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ERC-Z16

Jungheinrich ERC-Z12, ERC 14, ERC-12, ERC-Z14, ERC 16 Operating Instructions Manual

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Operating instructions
50126632
ERC/ERC-Z 12/14/16
G
10.01-
06.02
0108.GB
Foreword
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. Each chapter starts with page 1. The page identification consists of a chapter letter and a page number. For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following graphics:
f
Used before safety instructions which must be observed to avoid danger to personnel.
m
Used before notices which must be observed to avoid material damage.
A
Used before notices and explanations.
t Used to indicate standard equipment. o Used to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. No guarantee of particular features of the truck should therefore be inferred from the present operating instructions.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35 22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
0108.GB
I 1
0602.GB
Table of contents
A Correct use and application of the truck
B Truck description
1 Application ........................................................................................... B 1
2 Assemblies ......................................................................................... B 2
3 Technical data - standard version ....................................................... B 3
3.1 Performance data ................................................................................ B 3
3.2 Dimensions ......................................................................................... B 4
3.3 EN standards ...................................................................................... B 5
3.4 Conditions for application .................................................................... B 5
4 Location of instruction labels and identification labels ........................ B 6
4.1 Truck identification plate ..................................................................... B 7
4.2 Load capacity ...................................................................................... B 7
4.3 Load capacity, wheel-arm lifting device .............................................. B 8
4.4 Label/Order/Inventory/Service No. ..................................................... B 8
C Transportation and commissioning
1 Transportation by crane ...................................................................... C 1
2 First commissioning ............................................................................ C 1
3 Moving the truck with the drive unit inoperative .................................. C 2
D Battery - Servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ........ D 1
2 Battery type ......................................................................................... D 2
3 Exposing the battery ........................................................................... D 2
4 Charging the battery ............................................................................ D 3
4.1 Charging the battery with stationary battery charger .......................... D 3
4.2 Recharging the battery with integrated battery charger (o) ................ D 4
5 Removing and installing the battery .................................................... D 7
5.1 Remove battery by lifting it upwards (truck without
wheel-arm lifting device) ..................................................................... D 7
5.2 Remove battery by lifting it upwards (truck with wheel-arm
lifting device) ....................................................................................... D 8
5.3 Lateral battery change (o) .................................................................. D 9
0602.GB
I 2
E Operation
1 Safety regulations governing the operation of the fork lift truck .......... E 1
2 Description of controls and indicating instruments .............................. E 2
3 Starting up the truck ............................................................................ E 6
4 Operation of the fork lift truck .............................................................. E 8
4.1 Safety regulations applicable when operating the truck ...................... E 8
4.2 Driving, steering, braking .................................................................... E 9
5 Picking up and setting down loads ...................................................... E 12
5.1 Safe parking of the truck ..................................................................... E 16
6 Keyboard (CANCODE) (o) ................................................................. E 17
6.1 Functions ............................................................................................. E 17
6.2 Commissioning .................................................................................... E 18
6.3 Indicators ............................................................................................. E 19
6.4 Keys .................................................................................................... E 20
6.5 Master mode ....................................................................................... E 20
6.6 Parameter ........................................................................................... E 22
7 Display instrument (CANDIS) (o) ....................................................... E 26
7.1 Discharge monitor function ................................................................. E 27
7.2 Operating hours display ...................................................................... E 27
7.3 Switch-on test ...................................................................................... E 27
8 Fault location ....................................................................................... E 28
F Maintenance of the fork lift truck
1 Operational safety and environmental protection ................................ F 1
2 Safety regulations applicable to truck maintenance ............................ F 1
3 Servicing and inspection ..................................................................... F 3
4 Maintenance checklist ....................................................................... F 4
5 Lubrication schedule .......................................................................... F 6
5.1 Fuels, coolants and lubricants ............................................................. F 7
6 Notes on maintenance ........................................................................ F 8
6.1 Preparation of the truck for servicing and maintenance operation ...... F 8
6.2 Opening the front cover ....................................................................... F 8
6.3 Check hydraulic oil level ...................................................................... F 9
6.4 Check the transmission oil level .......................................................... F 9
6.5 Checking the electric fuses ................................................................. F 10
6.6 Recommissioning the truck ................................................................. F 11
7 Decommissioning the fork lift truck ..................................................... F 11
7.1 Operations to be performed prior to decommissioning ....................... F 11
7.2 Measures to be taken during decommissioning .................................. F 11
7.3 Recommissioning the truck ................................................................. F 12
8 Safety checks to be performed at regular intervals and following
any untoward incidents (D: Accident prevention check
according to VBG 36) .......................................................................... F 12
A 1
0600.GB
A Correct use and application of the truck
A
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are included in the scope of delivery for this truck. The guidelines are part of these oper- ating instructions and must always be heeded. National regulations are fully applica- ble.
The fork lift truck described in these operating instructions is a truck that is suitable for lifting and transporting loads. It must be used, operated and maintained according to the information in these oper- ating instructions. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. admis- sible load to be picked up is indicated on the identification plate or load diagram label shown on the truck. The fork lift truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres pre- vail.
Duties of the user: A “user” within the meaning of these operating instructions is de- fined as any natural or legal person who either uses the fork lift truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is consid- ered the person, who, in accordance with existing contractual agreements between the owner and the user of the fork lift truck, is charged with the observance of the op- erating duties. The user must ensure that the truck is not abused and only used within its design lim- its and that all danger to life and limb of the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety-related provisions, as well as the operating, servicing and mainte- nance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions.
m
If these operating instructions are not observed the warranty becomes void. The same applies if improper works are carried out at the device by the customer and/or third parties without permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after writ- ten approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained. Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary.
0600.GB
A 2
B 1
1001.GB
B Truck description
1 Application
The truck is an electric pedestrian stacker in four-wheel construction with foldable driver platform. It is designed for transporting and lifting goods on level ground. The wheel arm lift (on- ly for ERC-Z trucks) increases the ground clearance for transport over unevenground. Depending on the design, the hoist frame permits loads to be stacked and retrieved up to a max. height of 5.35 m and to be transported over longer distances. The truck capacity is indicated on the identification label or the capacity label Qmax. Due to its high travelling speed, the ERC 14/16 is equipped with safety extensions.
Truck types, capacities and motor output
Typ Capacity Motor output
ERC / ERC-Z 12 1,200kg 2.0kW
ERC / ERC-Z 14 1,400kg 2.0kW
ERC / ERC-Z 16 1,600kg 2.0kW
1001.GB
B 2
2 Assemblies
*
)
not with vehicles with load bearing capacity of 1200kg
Item Designation Item Designation
1 o Keyboard
(CANCODE)
8 t Wheel arms
2 o Display instrument
(CANDIS)
9 o Lifting linkage (Only for wheel-arm-
lifting)
3 t Key switch 10 o Charger 4 t Control shaft 11 t Supporting wheel 5 t Controller 12 t Hinged driver standing platform 6 t Free-view hoist frame 13 t Driven wheel 7 t Master switch 14 o Safety extension*
)
t = Standard equipment o = Optional equipment
6
8
9
10
11
7
5
1
13
14
12
2
3
4
B 3
1001.GB
3 Technical data - standard version
A
Indication of technical data according to VDI 2198, subject to modification and supplementing.
3.1 Performance data
Designation
ERC 12
ERC-Z12
ERC 14
ERC-Z14
ERC 16
ERC-Z16
Q Rated capacity 1,200 1,400 1,600 kg
c Load centre distance 600 600 600 mm
Travelling speed with / without rated load
6.0 / 6.0 7.5 / 8.5 7.0 / 8.5 km/h
Lifting speed with / without rated load (controllable (ZT))
19/26 18/26 17/26 cm/s
Lowering speed with / without rated load (controllable (ZT))
43/43 43/43 43/43 cm/s
Max. climbing capacity (5 min.) with / without rated load
9/16 8/16 7/16 %
167
188 428
983
h
14 min
b
1
h
14 max
h
1
h
2
h
3
h
5
h
13
s
b
5
500
b
11
a
/2
R
e
h
4
l
x
c
Q
m
2
l
2
y
l
1
A
st
a
/2
W
a
1001.GB
B 4
3.2 Dimensions
(all dimensions in mm)
*
)
at DZ+35
**
)
at DZ+43
Designation
ERC 12/
ERC-Z12
ERC 14/
ERC-Z14
ERC 16/
ERC-Z16
l
2
Design length of front 856*)/888*
)
856*)/888*
)
856**)/888**
)
h
13
Height of fork when lowered 90 90 90 h
1
Design height
(depending on the mast)
1,700 - 2,600 1,700 - 2,600 1,700 - 2,600
h
2
Free lift (ZZ and DZ) 1,219 - 2,119 1,219 - 2,119 1,169 - 2,069 h
3
Lift (depending on the mast) 2,500 - 5,350 2,500 - 5,350 2,400 - 5,250 h
4
Extended height of mast
(depending on the mast)
2,981 - 5,831 2,981 - 5,831 2,931 - 5,781
h
5
Initial lift 122 122 122 y Wheelbase 1,357/1,599 1,357/1,599 1,357/1,599 B/b
1
Overall width 800/836 800/836 800/836 W
a
Turning radius 1,565/1,804 1,565/1,804 1,565/1,804 Ast Width of aisle with pallets
800 × 1,200 lengthwise
2,414*
)
/
2,483*
)
2,414*)/
2,483*
)
2,414**)/
2,483**
)
Ast Width of aisle with pallets
1,000 × 1,200 crossways
2,441*)/
2,565*
)
2,441*)/
2,565*
)
2,441**)/
2,565**
)
Dead weight
Refer to truck identification label
167
188 428
983
h
14 min
b
1
h
14 max
h
1
h
2
h
3
h5h
13
s
b
5
500
b
11
a
/2
R
e
h
4
l
x
c
Q
m
2
l
2
y
l
1
A
st
a
/2
W
a
B 5
1001.GB
3.3 EN standards
Continuous sound level: 68 dB(A)
according to EN 12053 as stipulated in ISO 4871
A
The continuous sound level is a value averaged according to standard regulations, taking the sound pressure level into account when driving, lifting and idling. The sound pressure level is measured at the ear.
Vibration: 0.96 m/s
2
according to prEN 13059
A
The swinging acceleration acting on the body in its operating position is, according to standard regulations, the linear integrated, weighted acceleration in the vertical pla- ne. It is determined by driving over bumps with a constant speed.
Electromagnetic compatibility (EMC)
The manufacturer confirms compliance with the limit va- lues for electromagnetic emission and interference im- munity as well as testing of static electricity discharge ac- cording to prEN 12895 and the references to other standards contained therein.
A
Electrical or electronic components and their arrangement may only be modified after written approval by the manufacturer has been obtained.
3.4 Conditions for application
Ambient temperature:
- during operation: 5°C to 40°C
A
Industrial trucks must be specially equipped and approved for continuous use in en- vironments with temperatures below 5°C or in cold stores respectively with extreme temperatures or humidity changes.
1001.GB
B 6
4 Location of instruction labels and identification labels
A
The capacity label (21) indicates the maximum capacity of the truck as Qmax. The rated capacity as shown must not be exceeded. The “CAUTION: Low-voltage electronics” warning signs (23) are visible after opening the corresponding hood (refer to chapter F).
Item Designation
15 Capacity (only ERC-Z)
16 Truck identification plate
17 Attachment point of hooks for transportation by crane
18 Prohibitive sign “Keep away from under the load lifting device”
19 Prohibitive sign “Do not reach through the hoist frame”
20 UVV control label
21 Capacity
22 Battery identification plate (located in battery compartment)
23 Label “CAUTION: Low-voltage electronics”
16
18
23
17
17
17
15
19
kg
kg mm kg
Xxx Xxxx
Xxxxxxx Xxxxxxxxx
Xxxxxxxxx Xxxxxxxxxx
Xxxxx Xxxx
Xxxxxxx Xxxxxx
Xxxxxx Xxxxxx
Xxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
VkW
Xxxxxxxxx Xxxxxxxxxx
xxxxxxxxxx
xxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
2000
20
21
22
B 7
1001.GB
4.1 Truck identification plate
A
In the event of queries relating to the truck or spare part orders, please state the serial No. (25) of the truck.
4.2 Load capacity
f
The label (21) includes a table indicating the loading capacity (Q in kg) in relation to the load centre distance (D in mm) and the lifting height (H in mm).
The arrow-shaped markings on the inner mast (37) and outer mast (38) show the driver when he has reached the lifting height limits that is defined on the load capacity label (21).
Item Designation Item Designation
24 Type 31 Drive power in kW 25 Serial No. 32 Customer no. 26 Rated capacity in kg 33 Min./max. battery weight in kg 27 Battery: Voltage V 34 Dead weight without battery in kg 28 Manufacturer 35 Year of manufacture 29 Order no. 36 Manufacturer logo 30 Load centre distance in mm
kg
kg mm kg
Xxx Xxxx
Xxxxxxx Xxxxxxxxx
Xxxxxxxxx Xxxxxxxxxx
Xxxxx Xxxx
Xxxxxxx Xxxxxx
Xxxxxx Xxxxxx
Xxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
VkW
Xxxxxxxxx Xxxxxxxxxx
xxxxxxxxxx
xxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
24 25
26 27 28
29
31
35
34
33 32
30
36
-Nr.
Serien-Nr.
Dmm
Hmm
Q
kg
21
37
38
1001.GB
B 8
4.3 Load capacity, wheel-arm lifting device
Trucks with a wheel-arm lifting device are provided with an extra label (15) indicating the permissible assignment to wheel-arm lifting device and main lifting device.
4.4 Label/Order/Inventory/Service No.
A
This label contains the Full Service No. and is only handed out when a service con- tract is being concluded.
Item Description
39 Order no. 40 Inventory No. 41 Full Service No.
39
40
41
C 1
1001.GB
C Transportation and commissioning
1 Transportation by crane
f
Only use lifting equipment with sufficient bearing capacity (loading weight see identi- fication label on truck). If trucks are to be lifted that are provided with a wheel-arm lifting device, be careful not to protrude the lifting cylinders while the truck is being lifted. If the device is com- pletely protruded, there is the risk that the cylinder protection is being released due to overloading.
A
A hoisting point (2) is provided at the hoist frame for loading the truck with the help of hoisting gear. Trucks that are provided a with wheel-arm lifting device, have two more hoisting points (1) for loading.
– Park the truck and render it safe
(refer to chapter E).
– Attach the hoisting gear to the stop (2)
on the hoisting mast.
– In case of trucks that are provided with
a wheel-arm lifting device, the hoisting gear can also be attached to the stops (1) on the vehicle chassis.
m
Secure the hoisting gear to the hoisting points ensuring that the hoisting gear will not slip! The hoisting gear must be atta- ched in such a way that it does touch any add-on parts while the truck is being lif- ted. Trucks with wheel-arm lifting device must hang horizontally or slightly incli- ned in the direction of the lifting device.
2 First commissioning
m
The truck must only be operated on battery current. Rectified alternate current will da- mage the electronics. Cables connected to the battery (towing cable) must be less than 6 meters in length.
f
It is prohibited to hoist loads when the truck is operated via a towing cable with an external battery.
In order to prepare the truck for work following delivery or transportation, the following operations must be performed:
– Check whether the equipment is complete and in perfect condition. – If required, mount the battery, make sure not to damage the battery cable
(see chapter D).
2
1
1001.GB
C 2
A
At trucks with an optionally built-in battery charger, adjust the characteristics (loading cam) (see chapter D).
– Load the battery (see chapter D). – If required, check whether the settings of the combined instrument correspond to
the battery (see chapter D).
– Commission the truck as prescribed
(see chapter E).
A
If the truck is parked for longer periods, the running surfaces of the wheels may be flattened. However, this flattening will disappear quickly when the truck is being driven.
3 Moving the truck with the drive unit inoperative
f
This operating mode is not permitted when negotiating inclines and gradients.
If the truck has to be moved after a failure has rendered it immobile, proceed as fol- lows:
– Set the master switch to position “OFF”. – Set the key switch to position “OFF” (“0”)
and remove the key.
– If a code lock is installed, the
o-key must be pressed.
– Ensure that the truck cannot accidentally
move.
– Open the front cover and set it down
(refer to chapter F).
– Slacken the lock nuts (3) and tighten the
screws (4).
The brake has now been released and the truck can be moved.
f
After arriving at the repair bay, ensure that the brake is put back to its initial state. The truck must on no account be parked with the brake in the released condition.
– Loosen the screws (4) by approx. 5 mm and lock by tightening the lock nuts (3).
The brake is now applied again.
– Mount the front cover.
3
3
4
D 1
1001.GB
D Battery - Servicing, recharging,
replacement
1 Safety regulations governing the handling of lead-acid batteries
The truck must be parked and rendered safe before any operations on batteries are undertaken (refer to chapter E).
Servicing staff: Recharging, servicing and replacing of batteries must only be per- formed by qualified personnel. The instructions contained in this operating manual, and the instructions of the manufacturer of the battery and of the battery recharging station, must be observed when performing the above operations.
Fire protection measures: Smoking and naked flames are not permitted when handling batteries. No inflammable substances or spark-generating materials must be present or stored within a distance of 2 meters of the truck parked for battery re- charging. The location must be well ventilated and fire fighting equipment must be kept ready.
Servicing of batteries: The battery cell screw caps must be kept dry and clean. Ter- minals and cable shoes must be clean, lightly greased with pole grease and must be securely tightened. Batteries with bare terminal posts must be covered using a non- skid insulating mat.
Disposal of the battery: Batteries must only be disposed of as stipulated in the na- tional environmental protection regulations or waste disposal provisions. The manu- facturer’s specifications for the disposal must be heeded.
m
Before closing the battery hood, make sure that the battery cable cannot be dama- ged.
f
Batteries contain dissolved acid which is toxic and caustic. For this reason, protective clothing and goggles must be worn whenever work is undertaken on batteries. Avoid physical contact with battery acid. If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush the affected parts with clean water. Consult a doctor when skin or eyes come into con- tact with battery acid. Spilled battery acid must be immediately neutralized.
m
Only batteries with closed tray may be used.
f
Battery weight and dimensions have considerable influence on operational safety of the truck. Changing the battery equipment is not permitted without prior approval by the manufacturer.
1001.GB
D 2
2Battery type
Depending on the use, the truck is equipped with different types of batteries. The table below shows the capacity of the batteries and also the combinations used as standard equipment:
For the battery weight, refer to the battery identification plate.
m
When changing / replacing the battery you must make sure that the battery is safely fastened in the battery compartment of the truck.
3 Exposing the battery
f
Park the truck and render it safe (refer to chapter E).
– Fold up battery hood (1).
f
Carefully open or close the battery hood.
– Installation is in the reverse order.
f
All covers and connections must be restored to the normal operating condition before the truck is started up for work.
24V - 3PzSL - Battery 240Ah
24V - 3PzSL - Battery 270Ah
24V - 3PzSL - Battery 330Ah
2
1
D 3
1001.GB
4 Charging the battery
As default, the truck is to be loaded with a stationary battery charger. The truck wit- hout wheel-arm lifting device can optionally be supplied with an integrated battery charger.
m
For recharging the battery, the truck has to parked in-doors in a sufficiently ventilated environment.
A
Charging condition display (refer to chapter E).
4.1 Charging the battery with stationary battery charger
– Park the truck and render it safe (refer to chapter E).
m
Connection / disconnecting battery connector and socket as well as pressing the ma- ster switch (2) may only be performed with truck and battery charger being switched off.
– Expose the battery (refer to section 3).
f
During the recharging operation the tops of the battery cells must be exposed to en- sure adequate ventilation. Metal objects must not be placed on the battery. Prior to starting the recharging operation, check all cable connections and plugged connec- tions for visible damage. The safety instructions provided by the battery supplier and battery charger supplier must be strictly observed.
– Pull battery connector (3) from the plug and socket connection of the truck. – Remove insulation mat from battery, if necessary. – Connect the charging cable (4) of the battery recharging station with the battery
connector (3) and switch on the battery charger.
m
Recharge the battery observing the instructions provided by the battery supplier and by the battery charger supplier.
3
4
1001.GB
D 4
4.2 Recharging the battery with integrated battery charger (o)
f
The battery charger must not be opened. If it is damaged, it has to be exchanged.
A
Due to safety reasons, intermediate positions are available between the regulation
positions “1” to “6” of the switch (7).
If the truck is delivered without battery, an intermediate position is pre-selected as de- fault. The red light-emitting diode (5) flashes - the battery cannot be recharged.
Select charging curve in the integrated battery charger
Use switch (7) at the battery charger to adjust the charging curves to the appropriate battery according to the following table.
m
The power plug must be pulled before the corresponding charging curve is to be ad- justed!
Provided that a battery is connected, a new setting can be acknowledged via the LEDs (cf., indicator) which will then be immediately effective.
Position of switch (7) selected charging curves (characteristics)
1 Wet batteries: 100 - 330 Ah 2 Maintenance-free: 100 - 140 Ah 3 Maintenance-free: 150 - 200 Ah 4 Maintenance-free: 210 - 300 Ah 5F r e e 6F r e e
6
7
5
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