G ERD 220 Operating instructions 51133406 03.16 !'~ ] 11:1~ x i' ' _,, 06.10 ERO 220 1JUNGHEINRICH Machines. Ideas. Solutions.
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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.
Indicates standard equipment
Indicates optional equipment
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t o o 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 ( ) ........................................................................................................... 13 3.2 Internal Operation in Cold Stores with Cold Store Equipment ( ) .......... 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 18 4 Technical Specifications.......................................................................... 20 4.1 Performance data ........ .............. ............... .............. ............... ............... ... 20 4.2 Dimensions.............................................................................................. 22 4.3 Weights.................................................................................................... 26 4.4 Tyre type.................................................................................................. 26 4.5 EN norms................................................................................................. 27 4.6 Conditions of use..................................................................................... 28 4.7 Electrical Requirements........................................................................... 28 5 Identification Points and Data Plates....................................................... 29 5.1 Indication Points...................................................................................... 29 5.2 Data plate 31 5.3 Truck capacity plate................................................................................. 32 5.4 Wind loads............................................................................................... 35 5.5 Capacity Plate for Stacking, Transport and Double-Deck Operations..... 36 C Transport and Commissioning .... .... ... .... .... .... .... .... ..... .... ... .... . 39 1 Lifting by crane........................................................................................ 39 2 Transport 41 3 Using the Truck for the First Time .......... ... ............. .. .......... ......... ............ 42 D Battery - Servicing, Recharging, Replacement....................... 43 1 Safety Regulations Governing the Handling of Lead-Acid Batteries 43 2 Battery types............................................................................................ 45 3 Exposing the battery................................................................................ 46 4 Charging the battery................................................................................ 47 4.1 Charging the battery with a stationary charger........................................ 48 4.2 Charging the battery with an on-board charger ( ) .............. ..... ............. 50 z 5 UJ Battery removal and installation.............................................................. 56 tO .... C") 0 7
o o o E Operation 61 1 Safety Regulations for the Operation of the Forklift Truck 61 2 Displays and Controls ............................................................................. . 63 2.1 Battery discharge monitor ....................................................................... . 67 2.2 Battery discharge indicator 68 3 Preparing the Truck for Operation .......................................................... . 69 3.1 Checks and Operations to Be Performed Before Starting Daily Work 69 3.2 Preparing the truck for operation 71 3.3 Checks and operations to be carried out when the truck is operational .. 72 3.4 Parking the truck securely 73 4 Industrial Truck Operation 74 4.1 Safety regulations for truck operation 74 4.2 How to act in hazardous situations 76 4.3 Emergency Disconnect. .......................................................................... . 76 4.4 Automatic braking 78 4.5 Travel 79 4.6 Steering .................................................................................................. . 84 4.7 Brakes 84 4.8 Load handler raise/lower 87 4.9 Lifting, transporting and depositing loads 90 4.10 Use as a Lift Work Table 99 5 Troubleshooting ...................................................................................... . 101 5.1 Truck does not start 101 5.2 Load cannot be lifted 102 6 Operating the truck without its own drive system .................................. .. 103 6.1 Release and activate the drive wheel brake 103 7 Load handler emergency lowering 105 8 Optional equipment ................................................................................. 107 8.1 CanCode Keypad ( ) 107 8.2 Setting the truck parameters with CanCode .......................................... .. 126 8.3 Parameters 128 8.4 Setting the Battery Parameters with CanCode 136 8.5 Can Dis Display Instrument ( ) 138 8.6 ISM access module ( ) 139 8.7 Display unit (2 inch display) .................................................................... . 140 8.8 Keyless Access System ........................................................................ .. 145 8.9 General Information about the Use of Keyless Access Systems 146 8.10 Commissioning the Keypad and the Transponder Reader .................... .. 146 8.11 Using the Display: 149 8.12 Using the Keypad 154 8.13 Operating the transponder reader .......................................................... . 159 F Industrial Truck Maintenance 165 1 Operational Safety and Environmental Protection 165 2 Maintenance Safety Regulations ............................................................ . 165 2.1 Working on the electrical system 167 2.2 Consumables and used parts 167 2.3 Wheels .................................................................................................... . 167 2.4 2.5 Hydraulic system .................................................................................... Lift Chains 168 169 z w 3 Lubricants and Lubrication Schedule ..................................................... . 170 <O ..... (") 0 8
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 G 1 2 3 4 4.1 4.2 4.3 5 5.1 5.2 5.3 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 7 7.1 8 9 10 11 z H UJ tO .... C") 0 Handling consumables safely.................................................................. 170 Lubrication Schedule............................................................................... 172 Consumables........................................................................................... 173 Maintenance and repairs......................................................................... 174 Preparing the truck for maintenance and repairs.................................... 174 Front cover disassembly.......................................................................... 175 Lifting and jacking up the truck safely...................................................... 177 Cleaning 178 Checking the hydraulic oil level............................................................... 181 Check wheel attachment and wear 182 Checking electrical fuses......................................................................... 184 Restoring the truck to service after maintenance and repairs .......... ....... 185 Decommissioning the Industrial Truck..................................................... 186 Prior to decommissioning ............. .. ............... ............. ...... .. ............ .. ....... 186 Action to be taken during decommissioning ............... ............. ............. ... 186 Restoring the truck to service after decommissioning 187 Final de-commissioning, disposal............................................................ 188 Safety tests to be performed at intervals and after unusual incidents 188 Human vibration measurement 188 Traction battery ... .... .... .... .... ..... .... ... .... .... .... ..... .... .... .... .... .... ... 189 Correct Use and Application.................................................................... 189 Data plate ....... ............ ............... ................ ............ ............... ............. ...... 189 Safety Instructions, Warning Indications and other Notes....................... 190 Lead acid batteries with armour plated cells and liquid electrolyte.......... 191 Description............................................................................................... 191 Operation................................................................................................. 193 Servicing lead-acid batteries with armour plated cells............................. 196 PzV and PzV-BS lead-acid batteries with sealed armour plated cells..... 198 Description............................................................................................... 198 Operation................................................................................................. 199 Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated cells 202 Aquamatik water replenishment system.................................................. 203 Water replenishment system design 203 Functional Description 204 Adding water............................................................................................ 204 Water pressure 204 Filling time............................................................................................... 205 Water quality............................................................................................ 205 Battery tubing 205 Operating temperature ............... .. ................. ............ ............... ............ ... 205 Cleaning measures.................................................................................. 205 Service mobile vehicle............................................................................. 205 Electrolyte circulation............................................................................... 206 Functional Description 206 Cleaning batteries.................................................................................... 208 Storing the battery .... .............. ............... .............. ............... .............. ....... 21 O Troubleshooting....................................................................................... 210 Disposal................................................................................................... 210 Maintenance and Inspection 211 9
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• Thank you very much for reading the preview of the manual.
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