Declaration of Conformity
Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg Manufacturer or agent acting in the European Union
TypeOptionSerial no.Year of manufacture
ERE 120
ERE C20
Additional information
On behalf of Date
G EU Conformity Declaration
The undersigned hereby declare that the powered industrial truck described below in detail complies with the European Directives 2006/42/EC (Machinery Directive) and 2004/108/EEC (Electromagnetic Compatibility - EMC) including amendments as well as the legislative decree to incorporate the directives in national law. The signatories are in each case individually authorized to compile the technical documents.
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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.
Used before notices and explanations.
t Indicates standard equipment
o Indicates optional equipment
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Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - Germany
Tel: +49 (0) 40/6948-0
www.jungheinrich.com
6 Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
7 Contents ACorrect Use and Application...................................................11 1General................. ...........11 2Correct application.............. ...........11 3Approved application conditions..............................................................12 3.1Internal Operation Combined with Brief External or Cold Store Operation (t)...........................................................................................................13 3.2Internal Operation in Cold Stores with Cold Store Equipment (o)..........13 4Proprietor responsibilities..... ...........14 5Adding attachments and/or optional equipment......................................14 BTruck Description....................................................................15 1Application...............................................................................................15 1.1Truck models and rated capacity............... .............15 2Travel direction definition.........................................................................16 3Assemblies and Functional Description....... ...........17 3.1Assembly Overview.................................................................................17 3.2Functional Description........ ...........18 4Technical Specifications....... ...........20 4.1Performance data....................................................................................20 4.2Dimensions..............................................................................................21 4.3Weights............ ...........26 4.4Tyre type..................................................................................................26 4.5EN norms................ ...........27 4.6Conditions of use.....................................................................................28 4.7Electrical Requirements...........................................................................28 5Identification Points and Data Plates......... .............29 5.1Indication Points......................................................................................29 5.2Data plate........ ...........31 5.3Truck capacity plate............ 32 5.4Wind loads...............................................................................................32 CTransport and Commissioning................................................33 1Lifting by crane....... ...........33 2Remove the transport lock.......................................................................35 3Transport................ ...........36 4Using the Truck for the First Time...........................................................37
8 DBattery - Servicing, Recharging, Replacement.......................39 1Safety Regulations Governing the Handling of Lead-Acid Batteries.......39 2Battery types............................................................................................41 3Exposing the battery................................................................................43 4Charging the battery.... ...........44 4.1Charging the battery with a stationary charger........................................45 4.2Charging the battery with an on-board charger (o)................................46 5Battery removal and installation......... ...........51 5.1Removing the battery from the top..........................................................52 5.2Removing the battery from the side............. ...........53 EOperation............ ......................................55 1Safety Regulations for the Operation of the Forklift Tr uck.......................55 2Displays and Controls..............................................................................57 2.1Battery discharge monitor... ...........60 2.2Battery discharge indicator......................................................................60 3Starting up the truck............. ...........61 3.1Checks and Operations to Be Performed Before Starting Daily Work....61 3.2Preparing the truck for operation.............................................................62 3.3Checks and operations to be carried out when the truck is operational..64 3.4Parking the truck securely.......................................................................65 4Industrial Truck Operation.......................................................................67 4.1Safety regulations for truck operation.......... ...........67 4.2How to act in hazardous situations..........................................................68 4.3Emergency Disconnect......... ...........69 4.4Automatic braking............ ...........71 4.5Travel.......................................................................................................72 4.6Steering................ ...........77 4.7Brakes.....................................................................................................77 4.8Load handler raise/lower...... ...........79 4.9Lifting, transporting and depositing loads........... ........81 4.10Ergonomic Lift (o) (ERE C20)................................................................. 85 5Troubleshooting............. ...........88 5.1Truck does not start......... ...........89 5.2Load cannot be lifted...............................................................................90 6Operating the truck without its own drive system......... ...........91 6.1Release and activate the drive wheel brake.............. .............91 7Optional equipment.................................................................................93 7.1Emergency operation with service key GF60..... ........93 7.2CanCode Keypad (o)..............................................................................95 7.3Setting the truck parameters with CanCode................. ...........114 7.4Parameters............. ...........116 7.5Setting the Battery Parameters with CanCode........................................121 7.6Set ELH 2415 / 2425 / 2435 Charger Characteristics with CanCode......123 7.7CanDis Display Instrument (o)...............................................................125 7.8ISM access module (o)...........................................................................126
9 FIndustrial Truck Maintenance..................................................127 1Operational Safety and Environmental Protection........ ...........127 2Maintenance Safety Regulations.............................................................128 2.1Working on the electrical system.............................................................129 2.2Consumables and used parts.... .............129 2.3Wheels.....................................................................................................129 2.4Hydraulic system.....................................................................................130 2.5Lift Chains............. ...........131 3Lubricants and Lubrication Schedule......................................................132 3.1Handling consumables safely ...........132 3.2Lubrication Schedule............ ...........134 3.3Consumables...........................................................................................135 4Maintenance and repairs........... .............136 4.1Prepare the truck for maintenance and repairs.......................................136 4.2Front cover disassembly....... ...........137 4.3Lifting and jacking up the truck safely...... ........138 4.4Cleaning..................................................................................................139 4.5Replacing the drive wheel.... ...........142 4.6Checking the hydraulic oil level........................................... ........142 4.7Checking electrical fuses......................................................................... 143 4.8Restoring the truck to service after maintenance and repairs.................145 5Decommissioning the Industrial Truck.............. ...........146 5.1Prior to decommissioning..... ...........146 5.2Action to be taken during decommissioning................. ...........146 5.3Restoring the truck to service after decommissioning.............................147 6Safety tests to be performed at intervals and after unusual incidents.....148 7Final de-commissioning, disposal.............. .............148 8Human vibration measurement...............................................................148 9Servicing and Inspection........ ........149 10Maintenance checklist.............................................................................150 10.1Operating Company................................................................................150 10.2Customer Service............... ...........152
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ACorrect Use and Application
1General
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.
2Correct 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 page81.
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:
–Travelling with a raised load (>500 mm).
–Carrying and lifting passengers.
–Pushing or pulling loads.
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3Approved 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!
Use under extreme conditions
Using the truck under extreme conditions can result in malfunctions and accidents. Special equipment and authorisation are required if the truck is to be constantly used in extreme conditions, especially in dusty or corrosive atmospheres. The truck cannot be used in areas at risk of explosion. In adverse weather conditions (thunder, lightning) the industrial truck must not be operated outside or in endangered areas.
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3.1Internal 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.
3.2Internal Operation in Cold Stores with Cold Store Equipment ( o)
ERE 120 only, not on the ERE C20
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.
NOTE
Battery damage
As the temperature becomes increasingly cold, the battery can be damaged if the battery charge is low.
If the battery charge is low do not use the truck in areas of -28°C to -5°C.
If the battery charge is low it is preferable not to use the truck in areas of -5°C to +5°C.
Charge the battery, see "Charging the battery" on page44.
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