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Jungheinrich ERE 120, Operating Instructions Manual

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Jungheinrich ERE 120 Operating Instructions Manual Download Page 148

147

02.15 EN

5.3

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.
• Charge the battery, see "Charging the battery" on page 44.
• Replace transmission oil. Condensation water could have formed.
• Replace hydraulic oil. Condensation water could have formed.

Z

The manufacturer's customer service department is specially trained to carry out
these operations.

• Start up the truck, see "Starting up the truck" on page 61.

Summary of Contents for ERE 120

Page 1: ...07 12 02 15 51222183 ERE 120 Operating instructions G ERE C20 ERE 120...

Page 2: ...KHUHE GHFODUH WKDW WKH SRZHUHG LQGXVWULDO WUXFN GHVFULEHG EHORZ LQ GHWDLO FRPSOLHV ZLWK WKH XURSHDQ LUHFWLYHV 0DFKLQHU LUHFWLYH DQG 8 OHFWURPDJQHWLF RPSDWLELOLW 0 LQFOXGLQJ DPHQGPHQWV DV ZHOO DV WKH...

Page 3: ...02 15 EN 4...

Page 4: ...tee of particular features of the truck should therefore be assumed from the present operating instructions Safety notices and text mark ups Safety instructions and important explanations are indicate...

Page 5: ...2 15 EN 6 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: ...models and rated capacity 15 2 Travel direction definition 16 3 Assemblies and Functional Description 17 3 1 Assembly Overview 17 3 2 Functional Description 18 4 Technical Specifications 20 4 1 Perfo...

Page 7: ...perations to be carried out when the truck is operational 64 3 4 Parking the truck securely 65 4 Industrial Truck Operation 67 4 1 Safety regulations for truck operation 67 4 2 How to act in hazardous...

Page 8: ...assembly 137 4 3 Lifting and jacking up the truck safely 138 4 4 Cleaning 139 4 5 Replacing the drive wheel 142 4 6 Checking the hydraulic oil level 142 4 7 Checking electrical fuses 143 4 8 Restoring...

Page 9: ...02 15 EN 10...

Page 10: ...06 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 instruct...

Page 11: ...0506 GB 2...

Page 12: ...dicated on the capacity plate and must not be exceeded The load must rest on the load handler or be lifted by an attachment approved by the manufacturer The load must be fully raised see Lifting trans...

Page 13: ...not travel across or at an angle on inclines Travel with the load facing uphill Operation in partially public traffic WARNING Use under extreme conditions Using the truck under extreme conditions can...

Page 14: ...es with Cold Store Equipment o Z 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 store...

Page 15: ...ies are excluded Furthermore accident prevention regulations safety regulations and operating servicing and repair guidelines must be followed The operating company must ensure that all users have rea...

Page 16: ...he boards are outside the perimeter of the load wheels can be lifted The rated capacity of the truck is shown on the data plate or capacity plate Qmax 1 1 Truck models and rated capacity The rated cap...

Page 17: ...02 15 EN 16 2 Travel direction definition The following determinations have been made for travel direction specification Item Travel direction 1 Left 2 Drive direction 3 Load direction 4 Right 1 2 3 4...

Page 18: ...onent 5 t Travel switch 9 o CanDis 6 t Tiller t Charge indicator 7 t Key switch 10 t Folding operator platform o CanCode 11 o Folding side restraint o ISM 12 o Mains cable on board charger 8 t Emergen...

Page 19: ...ergency Stop CAUTION The truck brakes automatically If the truck detects that signals which are required have not been received or if it detects an error the system reacts by triggering an emergency s...

Page 20: ...application of the travel and hydraulic operations The battery discharge indicator shows the available battery capacity The CanDis display o shows information which is important for the operator such...

Page 21: ...n mode with without rated load 4 2 4 2 km h Travel speed rider mode with without rated load 7 5 8 5 6 0 6 0 km h Lift time with without rated load 3 3 2 9 s Lift time support arm lift with without rat...

Page 22: ...21 02 15 EN 4 2 Dimensions ERE 120 Wa 98 h14 1053 820 224 330 107 436 l2 x h3 h13 l1 s m2 248 y b12 b5 e l6 Ast a 2 a 2 b1 500...

Page 23: ...02 15 EN 22 ERE C20 l2 h5 h13 h14 98 330 107 1053 820 22 4 500 24 8 436 h3 l1 y m2 l D x Q s b1 1 Wa a 2 a 2 Ast e R b5 b1 l2...

Page 24: ...h3 Rated lift 122 mm b1 b2 Overall width 720 mm b5 Width across forks 510 540 670 mm b10 Track width front 338 368 498 mm b11 Track width rear 500 mm s e l Fork dimensions 55 172 1150 mm a Safety cle...

Page 25: ...h3 Mast lift 540 mm h5 Support arm lift 122 mm b1 b2 Overall width 720 mm b5 Width across forks 540 mm b10 Track width front 508 mm b11 Track width rear 500 mm s e l Fork dimensions 60 187 1150 mm a S...

Page 26: ...186 1756 1269 763 1000 800 1517 1954 1150 186 1906 1419 913 1200 800 1667 2154 1200 186 1956 1469 963 1200 800 1717 2154 1400 186 2156 1669 1163 1400 700 1917 2354 1600 186 2356 1869 1363 1600 1200 2...

Page 27: ...g Description ERE C20 Net weight excl battery 503 kg Axle loading laden front rear battery 1258 1399 kg Axle loading unladen front rear battery 128 525 kg Description ERE 120 Tyre size front 230 x 65...

Page 28: ...not be confused with the human vibrations of the 2002 44 EC Vibrations operator directive The manufacturer offers a special service to measure these human vibrations see Human vibration measurement on...

Page 29: ...d Stores with Cold Store Equipment o on page 13 Z Special equipment and authorisation are required if the truck is to be used continually in conditions of extreme temperature or condensing air humidit...

Page 30: ...ty charts strap points and data plates must be legible at all times Replace if necessary 5 1 Indication Points ERE 120 Item Component 14 Capacity Qmax 15 Attachment points for lifting by crane 16 Cold...

Page 31: ...15 Attachment points for lifting by crane 17 Model name 18 Battery data plate 19 Data plate 20 Serial number etched into the truck chassis 21 Ergonomic lift capacity plate Qmax XXX kg kg kg Q max Q ma...

Page 32: ...truck or ordering spare parts always quote the truck serial number 23 22 23 25 24 26 33 29 32 31 30 28 27 Item Description Item Description 22 Type 28 Year of manufacture 23 Serial number 29 Load cen...

Page 33: ...lowering and transporting loads with large surface areas Light loads must be especially secured when they are subjected to wind forces This will prevent the load from sliding or falling Stop the truc...

Page 34: ...ng lifting and avoid uncontrolled movements If necessary secure the truck with guide ropes XThe truck should only be loaded by personnel trained in the use of lifting slings and tools XWear personal p...

Page 35: ...02 15 EN 34 The truck can now be lifted by crane...

Page 36: ...n installed Remove the transport retainer Requirements Fold down the operator platform Remove the front panel see Front cover disassembly on page 137 Procedure Remove the cable binder latch 34 Undo th...

Page 37: ...idual case XThe truck must be securely fastened when transported on a lorry or a trailer XThe lorry or trailer must have lashing rings XUse wedges to prevent the truck from moving XUse only lashing st...

Page 38: ...ent is complete If necessary install the battery see Battery removal and installation on page 51 Charge the battery see Charging the battery on page 44 The truck can now be started see Starting up the...

Page 39: ...02 15 EN 38...

Page 40: ...on equipment must be available CAUTION The use of unsuitable fire protection equipment can result in scalding Extinguishing fires with water can cause a reaction with the battery acid This can result...

Page 41: ...y Jungheinrich for the truck can be hazardous The design weight and dimensions of the battery have a considerable effect on the operational safety of the truck in particular its stability and capacity...

Page 42: ...volt battery 2PzW 230 204 624X212X628 24 volt battery 2PzS 250 204 624X212X628 24 volt battery 2PzS 250 Lib Silver 204 624X212X628 24 volt battery 2PzM 250 204 624X212X628 24 volt battery 2PzV 220 Ha...

Page 43: ...2 133 652X147X560 24 volt battery 2PzB 150 144 662 x 147 x 592 24 volt battery 2PzB 150 Lib Silver 144 662 x 147 x 592 24 volt battery 2PzB 200 Lib Silver 176 657X147X686 24 volt battery 2PzMB 140 144...

Page 44: ...dges underneath the wheels of the truck to prevent it from moving CAUTION A closing battery panel can pose a trapping hazard If the battery cover is not opened fully it can suddenly close on its own a...

Page 45: ...nections for visible signs of damage XVentilate the room in which the truck is being charged XThe battery cover must be open and the battery cell surfaces must be exposed during charging to ensure ade...

Page 46: ...rdance with the charger operating instructions The battery is charging Completing battery charging restoring the truck to operation NOTE If charging has been interrupted the full battery capacity will...

Page 47: ...contact the manufacturer s customer service department XThe charger must only be used for batteries supplied by Jungheinrich or other approved batteries provided it has been adapted by the manufacture...

Page 48: ...8 block the charger and the battery is not charged 1 Wet cell battery PzS with 100 300 Ah Wet cell battery PzM with 100 179 Ah 2 Wet cell battery PzS with pulse characteristic 200 400 Ah Wet cell batt...

Page 49: ...posing the battery on page 43 Correct charging program set on charger Procedure Remove any insulating mats from the battery The battery connector must remain plugged Attach the mains connector to a ma...

Page 50: ...rtment with the cable If applicable place the existing insulating mats back over the battery Close the battery panel securely The truck is now ready for operation CAUTION Damaged mains cables can be h...

Page 51: ...ristic curve set Red LED fault Lit Charging characteristics or battery parameters invalid Slow flash 1xflash with noticeable interval Overvoltage detected before charging starts 2xflash with noticeabl...

Page 52: ...se only batteries with insulated cells and terminal connectors XPark the truck on a level surface to prevent the battery from sliding out XMake sure the crane slings have sufficient capacity to replac...

Page 53: ...battery cable on the tray so that it cannot be severed when the battery is pulled out Undo the screw 45 of the battery retainer and remove the battery retainer 44 Attach the crane lifting gear to the...

Page 54: ...edure Disconnect the battery connector 40 from the truck connector Undo the battery lock 47 Move the battery replacement station trolley up to the side of the truck Turn the battery lock as far as the...

Page 55: ...02 15 EN 54...

Page 56: ...he operating instructions Safety shoes must be worn on pedestrian operated trucks Unauthorised use of truck The operator is responsible for the truck during the time it is in use The operator must pre...

Page 57: ...ll within the hazardous area stop the truck immediately Safety devices warning signs and warning instructions Safety devices warning signs see Identification Points and Data Plates on page 29 and warn...

Page 58: ...57 02 15 EN 2 Displays and Controls V R 49 50 5 51 50 49 11 52 53 54 7 9 8 10 6 5 48 48...

Page 59: ...switch t Disconnects the battery supply All electric functions are deactivated and the truck decelerates 9 CanDis o Display instrument for Battery charge status Service hours Warning messages Paramet...

Page 60: ...support arm lift 50 Raise button t Raises the lift mechanism o Ergonomic lift ERE C20 The lift mechanism is raised first the support arm lift rises then the mast lift 51 Warning signal button horn t W...

Page 61: ...g the battery on page 44 If the residual capacity falls below the required level lifting is inhibited An alternating display 55 appears Lifting is only released when the battery connected is at least...

Page 62: ...of the truck for signs of damage and leaks Damaged hoses must be replaced immediately Check the battery attachment and wire connections for damage and make sure they are secure Check the battery conn...

Page 63: ...t will go Enter the code in CanCode o 54 Hold the card or transponder in front of the ISM access module and depending on the setting press the green button on the ISM access module o Z For trucks with...

Page 64: ...63 02 15 EN 54 56 51 6 9 52 8...

Page 65: ...ectified the fault Procedure Test warning indicators and safety devices Test the emergency disconnect function by pressing the emergency disconnect switch The main circuit is disconnected and no truck...

Page 66: ...ctions or attempts to use the truck by unauthorised persons immediately WARNING An unsecured truck can cause accidents Do not park the truck on an incline Do not park the truck without the brakes enga...

Page 67: ...rive wheel to forward travel Switch off the truck to do this Turn the key in the key switch 7 anti clockwise as far as it will go Remove the key from the key switch For CanCode 54 press the O key o Pr...

Page 68: ...not lean out or reach beyond the working and operating area Travel visibility The operator must look in the direction of travel and must always have a clear view of the route ahead If the truck is ca...

Page 69: ...f the load from tipping or falling down Prevent liquid loads from sloshing out WARNING Electromagnetic influence can result in accidents Strong magnets can cause electronic components such as Hall sen...

Page 70: ...y in emergencies CAUTION Faulty or non accessible Emergency Disconnect switches can cause accidents A faulty or non accessible Emergency Disconnect switch can cause accidents In dangerous situations t...

Page 71: ...he 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 tr...

Page 72: ...y WARNING Risk of collision due to a defective tiller Operating the truck with a defective tiller can lead to collisions with persons or objects XIf the tiller returns to the brake position slowly or...

Page 73: ...operator and other people XWear personal protective equipment e g safety shoes XThe truck must be operated with particular care and attention in pedestrian mode XEnsure there are no other people stan...

Page 74: ...ll functions are deactivated E 1926 Fold up the operator platform 10 Set the tiller 6 to the travel zone F Push the travel switch 5 to the desired travel direction forward V or reverse R Z When the tr...

Page 75: ...d travel direction forward V or reverse R Z When the travel switch is released it automatically returns to the neutral position Control the travel speed with the travel switch 5 The brakes are release...

Page 76: ...75 02 15 EN R V R V 0 B B B F 5 48 8 10 6 5 48 11...

Page 77: ...n unless the travel switch is released in time XAfter setting off in the opposite direction apply the travel switch gently or not at all XDo not perform any sudden steering operations XAlways face in...

Page 78: ...el route conditions when braking XBrake with care to prevent the load from slipping XAllow for increased braking distance when travelling with an attached load XUse the service brake in emergencies CA...

Page 79: ...5 is set to 0 the truck automatically brakes regeneratively The truck brakes to a halt regeneratively via the coasting brake Z When braking regeneratively energy is returned to the battery ensuring a...

Page 80: ...the truck Stop working with the truck if people do not leave the hazardous area XIf people do not leave the hazardous area despite the warning prevent the truck from being used by unauthorised people...

Page 81: ...mage The load handler is raised Ergonomic lift o ERE C20 When the Load handler lift 50 button is pressed when the load handler is loaded support arm lift is raised first and then mast lift see page 85...

Page 82: ...eave the hazardous area XOnly carry loads that have been correctly secured and positioned Use suitable precautions to prevent parts of the load from tipping over or falling off the truck XDamaged load...

Page 83: ...load must not extend by more than 50 mm beyond the load handler tips Raise the load handler until the desired height is reached see page 80 The load is being raised NOTE Risk of material damage to the...

Page 84: ...ground conditions Procedure Accelerate and decelerate with care Adapt your travel speed to the conditions of the route and the load you are transporting Travel at a constant speed Be prepared to brak...

Page 85: ...s the load handler Z To avoid damaging the load and the load handler avoid setting the load down abruptly Lower the load handler so that it is clear of the load see page 80 Carefully drive the load ha...

Page 86: ...t see Raising the load handler on page 80 Lowers the load handler When the Load handler lower 49 button is pressed when the load handler is loaded main lift is lowered first and then support arm lift...

Page 87: ...ue to internal leakage According to DIN EN ISO 3691 1 the load handler may lower by up to 100 mm during the first 10 minutes at the rated capacity with the hydraulic oil at normal operating temperatur...

Page 88: ...87 02 15 EN...

Page 89: ...if a fault in the electronics system is displayed with a corresponding error code contact the manufacturer s service department Troubleshooting must only be performed by the manufacturer s customer se...

Page 90: ...Dis o the event message E 0914 appears Swing the tiller into the top or the bottom brake zone see page 78 Only one side arm is folded out with CanDis o the event message E 1926 is shown Fold both side...

Page 91: ...or bottom brake zone see page 78 Only one side arm is folded out with CanDis o the event message E 1926 is shown Fold both side arms in out Operating sequence not observed with CanDis o the event mess...

Page 92: ...ines XDo not park the truck with the brake released XApply the brake again when you reach your destination CAUTION Open covers can cause injury and accidents XThe covers side panels drive compartment...

Page 93: ...02 15 EN 92 WARNING Only return the truck to service when you have identified and rectified the fault 57...

Page 94: ...braking or the tiller switch Operating the truck without its own drive system Requirements Truck prevented from rolling away Charged battery in truck Tools and Material Required GF60 service key with...

Page 95: ...ve the key Z When you switch back from level 2 to level 1 the bar returns to its original position The brake is now activated again Z The GF30 key without a bar is designed for normal truck operation...

Page 96: ...on a sticker When using the truck for the first time change the master and user codes and remove the sticker User code factory setting 2 5 8 0 Master code factory setting 7 2 9 5 WARNING Lack of usage...

Page 97: ...key Pressing the o key switches the truck off and sets it to non operational status The o key indicates the follow operating conditions via a red green LED 62 Code lock function commissioning the truc...

Page 98: ...d Enter the code again The Set key 61 has no function in operating mode 7 2 3 Switching off the truck with the keypad CanCode Switching off the truck Procedure Press the O key 63 The truck is switched...

Page 99: ...0 with the digit keys Confirm with the SET key 61 The LEDs 58 62 flash green Enter the valid master code again with the digit keys Confirm with the SET key 61 The LEDs 59 62 flash green Enter the val...

Page 100: ...see Change operator code on page 102 Delete the user code so that the required master code can be used see Delete individual user codes on page 104 The master codes to be changed do not match Switch o...

Page 101: ...user code must also be different from the existing master code Confirm with the SET key 61 The LEDs 60 62 flash green Enter the new user code again with the digit keys Confirm with the SET key 61 Wait...

Page 102: ...a master code Switch off the truck see Switching off the truck with the keypad CanCode on page 97 Choose a different user code see Add operator code on page 100 The newly entered user codes do not ma...

Page 103: ...e as that of the previously entered master code The new user code must also be different from the existing master code Confirm with the SET key 61 The LEDs 60 62 flash green Enter the new user code ag...

Page 104: ...to be changed does not exist Switch off the truck see Switching off the truck with the keypad CanCode on page 97 Check the user code entered The user codes to be changed do not match Switch off the t...

Page 105: ...keys Confirm with the SET key 61 The LEDs 60 62 flash green Enter the user code to be deleted again with the digit keys Confirm with the SET key 61 Wait until the LED 62 flashes green The user code i...

Page 106: ...n page 97 Repeat the entry making sure that the master code is the same length as the user code Tried to delete an operator code that does not exist Switch off the truck see Switching off the truck wi...

Page 107: ...62 flash green Enter the code 3 2 6 5 with the digit keys Confirm with the SET key 61 Wait until the LED 62 flashes green All user codes are deleted Press the O key 63 The truck is switched off and th...

Page 108: ...user code 4 6 digit is always determined by the length of the master code Requirements To prepare the truck for operation see Preparing the truck for operation with the keypad CanCode on page 97 Proce...

Page 109: ...10 seconds the truck cuts out automatically Confirm with the SET key 61 Wait until the LED 62 flashes green The setting is saved Press the O key 63 The truck is switched off and the LED 62 lights up r...

Page 110: ...he cutout time is factory set to 5 minutes Z This setting can be changed if required Cause Remedy Cutout time entered is out of range Switch off the truck see Switching off the truck with the keypad C...

Page 111: ...is displayed by the 58 59 60 LEDs LED 58 lit travel program 1 activated LED 59 lit travel program 2 activated LED 60 lit travel program 3 activated The configuration code is four digit and is comprise...

Page 112: ...program 2 is blocked for the user code selected 1 Travel program 2 is enabled for the user code selected 3rd digit 0 Travel program 3 is blocked for the user code selected 1 Travel program 3 is enable...

Page 113: ...for the travel programs again using the digit keys Confirm with the SET key 61 Wait until the LED 62 flashes green The travel programs are now assigned to the user code Press the O key 63 The truck i...

Page 114: ...the following events the LED 62 flashes red Cause Remedy Blocked travel program defined as start travel program Switch off the truck see Switching off the truck with the keypad CanCode on page 97 Try...

Page 115: ...confirm with the SET key 61 Enter sub index enter 2 and confirm with the SET key 61 Z The parameter and sub index are displayed alternately with the current reading 0256 2 0000 3 Enter the parameter...

Page 116: ...5 02 15 EN Z 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...

Page 117: ...RE 120 Maximum speed in load direction using travel switch 0 9 4 5 9 0 km h 3 6 0 km h ERE C20 Maximum speed1 in load direction using travel switch 0 9 4 5 6 0 km h 3 6 0 km h 0257 Acceleration in ped...

Page 118: ...um speed in load direction using travel switch 0 9 4 5 9 0 km h 8 8 5 km h ERE C20 Maximum speed1 in load direction using travel switch 0 9 4 5 6 0 km h 8 6 0 km h 0273 Acceleration in pedestrian mode...

Page 119: ...um speed in load direction using travel switch 0 9 4 5 9 0 km h 8 8 5 km h ERE C20 Maximum speed1 in load direction using travel switch 0 9 4 5 6 0 km h 8 6 0 km h 0289 Acceleration in pedestrian mode...

Page 120: ...dard setting Comments 1377 Battery type normal high performance dry 0 5 7 9 1 0 Normal wet 1 High performance wet 2 Dry maintenance free 3 US Flat Plate type 4 US Pallet Pro type 5 US Tubular Plate ty...

Page 121: ...batteries with pulse characteristics 200 400 Ah and PzM batteries from 180 400 Ah 3 PzV batteries maintenance free 100 150 Ah 4 PzV batteries maintenance free 151 200 Ah 5 PzV batteries maintenance f...

Page 122: ...ly with the current reading E g 1377 2 0000 1 corresponds to battery type high performance wet Enter parameter 2 according to the parameter list and confirm with the Set key The LED of the O key switc...

Page 123: ...r 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 rea...

Page 124: ...confirm with the SET key Z The LED of the O key 63 switches briefly to steady light and start flashing again after approx 2 seconds Z If the entry is incorrect the LED of the O key 63 turns red Enter...

Page 125: ...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 par...

Page 126: ...n is applied in this case see Discharge monitor function on page 126 Z The point at which the Attention 66 and Stop 67 symbols start to light up differs depending on the battery type 64 Battery charge...

Page 127: ...isplay 7 7 3 Event Messages The service hours display is also used to display event messages The event messages overwrite the service hour display Event message start with an E for Event and a four di...

Page 128: ...rised the respective changes to the capacity data plates decals and stickers as well as the operator and service manuals Attach permanent and clearly visible marking to the truck indicating the types...

Page 129: ...ups Customer Services Customer Services are specially trained in the use of the truck and are able to carry out maintenance and repairs independently Customer Services are aware of the relevant standa...

Page 130: ...parts are an environmental hazard Used parts and consumables must be disposed of in accordance with the applicable environmental protection regulations Oil changes should be carried out by the manufa...

Page 131: ...XCall for a doctor immediately in the event of an injury XDo not touch pressurised hydraulic hoses XReport any defects immediately to your supervisor XMark defective truck and take it out of service...

Page 132: ...ins must always be clean and well lubricated XLift chains should only be cleaned with paraffin derivatives e g petroleum or diesel fuels XDo not clean lift chains with high pressure jets or chemical c...

Page 133: ...s in prescribed containers XAlways fill consumables in clean containers XDo not mix up different grades of consumable The only exception to this is when mixing is expressly stipulated in the operating...

Page 134: ...XDo not smoke when handling oil XAvoid contact and digestion If you swallow oil do not induce vomiting but seek medical assistance immediately XSeek fresh air after breathing in oil fumes or vapours...

Page 135: ...nd ratio for cold store usage 1 1 g Contact surfaces Cold Store Application s Grease nipple b Transmission oil filler neck Transmission oil overflow and dipstick a Transmission oil drain plug Hydrauli...

Page 136: ...ed alternative hydraulic oils Z For cold store operations the Jungheinrich hydraulic oil and the cold store hydraulic oil must be mixed in a 1 1 ratio Code Order no Quantity Description Used for A 511...

Page 137: ...ly on page 65 Disconnect the battery to prevent the truck from being switched on accidentally WARNING Risk of accidents when working under the load handler and lift truck XWhen working under a raised...

Page 138: ...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 Remove the front cover 70 and set it down next to...

Page 139: ...it from slipping or tipping over e g wedges wooden blocks XIn order to raise the truck the lifting gear must only be secured to the points specially provided for this purpose see Transport and Commiss...

Page 140: ...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 XCover all electronic system assemblies contr...

Page 141: ...with water based solvents and water Use a sponge or cloth to clean In particular clean the following areas Window s Oil filler ports and their surroundings Grease nipples before lubrication Dry the t...

Page 142: ...nance and repairs see Prepare the truck for maintenance and repairs on page 136 Tools and Material Required Compressor with water separator Non conductive antistatic brush Procedure Expose the electri...

Page 143: ...s see Prepare the truck for maintenance and repairs on page 136 Remove the front panel see Front cover disassembly on page 137 Procedure Check the oil level in the hydraulic reservoir 73 Z With the lo...

Page 144: ...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 a...

Page 145: ...Rating A 76 9F22 Control fuse 2 after main contactor 10 75 6F1 Display battery hour meter 2 74 F1 Control fuse 1 before main contactor 10 77 3F6 Spare 30 78 F17 Spare for option 10 79 F15 Drive lift...

Page 146: ...ion Schedule on page 134 Clean the battery grease the terminals and connect the battery Charge the battery see Charging the battery on page 44 Replace transmission oil Condensation water could have fo...

Page 147: ...issioning Procedure Thoroughly clean the truck see Cleaning on page 139 Prevent the truck from rolling away accidentally Check the hydraulic oil level and replenish if necessary see Checking the hydra...

Page 148: ...ule on page 134 Clean the battery grease the terminals and connect the battery Charge the battery see Charging the battery on page 44 Replace transmission oil Condensation water could have formed Repl...

Page 149: ...Final de commissioning or disposal of the truck in must be performed in accordance with the regulations of the country of use In particular regulations governing the disposal of batteries consumables...

Page 150: ...st temperature fluctuations or multiple shifts NOTE To prevent damage due to wear the manufacturer recommends an on site application analysis to agree on appropriate service intervals The following ma...

Page 151: ...cessary t 2 Check battery and battery components t 3 Check battery connector for damage proper function and secure mounting t Travel W A B C 1 Check wheels for wear and damage t Chassis and superstruc...

Page 152: ...151 02 15 EN On board charger 35A Standard on board charger Battery charger W A B C 1 Check mains connector and mains cable t Battery charger W A B C 1 Check mains connector and mains cable t...

Page 153: ...or t 9 Carry out a frame leakage test t 10 Check electrical wiring for damage insulation damage connections Make sure wire connections are secure t Power Supply W A B C 1 Check battery cable connectio...

Page 154: ...e secure t 4 Test hydraulic system t 5 Replace hydraulic oil filter ventilation discharge filter k t 6 Check that hydraulic connections hoses and pipes are secure and check for leaks and damage t 7 Ch...

Page 155: ...dirt and damage t 4 Check that cables and electrical connections are secure and not damaged t 5 Carry out a potential measurement on the chassis while charging is in progress t Battery charger W A B C...

Page 156: ...tension if necessary t 4 Check lateral clearance of the mast connections and the fork carriage t 5 Visually inspect the mast rollers and check contact surface wear level t 6 Test emergency lowering s...

Page 157: ......

Page 158: ...ealed armour plated cells 9 5 1 Description 9 5 2 Operation 10 5 3 Servicing PzV and PzV BS lead acid batteries with sealed armour plated cells 13 6 Aquamatik water replenishment system 14 6 1 Water r...

Page 159: ...ring operation for batteries in accordance with Ex I and Ex II see relevant certification 2 Data plate 1 2 4 8 10 11 6 3 5 9 7 12 13 14 15 1 Battery name 2 Battery type 3 Production week year manf 4 S...

Page 160: ...ng Keep away from naked flames and strong heat sources Always wear protective clothing e g safety goggles and safety gloves when working on cells and batteries batteries Always wash your hands after c...

Page 161: ...adjustment factor is 0 0007 kg l per K e g electrolyte density 1 28 kg l at 45 C corresponds to a density of 1 29 kg l at 30 C The electrolyte must conform to DIN 43530 Part 2 purity regulations 4 1...

Page 162: ...tive to negative and check that contacts on the battery terminal conducting system are secure Check the terminal screw torques M10 23 1 Nm of the terminal conductors and connectors Charge up the batte...

Page 163: ...ate the room in which the truck is being charged XBattery cell surfaces must remain exposed during charging in order to ensure sufficient ventilation see truck operating instructions chapter D Chargin...

Page 164: ...charger ensuring the terminals are connect positive to positive and negative to negative Switch on the charger Battery charged Z Charging is considered to be complete when the electrolyte density and...

Page 165: ...a visual inspection for dirt and physical damage If the battery is charged regularly according to the IU characteristic carry out a compensation charge 4 3 3 Monthly Towards the end of the charging pr...

Page 166: ...s or hazardous electrolyte burns if the cell vessels are destroyed Z PzV batteries are low gassing but not gassing free Electrolyte The electrolyte is sulphuric acid which is fixed in gel The density...

Page 167: ...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 XAlways d...

Page 168: ...ells XAlways charge the battery with DC current XAll DIN 41773 charging procedures are permitted in the format approved by the manufacturer XAlways connect the battery to a charger that is appropriate...

Page 169: ...lied with 0 004 V C per K Battery charged Z Charging is considered to be complete when the electrolyte density and battery voltage remain constant for more than 2 hours Compensation charging Compensat...

Page 170: ...the previous ones Z Carry out the measurements after full charging and subsequent resting for at least 5 hours Z If you find significant differences compared with the previous measurements or differen...

Page 171: ...k water replenishment system 6 1 Water replenishment system design 15 Water container 16 Tap connection with ball cock 17 Flow indicator 18 Shut off cock 19 Locking coupling 20 Battery lock connector...

Page 172: ...securely The plug systems have an optical level indicator a diagnostic port to measure the temperature and electrolyte density and a degassing port 6 3 Adding water Water should be added to the batter...

Page 173: ...r 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 electrolyt...

Page 174: ...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...

Page 175: ...nds for an unknown reason the filters must be checked and replaced if necessary Battery connection A hose is attached to the pump module which together with the charge leads is routed from the charger...

Page 176: ...d to severe temperature fluctuations the electrolyte may flow back into the hose system XAttach a separate coupling system to the air inlet line such as locking coupling on the battery side and throug...

Page 177: ...close to a drainage system for processing the electrolytic rinsing water All health and safety as well as water and waste disposal regulations are observed when disposing of used electrolyte or rinsin...

Page 178: ...t the temperature does not exceed 60 C at a distance of 30cm behind the outlet nozzle Observe the maximum operating pressure of 50 bar Observe a minimum distance of 30 cm from the top of the battery T...

Page 179: ...cells for PzV batteries If the battery is to be taken out of service for a long period 3 months it should as far as possible be charged to 50 of its charge level and stored in a dry room protected fro...

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