Jungheinrich ERE 120 Operating Instructions Manual
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Jungheinrich ERE 120 Operating Instructions Manual

Stand-on electric pallet truck
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ERE 120
Operating instructions
51222183
02.15
07.12 -
G
ERE 120
ERE C20

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Summary of Contents for Jungheinrich ERE 120

  • Page 1 ERE 120 07.12 - Operating instructions 51222183 02.15 ERE 120 ERE C20...
  • Page 4 Foreword Notes on the operating instructions The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter and the pages are numbered continuously.
  • Page 5 Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG. Jungheinrich Aktiengesellschaft Am Stadtrand 35 22047 Hamburg - Germany Tel: +49 (0) 40/6948-0 www.jungheinrich.com...

  • Page 6: Table Of Contents

    Contents Correct Use and Application ........... General....................Correct application................... Approved application conditions.............. Internal Operation Combined with Brief External or Cold Store Operation (t) ......................Internal Operation in Cold Stores with Cold Store Equipment (o) ..Proprietor responsibilities ................ Adding attachments and/or optional equipment ........Truck Description ..............
  • Page 7 Battery - Servicing, Recharging, Replacement ....... 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 ..............
  • Page 8 Industrial Truck Maintenance ..........127 Operational Safety and Environmental Protection........127 Maintenance Safety Regulations............. 128 Working on the electrical system............. 129 Consumables and used parts..............129 Wheels..................... 129 Hydraulic system ..................130 Lift Chains....................131 Lubricants and Lubrication Schedule ............132 Handling consumables safely ..............
  • Page 10 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.

  • Page 12: A Correct Use And Application

    A Correct Use and Application General The truck must be used, operated and serviced in accordance with the present instructions. All other types of use are beyond its scope of application and may result in damage to personnel, the industrial truck or property. Correct application NOTE The maximum load and load distance are indicated on the capacity plate and must...

  • Page 13: Approved Application Conditions

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

  • Page 14: Internal Operation Combined With Brief External Or Cold Store Operation (T)

    – Do not charge the battery below +5°C. Internal 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.

  • Page 15: Proprietor Responsibilities

    Proprietor responsibilities For the purposes of the present operating instructions the “operating company” is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties.

  • Page 16: B Truck Description

    B Truck Description Application The industrial truck is a tiller operated electric pallet truck with a folding standing platform and side arms. It is designed for transporting goods on level surfaces. Open bottom pallets or pallets with transverse boards (provided that the boards are outside the perimeter of the load wheels) can be lifted.

  • Page 17: Travel Direction Definition

    Travel direction definition The following determinations have been made for travel direction specification: Item Travel direction Left Drive direction Load direction Right...

  • Page 18: Assemblies And Functional Description

    Assemblies and Functional Description Assembly Overview Item Component Item Component t Travel switch o CanDis t Tiller t Charge indicator t Key switch 10 t Folding operator platform o CanCode 11 o Folding side restraint o ISM 12 o Mains cable (on-board charger) t Emergency Disconnect (main Support wheel 13 t...

  • Page 19: Functional Description

    Functional Description Safety Mechanisms An enclosed, smooth truck perimter with rounded edges ensures safe handling of the truck. The wheels are surrounded by a solid skirt. When released a gas pressure spring pushes the tiller up and activates braking. If the truck touches a person, the red collision safety switch changes the travel direction in pedestrian mode when travelling in drive direction with the platform and the side restraints folded up (o).
  • Page 20 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.

  • Page 21: Technical Specifications

    The technical specifications comply with the German "Industrial Truck Data Sheet" Guidelines. Technical modifications and additions reserved. Performance data Description ERE 120 ERE C20 Q Rated capacity 2000 Q Rated capacity (support arm lift / mast lift) 2000 / 700...

  • Page 22: Dimensions

    Dimensions ERE 120 1053...
  • Page 23 ERE C20 1053 22 4 24 8 b1 1...
  • Page 24 Description ERE 120 Tiller height in travel position 1146/1428 Lowered fork height Rated lift b1/b2 Overall width Width across forks 510/540/670 Track width, front 338/368/498 Track width, rear s/e/l Fork dimensions 55/172/1150 Safety clearance Overall length (M/L) 1834/1906 Headlength (M/L)
  • Page 25 Description ERE C20 Tiller height in travel position 1146/1428 Lowered fork height Mast lift Support arm lift b1/b2 Overall width Width across forks Track width, front Track width, rear s/e/l Fork dimensions 60/187/1150 Safety clearance Overall length 1850 Length to fork face Ground clearance, centre of wheelbase 1)3)4) Aisle width for pallets 1000x1200...
  • Page 26 Aisle widths ERE 120 / ERE C20 (all dimensions in mm) 3)4) 1)3)4) 1)2)3) 2)3)4) Battery compartment L - Headlength l = 754 mm 1000 1756 1269 1000 1517 1954 1150 1906 1419 1200 1667 2154 1200 1956 1469 1200...

  • Page 27: Weights

    Weights Description ERE 120 Net weight excl. battery (M/L) 440/443 Axle loading, laden 1702/1043 front/rear + battery (L) Axle loading, unladen 155/590 front/rear + battery (L) Weights and axle loads vary depending on truck features. Description ERE C20 Net weight excl. battery...

  • Page 28: En Norms

    EN norms Continuous sound pressure level – ERE 120 / ERE C20: 73 dB(A) in accordance with EN 12053 as harmonised with ISO 4871. The continuous sound pressure level is calculated according to standard procedures and takes into account the sound pressure level when driving, lifting and idling.

  • Page 29: Conditions Of Use

    Conditions of use Ambient temperature – without cold store equipment: operating at -10°C to 40°C, see "Internal Operation Combined with Brief External or Cold Store Operation (t)" on page 13 – with cold store equipment: operating at -28°C to +25°C, see "Internal Operation in Cold Stores with Cold Store Equipment (o)"...

  • Page 30: Identification Points And Data Plates

    Identification Points and Data Plates Warnings and notices such as capacity charts, strap points and data plates must be legible at all times. Replace if necessary. Indication Points ERE 120 Item Component Capacity Qmax Attachment points for lifting by crane...

  • Page 31: Data Plate

    ERE C20 2000 Q max Q max Item Component Capacity Qmax Attachment points for lifting by crane Model name Battery data plate Data plate Serial number (etched into the truck chassis) Ergonomic lift capacity plate...
  • Page 32 Data plate The illustration shows the standard version for EU member states. The data plate may differ in other countries. Item Description Item Description Type Year of manufacture Serial number Load centre (mm) Rated capacity (kg) Output Battery voltage (V) Min./max.

  • Page 33: Truck Capacity Plate

    Truck capacity plate The capacity plate (14) gives the maximum load-bearing capacity (Q) of the truck in kg assuming the load on the load handler is evenly distributed. Capacity plate, ergonomic lift(o) (ERE C20) 2000 Q max Q max Travelling with a raised load prohibited Max.

  • Page 34: C Transport And Commissioning

    C Transport and Commissioning Lifting by crane WARNING! All persons involved in loading by crane must be trained Incorrect crane loading procedures due to untrained personnel can cause the truck to fall. There is a risk of injury to personnel and a risk of material damage to the truck. Loading must only be performed by specialist personnel trained for this purpose.
  • Page 35 The truck can now be lifted by crane.

  • Page 36: Remove The Transport Lock

    Remove the transport lock The transport lock ensures that the truck is braked during transport without the mass of the battery. There is an instruction decal by the front cover for the transport lock (35). This must be removed once the battery has been installed. Remove the transport retainer Requirements –...

  • Page 37: Transport

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

  • Page 38: Using The Truck For The First Time

    Using the Truck for the First Time WARNING! The use of unsuitable energy sources can be hazardous Rectified AC current will damage the assemblies (controllers, sensors, motors etc.) of the electronic system. Unsuitable cable connections (too long, insufficient wire cross-section) to the battery (tow cables) can overheat, setting the truck and battery on fire.

  • Page 40: D Battery - Servicing, Recharging, Replacement

    D Battery - Servicing, Recharging, Replacement 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.
  • Page 41 The use of unsuitable batteries that have not been approved for the truck by Jungheinrich, can lead to a deterioration of the braking characteristics of the truck during energy recovery, causing considerable damage to the electric controller and resulting in serious danger to the health and safety of individuals.

  • Page 42: Battery Types

    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. ERE 120 Battery tray M Battery type Capacity (Ah) Min.
  • Page 43 ERE C20 Battery tray S Battery type Capacity (Ah) Min. weight Max. dimensions (kg) (mm) 24 volt battery 2PzB 200 662X147X686 24 volt battery 2PzVB 170 657X147X686 24 volt battery 2PzVB 142 652X147X560 24 volt battery 2PzB 150 662 x 147 x 592 24 volt battery 2PzB 150 Lib.Silver 144 662 x 147 x 592...

  • Page 44: Exposing The Battery

    Exposing the battery WARNING! An unsecured truck can cause accidents Parking the truck on an incline or with a raised load handler is dangerous and is strictly prohibited. Park the truck on a level surface. In special cases the truck may need to be secured with wedges.

  • Page 45: Charging The Battery

    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. Switch the charging station and truck off first before connecting/disconnecting the charging cable of the battery charging station to/from the battery connector.

  • Page 46: Charging The Battery With A Stationary Charger

    Charging the battery with a stationary charger Charging the battery Requirements – Expose the battery, see "Exposing the battery" on page 43. Procedure • Disconnect battery connector (40) from truck connector. • Connect the battery connector (40) to charging cable (41) stationary charger.

  • Page 47: Charging The Battery With An On-Board Charger (O)

    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. The 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.
  • Page 48 Flashing sequence / charging curve assignment (ELH 2415/2425/2435) Flashing sequence Selected charging curves (characteristics) Wet cell battery: PzS with 100 - 300 Ah Wet cell battery: PzM with 100 - 179 Ah Wet cell battery: PzS with pulse characteristic 200 - 400 Ah Wet cell battery: PzM with pulse characteristic 180 - 400 Ah...
  • Page 49 Mains frequency: 50 Hz / 60 Hz The mains connector of the charger (42) is integrated in the battery compartment (the illustration shows the battery compartment of the ERE 120). Charging the battery Requirements – Park the truck securely, see "Parking the truck securely" on page 65.
  • Page 50 Completing the battery charge, restoring the truck to operation NOTE If charging has been interrupted, the full battery capacity will not be available Requirements – Battery charging is complete. Procedure • Remove the mains connector from the socket and store it in the battery compartment with the cable.
  • Page 51 LED display (43) Green LED (charge status) Charging complete, battery full. (Charge interval, float or compensation charge). Slow flash Charging. Rapid flash Display at beginning of charge or after setting a new characteristic curve. Number of flash pulses corresponds to the characteristic curve set.

  • Page 52: Battery Removal And Installation

    Battery removal and installation WARNING! Accident risk during battery removal and installation Due to the battery weight and acid there is a risk of trapping or scalding when the battery is removed and installed. Note the "Safety regulations for handling acid batteries" section in this chapter. Wear safety shoes when removing and installing the battery.

  • Page 53: Removing The Battery From The Top

    Removing the battery from the top Battery removal Requirements – Park the truck securely, see "Parking the truck securely" on page 65. – Expose the battery, see "Exposing the battery" on page 43. Procedure • Remove the battery panel on trucks with a protective grille (o). •...

  • Page 54: Removing The Battery From The Side

    Removing the battery from the side CAUTION! Trapping hazard Trapping hazard when removing and installing the battery. When removing and installing the battery do not put your hands between the battery and the chassis. Battery removal Requirements – Park the truck securely, see "Parking the truck securely"...

  • Page 56: E Operation

    E Operation Safety Regulations for the Operation of the Forklift Truck Driver authorisation The truck may only be used by suitably trained personnel, who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to operate the truck by the proprietor or his representative.
  • Page 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.

  • Page 58: Displays And Controls

    Displays and Controls 52,53,54 7, 9...
  • Page 59 Item Control /Display Function t – Controls the direction of travel as well as Travel switch the travel speed. t – Set to brake zone (B) (see "Brakes" on Tiller page 77): The truck brakes mechanically. – Set to travel zone (F) (see "Brakes" on page 77): The mechanical brake is released and the truck is ready for operation.
  • Page 60 Item Control /Display Function t Safety feature Collision safety switch – Pedestrian mode: When applied, the truck travels for approx. 3 seconds in the fork direction. The parking brake then applies. The truck remains switched off until the travel switch is set to neutral. –...

  • Page 61: Battery Discharge Monitor

    Battery discharge monitor 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.

  • Page 62: Starting Up The Truck

    Starting up the truck Checks and Operations to Be Performed Before Starting Daily Work WARNING! Damage and other truck or attachment (optional equipment) defects can result in accidents. If damage or other truck or attachment (optional equipment) defects are discovered during the following checks, the truck must be taken out of service until it has been repaired.

  • Page 63: Preparing The Truck For Operation

    Preparing the truck for operation Switching on the truck Requirements – For checks and operations to be performed before starting daily operation, see "Checks and Operations to Be Performed Before Starting Daily Work" on page 61. Procedure • For rider mode, fold out the operator platform (10) and the side arms (o) (11). •...
  • Page 64 9, 52 54, 56...

  • Page 65: Checks And Operations To Be Carried Out When The Truck Is Operational

    Checks and operations to be carried out when the truck is operational WARNING! Risk of accident due to damage to or other defects in the truck and optional features If damage or other truck or attachment (optional equipment) defects are discovered during the following checks, the truck must be taken out of service until it has been repaired.

  • Page 66: Parking The Truck Securely

    Parking the truck securely WARNING! An unsecured truck can cause accidents Do not leave an unsecured truck. Park the truck securely when leaving it. Exception: If the operator intends to remain in the immediate vicinity and is leaving the truck for only a short while, the applied parking brake is sufficient to hold the truck, see page 78.
  • Page 67 Parking the truck securely Procedure • Park the truck on a level surface. • Fully lower the load handler. • Press the “Lower load handler” button. • Using the tiller, set the drive wheel to "forward travel". • Switch off the truck, to do this: •...

  • Page 68: Industrial Truck Operation

    Industrial Truck Operation 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.

  • Page 69: How To Act In Hazardous Situations

    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.

  • Page 70: Emergency Disconnect

    Emergency Disconnect CAUTION! Applying maximum braking can result in accidents Applying the Emergency Disconnect switch during travel will cause the truck to decelerate to a halt at maximum force. This may cause the load to slide off the load handler. There is a higher risk of accidents and injury. Do not use the Emergency Disconnect switch as a service brake.
  • Page 71 Press the Emergency Disconnect switch Procedure • Press the Emergency Disconnect (8). All electrical functions are deactivated. The truck brakes to a halt. Press the Emergency Disconnect switch on in emergencies. Releasing the Emergency Disconnect switch Procedure • Pull the Emergency Disconnect switch (8) 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).

  • Page 72: Automatic Braking

    Automatic braking When the tiller is released, it returns automatically to the upper brake zone (B) and the brakes are applied automatically. WARNING! Risk of collision due to a defective tiller Operating the truck with a defective tiller can lead to collisions with persons or objects. If 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.

  • Page 73: Travel

    Travel WARNING! Collision hazard when operating the truck Collisions with personnel and equipment can result if the truck is operated with open panels. Do not operate the truck unless the panels and covers are closed and properly locked. When travelling through swing doors etc. make sure that the doors do not activate the collision safety button.
  • Page 74 – Travel in pedestrian mode – Travel in rider mode Travelling in pedestrian mode Requirements – Start up the truck, see "Starting up the truck" on page 61 Procedure • Swing in both folding side arms (11) (o). Both side arms must always be folded in, otherwise all functions are deactivated (E-1926).
  • Page 75 Travelling is inhibited when the operator platform is vacated and the side arms are not folded out. ERE 120: If the standing platform is occupied and the side arms are not folded out, the truck can only be operated at reduced speed.
  • Page 77 4.5.1 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. After setting off in the opposite direction, apply the travel switch gently or not at all.

  • Page 78: Steering

    Steering Procedure • Move the tiller (6) to the left or right. The truck is steered in the required direction. Brakes WARNING! Accident risk The brake pattern of the truck depends largely on the ground conditions. The operator must take into account the travel route conditions when braking. Brake with care to prevent the load from slipping.
  • Page 79 4.7.1 Braking with the service brake Procedure • Move the tiller (6) up or down to one of the brake zones (B). The truck brakes to a halt regeneratively via the service brake. When braking regeneratively, energy is returned to the battery, ensuring a longer service time.

  • Page 80: Load Handler Raise/Lower

    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.
  • Page 81 4.8.1 Raising the load handler Requirements – Prepare truck operation, "Preparing the truck for operation" on page 62. 49 50 Procedure • Press the “Raise load handler ” button (50) until you reach the desired lift height. NOTE Risk of material damage to the hydraulic unit When the mechanical end stop of the load has been reached, release the "Raise load handler"...

  • Page 82: Lifting, Transporting And Depositing Loads

    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. Instruct other people to move out of the hazardous area of the truck. Stop working with the truck if people do not leave the hazardous area.
  • Page 83 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).
  • Page 84 4.9.2 Transporting a load Requirements – Load raised correctly. – ERE 120: Raise the forks completely from the ground to transport correctly (approx. 150 - 200 mm above the ground). – ERE C20: Raise the forks completely from the ground to transport correctly (approx. 150 - 500 mm above the ground ).
  • Page 85 4.9.3 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 •...

  • Page 86: Ergonomic Lift (O) (Ere C20)

    4.10 Ergonomic Lift (o) (ERE C20) For lifting and lowering, the truck is equipped with support arm lift (initial lift) with the maximum lift capacity and mast lift (high lift) with a lower lift capacity, see "Truck capacity plate" on page 32. Raises the load handler When the "Load handler lift"...
  • Page 87 4.10.1 Use as a Lift Work Table The load handler can remain in a raised position to be used as a lift work table when the truck is switched off, provided the operator is close to the truck. Immediate vicinity of the truck is when the operator is able to respond to malfunctions or attempts to use the truck by unauthorised persons immediately.

  • Page 89: Troubleshooting

    Troubleshooting This chapter enables the operator to localize and rectify basic faults or the results of incorrect operation himself. When trying to locate a fault, proceed in the order shown in the remedy table. If, after carrying out the following remedial action, the truck cannot be restored to operation or if a fault in the electronics system is displayed with a corresponding error code, contact the manufacturer’s service department.

  • Page 90: Truck Does Not Start

    Truck does not start Possible cause Corrective measures Battery connector not plugged in. Check the battery connector and connect if necessary. Emergency disconnect switch pressed Unlock the emergency disconnect switch Key switch set to O Set the key switch to “I” Battery charge too low Check battery charge, charge the battery if necessary...

  • Page 91: Load Cannot Be Lifted

    Load cannot be lifted Possible cause Corrective measures Truck not operational Carry out all measures listed under “Truck does not start” Hydraulic oil level too low Check the hydraulic oil level, see page 142 Battery discharge monitor has switched Charge the battery, see page 44 Faulty fuse Check the fuses, see page 143 Excessive load...

  • Page 92: Operating The Truck Without Its Own Drive System

    Operating the truck without its own drive system 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 "Emergency operation with service key GF60"...
  • Page 93 WARNING! Only return the truck to service when you have identified and rectified the fault.

  • Page 94: Optional Equipment

    Optional equipment Emergency operation with service key GF60 WARNING! The truck can move accidentally when the brake is released The GF60 service key must not remain on the truck during normal operation. The service key should only be used by an authorised person (e.g. warehouse manager).
  • Page 95 Parking the truck securely Procedure • Set the key switch to the “0” position and remove the key. When you switch back from level 2 to level 1 the bar returns to its original position. The brake is now activated again. GF 30 The GF30 key without a bar is designed for normal truck operation.

  • Page 96: Cancode Keypad (O)

    CanCode Keypad (o) 7.2.1 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.
  • Page 97 The keypad consists of 10 digit keys, a Set key (61) and a o key (63). 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 (58, 59, 60) show the travel program setting.
  • Page 98 7.2.2 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 "Emergency Disconnect" on page 69. The LED (62) lights up red. •...
  • Page 99 7.2.4 Changing the master code 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 "Choose length of the new master code (4-6 digit) and add user codes" on page 107. 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.
  • Page 100 Error displays changing the master code For the following events the LED (62) flashes red: Cause Remedy – New master code is already – Switch off the truck, see "Switching off the truck occupied by a user code with the keypad (CanCode)" on page 97. –...
  • Page 101 7.2.5 Add operator code Requirements – To prepare the truck for operation, see "Preparing the truck for operation with the keypad (CanCode)" on page 97. Procedure • Press the O key (63). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (62) flashes green.
  • Page 102 Error displays adding a user code For the following events the LED (62) flashes red: Cause Remedy – The user code entered is not – Switch off the truck, see "Switching off the truck the same length as the with the keypad (CanCode)" on page 97. master code –...
  • Page 103 7.2.6 Change operator code Requirements – To prepare the truck for operation, see "Preparing the truck for operation with the keypad (CanCode)" on page 97. Procedure • Press the O key (63). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (62) flashes green.
  • Page 104 Error displays changing a user code For the following events the LED (62) flashes red: Cause Remedy – The user code entered is not – Switch off the truck, see "Switching off the truck the same length as the with the keypad (CanCode)" on page 97. master code –...
  • Page 105 7.2.7 Delete individual user codes Requirements – To prepare the truck for operation, see "Preparing the truck for operation with the keypad (CanCode)" on page 97. Procedure • Press the O key (63). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (62) flashes green.
  • Page 106 Error displays deleting individual user codes For the following events the LED (62) flashes red: Cause Remedy – The user code entered is not – Switch off the truck, see "Switching off the truck the same length as the with the keypad (CanCode)" on page 97. master code –...
  • Page 107 7.2.8 Delete all user codes, Requirements – To prepare the truck for operation, see "Preparing truck operation with keypad (CanCode)" on page 97. Procedure • Press the O key (63). • Enter the valid master code with the digit keys. When you enter the valid master code the LED (62) flashes green.
  • Page 108 7.2.9 Choose length of the new master code (4-6 digit) and add user codes 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.
  • Page 109 7.2.10 Setting the automatic truck cutout (timeframe) Requirements – To prepare the truck for operation, see "Preparing the truck for operation with the keypad (CanCode)" on page 97. Procedure • Press the O key (63). • Enter the valid master code with the digit keys. When you enter the correct master code the LED (62) flashes green.
  • Page 110 Cause Remedy – Cutout time entered is out of – Switch off the truck, see "Switching off the truck range with the keypad (CanCode)" on page 97. – Enter the time again while making sure it is within range. Fixed cutout time (o) An automatic truck cutout is factory-set.
  • Page 111 7.2.11 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. The starting travel program is the travel program that is activated when the truck is switched on and is displayed by the (58,59,60) LEDs.
  • Page 112 Specifying a configuration code: Setting Description – Travel program 1 is blocked for the user code selected 1st digit – Travel program 1 is enabled for the user code selected – Travel program 2 is blocked for the user code selected 2nd digit –...
  • Page 113 Adapting the travel program configuration to the user code Procedure • Press the O key (63). • Enter the valid master code with the digit keys. When you enter the valid master code the green LED (62) flashes green. • Enter the parameters 0-2-4 with the digit keys. •...
  • Page 114 Error displays configuring the travel programs For the following events the LED (62) flashes red: Cause Remedy – Blocked travel program – Switch off the truck, see "Switching off the truck defined as start travel with the keypad (CanCode)" on page 97. program –...

  • Page 115: Setting The Truck Parameters With Cancode

    Setting the truck parameters with CanCode CAUTION! Faulty entry Without CanDis only CanCode internal parameters can be changed. Traction controller parameters can only be changed with CanDis, without CanDis the settings must be performed 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.
  • Page 116 To continue setting, confirm with the Set key (61) again. Saving travel parameters Requirements – Enter all parameters. Procedure • Run "SaveParameters" by pressing 1-2-3-Set. • Confirm with the O key (63).

  • Page 117: Parameters

    0256 Acceleration 0 - 9 Platform folded (0.13 - 1.88 m/s 0.67 m/s out, side arms folded out 0264 ERE 120: Maximum speed in drive 0 - 9 direction using travel (4.5 - 9.0 km/h) 6.0 km/h switch ERE C20:...
  • Page 118 0272 Acceleration 0 - 9 Platform folded (0.13 - 1.88 m/s 1.08 m/s out, side arms folded out 0280 ERE 120: Maximum speed in drive 0 - 9 direction using travel (4.5 - 9.0 km/h) 8.5 km/h switch ERE C20:...
  • Page 119 0288 Acceleration 0 - 9 Platform folded (0.13 - 1.88 m/s 1.62 m/s out, side arms folded out 0296 ERE 120: Maximum speed in drive 0 - 9 direction using travel (4.5 - 9.0 km/h) 8.5 km/h switch ERE C20:...
  • Page 120 Battery parameters Function Range Standard Comments setting 1377 Battery type 0 - 5 0 = Normal (wet) (normal / high 1 = High performance performance / dry) (wet) 2 = Dry (maintenance-free) 3 = US "Flat Plate" type 4 = US "Pallet Pro" type 5 = US "Tubular Plate"...
  • Page 121 Function Range Standard Comments setting 1388 ELH charger 0 - 6 characteristic curve No charging function 1 = PzS wet cell batteries 100 - 300 Ah and PzM batteries from 0 - 179 Ah 2 = PzS wet cell batteries with pulse characteristics 200 - 400 Ah and PzM batteries from 180 -...

  • Page 122: Setting The Battery Parameters With Cancode

    Setting the Battery Parameters with CanCode WARNING! Altering parameters cause accidents Altering settings cause accidents. This 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".
  • Page 123 Testing an altered parameter Requirements – The parameter is now saved. Procedure • Press the O key (63). • 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.

  • Page 124: Set Elh 2415 / 2425 / 2435 Charger Characteristics With Cancode

    Set ELH 2415 / 2425 / 2435 Charger Characteristics with CanCode Parameter setting example The following example shows the charging characteristics parameter setting for a maintenance-free battery with 201 - 300 Ah. Requirements – CanCode and CanDis are available. Procedure •...
  • Page 125 The parameter with sub index are displayed alternately with the current reading. E.g. (1388-2<->0000-5) corresponds to the charging characteristics for the maintenance-free battery with 201 - 300 Ah. • Press the O key. The parameter has now been checked.

  • Page 126: Candis Display Instrument (O)

    CanDis Display Instrument (o) The instrument indicates: Battery charge display (on board charger only) LED bars for battery charge status "Warning" symbol (yellow), Battery charge recommended "Stop" symbol (red); lift cutout, Battery charge essential No symbol when battery type set to normal or enhanced performance wet cell battery "T"...

  • Page 127: Ism Access Module (O)

    7.7.1 Discharge monitor function The discharge limit has been reached when the "Stop" symbol (67) lights up. When the discharge monitor function is activated lifting operations are disabled. Travel and lowering are still possible. Lifting is only enabled again when the battery is 70% charged.

  • Page 128: F Industrial Truck Maintenance

    F Industrial Truck Maintenance Operational Safety and Environmental Protection The checks and servicing operations contained in this chapter must be performed in accordance with the maintenance checklist service intervals. WARNING! Risk of accidents and component damage Any modification to the truck, in particular the safety mechanisms, is prohibited. Exception: Operating companies should only make changes or have changes made to powered industrial trucks if the manufacturer is no longer operating in the field and there is no successor to the business;...

  • Page 129: Maintenance Safety Regulations

    Maintenance Safety Regulations Maintenance and repair personnel The manufacturer has a service department specially trained for these tasks. A maintenance contract with the manufacturer will ensure trouble-free operation. Truck maintenance and repair work must only be carried out by specially trained personnel.

  • Page 130: Working On The Electrical System

    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: Only suitably trained electricians may operate on the truck's electrical system.

  • Page 131: Hydraulic System

    Hydraulic system WARNING! Leaky hydraulic systems can result in accidents Hydraulic oil can escape from leaky and faulty hydraulic systems. Report any defects immediately to your supervisor. Mark defective truck and take out of service. Do not return the industrial truck to service until you have identified and rectified the fault.

  • Page 132: Lift Chains

    Lift Chains WARNING! Non-lubricated and incorrectly cleaned lift chains can cause accidents Lift chains are safety-critical parts. They must not contain any serious contamination. Lift chains and pivot pins must always be clean and well lubricated. Lift chains should only be cleaned with paraffin derivatives e.g. petroleum or diesel fuels.

  • Page 133: Lubricants And Lubrication Schedule

    Lubricants and Lubrication Schedule Handling consumables safely Handling consumables Consumables must always be handled correctly. Follow the manufacturer’s instructions. WARNING! Improper handling is hazardous to health, life and the environment Consumables can be flammable. Keep consumables away from hot components and naked flames. Always keep consumables in prescribed containers.
  • Page 134 WARNING! Improper handling of oils can be hazardous Oils (chain spray / hydraulic oil) are flammable and poisonous. Dispose of used oils in accordance with regulations. Store used oil safely until it can be disposed of in accordance with regulations. Do not spill oil.

  • Page 135: Lubrication Schedule

    Lubrication Schedule 0,7l 0,55 l g Contact surfaces Cold Store Application s Grease nipple b Transmission oil filler neck a Transmission oil drain plug Transmission oil overflow and dipstick Hydraulic oil filler neck 1 Compound ratio for cold store usage 1:1...

  • Page 136: Consumables

    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.

  • Page 137: Maintenance And Repairs

    Maintenance and repairs Prepare 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 "Parking the truck securely" on page 65. •...

  • Page 138: Front Cover Disassembly

    Front cover disassembly Front cover disassembly Procedure • Fold down the operator platform (10). • Release the compartment panel latch using a spanner (width 8) and expose the panel latch. • Release the panel latch (71) using a spanner (width 8). •...

  • Page 139: Lifting And Jacking Up The Truck Safely

    Lifting and jacking up the truck safely WARNING! Lifting and jacking up the truck safely In order to raise the truck, the lifting gear must only be secured to the points specially provided for this purpose. You may only work under a raised load handler if it has been secured with a sufficiently strong chain or the fastening bolt.

  • Page 140: Cleaning

    Cleaning 4.4.1 Cleaning the truck CAUTION! Fire hazard Do not use flammable liquids to clean the industrial truck. Disconnect the battery before starting cleaning work. Carry 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.
  • Page 141 Cleaning the truck Requirements – Prepare the truck for maintenance and repairs (see "Prepare the truck for maintenance and repairs" on page 136). 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.
  • Page 142 4.4.2 Cleaning the electrical system assemblies CAUTION! Risk of electrical system damage Cleaning the assemblies (controllers, sensors, motors etc.) of the electronic system with water can damage the electrical system. Do not clean the electrical system with water. Clean the electrical system with weak suction or compressed air (use a compressor with a water trap) and not a conductive, anti-static brush.

  • Page 143: Replacing The Drive Wheel

    Replacing the drive wheel The drive wheel must only be replaced by authorised service personnel. Checking the hydraulic oil level Check oil level Requirements – Lower the load handler. – Prepare the truck for maintenance and repairs, see "Prepare the truck for maintenance and repairs"...

  • Page 144: Checking Electrical Fuses

    Checking electrical fuses Check fuses Requirements – Truck prepared for maintenance and repairs, see "Prepare the truck for maintenance and repairs" on page 136. – Front cover removed, see "Front cover disassembly" on page 137. Procedure • Check the fuse ratings against the table and replace if necessary. The fuses are now checked.
  • Page 145 Item Component To protect Rating (A) 9F22 Control fuse 2 (after main contactor) Display / battery hour meter Control fuse 1 (before main contactor) Spare Spare for option Drive / lift motor main fuse...

  • Page 146: Restoring The Truck To Service After Maintenance And Repairs

    Restoring the truck to service after maintenance and repairs Procedure • Thoroughly clean the truck, see "Cleaning the truck" on page 139. • Lubricate the truck according to the lubrication schedule, see "Lubrication Schedule" on page 134. • Clean the battery, grease the terminals and connect the battery. •...

  • Page 147: Decommissioning The Industrial Truck

    Decommissioning the Industrial Truck If the truck is to be out of service for more than a month, it must be stored in a frost- free and dry room. All necessary measures must be taken before, during and after decommissioning as described hereafter. When the truck is out of service it must be jacked up so that all the wheels are clear of the ground.

  • Page 148: Restoring The Truck To Service After Decommissioning

    Restoring the truck to service after decommissioning Procedure • Thoroughly clean the truck, see "Cleaning" on page 139. • Lubricate the truck according to the lubrication schedule, see "Lubrication Schedule" on page 134. • Clean the battery, grease the terminals and connect the battery. •...

  • Page 149: Safety Tests To Be Performed At Intervals And After Unusual Incidents

    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.

  • Page 150: Servicing And Inspection

    Servicing and Inspection WARNING! Lack of maintenance can result in accidents Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment. Thorough and expert servicing is one of the most important requirements for the safe operation of the industrial truck.

  • Page 151: Maintenance Checklist

    Maintenance checklist 10.1 Operating Company 10.1.1 Standard Equipment Braking W A B C Test brakes. Electrical W A B C Test warning and safety devices in accordance with operating instructions. Test emergency disconnect switch. Power supply W A B C Check battery cable connections are secure, check for dirt and grease terminals if necessary.
  • Page 152 On-board charger 35A Battery charger W A B C Check mains connector and mains cable. Standard on-board charger Battery charger W A B C Check mains connector and mains cable.

  • Page 153: 10.2 Customer Service

    10.2 Customer Service 10.2.1 Standard Equipment Braking W A B C Test brakes. Check the air gap of the magnetic brake. Electrical W A B C Check cables and motor mounting are secure. Test warning and safety devices in accordance with operating instructions.
  • Page 154 Chassis and Superstructure W A B C Check chassis and screw connections for damage. Check doors and/or covers. Check labels are legible, complete and make sense. Test the operator platform and check for damage. Check operator mat and steps are non-slip and damage-free. Hydraulic Operations W A B C Test "hydraulic"...
  • Page 155 Automatic crawl speed Travel W A B C Check that sensors/switches are secured, not damaged, clean and operational. Battery refill system Power supply W A B C Test battery refill system and check for leaks. On-board charger 35A Battery charger W A B C Check mains connector and mains cable.
  • Page 156 Ergonomic lift Hydraulic Operations W A B C Test the lift sensors in the mast and initial lift and check for damage. Check settings and wear levels of slide pieces and stops and adjust the slide pieces if necessary. Check load chain setting and tension if necessary. Check lateral clearance of the mast connections and the fork carriage.
  • Page 158 A Traction Battery Appendix Contents Traction Battery Appendix............Correct Use and Application..............Data plate ....................Safety Instructions, Warning Indications and other Notes ....... Lead acid batteries with armour plated cells and liquid electrolyte..Description....................Operation....................Servicing lead-acid batteries with armour plated cells......PzV and PzV-BS lead-acid batteries with sealed armour plated cells..

  • Page 159: Correct Use And Application

    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).

  • Page 160: Safety Instructions, Warning Indications And Other Notes

    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. waste.

  • Page 161: Lead Acid Batteries With Armour Plated Cells And Liquid Electrolyte

    Lead acid batteries with armour plated cells and liquid electrolyte 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. Electrolyte The rated density of the electrolyte assumes a temperature of 30°C and the rated electrolyte level is fully charged.

  • Page 162: Operation

    Operation 4.2.1 Commissioning unfilled batteries 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 Checks and operations to be performed before starting daily work Procedure •...
  • Page 163 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. Always disconnect the charger and truck before connecting or disconnecting the charger and battery.
  • Page 164 The electrolyte temperature rises by approx. 10 K 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.

  • Page 165: Servicing Lead-Acid Batteries With Armour Plated Cells

    Servicing lead-acid batteries with armour plated cells Water quality 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. 4.3.1 Daily –...

  • Page 166: Pzv And Pzv-Bs Lead-Acid Batteries With Sealed Armour Plated Cells

    PzV and PzV-BS lead-acid batteries with sealed armour plated cells 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.

  • Page 167: Operation

    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. •...
  • Page 168 NOTE 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 cells. Always charge the battery with DC current. All DIN 41773 charging procedures are permitted in the format approved by the manufacturer.
  • Page 169 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).

  • Page 170: Servicing Pzv And Pzv-Bs Lead-Acid Batteries With Sealed Armour Plated Cells

    Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated cells 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. –...

  • Page 171: Aquamatik Water Replenishment System

    Aquamatik water replenishment system Water replenishment system design > 3 m Water container Tap connection with ball cock Flow indicator Shut-off cock Locking coupling Battery lock connector...

  • Page 172: Functional Description

    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.

  • Page 173: Filling Time

    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. Water quality The quality of the water used to fill up electrolyte must correspond to purified or distilled water.

  • Page 174: Cleaning Measures

    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.

  • Page 175: Electrolyte Circulation

    Electrolyte circulation 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.
  • Page 176 NOTE 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. Attach a separate coupling system to the air inlet line, such as: locking coupling on the battery side and through-coupling on the air supply side.

  • Page 177: Cleaning Batteries

    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.
  • Page 178 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. This generally ensures that the temperature does not exceed 60°C at a distance of 30cm behind the outlet nozzle.

  • Page 179: Storing The Battery

    Storing the battery NOTE 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.

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