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ERE 224

Jungheinrich ERE 224 Operating Instructions Manual

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Operating instructions
50468220
ERE 224
G
09.05-
01.06
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.
Z
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
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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 ..................................................................................... 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 plates ........................ B 6
4.1 Truck identification plate ..................................................................... B 7
C Transportation and commissioning
1 Transportation by crane ...................................................................... C 1
2 Commissioning .................................................................................... C 2
3 Moving the truck with the drive unit inoperative .................................. C 3
D Battery - Servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ........ D 1
2 Battery types ....................................................................................... D 2
3 Exposing the battery ........................................................................... D 2
3.1 Standard version ................................................................................. D 2
3.2 Battery removal from the side (o) ....................................................... D 3
4 Charging the battery ............................................................................ D 4
5 Removing and installing the battery .................................................... D 5
5.1 Removal - standard version ................................................................ D 5
5.2 Removal “Battery removal from the side” (o) ..................................... D 6
5.3 Installation of the battery ..................................................................... D 6
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E Operation
1 Safety regulations governing the operation of the fork-lift truck .......... E 1
2 Description of the operating controls and displays .............................. E 2
3 Starting up the truck ............................................................................ E 6
3.1 Truck variants ...................................................................................... E 6
3.2 Switching on the truck ......................................................................... E 6
4 Operation of the fork-lift truck .............................................................. E 7
4.1 Safety regulations applicable when operating the truck ...................... E 7
4.2 Driving, steering, braking .................................................................... E 8
4.3 Picking up and setting down loads ...................................................... E 14
4.4 Safe parking of the truck ..................................................................... E 15
5 Keyboard (CANCODE) (o) ................................................................. E 16
5.1 Code lock ............................................................................................ E 16
5.2 Drive programme ................................................................................ E 18
5.3 Parameters .......................................................................................... E 18
5.4 Parameter settings .............................................................................. E 19
5.5 Travel parameters ............................................................................... E 23
6 Display instrument (CANDIS) (o) ....................................................... E 25
6.1 Discharge monitor function ................................................................. E 26
6.2 Operating hours display ...................................................................... E 26
6.3 Switch-on test ...................................................................................... E 26
7 Fault location ....................................................................................... E 27
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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 Consumption-type materials ............................................................... F 7
6 Description of the servicing and maintenance operations ................... F 8
6.1 Preparing the truck for the performance of the servicing and
maintenance operations ...................................................................... F 8
6.2 Opening the front hood ....................................................................... F 8
6.3 Opening the front hood ....................................................................... F 8
6.4 Checking the mounting and the attachment of the drive wheel .......... F 9
6.5 Checking the hydraulic oil level ........................................................... F 9
6.6 Checking the electric fuses ................................................................. F 10
6.7 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 BGV D27) ........................................................................................ F 12
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0506.GB
Appendix
JH Traction Battery Operating Instructions
Z
These operating instructions apply only to Jungheinrich battery models. If using another brand, refer to the manufacturer's operating instructions.
2
A 1
0600.GB
A Correct use and application of the truck
Z
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.
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B 1
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B Truck description
1 Application
The truck is an electric control shaft lift truck with hinged driver's platform and safety frames. A fixed driver standing platform is available as an option. The truck has been designed for lifting operations and transportation on level ground and is able to pick up, outside the load-bearing wheel range, pallets with open bases or lateral boards, as well as trolleys. The rated capacity of the truck is shown on the identification plate or can be seen on the capacity label Qmax.
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B 2
2 Assemblies
Item Designation Item Designation
1 t Controller 8 t Hinged driver standing platform 2 t Control shaft 9 t Collision guard 3 o Display instrument
(CANDIS)
10 t Safety extension
4 t Key switch 11 t Master switch 5 o Keyboard
(CANCODE)
12 o Fixed driver standing platform
6 t Supporting wheel 13 o Deadman key 7 t Driven wheel
t = Standard equipment o = Optional equipment
1 2
3 4
5
66
9
10
11
8
7
12
13
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3 Technical data
Z
Indication of technical data according to VDI 2198. Subject to modification and supplements.
3.1 Performance data
* approx. 465 mm with fixed driver standing platform ** Chassis height
Designation
Q Capacity 2.400 kg
c Load centre distance 600 mm
Travelling speed, pedestrian-controlled operation with/without load
4,5 km/h
Travelling speed, stand-on operating mode with/without load
8,5 / 10 km/h
Lift speed with/without load 0,04 / 0,05 m/s Lowering speed with/without load 0,065 / 0,04 m/s Max. climbing capacity (5 min.) with/without load 8,0 / 15,0 %
**
*
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3.2 Dimensions
(all dimensions in mm)
Length including fork back I2 = 788 mm (pedestrian-controlled operation)
1)Lifted: - 90 mm
2)Stand-on operating mode: +388 mm
3)Short version (I2=723 mm):- 65 mm
Designation
h
13
Height of fork when lowered 85 h2Lift 125 b5Distance between forks, outside 510 / 540 / 670 b3Distance between forks, inside 170 / 200 / 330
e Fork width 170
b
11
Track width 340 / 370 / 500
a Safety distance 200
Dead weight: Refer to truck identification label
lI
1
3
)y
1
1)3
)x
1
)I6b
12
W
a
1)2)3
)A
st
2)3
)
1.000 1.723 1.509 814 1.000 800 1.619 2.005
1.150 1.873 1.659 964 1.200 800 1.768 2.204
1.200 1.923 1.709 1.014 1.200 800 1.817 2.203
1.400 2.193 1.979 1.214 1.400 700 2.016 2.402
1.600 2.393 2.179 1.414 1.600 1.200 2.215 2.601
1.950 2.743 2.529 1.392 2.000 800 2.193 3.001
2.150 2.943 2.729 1.592 2.100 700 2.392 3.100
2.400 3.193 2.979 1.840 2.400 1.200 2.639 3.399
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3.3 EN standards
Continuous sound level: 68 dB(A)
according to EN 12053 as stipulated in ISO 4871
Z
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: 0.67 m/s
2
according to EN 13059
Z
The swinging acceleration acting on the body in its operating position is, according to standard regulations, the linear integrated, weighted acceleration in the vertical plane. It is determined by driving over bumps with a constant speed.
Electromagnetic compatibility (EMC)
The manufacturer confirms compliance with the limit val- ues for electromagnetic emission and interference immu- nity as well as testing of static electricity discharge ac- cording to EN 12895 and the references to other standards contained therein.
Z
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
Z
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.
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B 6
4 Location of instruction labels and identification plates
Z
The truck identification plate (14) is visible after the front hood has been opened (refer to chapter F).
The battery identification plate (18) is visible after the battery hood has been opened (refer to chapter D).
Item Designation
14 Truck identification plate 15 Caution: Heed the operating instructions! (see chapter C) 16 Rated capacity 17 Attachment point of hooks for transportation by crane 18 Battery identification plate 19 Accident prevention inspection label
1615
17
18
14
19
B 7
09.05.GB
4.1 Truck identification plate
Z
In the event of queries relating to the truck or spare part orders, please give the serial No. (21) of the truck.
Item Designation Item Designation
20 Type 26 Manufacturer logo
21 Serial No. 27 Min./max. battery weight in kg
22 Rated capacity in kg 28 Drive power in kW
23 Battery voltage 29 Load centre distance in mm
24 Empty weight without battery in kg 30 Year of manufacture
25 Manufacturer 31 Option
31 30 29 28 27
26
20 21 22 23 24
25
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C Transportation and commissioning
1 Transportation by crane
F
Only lifting gear of adequate capacity must be used (for the weight of the truck, refer to the truck identification plate - see chapter B).
Z
Attachment points (1) are provided on the chassis and the fork for transport- ing the truck with lifting gear.
– Park the truck and render it safe (re-
fer to chapter E).
– Secure the lifting gear to the attach-
ment points (1).
M
The lifting gear must be attached to the attachment points in such a manner that it cannot slip and does not come into contact with any attachments!
M
If the battery hood is marked according to the figure, proceed as follows.
– Lift up battery hood (2) by means
of handle recess and fold over (t).
– Unlock hood lock by pushing down, fold battery hood forward, unlock hood safety
lock, and fold down battery hood and place on the load fork (o) (refer to chapter D).
Z
The battery compartment contains a spanner (19 SW ring/open-end) and the disas- sembly and assembly instructions for the transport plugs.
11
2
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C 2
2 Commissioning
M
The truck must only be operated on battery current! Rectified alternate current will damage the electronic components. Cables connected to the battery (trailing cables) must be less than 6 meters in length.
Z
For trucks starting from February 2001, transport plugs have been introduced.
F
When there is no battery in the truck, the truck cannot be braked with counter-current brake and service brake.
In the front hood area there is a warning sign for the transport plugs (3), which must be removed after installing the battery.
– Fold down the foldable standing platform. – Open front hood (see chapter F). – Loosen nut M12 (19 SW) and remove transport plugs. – Leave the transport plugs at the truck for later transports of the battery.
3
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In order to prepare the truck for work following delivery or transportation, the following operations must be performed:
– Check the truck for completeness and satisfactory condition of the equipment. – If necessary, install the battery. Do not damage the battery cable. – Charge the battery (refer to chapter D). – If necessary, check whether the setting of the combined instrument matches the
type of battery (refer to chapter D)
– Start the truck as described (refer to chapter E).
Z
When parked, the running surface of the tyres will flatten. The flattening will disappear after a short operating time of the truck.
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 failu- re affecting proper operation has rende- red it immobile, proceed as follows:
– Set the master switch to position
“OFF”.
– Set the key switch to position “OFF”
and withdraw the key.
– Immobilise the truck, ensuring that it
cannot move.
– Open the front hood and remove it (re-
fer to chapter F).
– Loosen the lock nuts (5) and tighten
the screws (4).
This releases the brake so that the truck can now be moved.
F
After arriving at the destination, ensure that the brake system is restored to its initial state. The truck must on no ac- count be parked with the brake in the re- leased condition.
– Turn out the screws (4) by approx. 5
mm again and secure them with the lock nuts (5).
The brake is now applied again.
5
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C 4
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D Battery - Servicing, recharging, replace-
ment
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 han- dling 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 recharg- ing. 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 dam- aged.
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.
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D 2
2Battery types
The battery types meet the EN 60254-2 standards. The following table shows the battery combinations and battery capacities:
The battery weight is indicated on the battery identification plate.
Depending on the type of battery used, it is also possible to use models with en- hanced performance or maintenance-free batteries.
F
When replacing or installing batteries, ensure that the battery is correctly secured in the battery compartment of the truck.
3 Exposing the battery
F
Park the truck and render it safe (refer to chapter E).
3.1 Standard version
– Set the master switch (1) to position “OFF”. – Lift up and swing forward the battery hood (2) using the handle (3).
Battery type Battery compartment ap-
prox. 225 mm
Battery compartment ap-
prox. 295 mm 24 V batteries 3 EPzB 300 Ah 3 EPzS 345 Ah 24 V batteries
(performance-enhanced)
3 EPzS 375 Ah
3
2
1
D 3
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3.2 Battery removal from the side (o)
– Set the master switch (7) to position “OFF”. – Unlock the hood locking mechanism (4) by pressing it down,
tilt the battery hood (5) towards the front and unlock the hood catch (6)r.
– Fold the battery hood (5) down and place it onto the fork.
64
5
6
7
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D 4
4 Charging the battery
– Park the truck and render it safe (refer to chapter E).
F
Do not connect or disconnect the battery connector and the socket unless the truck is 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. No metal objects must be placed on the battery. Prior to starting the recharging operation, check all cable connections and plugged connec- tions for visible damage. All safety instructions as provided by the supplier of the battery and the charging sta- tion must be strictly observed.
– Disconnect the battery connector (8). – If present, remove any insulating mats from the battery. – Connect the charging cable (9) to the battery connector (8) and switch on the bat-
tery charger.
M
Recharge the battery observing the instructions provided by the battery supplier and by the charging station supplier.
8
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