

To return to the main menu, press the

key below the "Back" symbol (89).

A new access code has been added.

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141
7.10.5 Deleting an access code

Requirements
– The truck is switched on, see 85
page 139.
Procedure
• Press the key below the "Settings"
90
symbol (85).
• Press the key below the "Edit access
code" symbol (90).
The set-up code is requested.
87
• Enter the set-up code using the keys
below the display unit (55).
All the access codes are displayed.

• Select the access code to be deleted

using the key below the "Down
55
selection" symbol (92).
• Press the key below the "Delete"
symbol (87).
The access code has been deleted.

• To return to the main menu, press the

key below the "Back" symbol (89).

87

89 92

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142
 7.10.6 Displaying the Log-in Process
The use of the last different access codes is displayed during the log-in process. The
last log-in is displayed first.

Z If multiple access codes are logged as being displayable simultaneously, the display
area can be moved by scrolling forward or back.

Requirements
– The truck is switched on, see 85
page 139.
Procedure
• Press the key below the "Settings" 93
symbol (85).
• Press the key below the "Log-in
process" symbol (93).
• Enter the set-up code using the keys
below the display unit (55).
The set-up code entered is shown as
filled-in circles. 55

• To scroll forward, press the button

under the "Down selection" symbol (92)
as many times as necessary.
The display area moves: Additional
earlier log-ins are displayed.

• To scroll back, press the button under

the "Up selection" symbol (94) as many
times as necessary.
The display area moves: More recent
log-ins are displayed.

• To return to the main menu, press the

key below the "Back" symbol (89).
89 92 94
The log-in process is displayed.

7.11 ISM access module (o)

Z *If the truck is equipped with an ISM access module or Can Code refer to the “ISM
Access Module” or "CanCode" operator manuals.
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143
144
04.19 en-GB
 F Industrial Truck Maintenance
1 Operational Safety and Environmental Protection
The inspections and maintenance tasks listed in chapter "Maintenance, Inspection
and Changing of Maintenance Parts Requiring Replacement" must be performed
according to the defined service intervals (see page 171).

The manufacturer recommends the replacement of the maintenance parts also listed
in chapter "Maintenance, Inspection and Changing of Maintenance Parts Requiring
Replacement" according to the specified replacement intervals (see page 171).

WARNING!
Risk of accidents and component damage
Any modification to the truck, in particular the safety mechanisms, is prohibited.

Exception: Operating companies may make changes or have changes made to

powered industrial trucks only if the truck 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 an
engineer specialising in industrial trucks taking safety into account.
– Keep permanent records of plans, tests and completion of changes.
– Carry out and have authorised the respective changes to the capacity data plates,
decals and stickers as well as the operating instructions and workshop manuals.
– Attach a permanent and clearly visible marking to the truck indicating the type of
changes made, the date of the changes and the name and address of the
organisation responsible for the work.

NOTICE
Only original spare parts are subject to the manufacturer's quality control. To ensure
safe and reliable operation, use only the manufacturer's spare parts.

Z On completion of inspection and service work, carry out the operations listed in the
“Recommissioning the truck after cleaning or maintenance work” section (see
page 166).
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145
2 Maintenance Safety Regulations

Maintenance and repair personnel

Z 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. The activities to be carried out are
divided into the following target groups.

Customer Services

Customer Services are specially trained in the use of the truck and are able to carry
out maintenance and repairs independently. Customer Services are aware of the
relevant standards, guidelines and safety regulations as well as potential risks.

Operating company

The maintenance personal of the operating company has the technical expertise and
experience to perform the activities in the maintenance check list for the operating
company. The maintenance and repair work to be performed by the operating
company are also written down, see page 154.

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).

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146
 2.1 Working on the electrical system
WARNING!
Electrical current can cause accidents
Make sure the electrical system is voltage-free before starting work on it. The
capacitors in the controller must be completely discharged. The capacitors are
completely discharged after approximately 10 minutes. Before starting maintenance
on the electrical system:
uOnly suitably trained electricians may operate on the truck's electrical system.
uBefore working on the electrical system, take all precautionary measures to avoid
electric shocks.
uPark the truck securely (see page 71).
uRemove the battery, see page 44.
uRemove any rings, metal wristbands etc.

2.2 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.
uNote the safety regulations when handling these materials.

2.3 Wheels
WARNING!
The use of wheels that do not comply with the manufacturer's specifications
can result in accidents
The quality of wheels affects the stability and driving characteristics of the truck.
Uneven wear affects the truck's stability and increases the stopping distance.
uAfter replacing wheels, make sure the truck is not skewed.
uAlways replace wheels in pairs, i.e. the left- and right-hand wheels at the same
time.

Z When replacing wheels fitted at the factory, only use the manufacturer’s original
spare parts. Otherwise the manufacturer's specification will not be adhered to.
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147
2.4 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.
uRemove any spilled hydraulic immediately with an appropriate bonding agent.
uThe bonding agent / consumable mixture must be disposed of in accordance with
regulations.

WARNING!
Faulty hydraulic hoses can result in injury and infection
Pressurised hydraulic oil can escape from fine holes or hairline cracks in the
hydraulic hoses. Brittle hydraulic hoses can burst during operation. People standing
near the truck can be injured by the hydraulic oil.
uCall for a doctor immediately in the event of an injury.
uDo not touch pressurised hydraulic hoses.
uReport any defects immediately to your supervisor.
uMark defective truck and take it out of service.
uDo not return the industrial truck to service until you have identified and rectified
the fault.

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148
 NOTICE
Testing and replacing hydraulic hoses
Hydraulic hoses can become brittle through age and must be checked at regular
intervals. The application conditions of the industrial truck have a considerable
impact on the ageing of the hydraulic hoses.
uCheck the hydraulic hoses at least annually and replace if necessary.
uIf the operating conditions become more arduous the inspection intervals must be
reduced accordingly.
uIn normal operating conditions a precautionary replacement of the hydraulic hoses
is recommended after 6 years. The owner must carry out a risk assessment to
ensure safe, prolonged use. The resulting protection measures must be observed
and the inspection interval reduced accordingly.

Z The auxiliary hydraulics of the EJE 220r / 225r is a closed system. The auxiliary
hydraulics must only be replaced or topped up by the manufacturer's customer
service department who are specially trained for this task.

Z Mini measurement connections on the truck should only be used by the

manufacturer's trained customer service department.
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149
3 Lubricants and Lubrication Schedule

3.1 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.
uAlways fill consumables in clean containers.
uDo not mix up different grades of consumable. The only exception to this is when
mixing is expressly stipulated in the operating instructions.

CAUTION!
Spilled consumables can cause slipping and endanger the environment
Risk of slipping from spilled consumables. The risk is greater when combined with
water.
uDo not spill consumables.
uSpilled consumables must be removed immediately with an appropriate bonding
agent.
uThe bonding agent / consumable mixture must be disposed of in accordance with
regulations.

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150
 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.
uSpilled oils must be removed immediately with an appropriate bonding agent.
uThe mixture consisting of the bonding agent and oil must be disposed of in
accordance with regulations.
uObserve national regulations when handling oils.
uWear safety gloves when handling oils.
uPrevent oil from coming into contact with hot motor parts.
uDo not smoke when handling oil.
uAvoid contact and digestion. If you swallow oil do not induce vomiting but seek
medical assistance immediately.
uSeek fresh air after breathing in oil fumes or vapours.
uIf oil has come into contact with your skin, rinse your skin with water.
uIf oil has come into contact with your eyes, rinse them with water and seek medical
assistance immediately.
uReplace oil-soaked clothing and shoes immediately.

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.
uNote the safety regulations when handling these materials.
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151
3.2 Lubrication Schedule

0,9 l

B 0,55 l

Cold-store application
g Running surfaces Mixing ratio 1:1
s Grease nipple a Transmission-oil drain plug
b Transmission-oil filler neck Gear-oil overflow and dipstick

Hydraulic-oil filler plug

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152
 3.3 Consumables
Cod Order no. Quantity Description Used for
e
A 5044 9669 5.0 l H-LP 46, DIN 51524 Hydraulic system
5113 2827 * 5.0 l Jungheinrich
hydraulic oil
B 5038 0904 5.0 l Fuchs Titan Gear Transmission
HSY 75W-90
C 5103 7497 * 5.0 l H-LP 22, DIN 51524 Hydraulic system
Cold-store hydraulic oil Additive for use in
cold stores
E 2920 1430 1.0 kg Grease, DIN 51825 Lubrication
F 5043 0702 1.0 kg Grease, DIN 51818 Lubrication
Low temperature

*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 can only be obtained from the
Jungheinrich service department. The use of named alternative hydraulic oils is
not prohibited but may lead to a decline in functionality. The Jungheinrich
hydraulic oil may be mixed with one of the named alternative hydraulic oils.

Z For cold store operations the Jungheinrich hydraulic oil and the cold store hydraulic
oil must be mixed in a 1:1 ratio.

Grease guidelines

Code Saponification Dew point Worked NLG1 class Application

°C penetration temperature
at 25 °C °C
E Lithium 185 265 - 295 2 -35/+120
F -- -- 310 - 340 1 -52/+100
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153
4 Maintenance and repairs

4.1 Preparing the truck for maintenance and repairs

All necessary safety measures must be taken to avoid accidents when carrying out
maintenance and repairs. The following preparations must be made:
Procedure
• Park the truck securely, see page 71.
• Disconnect the battery to prevent the truck from being switched on accidentally.

WARNING!
Risk of accidents when working under the load handler and lift truck
uWhen working under a raised load handler or a raised truck, secure them to
prevent the truck from from lowering, tipping or sliding away.
uWhen raising the truck, follow the instructions, see page 35. When working on the
parking brake, prevent the truck from accidentally rolling away (e.g. with wedges).

4.2 Lifting and jacking up the truck safely

WARNING!
A truck tipover can cause accidents
In order to raise the truck, use only suitable lifting gear at the points specially
provided for this purpose.
uNote the weight of the truck on the data plate.
uAlways use a jack with sufficient capacity.
uRaise the unladen truck on a level surface.
uWhen raising the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).

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154
 Raising and jacking up the truck securely

Requirements
– Prepare the truck for maintenance and repairs (see page 154).
Tools and Material Required
– Jack
– 4 hard wooden blocks
Procedure
• Apply the jacks in turn:
• On the right-hand side of the drive chassis
• On the right-hand side of the load handler
• On the left-hand side of the drive chassis
• On the left-hand side of the load handler
• Raise the truck.
• Support the truck with hard wooden blocks.
• Remove the jack.

The truck is now securely raised and jacked up.

4.3 Cleaning

4.3.1 Cleaning the truck

04.19 en-GB

Z The truck may only be cleaned in the designated locations, which adhere to the
stipulations of the country of use.

155
 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.
uCover all electronic system assemblies (controllers, sensors, motors etc.) before
cleaning the truck with a pressure washer.
uDo not hold the jet of the pressure washer by the marked points to avoid damaging
them (see page 31).
uDo not clean the truck with pressurised water.

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156
 Cleaning the truck

Requirements
– Prepare the truck for maintenance and repairs (see page 154).
Tools and Material Required
– Water-based solvents
– Sponge or cloth
Procedure
• Clean the surface of the truck with water-based solvents and water. Use a sponge
or cloth to clean.
• In particular, clean the following areas:
• Window(s)
• Oil filler ports and their surroundings
• Grease nipples (before lubrication)
• Dry the truck after cleaning, e.g. with compressed air or a dry cloth.
• Carry out all the tasks in the section "Recommissioning the truck after cleaning or
maintenance work" (see page 166).

The truck is now clean.

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157
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.
Cleaning the electrical system assemblies

Requirements
– Prepare the truck for maintenance and repairs (see page 154).
Tools and Material Required
– Compressor with water separator
– Non-conductive, antistatic brush
Procedure
• Expose the electrical system, see page 159.
• Clean the electrical system assemblies with weak suction or compressed air (use
a compressor with a water trap) and not a conductive, anti-static brush.
• Fit the electrical system panel, see page 159.
• Carry out all the tasks in the section "Recommissioning the truck after cleaning or
maintenance work" (see page 166).

The electrical system assemblies are now clean.

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158
 4.4 Front cover disassembly

95
Front cover disassembly

Requirements
– Prepare the truck for maintenance
and repairs, see page 154.
Tools and Material Required
– Allen key size 8
15
Procedure
• Remove the screws (95) with the
Allen key.
• Lift and remove the front panel
(15).
• Place the front panel (15) safely to
one side.

The front cover has been removed.

Front panel assembly

Tools and Material Required

– Allen key size 8
Procedure
• Insert the front panel (15) carefully and secure it.
• Attach the front cover (15) to the truck with the screws (95). Tighten the
screws (95) with the Allen key.

The front panel is now assembled.

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4.5 Drive panel disassembly and assembly
The drive panel consists of two halves (63 and 97).

Drive panel disassembly

Tools and Material Required

– Allen key
Procedure
• Turn the tiller to the right limit position.
• Remove 2 screws (96).
• Carefully remove the first half (63).
• Turn the tiller to the left limit position.
• Release the second half (97) and
carefully remove it.

The drive panel is now disassembled.

96 97 63 96

Drive panel assembly

Tools and Material Required

– Allen key
Procedure
• Turn the tiller to the right limit position.
• Carefully insert the first half (63).
• Tighten the first half (63) with 2 screws (96).
• Turn the tiller to the left limit position.
• Carefully insert the second half (97).
• Tighten the second half (97) with 2 screws (96).

The drive panel is now assembled.

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 4.6 Tightening the wheel nuts

Z The wheel nuts on the drive wheel must be retightened in accordance with the
maintenance intervals indicated in the maintenance checklist, see page 171.
Tightening the wheel nuts

Requirements
– Prepare the truck for maintenance and repairs, see page 154.
Tools and Material Required
– Torque wrench
Procedure
• Position the drive wheel (99) so that the wheel nuts (98) can be pulled through the
hole (100).
• Tighten all the wheel nuts (98) through the hole (100) in the impact buffer with the
socket wrench.
To do this, tighten the wheel nuts in the prescribed order.
• First of all tighten to 10 Nm.
• and then to 150 Nm.

The wheel nuts have now been tightened.

98

99 99

100
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4.7 Checking the hydraulic oil level

Checking the hydraulic oil level and

replenishing

Requirements
101
– Fully lower the load handler.
102
– Prepare the truck for maintenance and
repairs, see page 154.
Procedure
• Remove the front panel, see page 159. 103
• Check the oil level in the hydraulic
reservoir (103).

Z The hydraulic reservoir (103) has two

markings (101). With the load handler
completely lowered, the hydraulic oil level in
the reservoir should lie between the min. and
max. markings (101).
• Add hydraulic oil if necessary:
• Turn the lid (102) anti-clockwise from the hydraulic reservoir (103).
• Add hydraulic oil of the correct grade until the oil level lies between the
markings (see page 153).
• Turn the lid (102) clockwise on the hydraulic reservoir (103).
• Install the front panel, see page 159.
• To restore the industrial truck to service after maintenance or repair work, see
page 168.

The hydraulic oil level is now checked.

Z If a leak is discovered in the hydraulic system (cylinder; unions, lines), the truck must
be decommissioned and repaired by specialist personnel.

4.7.1 Top up the auxiliary hydraulics on the EJE 220r / 225r

Z The auxiliary hydraulics of the EJE 220r / 225r is a closed system. The auxiliary
hydraulics must only be replaced or topped up by the manufacturer's customer
service department who are specially trained for this task.

Z Mini measurement connections on the truck should only be used by the

manufacturer's trained customer service department.
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 4.8 Check the gear oil level
Check the transmission oil level

Requirements
– Park the truck securely, see page 71.
Tools and Material Required
– Oil sump
Procedure
• Place the oil drain tray underneath the transmission (105).
• Remove the front panel (15), see page 159.
• Turn the tiller (8) to the right limit position.
• Check transmission oil level and, if necessary, top up with the correct grade
through the filler hole (104).

Z The oil level should reach the lower edge of the oil control screw (106) .

The transmission oil level is now checked.

15

104

105

106
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4.9 Checking electrical fuses
Checking fuses

Requirements
– Truck prepared for maintenance and repairs, see page 154.
– Front panel removed, see page 159.
Procedure
• Check the fuse ratings against the table and replace if necessary.

The fuses have been checked.

EJE 220 / 225 / 230 / 235

107 108 109 110

Item Description To protect Rating

107 F13 Solenoid / magnetic brake control fuse 10 A
108 1F9 Traction / lift electronics control fuse 5A
109 6F1 Discharge indicator control fuse 2A
110 F15 Travel / lift fuse 200 A
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164
 EJE 220r / 225r

111 107 108 109 110

Item Component To protect Rating

107 F13 Solenoid / magnetic brake control fuse 10 A
108 1F9 Travel / lift electronics control fuse 5A
109 6F1 Discharge indicator control fuse 2A
110 F15 Travel / lift fuse 200 A
111 9F17 EJE 220r / 225r auxiliary hydraulics fuse 2A
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165
4.10 Restoring the truck to service after maintenance and repairs
Procedure
• Thoroughly clean the truck, see page 155.
• Lubricate the truck according to the lubrication schedule, see page 152.
• Clean the battery, grease the terminal screws and connect the battery.
• Charge the battery, see page 45.
• Start up the truck, see page 67.

WARNING!
Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times.
uReport any defects immediately to your supervisor.
uTag out and decommission the faulty industrial truck.
uOnly return the truck to service when you have identified and rectified the fault.

Z If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly.

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166
 5 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. This is the only way of ensuring that the wheels and wheel bearings
are not damaged.

Z Jack up the truck, see page 154.

If the truck is to be out of service for more than 6 months, agree further measures
with the manufacturer's customer service department.

5.1 Prior to decommissioning

Procedure
• Thoroughly clean the truck, see page 155.
• Prevent the truck from rolling away accidentally.
• Check the hydraulic oil level and replenish if necessary, see page 162.
• Apply a thin layer of oil or grease to any non-painted mechanical components.
• Lubricate the truck according to the lubrication schedule, see page 152.
• Charge the battery, see page 45.
• Disconnect the battery, clean it and grease the terminals.

Z In addition, follow the battery manufacturer’s instructions.

5.2 Action to be taken during decommissioning

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.

Z Charge the battery, see page 45.

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167
5.3 Restoring the truck to service after decommissioning
Procedure
• Thoroughly clean the truck, see page 155.
• Lubricate the truck according to the lubrication schedule, see page 152.
• Clean the battery, grease the terminal screws and connect the battery.
• Charge the battery, see page 45.
• Start up the truck, see page 67.

WARNING!
Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times.
uReport any defects immediately to your supervisor.
uTag out and decommission the faulty industrial truck.
uOnly return the truck to service when you have identified and rectified the fault.

Z If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly.

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168
 6 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.

A complete test must be carried out on the technical condition of the truck with
regard to safety. The truck must also be examined thoroughly for damage.

The operating company is responsible for ensuring that faults are rectified
immediately.

7 Final de-commissioning, disposal

Z Final de-commissioning or disposal of the truck in must be performed in accordance

with the regulations of the country of use. In particular, regulations governing the
disposal of batteries, consumables and electronic and electrical systems must be
observed.
The truck must only be disassembled by trained personnel in accordance with the
procedures as specified by the manufacturer.

8 Human vibration measurement

Z Vibrations that affect the operator over the course of the day are known as human
vibrations. Excessive human vibrations will cause the operator long term health
problems. The European "2002/44/EC/Vibration" operator directive has therefore
been established to protect operators. To help operators to assess the application
situation, the manufacturer offers a service of measuring these human vibrations.
04.19 en-GB

169
170
04.19 en-GB
 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.
NOTICE
The application conditions of an industrial truck have a considerable impact on
component wear. The following service, inspection and replacement intervals are
based on single-shift operation under normal operating conditions. The intervals
must be reduced accordingly if more stringent requirements are placed on the
equipment, e.g., use in conditions of extreme dust, temperature fluctuations or
multiple shifts.
uTo prevent damage due to wear, the manufacturer recommends an on-site
application analysis to agree on appropriate intervals.

The following chapter defines the tasks to be performed, the respective intervals to
be observed and the maintenance parts for which replacement is recommended.
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1 Maintenance Contents EJE 235
Issued on: 2019-04-24 12:00

1.1 Owner
To be performed every 50 service hours, but at least once a week.

1.1.1 Maintenance contents

1.1.1.1 Standard equipment

Brakes
Test the function of the brakes

Hydraulic operations
Correct the hydraulic oil level.

Steering
Test the tiller return function.

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172
 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.
04.19 en-GB

173
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
The function of the collision safety switch and for damage
Wheels for wear and damage

Chassis/structure
Industrial truck for damage and leaks
Labels are legible, complete and plausible
Doors and/or covers for damage
Protective mechanism against trapping and shearing is present, secure, functions
correctly and is free of dirt and damage

Hydraulic operations
The function of the hydraulic system
The forks or load handler for wear and damage

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174
 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
04.19 en-GB

175
1.2 Customer Service

1.2.1 Maintenance contents

In accordance with the EJE 235 service interval, to be performed every 1000 service
hours, but at least once a year.

1.2.1.1 Standard equipment

Brakes
Test the brake with the tiller in the maximum vertical and horizontal positions.
Measure the air gap of the magnetic brake.

Electrical system
Test the contactors and/or relays.
Carry out a chassis insulation-resistance test.

Chassis/structure
Check that the panels and covers as well as mounting brackets are secure. Ensure they
function correctly and are safe.

Hydraulic operations
Correct the hydraulic oil level.
Test the pressure relief valve.

Agreed services
Carry out a test run with the rated load or a customer-specific load.
Demonstration after maintenance.
Lubricate truck according to the lubrication diagram.

Steering
Test the tiller return function.

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176
 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.

Lead-acid battery, international

Power supply
Clean and grease the battery terminals.
Clean the battery.
Measure the acid density and battery voltage.
Correct the battery acid level using demineralised water.

Lead-acid battery

Power supply
Clean and grease the battery terminals.
Clean the battery.
Measure the acid density and battery voltage.
Correct the battery acid level using demineralised water.
04.19 en-GB

177
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
The function of the battery latch and battery attachment and for damage
The function and secure seating of the battery connector and for damage

Travel
Drivetrain bearings for wear and damage
Transmission for noise and leaks
Wheel bearings and attachment for wear and damage
Wheels for wear, damage and secure mounting

Chassis/structure
Industrial truck for damage and leaks
The secure seating of the chassis and screw connections and for damage
Labels are legible, complete and plausible
Protective mechanism against trapping and shearing is present, secure, functions
correctly and is free of dirt and damage

Hydraulic operations
The function of the "hydraulic system" controls and for legibility, completeness and
plausibility
The function of the lift mechanism and for wear and damage
The secure seating of the cylinders and piston rods and for leaks 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
The secure seating of the hoses, pipes and connections and for wear, leaks, damage,
blisters and kinks

Steering
04.19 en-GB

Lateral play of the tiller

The steering components for play and damage

178
 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
The function of the flow indicator and for leaks

Lateral battery removal

Power supply
The function of the battery latch and battery attachment and for damage

Shock sensor / data recorder

Electrical system
The shock sensor/data recorder is secure and for damage

Data radio

System components
The function and secure seating of the scanner and terminal and for damage
Fuse ratings
The secure seating of the cables and for damage

Access module

Electrical system
Access module is secure and functions correctly and for damage

Entry skids/rollers

Hydraulic operations
The function of entry skids or entry rollers and for damage and wear
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 Lead-acid battery, international

Power supply
The secure seating of the battery, battery cables and cell connectors and for damage
The presence of safety labels are present and for damage

Lead-acid battery

Power supply
The secure seating of the battery, battery cables and cell connectors and for damage

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180
 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 12
Hydraulic system - breather filter 2000 12
Transmission oil 10000

1.2.3.2 Optional equipment

Cold-store application

maintenance part service hours months

Hydraulic oil 1000 12
Hydraulic oil additive 1000 12
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181
2 Maintenance Contents EJE 220r-225r
Issued on: 2019-04-24 12:00

2.1 Owner
To be performed every 50 service hours, but at least once a week.

2.1.1 Maintenance contents

2.1.1.1 Standard equipment

Brakes
Test the function of the brakes

Hydraulic operations
Correct the hydraulic oil level.

Steering
Test the tiller return function.

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182
 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.
04.19 en-GB

183
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
The function of the collision safety switch and for damage
Wheels for wear and damage

Chassis/structure
Industrial truck for damage and leaks
Labels are legible, complete and plausible
Doors and/or covers for damage

Hydraulic operations
The function of the hydraulic system
The forks or load handler for wear and damage

04.19 en-GB

184
 2.1.2.2 Optional equipment
The following points must be checked:
Standard on-board charger

Battery charger
The mains plug and mains cable for damage

Lead-acid battery, international

Power supply
Battery and battery components for damage
Battery cable connections are secure

Lead-acid battery

Power supply
Battery cable connections are secure
04.19 en-GB

185
2.2 Customer Service

2.2.1 Maintenance contents

In accordance with the EJE 220r-225r service interval, to be performed every 1000
service hours, but at least once a year.

2.2.1.1 Standard equipment

Brakes
Test the function of the brakes
Measure the air gap of the magnetic brake.

Electrical system
Adjust the microswitches.
Test the contactors and/or relays.
Carry out a chassis insulation-resistance test.
Clean the motor (engine?) with compressed air.

Hydraulic operations
Test ramp lift and cut-off.
Adjust the lift mechanism.
Correct the hydraulic oil level.
Test the pressure relief valve.

Agreed services
Carry out a test run with the rated load or a customer-specific load.
Demonstration after maintenance.
Lubricate truck according to the lubrication diagram.

Steering
Test the tiller return function.
04.19 en-GB

186
 2.2.1.2 Optional equipment

Standard on-board charger

Battery charger
Test the immobiliser on trucks with on-board chargers.
Carry out a potential measurement on the chassis while charging is in progress.

Lead-acid battery, international

Power supply
Clean and grease the battery terminals.
Clean the battery.
Measure the acid density and battery voltage.
Correct the battery acid level using demineralised water.

Lead-acid battery

Power supply
Clean and grease the battery terminals.
Clean the battery.
Measure the acid density and battery voltage.
Correct the battery acid level using demineralised water.
04.19 en-GB

187
2.2.2 Inspection contents
The following points must be checked:

2.2.2.1 Standard equipment

Electrical system
Cables and engine are secure and for damage
Warning and safety devices are in accordance with the operating instructions
Function of display and controls
Microswitches for function and damage
The function of the emergency disconnect and for damage
Contactors and/or relays for wear and damage
Carbon brushes for wear
Connections and cables are secure and for insulation damage and other damage

Power supply
The function of the battery latch and battery attachment and for damage
The function and secure seating of the battery connector and for damage

Travel
Drivetrain bearings for wear and damage
Transmission for noise and leaks
Wheel bearings and attachment for wear and damage
Wheels for wear, damage and secure mounting

Chassis/structure
Industrial truck for damage and leaks
The secure seating of the chassis and screw connections and for damage
Labels are legible, complete and plausible
Doors and/or covers for damage

Hydraulic operations
The function of the "hydraulic system" controls and for legibility, completeness and
plausibility
The function of the lift mechanism and for wear and damage
The secure seating of the cylinders and piston rods and for leaks and damage
The function of the hydraulic system
The secure seating and function of the accumulator and for leaks
The forks or load handler for wear and damage
Tie/plunger rods are uniformly adjusted and for wear and damage
04.19 en-GB

188
 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
The function of the flow indicator and for leaks

Battery refill system

Power supply
The function of the battery refill system and for leaks

Lateral battery removal

Power supply
The function of the battery latch and battery attachment and for damage

Shock sensor / data recorder

Electrical system
The shock sensor/data recorder is secure and for damage

Access module

Electrical system
Access module is secure and functions correctly and for damage

Entry skids/rollers

Hydraulic operations
The function of entry skids or entry rollers and for damage and wear

Automatic crawl speed

Travel
Sensors/switches are secure and function correctly and for damage
04.19 en-GB

189
 Lead-acid battery, international

Power supply
The secure seating of the battery, battery cables and cell connectors and for damage
The presence of safety labels are present and for damage

Lead-acid battery

Power supply
The secure seating of the battery, battery cables and cell connectors and for damage

04.19 en-GB

190
 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 12
Hydraulic system - breather filter 2000 12
Transmission oil 10000

2.2.3.2 Optional equipment

Cold-store application

maintenance part service hours months

Hydraulic oil 1000 12
Hydraulic oil additive 1000 12
04.19 en-GB

191
3 Maintenance Contents EJE 230
Issued on: 2019-04-24 12:00

3.1 Owner
To be performed every 50 service hours, but at least once a week.

3.1.1 Maintenance contents

3.1.1.1 Standard equipment

Brakes
Test the function of the brakes

Hydraulic operations
Correct the hydraulic oil level.

Steering
Test the tiller return function.

04.19 en-GB

192
 3.1.1.2 Optional equipment

Lead-acid battery, international

Power supply
Correct the battery acid level using demineralised water.

Lead-acid battery

Power supply
Correct the battery acid level using demineralised water.
04.19 en-GB

193
3.1.2 Inspection contents

3.1.2.1 Standard equipment

The following points must be checked:

Electrical system
Warning and safety devices are in accordance with the operating instructions
Function of display and controls
The function of the emergency disconnect and for damage

Power supply
Battery and battery components for damage
The function and secure seating of the battery connector and for damage

Travel
The function of the collision safety switch and for damage
Wheels for wear and damage

Chassis/structure
Industrial truck for damage and leaks
Labels are legible, complete and plausible
Doors and/or covers for damage

Hydraulic operations
The function of the hydraulic system
The forks or load handler for wear and damage

04.19 en-GB

194
 3.1.2.2 Optional equipment
The following points must be checked:
Standard on-board charger

Battery charger
The mains plug and mains cable for damage

Lead-acid battery, international

Power supply
Battery and battery components for damage
Battery cable connections are secure

Lead-acid battery

Power supply
Battery cable connections are secure
04.19 en-GB

195
3.2 Customer Service

3.2.1 Maintenance contents

In accordance with the EJE 230 service interval, to be performed every 1000 service
hours, but at least once a year.

3.2.1.1 Standard equipment

Brakes
Test the function of the brakes
Measure the air gap of the magnetic brake.

Electrical system
Adjust the microswitches.
Test the contactors and/or relays.
Carry out a chassis insulation-resistance test.
Clean the motor (engine?) with compressed air.

Hydraulic operations
Correct the hydraulic oil level.
Test and adjust the pressure relief valve.

Agreed services
Carry out a test run with the rated load or a customer-specific load.
Demonstration after maintenance.
Lubricate truck according to the lubrication diagram.

Steering
Test the tiller return function.

04.19 en-GB

196
 3.2.1.2 Optional equipment

Standard on-board charger

Battery charger
Test the immobiliser on trucks with on-board chargers.
Carry out a potential measurement on the chassis while charging is in progress.

Lead-acid battery, international

Power supply
Clean and grease the battery terminals.
Clean the battery.
Measure the acid density and battery voltage.
Correct the battery acid level using demineralised water.

Lead-acid battery

Power supply
Clean and grease the battery terminals.
Clean the battery.
Measure the acid density and battery voltage.
Correct the battery acid level using demineralised water.
04.19 en-GB

197
3.2.2 Inspection contents
The following points must be checked:

3.2.2.1 Standard equipment

Electrical system
Cables and engine are secure and for damage
Warning and safety devices are in accordance with the operating instructions
Function of display and controls
Microswitches for function and damage
The function of the emergency disconnect and for damage
Contactors and/or relays for wear and damage
Carbon brushes for wear

Power supply
The function of the battery latch and battery attachment and for damage
The function and secure seating of the battery connector and for damage

Travel
Drivetrain bearings for wear and damage
Transmission for noise and leaks
Wheel bearings and attachment for wear and damage
Wheels for wear, damage and secure mounting

Chassis/structure
Industrial truck for damage and leaks
The secure seating of the chassis and screw connections and for damage
Labels are legible, complete and plausible
Doors and/or covers for damage

Hydraulic operations
The function of the "hydraulic system" controls and for legibility, completeness and
plausibility
The function of the lift mechanism and for wear and damage
The secure seating of the cylinders and piston rods and for leaks 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
04.19 en-GB

198
 3.2.2.2 Optional equipment

Standard on-board charger

Battery charger
The mains plug and mains cable for damage
The secure seating of the cables and electrical connections and for damage

Electrolyte circulation

Power supply
The function of the hose connections and pump

Aquamatik

Power supply
The function of the Aquamatik plug, hose connections and float and for leaks
The function of the flow indicator and for leaks

Lateral battery removal

Power supply
The function of the battery latch and battery attachment and for damage

Shock sensor / data recorder

Electrical system
The shock sensor/data recorder is secure and for damage

Access module

Electrical system
Access module is secure and functions correctly and for damage

Entry skids/rollers

Hydraulic operations
The function of entry skids or entry rollers and for damage and wear

Lead-acid battery, international

Power supply
The secure seating of the battery, battery cables and cell connectors and for damage
The presence of safety labels are present and for damage

Lead-acid battery

Power supply
04.19 en-GB

The secure seating of the battery, battery cables and cell connectors and for damage

199
3.2.3 Maintenance parts
The manufacturer recommends the replacement of the following maintenance parts
at the specified intervals.

3.2.3.1 Standard equipment

maintenance part service hours months
Hydraulic oil 2000 12
Hydraulic system - breather filter 2000 12
Transmission oil 10000

3.2.3.2 Optional equipment

Cold-store application

maintenance part service hours months

Hydraulic oil 1000 12
Hydraulic oil additive 1000 12

04.19 en-GB

200
 4 Maintenance Contents EJE 220/225
Issued on: 2019-04-24 12:00

4.1 Owner
To be performed every 50 service hours, but at least once a week.

4.1.1 Maintenance contents

4.1.1.1 Standard equipment

Hydraulic operations
Correct the hydraulic oil level.

Steering
Test the tiller return function.
04.19 en-GB

201
4.1.1.2 Optional equipment

Lead-acid battery, international

Power supply
Correct the battery acid level using demineralised water.

Lead-acid battery

Power supply
Correct the battery acid level using demineralised water.

04.19 en-GB

202
 4.1.2 Inspection contents

4.1.2.1 Standard equipment

The following points must be checked:

Electrical system
Warning and safety devices are in accordance with the operating instructions
Function of display and controls
The function of the emergency disconnect and for damage

Power supply
Battery and battery components for damage
The function and secure seating of the battery connector and for damage

Travel
The function of the collision safety switch and for damage
Wheels for wear and damage

Chassis/structure
Industrial truck for damage and leaks
Labels are legible, complete and plausible
Doors and/or covers for damage
Protective mechanism against trapping and shearing is present, secure, functions
correctly and is free of dirt and damage

Hydraulic operations
The function of the hydraulic system
The forks or load handler for wear and damage
04.19 en-GB

203
4.1.2.2 Optional equipment
The following points must be checked:
Standard on-board charger

Battery charger
The mains plug and mains cable for damage

Lead-acid battery, international

Power supply
Battery and battery components for damage
Battery cable connections are secure

Lead-acid battery

Power supply
Battery cable connections are secure

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204
 4.2 Customer Service

4.2.1 Maintenance contents

In accordance with the EJE 220/225 service interval, to be performed every 1000
service hours, but at least once a year.

4.2.1.1 Standard equipment

Brakes
Test the brake with the tiller in the maximum vertical and horizontal positions.
Measure the air gap of the magnetic brake.

Electrical system
Test the contactors and/or relays.
Carry out a chassis insulation-resistance test.

Chassis/structure
Check that the panels and covers as well as mounting brackets are secure. Ensure they
function correctly and are safe.

Hydraulic operations
Correct the hydraulic oil level.
Test the pressure relief valve.

Agreed services
Carry out a test run with the rated load or a customer-specific load.
Demonstration after maintenance.
Lubricate truck according to the lubrication diagram.

Steering
Test the tiller return function.
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205
4.2.1.2 Optional equipment

Standard on-board charger

Battery charger
Test the immobiliser on trucks with on-board chargers.
Carry out a potential measurement on the chassis while charging is in progress.

Data radio

System components
Clean the scanner and terminal.

Other inspections

Agreed services
Note: Tests on other options and special parts such as radio data and access modules
(ISM) must be recorded in the test report.

Lead-acid battery, international

Power supply
Clean and grease the battery terminals.
Clean the battery.
Measure the acid density and battery voltage.
Correct the battery acid level using demineralised water.

Lead-acid battery

Power supply
Clean and grease the battery terminals.
Clean the battery.
Measure the acid density and battery voltage.
Correct the battery acid level using demineralised water.
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206
 4.2.2 Inspection contents
The following points must be checked:

4.2.2.1 Standard equipment

Electrical system
Cables and engine are secure and for damage
Warning and safety devices are in accordance with the operating instructions
Function of display and controls
The function of the emergency disconnect and for damage
Contactors and/or relays for wear and damage
The electric wiring for damage (insulation damage, connections) and the fuse ratings

Power supply
The function of the battery latch and battery attachment and for damage
The function and secure seating of the battery connector and for damage

Travel
Drivetrain bearings for wear and damage
Transmission for noise and leaks
Wheel bearings and attachment for wear and damage
Wheels for wear, damage and secure mounting

Chassis/structure
Industrial truck for damage and leaks
The secure seating of the chassis and screw connections and for damage
Labels are legible, complete and plausible
Protective mechanism against trapping and shearing is present, secure, functions
correctly and is free of dirt and damage

Hydraulic operations
The function of the "hydraulic system" controls and for legibility, completeness and
plausibility
The function of the lift mechanism and for wear and damage
The secure seating of the cylinders and piston rods and for leaks 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
The secure seating of the hoses, pipes and connections and for wear, leaks, damage,
blisters and kinks

Steering
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Lateral play of the tiller

The steering components for play and damage

207
4.2.2.2 Optional equipment

Standard on-board charger

Battery charger
The mains plug and mains cable for damage
The secure seating of the cables and electrical connections and for damage

Electrolyte circulation

Power supply
The function of the hose connections and pump

Aquamatik

Power supply
The function of the Aquamatik plug, hose connections and float and for leaks
The function of the flow indicator and for leaks

Lateral battery removal

Power supply
The function of the battery latch and battery attachment and for damage

Shock sensor / data recorder

Electrical system
The shock sensor/data recorder is secure and for damage

Data radio

System components
The function and secure seating of the scanner and terminal and for damage
Fuse ratings
The secure seating of the cables and for damage

Access module

Electrical system
Access module is secure and functions correctly and for damage

Entry skids/rollers

Hydraulic operations
The function of entry skids or entry rollers and for damage and wear
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208
 Lead-acid battery, international

Power supply
The secure seating of the battery, battery cables and cell connectors and for damage
The presence of safety labels are present and for damage

Lead-acid battery

Power supply
The secure seating of the battery, battery cables and cell connectors and for damage
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209
4.2.3 Maintenance parts
The manufacturer recommends the replacement of the following maintenance parts
at the specified intervals.

4.2.3.1 Standard equipment

maintenance part service hours months
Hydraulic oil 2000 12
Hydraulic system - breather filter 2000 12
Transmission oil 1000

4.2.3.2 Optional equipment

Cold-store application

maintenance part service hours months

Hydraulic oil 1000 12
Hydraulic oil additive 1000 12

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210
 H Traction battery
1 Correct Use and Application
Failure to observe the operating instructions, carrying out repairs with non-original
spare parts, tampering with the battery or using electrolyte additives will invalidate
the warranty.

Observe the instructions for maintaining the safety rating during operation for
batteries in accordance with Ex I and Ex II (see relevant certification).

2 Data plate

112 33

113 114

30 115

116 117

118 119

37

39
120

121

112 Model (battery name)

33 Production week / production year
113 Serial number
114 Supplier number
30 Rated voltage
115 Capacity
116 Number of cells
117 Weight
118 Part no.
119 Acid quantity
37 Manufacturer
39 Manufacturer's logo
120 CE mark (for batteries above 75 V only)
121 Safety instructions and warning information
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211
3 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 § 8 of the battery legislation.

Do not smoke!
No naked flames, glowing embers or sparks near the battery - fire and
explosion hazard!

Avoid fire and explosion hazards and short circuits due to overheating!

Keep away from naked flames and strong heat sources.

Always wear protective clothing (e.g. safety goggles and safety
gloves) when working on cells and batteries.
Always wash your hands after completing the work. Use only
insulated tools. Do not mechanically machine the battery, strike, crush,
compress, notch, dent or modify it in any way.
Hazardous electric voltage! The metal parts of the battery cells are
permanently live. Therefore do not place any foreign objects or tools
on the battery.
Observe national health and safety regulations.

If the materials leak, do not inhale the fumes. Wear safety gloves.

Follow the user instructions and keep them in a visible position in the
charging area.
Work on the batteries should be performed only as instructed by
specialist personnel.
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212
 4 Lead acid batteries with armour plated cells and liquid
electrolyte

4.1 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
– Lead acid battery with "Standard" armour plated cells and liquid
PzS electrolyte
– Battery cell width: 198 mm
– Lead acid battery with "British Standard" armour plated cells
PzB and liquid electrolyte
– Battery cell width: 158 mm
PzS Lib – Lead acid battery with "Standard" armour plated cells and liquid
electrolyte
PzM – Lead acid battery with extended maintenance interval
– Battery cell width: 198 mm

Electrolyte

The rated density of the electrolyte assumes a temperature of 30°C and the rated
electrolyte level is fully charged. Higher temperatures will reduce, lower
temperatures will increase the electrolyte density.
The corresponding adjustment factor is ± 0.0007 kg/l per K, e. g. electrolyte density
1.28 kg/l at 45 °C corresponds to a density of 1,29 kg/l at 30 °C.

The electrolyte must comply with the purity regulations of DIN 43530 Part 2.
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213
4.1.1 Battery nominal data
1. Product Traction battery
2. Nominal voltage 2.0 V x number of cells
3. Rated capacity C5 See data plate
4. Discharge current C5/5h
2
5. Nominal electrolyte density 1.29 kg/l
3
6. Nominal temperature 30 °C
7. System rated electrolyte level up to "Max" electrolyte level marking
4
Limit temperature 55 °C

04.19 en-GB

2) Reached within the first 10 cycles.

3) Higher temperatures shorten the useful life, lower temperatures reduce the available capacity.

4) Not permissible as operating temperature.

214
 4.2 Operation

4.2.1 Commissioning unfilled batteries

Z 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

122 123 124

122 123 124

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.
• Check the M10 terminal screws of the conductors and connectors are secure and
if necessary torque to 23 ±1 Nm.
• Charge the battery, see page 216.
• Check the electrolyte level of each battery cell after charging and top up if
necessary:
• Open the plug (122).
Z The electrolyte level should not be less than the "Min" electrolyte marking (123)
and must not exceed the "Max" (124) marking.
• If necessary, add electrolyte with pure water up to the "Max" electrolyte level
marking (124), see page 218.
• Close the plug (122).

The test is now complete.

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215
4.2.3 Discharging the battery

Z 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.

4.2.4 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.
uAlways disconnect the charger and truck before connecting or disconnecting the
charger and battery.
uThe charger must be adapted to the battery in terms of voltage, charge capacity
and battery technology.
uBefore charging, check all cables and plug connections for visible signs of
damage.
uVentilate the room in which the truck is being charged.
uBattery cell surfaces must remain exposed during charging in order to ensure
sufficient ventilation, see truck operating instructions, chapter D, Charging the
Battery.
uDo not smoke and avoid naked flames when handling batteries.
uWherever an industrial truck is parked for charging there must be no inflammable
material or consumables capable of creating sparks within a minimum distance of
2 m from the truck.
uFire protection equipment must be available.
uDo not place any metallic objects on the battery.
uAlways follow the safety regulations of the battery and charger station
manufacturers.
NOTICE
The battery must only be charged with DC current. All charging procedures in
accordance with DIN 41773 and DIN 41774 are permissible.
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216
 Z 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.
Charging the battery

Requirements
– Permissible electrolyte temperature 10°C to 45°C).
Procedure
• Open or take off the tray lid or covers from the battery compartment.

Z Deviations are outlined in the truck's operating instructions. The plugs remain on
the cells or remain closed.
• Connect the battery to the switched off charger, ensuring the terminals are
connect (positive to positive and negative to negative).
• Switch on the charger.

The battery is charged.

Z Charging is considered to be complete when the electrolyte density and battery

voltage remain constant for more than 2 hours.

Compensation charging

Compensation charging is used to ensure the useful life and maintain capacity after
full discharge and repeated insufficient charging. The maximum compensation
charge current is 5 A/100 Ah rated capacity.

Z Compensation charging should be carried out weekly.

Trickle charging

Battery trickle charging is partial charging that extends the daily application time.
Higher average temperatures occur during trickle charging which reduce the useful
life of the batteries.

Z Trickle charges should only be performed when the charge level is below 60 %. Use
replacement batteries instead of regular trickle charging.
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217
4.3 Servicing lead-acid batteries with armour plated cells

4.3.1 Quality of Water for Adding Electrolyte

Z 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

122 123 124

122 123 124

– Charge the battery after each discharge.

– After charging, check the electrolyte level of each battery cell and replenish as
required:
– Open the plug (122).
– If necessary, add electrolyte with pure water up to the "Max" electrolyte level
marking (124).
– Close the plug (122).

Z The electrolyte level should not be less than the "Min" electrolyte marking (123) and
must not exceed the "Max" (124) marking.

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218
 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.
– After charging measure and record the electrolyte density and the electrolyte
temperature in all the cells.
– Compare the results with the previous ones.

Z If you find significant differences compared with the previous measurements or

differences between the cells, contact the manufacturer's customer service
department.

4.3.5 Annually
– Measure the insulation resistance of the truck in accordance with EN 1175-1.
– Measure the insulation resistance of the battery in accordance with DIN EN
1987-1.

Z In accordance with DIN EN 50272-3 the battery insulation resistance should not be
less than 50 Ω per volt of rated voltage.
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219
5 PzV and PzV-BS lead-acid batteries with sealed armour
plated cells

5.1 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. During operation the same safety requirements apply
to the sealed batteries as for batteries with liquid electrolyte. This is to avoid electric
shock, explosion of the electrolyte charging gases or hazardous electrolyte burns if
the cell vessels are destroyed.

Z PzV batteries are low gassing, but not gassing-free.

Electrolyte

The electrolyte is sulphuric acid which is fixed in gel. The density of the electrolyte
cannot be measured.

Name Explanation
– Lead acid battery with "Standard" closed armour plated cells
PzV and electrolyte in gel compound
– Battery cell width: 198 mm
– Lead acid battery with "British Standard" closed armour plated
PzV-BS cells and electrolyte in gel compound
– Battery cell width: 158 mm

5.1.1 Battery nominal data

1. Product Traction battery
2. Nominal voltage 2.0 V x number of cells
3. Rated capacity C5 See data plate
4. Discharge current C5/5h
5. Rated temperature 30°C
5
Limit temperature 45°C, not permissible as operating
temperature
6. Rated density of the electrolyte Cannot be measured
7. System rated electrolyte level Cannot be measured
04.19 en-GB

5) Higher temperatures shorten the useful life, lower temperatures reduce the available capacity.

220
 5.2 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.
• Check the M10 terminal screws of the conductors and connectors are secure and
if necessary torque to 23 ±1 Nm.
• Charge the battery, see page 221.

The test is now complete.

5.2.2 Discharging the battery

Z To achieve an optimum useful life avoid operational discharges of more than 60% of
nominal capacity.

Z If the battery is discharged during operation by more than 80% of rated capacity the
useful life of the battery will reduce significantly. Fully or partially discharged batteries
must be re-charged immediately and not left unattended.

5.2.3 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.
uAlways disconnect the charger and truck before connecting or disconnecting the
charger and battery.
uThe charger must be adapted to the battery in terms of voltage, charge capacity
and battery technology.
uBefore charging, check all cables and plug connections for visible signs of
damage.
uVentilate the room in which the truck is being charged.
uBattery cell surfaces must remain exposed during charging in order to ensure
sufficient ventilation, see truck operating instructions, chapter D, Charging the
Battery.
uDo not smoke and avoid naked flames when handling batteries.
uWherever an industrial truck is parked for charging there must be no inflammable
material or consumables capable of creating sparks within a minimum distance of
2 m from the truck.
uFire protection equipment must be available.
uDo not place any metallic objects on the battery.
04.19 en-GB

uAlways follow the safety regulations of the battery and charger station
manufacturers.

221
 NOTICE
Charging the battery incorrectly can result in material damage.
Incorrect battery charging can result in overloading of the electric wires and contacts,
hazardous gas formation and electrolyte leakage from the battery cell.
uAlways charge the battery with DC current.
uAll DIN 41773 charging procedures are permitted in the format approved by the
manufacturer.
uAlways connect the battery to a charger that is appropriate to the size and type of
the battery.
uIf necessary have the charger checked by the manufacturer's customer service
department for suitability.
uDo not exceed the limit curents in accordance with DIN EN 50272-3 in the gassing
area.

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222
 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).
• Switch on the charger.

Z The electrolyte temperature rises by approx. 10°C during charging. If the

temperatures are permanently higher than 40°C or lower than 15°C, a
temperature-dependent constant voltage control of the charger is required. The
adjustment factor must be applied with -0.004 V/C per °C.

The battery is charged.

Z Charging is considered to be complete when the electrolyte density and battery

voltage remain constant for more than 2 hours.

Compensation charging

Compensation charging is used to ensure the useful life and maintain capacity after
full discharge and repeated insufficient charging.

Z Compensation charging should be carried out weekly.

Trickle charging

Battery trickle charging is partial charging that extends the daily application time.
Higher average temperatures occur during trickle charging which can reduce the
useful life of the batteries.

Z Trickle charges should only be performed when the charge level is below 50%. Use
replacement batteries instead of regular trickle charging.

Z Avoid trickle charging with PzV batteries.

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223
5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour
plated cells

Z 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.
– Measure and record the individual voltages.
– Compare the results with the previous ones.

Z Carry out the measurements after full charging and subsequent resting for at least 5
hours.

Z If you find significant differences compared with the previous measurements or

differences between the cells, contact the manufacturer's customer service
department.

5.3.4 Annually
– Measure the insulation resistance of the truck in accordance with EN 1175-1.
– Measure the insulation resistance of the battery in accordance with DIN EN
1987-1.

Z In accordance with DIN EN 50272-3 the battery insulation resistance should not be
less than 50 Ω per volt of rated voltage.

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224
 6 Aquamatik water replenishment system

6.1 Water replenishment system design

125

126

127

>3m 128

129

130

+ -

125 Water container

126 Tap connection with ball cock
127 Flow indicator
128 Shut-off cock
129 Locking coupling
130 Battery lock connector
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225
6.2 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. The Aquamatik plug controls the amount of
water required and, at the relevant water pressures, ensures the water supply is shut
off and the valve is closed securely.

The plug systems have an optical level indicator, a diagnostic port to measure the
temperature and electrolyte density and a degassing port.

6.3 Adding water

Water should be added to the batteries just before the battery is fully charged. This
ensures that the amount of water added is mixed with the electrolyte.

6.4 Water pressure

The water replenishment system must be operated with a water pressure in the
water line of 0.3 bar - 1.8 bar. Any deviations from the permissible pressure ranges
will affect the operation of the systems.
Water drop

Assembly height above battery surface is between 3 - 18 m.

1 m corresponds to 0.1 bar.
Pressure water

The pressure regulating valve is adjusted to suit the system and must lie between
0.3 - 1.8 bar.

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226
 6.5 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.

6.6 Water quality

Z The quality of the water used to fill up 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.

6.7 Battery tubing

The tubing of the individual plugs is in accordance with the existing electric circuit.
No changes should be made.

6.8 Operating temperature

Batteries with automatic water replenishment systems should only be stored in
rooms with temperatures > 0°C, as otherwise the systems could freeze.

6.9 Cleaning measures

The plug systems must only be cleaned with purified water in accordance with DIN
43530-4. No parts of the plugs must come into contact with solvent-based materials
or soap.

6.10 Service mobile vehicle

Mobile water filling vehicle with pump and filling gun to fill individual cells. The
immersion pump in the container generates the necessary filling pressure. The
service mobile must be at exactly the same height as the battery base.
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227
7 Electrolyte circulation

7.1 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.

A pump in the charger produces the necessary compressed air which is introduced
to the battery cells via a hose system. The electrolyte is circulated via the inlet air
and the electrolyte density level is constant over the entire length of the electrode.
Pump

In the event of a fault, e.g. if the pressure control system responds for an unknown
reason, the filters must be checked and replaced if necessary.
Battery connection

A hose is attached to the pump module which together with the charge leads is
routed from the charger to the charging connector. The air is passed on to the
battery via the electrolyte circulation coupling ducts in the connector. When routing
make sure the hose is not bent.
Pressure-monitoring module

The electrolyte circulation pump is activated when charging begins. The pressure
monitoring module monitors the build-up of pressure during charging. This ensures
that the required air pressure is provided for electrolyte circulation charging.
In the event of malfunctions, a visual error message appears on the battery charger.
Some examples of malfunctions are listed below:
– No connection between the air coupling of the battery and the recirculation
module (for separate coupling) or faulty air coupling
– Leaking or faulty hose connections on battery
– Contaminated intake filter

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228
 NOTICE
If an installed electrolyte circulation system is seldom used or not used at all, or if the
battery is subjected to severe temperature fluctuations, the electrolyte may flow back
into the hose system.
uAttach a separate coupling system to the air inlet line, such as: locking coupling to
the battery side and through-coupling to the air supply side.

Schematic illustration

Electrolyte circulation on the battery and air supply via the charger.
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229
8 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.
– Avoid electric sparking due to stray currents.
When cleaning the batteries make sure that:
– The assembly site chosen for cleaning is close to a drainage system for
processing the electrolytic rinsing water.
– All health and safety as well as water and waste disposal regulations are
observed when disposing of used electrolyte or rinsing water.
– Protective goggles and clothing are worn.
– Cell plugs are not removed or opened.
– Clean the plastic components of the battery, in particular the cell containers, only
with water or water-based cloths without any additives.
– After cleaning, the top of the battery is dried with suitable equipment, e.g.
compressed air or cloths.
– Any fluid that has entered the battery tray must be suctioned off and disposed of
in accordance with the above-mentioned regulations.

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230
 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.

Z This generally ensures that the temperature does not exceed 60°C at a distance
of 30cm behind the outlet nozzle.
• Observe the maximum operating pressure of 50 bar.
• Observe a minimum distance of 30 cm from the top of the battery.
• The battery should be sprayed over its entire surface to avoid localised
overheating.

Z Do not clean one spot for more than 3 seconds with the jet to avoid exceeding the
maximum battery surface temperature of 60°C.
• After cleaning dry the battery surface with suitable materials e.g. compressed air
or cleaning cloths.

Battery cleaned.
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231
9 Storing the battery
NOTICE
The battery should not be stored for longer than 3 months without charging as
otherwise it will no longer be functional.

If the battery is to be taken out of service for a long period, it should be stored fully
charged in a dry room protected from frost. To ensure the availability of the battery
the following charges can be selected:

– Monthly compensation charge for PzS and PzB batteries or 4-monthly full charge
for PzV batteries.
– Trickle charge for a charging voltage of 2.23 V x number of cells for PzS, PzM and
PzB batteries or 2.25 V x number of cells for PzV batteries.
If the battery is to be taken out of service for a long period ( > 3 months), it should,
as far as possible, be charged to 50% of its charge level and stored in a dry room
protected from frost.

10 Troubleshooting
If any faults are found on the battery or charger, contact the manufacturer's customer
service department immediately.

Z The operations required must be carried out by the manufacturer's customer service
department or a customer service organisation authorised by the manufacturer.

11 Disposal

Batteries marked with the recycling symbol and the sign showing a
crossed-out rubbish bin 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 § 8 of the battery legislation.
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232