Jungheinrich ERE 120 ERE C20 Operating instructions Manual 51222183 - PDF DOWNLOAD

ERE 120 Operating instructions

07.12 -

G

51222183 02.15

ERE 120 ERE C20

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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.

NOTE Indicates a material hazard. Failure to comply with this instruction may result in material damage.

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Used before notices and explanations.

Indicates standard equipment Indicates optional equipment

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Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG. Jungheinrich Aktiengesellschaft Am Stadtrand 35 22047 Hamburg - Germany Tel: +49 (0) 40/6948-0

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www.jungheinrich.com

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Contents Correct Use and Application ...................................................

11

1 2 3 3.1

11 11 12

3.2 4 5

General....................................................................................................

Correct application...................................................................................

Approved application conditions ..............................................................

Internal Operation Combined with Brief External or Cold Store Operation (t) ...........................................................................................................

Internal Operation in Cold Stores with Cold Store Equipment (o) ..........

Proprietor responsibilities ........................................................................

Adding attachments and/or optional equipment ......................................

13 13 14 14

B

Truck Description ....................................................................

15

1 1.1 2 3 3.1 3.2 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 5 5.1 5.2 5.3 5.4

Application ...............................................................................................

Truck models and rated capacity.............................................................

Travel direction definition.........................................................................

Assemblies and Functional Description...................................................

Assembly Overview .................................................................................

Functional Description .............................................................................

Technical Specifications ..........................................................................

Performance data ....................................................................................

Dimensions..............................................................................................

Weights....................................................................................................

Tyre type..................................................................................................

EN norms.................................................................................................

Conditions of use.....................................................................................

Electrical Requirements...........................................................................

Identification Points and Data Plates.......................................................

Indication Points ......................................................................................

Data plate ................................................................................................

Truck capacity plate.................................................................................

Wind loads...............................................................................................

15 15 16 17 17 18 20 20 21 26 26 27 28 28 29 29 31 32 32

C

Transport and Commissioning ................................................

33

1 2 3 4

Lifting by crane ........................................................................................

Remove the transport lock.......................................................................

Transport .................................................................................................

Using the Truck for the First Time ...........................................................

33 35 36 37

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Battery - Servicing, Recharging, Replacement .......................

39

1 2 3 4 4.1 4.2 5 5.1 5.2

Safety Regulations Governing the Handling of Lead-Acid Batteries .......

Battery types............................................................................................

Exposing the battery................................................................................

Charging the battery ................................................................................

Charging the battery with a stationary charger........................................

Charging the battery with an on-board charger (o) ................................

Battery removal and installation ..............................................................

Removing the battery from the top ..........................................................

Removing the battery from the side.........................................................

39 41 43 44 45 46 51 52 53

E

Operation ................................................................................

55

1 2 2.1 2.2 3 3.1 3.2 3.3 3.4 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 5 5.1 5.2 6 6.1 7 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8

Safety Regulations for the Operation of the Forklift Truck.......................

Displays and Controls..............................................................................

Battery discharge monitor........................................................................

Battery discharge indicator ......................................................................

Starting up the truck ................................................................................

Checks and Operations to Be Performed Before Starting Daily Work ....

Preparing the truck for operation .............................................................

Checks and operations to be carried out when the truck is operational ..

Parking the truck securely .......................................................................

Industrial Truck Operation .......................................................................

Safety regulations for truck operation......................................................

How to act in hazardous situations..........................................................

Emergency Disconnect............................................................................

Automatic braking....................................................................................

Travel.......................................................................................................

Steering ...................................................................................................

Brakes .....................................................................................................

Load handler raise/lower .........................................................................

Lifting, transporting and depositing loads ................................................

Ergonomic Lift (o) (ERE C20).................................................................

Troubleshooting.......................................................................................

Truck does not start.................................................................................

Load cannot be lifted ...............................................................................

Operating the truck without its own drive system ....................................

Release and activate the drive wheel brake............................................

Optional equipment .................................................................................

Emergency operation with service key GF60 ..........................................

CanCode Keypad (o)..............................................................................

Setting the truck parameters with CanCode............................................

Parameters ..............................................................................................

Setting the Battery Parameters with CanCode........................................

Set ELH 2415 / 2425 / 2435 Charger Characteristics with CanCode ......

CanDis Display Instrument (o) ...............................................................

ISM access module (o)...........................................................................

55 57 60 60 61 61 62 64 65 67 67 68 69 71 72 77 77 79 81 85 88 89 90 91 91 93 93 95 114 116 121 123 125 126 02.15 EN

D

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F

Industrial Truck Maintenance .................................................. 127

1 2 2.1 2.2 2.3 2.4 2.5 3 3.1 3.2 3.3 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 5 5.1 5.2 5.3 6 7 8 9 10 10.1 10.2

Operational Safety and Environmental Protection...................................

Maintenance Safety Regulations.............................................................

Working on the electrical system.............................................................

Consumables and used parts..................................................................

Wheels.....................................................................................................

Hydraulic system .....................................................................................

Lift Chains................................................................................................

Lubricants and Lubrication Schedule ......................................................

Handling consumables safely ..................................................................

Lubrication Schedule ...............................................................................

Consumables...........................................................................................

Maintenance and repairs .........................................................................

Prepare the truck for maintenance and repairs .......................................

Front cover disassembly..........................................................................

Lifting and jacking up the truck safely......................................................

Cleaning ..................................................................................................

Replacing the drive wheel .......................................................................

Checking the hydraulic oil level ...............................................................

Checking electrical fuses.........................................................................

Restoring the truck to service after maintenance and repairs .................

Decommissioning the Industrial Truck.....................................................

Prior to decommissioning ........................................................................

Action to be taken during decommissioning ............................................

Restoring the truck to service after decommissioning .............................

Safety tests to be performed at intervals and after unusual incidents .....

Final de-commissioning, disposal............................................................

Human vibration measurement ...............................................................

Servicing and Inspection .........................................................................

Maintenance checklist .............................................................................

Operating Company ................................................................................

Customer Service ....................................................................................

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127 128 129 129 129 130 131 132 132 134 135 136 136 137 138 139 142 142 143 145 146 146 146 147 148 148 148 149 150 150 152

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Appendix JH Traction Battery Operating Instructions These operating instructions apply only to Jungheinrich battery models. If using another brand, refer to the manufacturer's operating instructions.

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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 NOTE 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 "Lifting, transporting and depositing loads" on page 81.

The following operations are in accordance with regulations and are permitted: – Lifting and lowering of loads.

– Stacking and retrieving loads.

– Transporting lowered loads.

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The following operations are prohibited: – Travelling with a raised load (>500 mm).

– Carrying and lifting passengers.

– Pushing or pulling loads.

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3

Approved application conditions – Operation in industrial and commercial environments.

– Operation only on secure, level surfaces with sufficient capacity.

– Do not exceed the permissible surface and spot load limits on the travel routes.

– Operation only on routes that are visible and approved by the operating company.

– Negotiating inclines up to a maximum of 16 %.

– Do not travel across or at an angle on inclines. Travel with the load facing uphill.

– Operation in partially public traffic.

WARNING!

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Use under extreme conditions Using the truck under extreme conditions can result in malfunctions and accidents.

XSpecial equipment and authorisation are required if the truck is to be constantly used in extreme conditions, especially in dusty or corrosive atmospheres.

XThe truck cannot be used in areas at risk of explosion.

XIn adverse weather conditions (thunder, lightning) the industrial truck must not be operated outside or in endangered areas.

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