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AM 20T

Jungheinrich AM 20T Operating Instructions Manual

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Operating instructions
51093842
AM 20T
01.07-
07.08
G
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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
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
0108.GB
0108.GB
I 1
0708.GB
Table of Contents
A Correct Use and Application
B Truck Description
1 Application ........................................................................................... B 1
2 Assemblies and Operational Description ............................................ B 1
3 Standard Version Specifications ......................................................... B 2
3.1 Performance data for standard trucks ................................................. B 2
3.2 Dimensions ......................................................................................... B 3
4 Conditions for application .................................................................... B 3
5 Identification points, warning labels and data plates ........................... B 4
5.1 Data plate ............................................................................................ B 4
C Transport and Commissioning
1 Transport ............................................................................................. C 1
1.1 Dismantling the Hand Pallet Truck ...................................................... C 1
1.2 Transporting the Hand Pallet Truck .................................................... C 2
1.3 Assembling the Hand Pallet Truck ...................................................... C 3
2 Securing the truck during transport. .................................................... C 4
3 Using the truck for the first time .......................................................... C 4
D Operation
1 Safety Regulations for the Operation of Industrial Trucks ................... D 1
2 Controls ............................................................................................... D 2
3 Starting up the truck ............................................................................ D 2
3.1 Checks and operations to be performed before starting daily work .... D 2
4 Industrial Truck Operation ................................................................... D 3
4.1 Safety regulations for truck operation ................................................. D 3
4.2 Travel, Steering, Braking ..................................................................... D 4
4.3 Lifting and depositing loads ................................................................. D 5
5 Parking the truck securely ................................................................... D 5
6 Assembling the Wheel Support with Fork Shoes (o) ......................... D 6
I 1
0708.GB
Table of Contents
A Correct Use and Application
B Truck Description
1 Application ........................................................................................... B 1
2 Assemblies and Operational Description ............................................ B 1
3 Standard Version Specifications ......................................................... B 2
3.1 Performance data for standard trucks ................................................. B 2
3.2 Dimensions ......................................................................................... B 3
4 Conditions for application .................................................................... B 3
5 Identification points, warning labels and data plates ........................... B 4
5.1 Data plate ............................................................................................ B 4
C Transport and Commissioning
1 Transport ............................................................................................. C 1
1.1 Dismantling the Hand Pallet Truck ...................................................... C 1
1.2 Transporting the Hand Pallet Truck .................................................... C 2
1.3 Assembling the Hand Pallet Truck ...................................................... C 3
2 Securing the truck during transport. .................................................... C 4
3 Using the truck for the first time .......................................................... C 4
D Operation
1 Safety Regulations for the Operation of Industrial Trucks ................... D 1
2 Controls ............................................................................................... D 2
3 Starting up the truck ............................................................................ D 2
3.1 Checks and operations to be performed before starting daily work .... D 2
4 Industrial Truck Operation ................................................................... D 3
4.1 Safety regulations for truck operation ................................................. D 3
4.2 Travel, Steering, Braking ..................................................................... D 4
4.3 Lifting and depositing loads ................................................................. D 5
5 Parking the truck securely ................................................................... D 5
6 Assembling the Wheel Support with Fork Shoes (o) ......................... D 6
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I 2
E Industrial Truck Maintenance
1 Operational safety and environmental protection ................................ E 1
2 Maintenance Safety Regulations ........................................................ E 1
3 Servicing and inspection ..................................................................... E 2
4 Recommissioning ................................................................................ E 2
5 Decommissioning the industrial truck .................................................. E 3
5.1 Prior to decommissioning: ................................................................... E 3
5.2 During decommissioning: .................................................................... E 3
5.3 Returning the truck to operation after decommissioning ..................... E 3
6 Safety checks to be performed at regular intervals and
following any unusual incidents ........................................................... E 4
7 Final de-commissioning, disposal ....................................................... E 4
0708.GB
I 2
E Industrial Truck Maintenance
1 Operational safety and environmental protection ................................ E 1
2 Maintenance Safety Regulations ........................................................ E 1
3 Servicing and inspection ..................................................................... E 2
4 Recommissioning ................................................................................ E 2
5 Decommissioning the industrial truck .................................................. E 3
5.1 Prior to decommissioning: ................................................................... E 3
5.2 During decommissioning: .................................................................... E 3
5.3 Returning the truck to operation after decommissioning ..................... E 3
6 Safety checks to be performed at regular intervals and
following any unusual incidents ........................................................... E 4
7 Final de-commissioning, disposal ....................................................... E 4
A 1
0107.GB
A Correct Use and Application
Z
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are supplied with the truck. The guidelines form part of these operating instructions and must be observed. National regulations apply in full.
The truck described in the present operating instructions is an industrial truck designed for lifting and transporting loads.
It must be used, operated and serviced in accordance with the present instructions. All other types of use lie beyond the scope of application and can result in damage to personnel, the truck or property. In particular, avoid overloading the truck with loads which are too heavy or placed on one side. The data plate attached to the truck or the load chart are binding for the maximum load capacity. The industrial truck must not be used in fire or explosion endangered areas, or areas threatened by corrosion or excessive dust.
Proprietor responsibilities: For the purposes of the present operator manual the “proprietor” 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.
The owner must ensure that the truck is used only for the purpose for which it is intended and that there is no danger to life and limb of the user or third parties. Furthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The owner must ensure that all truck users have read and understood these operating instructions.
M
Failure to comply with the operating instructions shall invalidate the warranty. The same applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufacturer’s customer service department.
Attaching accessories: The mounting or installation of additional equipment which affects or enhances the performance of the industrial truck requires the written permission of the manufacturer. In some cases, local authority approval shall be required.
Local authority approval does not however constitute manufacturer’s approval.
A 1
0107.GB
A Correct Use and Application
Z
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are supplied with the truck. The guidelines form part of these operating instructions and must be observed. National regulations apply in full.
The truck described in the present operating instructions is an industrial truck designed for lifting and transporting loads.
It must be used, operated and serviced in accordance with the present instructions. All other types of use lie beyond the scope of application and can result in damage to personnel, the truck or property. In particular, avoid overloading the truck with loads which are too heavy or placed on one side. The data plate attached to the truck or the load chart are binding for the maximum load capacity. The industrial truck must not be used in fire or explosion endangered areas, or areas threatened by corrosion or excessive dust.
Proprietor responsibilities: For the purposes of the present operator manual the “proprietor” 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.
The owner must ensure that the truck is used only for the purpose for which it is intended and that there is no danger to life and limb of the user or third parties. Furthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The owner must ensure that all truck users have read and understood these operating instructions.
M
Failure to comply with the operating instructions shall invalidate the warranty. The same applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufacturer’s customer service department.
Attaching accessories: The mounting or installation of additional equipment which affects or enhances the performance of the industrial truck requires the written permission of the manufacturer. In some cases, local authority approval shall be required.
Local authority approval does not however constitute manufacturer’s approval.
0107.GB
A 2
0107.GB
A 2
B 1
0107.GB
B Truck Description
1 Application
The vehicle is a hand pallet truck, designed for transporting goods on level surfaces. Open bottom pallets or pallets with transverse boards can be lifted beyond the load wheel area.
In the dismantled version the truck can be separated into two parts to facilitate transport without the need for tools.
The optional wheel support with a fork shoe makes the truck more suitable for difficult terrain. The optional wheel support with a fork shoe enables the truck to be transported on uneven ground through docks, loose top soil or honeycomb brick.
The capacity is shown on the data plate and on the data capacity plate Qmax.
2 Assemblies and Operational Description
t = Standard equipment o = Optional equipment
Item Component
1 t Steer wheels 2 t Tiller 3 t “Lift/lower forks” handle 4 t Handle 5 t Travel and parking brake 6 t Fork 7 t Load wheels 8 t Data plate 9 t Foot parking brake
5
4 3
2
6
7
8
9
1
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H
B 1
0107.GB
B Truck Description
1 Application
The vehicle is a hand pallet truck, designed for transporting goods on level surfaces. Open bottom pallets or pallets with transverse boards can be lifted beyond the load wheel area.
In the dismantled version the truck can be separated into two parts to facilitate transport without the need for tools.
The optional wheel support with a fork shoe makes the truck more suitable for difficult terrain. The optional wheel support with a fork shoe enables the truck to be transported on uneven ground through docks, loose top soil or honeycomb brick.
The capacity is shown on the data plate and on the data capacity plate Qmax.
2 Assemblies and Operational Description
t = Standard equipment o = Optional equipment
Item Component
1 t Steer wheels 2 t Tiller 3 t “Lift/lower forks” handle 4 t Handle 5 t Travel and parking brake 6 t Fork 7 t Load wheels 8 t Data plate 9 t Foot parking brake
5
4 3
2
6
7
8
9
1
S
H
0107.GB
B 2
3 Standard Version Specifications
Z
Technical specification details in accordance with VDI 2198. Technical modifications and additions reserved.
3.1 Performance data for standard trucks
Component
AM20T
(795 mm)
AM20T
(1150 mm)
Drive System Manual Manual
Q Rated capacity 2000 2000 kg
c Load center of gravity distance 400 600 mm x Load distance 535 890 mm
Lower speed w / w.o. load
0.09 / 0.02 0.09 / 0.02 m/s
0107.GB
B 2
3 Standard Version Specifications
Z
Technical specification details in accordance with VDI 2198. Technical modifications and additions reserved.
3.1 Performance data for standard trucks
Component
AM20T
(795 mm)
AM20T
(1150 mm)
Drive System Manual Manual
Q Rated capacity 2000 2000 kg
c Load center of gravity distance 400 600 mm x Load distance 535 890 mm
Lower speed w / w.o. load
0.09 / 0.02 0.09 / 0.02 m/s
B 3
0107.GB
3.2 Dimensions
4 Conditions for application
Ambient temperature
- operating at -10 °C to 50 °C
Ambient lighting
- during operation min. 50 Lux
Component
AM20T
(795 mm)
AM20T
(1150 mm)
h3Lift 122 122 mm h13Lowered height 83 83 mm h14Tiller in neutral position. 1234 1234 mm
y Wheel base 755 1110 mm
s/e/l Fork dimensions 53/150/795 53/150/1150 mm
L1Overall length 1165 1520 mm
L2Overall length, including fork shank 373 373 mm
b1/b2Overall width 520/680 520/680 mm
b5Outer load fork distance 520/680 520/680 mm
m2Ground clearance 30 30 mm Ast Aisle width 800 x 1200 longit. 1784 1784 mm Ast Aisle width 1000 x 1200 longit. 1584 1734 mm Wa Turning radius 919 1274 mm
B 3
0107.GB
3.2 Dimensions
4 Conditions for application
Ambient temperature
- operating at -10 °C to 50 °C
Ambient lighting
- during operation min. 50 Lux
Component
AM20T
(795 mm)
AM20T
(1150 mm)
h3Lift 122 122 mm h13Lowered height 83 83 mm h14Tiller in neutral position. 1234 1234 mm
y Wheel base 755 1110 mm
s/e/l Fork dimensions 53/150/795 53/150/1150 mm
L1Overall length 1165 1520 mm
L2Overall length, including fork shank 373 373 mm
b1/b2Overall width 520/680 520/680 mm
b5Outer load fork distance 520/680 520/680 mm
m2Ground clearance 30 30 mm Ast Aisle width 800 x 1200 longit. 1784 1784 mm Ast Aisle width 1000 x 1200 longit. 1584 1734 mm Wa Turning radius 919 1274 mm
0107.GB
B 4
5 Identification points, warning labels and data plates
5.1 Data plate
Z
For queries relating to the truck or spare parts orders, please quote the serial no. (12).
Item Component
8 Data plate
Item Component
10 Model 11 Option 12 Serial no. 13 Year of Manufacture 14 Rated capacity (kg) 15 Truck weight 16 Manufacturer
8
10
11
12
13
14
15
16
0107.GB
B 4
5 Identification points, warning labels and data plates
5.1 Data plate
Z
For queries relating to the truck or spare parts orders, please quote the serial no. (12).
Item Component
8 Data plate
Item Component
10 Model 11 Option 12 Serial no. 13 Year of Manufacture 14 Rated capacity (kg) 15 Truck weight 16 Manufacturer
8
10
11
12
13
14
15
16
C 1
0107.GB
C Transport and Commissioning
1 Transport
1.1 Dismantling the Hand Pallet Truck
– Position the truck on a level surface. – Fully lower the forks. – Fold out both retaining straps (1)
.
– Pull the unlatching lever (3) towards
the fork tips while at the same time pulling on the “Lift/lower forks” handle (2).
– With the unlatching lever and the
control lever pulled, move the tiller (4) in the direction of the fork tips.
The centring pivots (5) slide out of the bearings (6) of the link and the ball head (9) is released from the receptacle (8).
The hand pallet truck can be dismantled into two parts.
1
2
3
7
9
4
5
8
6
C 1
0107.GB
C Transport and Commissioning
1 Transport
1.1 Dismantling the Hand Pallet Truck
– Position the truck on a level surface. – Fully lower the forks. – Fold out both retaining straps (1)
.
– Pull the unlatching lever (3) towards
the fork tips while at the same time pulling on the “Lift/lower forks” handle (2).
– With the unlatching lever and the
control lever pulled, move the tiller (4) in the direction of the fork tips.
The centring pivots (5) slide out of the bearings (6) of the link and the ball head (9) is released from the receptacle (8).
The hand pallet truck can be dismantled into two parts.
1
2
3
7
9
4
5
8
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C 2
1.2 Transporting the Hand Pallet Truck
– Carry the tiller and fork components
as shown in the illustration.
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C 2
1.2 Transporting the Hand Pallet Truck
– Carry the tiller and fork components
as shown in the illustration.
C 3
0107.GB
1.3 Assembling the Hand Pallet Truck
– Place the fork (7) on a level surface. – Open both retaining straps (1). – Pull down on the “Lift/lower forks”
handle (lowered position).
– Place the tiller (4) at an angle with the
ball head (9) under the receptacle (8) of the fork.
– Set the tiller upright while ensuring
that the centring pivots (5) grasp the bearings (6) of the link.
– Close the retaining straps (1) on both
sides.
Z
Always discharge the truck after assembly.
– Pump up the forks fully. – Set the tiller (4) to the horizontal
position and fully lower the forks.
– Set the tiller upright again.
7
9
4
5
8
6
1
4
C 3
0107.GB
1.3 Assembling the Hand Pallet Truck
– Place the fork (7) on a level surface. – Open both retaining straps (1). – Pull down on the “Lift/lower forks”
handle (lowered position).
– Place the tiller (4) at an angle with the
ball head (9) under the receptacle (8) of the fork.
– Set the tiller upright while ensuring
that the centring pivots (5) grasp the bearings (6) of the link.
– Close the retaining straps (1) on both
sides.
Z
Always discharge the truck after assembly.
– Pump up the forks fully. – Set the tiller (4) to the horizontal
position and fully lower the forks.
– Set the tiller upright again.
7
9
4
5
8
6
1
4
0107.GB
C 4
2 Securing the truck during transport.
When transporting the truck on a lorry or trailer, it must always be loaded correctly with chocks applied to the wheels.
3 Using the truck for the first time
To prepare the truck for operation after delivery or transport, carry out the following tasks:
– Make sure the truck’s equipment is complete and in a satisfactory condition. – Assemble the truck as indicated (see chapter C).
Z
When the truck is parked the surface of the tyres will flatten. The flattening will disappear after a short period of operation.
0107.GB
C 4
2 Securing the truck during transport.
When transporting the truck on a lorry or trailer, it must always be loaded correctly with chocks applied to the wheels.
3 Using the truck for the first time
To prepare the truck for operation after delivery or transport, carry out the following tasks:
– Make sure the truck’s equipment is complete and in a satisfactory condition. – Assemble the truck as indicated (see chapter C).
Z
When the truck is parked the surface of the tyres will flatten. The flattening will disappear after a short period of operation.
D 1
0107.GB
D Operation
1 Safety Regulations for the Operation of Industrial Trucks
Operator’s rights, obligations and responsibilities: The operator must be
informed of his duties and responsibilities and be instructed in the operation of the truck and shall be familiar with the operator manual. He shall be afforded all due rights.
Prohibition of unauthorized use: The operator is responsible for the truck during the time it is in use. The operator must prevent unauthorised persons from driving or operating the truck. Do not carry passengers or lift other people.
Damage and faults: The supervisor must be immediately informed of any damage or faults to the industrial truck or attachment. Trucks which are unsafe for operation (e.g. if the wheels have come off) must not be used until they have been rectified.
Repairs: The operator must not carry out any repairs or alterations to the industrial truck without the necessary training and authorisation to do so. The operator must never disable or adjust safety mechanisms or switches.
Dangerous area: A hazardous area is defined as the area in which a person is at risk due to truck movement, lifting operations, the forks or the load itself. This also includes areas which can be reached by falling loads or lowering operating equipment.
Z
Unauthorised persons must be kept away from the hazardous area. Where there is danger to personnel, a warning must be sounded with sufficient notice. If unauthorised personnel are still within the hazardous area the truck shall be brought to a halt immediately.
Safety devices and warning signs: Safety devices and warnings must be strictly observed.
D 1
0107.GB
D Operation
1 Safety Regulations for the Operation of Industrial Trucks
Operator’s rights, obligations and responsibilities: The operator must be
informed of his duties and responsibilities and be instructed in the operation of the truck and shall be familiar with the operator manual. He shall be afforded all due rights.
Prohibition of unauthorized use: The operator is responsible for the truck during the time it is in use. The operator must prevent unauthorised persons from driving or operating the truck. Do not carry passengers or lift other people.
Damage and faults: The supervisor must be immediately informed of any damage or faults to the industrial truck or attachment. Trucks which are unsafe for operation (e.g. if the wheels have come off) must not be used until they have been rectified.
Repairs: The operator must not carry out any repairs or alterations to the industrial truck without the necessary training and authorisation to do so. The operator must never disable or adjust safety mechanisms or switches.
Dangerous area: A hazardous area is defined as the area in which a person is at risk due to truck movement, lifting operations, the forks or the load itself. This also includes areas which can be reached by falling loads or lowering operating equipment.
Z
Unauthorised persons must be kept away from the hazardous area. Where there is danger to personnel, a warning must be sounded with sufficient notice. If unauthorised personnel are still within the hazardous area the truck shall be brought to a halt immediately.
Safety devices and warning signs: Safety devices and warnings must be strictly observed.
0107.GB
D 2
2 Controls
t = Standard equipment o = Optional equipment
3 Starting up the truck
F
Before the truck can be started, operated or a load lifted, the operator must ensure that there is nobody within the hazardous area.
3.1 Checks and operations to be performed before starting daily work
– Inspect the entire truck (especially the wheels and forks) for visible signs of
damage.
Item
Control / Display
Function
1 “Lift/lower forks” handle t Manually lifts / lowers load fork. 2 Tiller t Moves and steers the truck.
1
2
0107.GB
D 2
2 Controls
t = Standard equipment o = Optional equipment
3 Starting up the truck
F
Before the truck can be started, operated or a load lifted, the operator must ensure that there is nobody within the hazardous area.
3.1 Checks and operations to be performed before starting daily work
– Inspect the entire truck (especially the wheels and forks) for visible signs of
damage.
Item
Control / Display
Function
1 “Lift/lower forks” handle t Manually lifts / lowers load fork. 2 Tiller t Moves and steers the truck.
1
2
D 3
0107.GB
4 Industrial Truck Operation
4.1 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.
Travel conduct: The operator must adapt the travel speed to local conditions. The truck must be driven at slow speed when negotiating bends or narrow passageways, when passing through swing doors and at blind spots. The driver must always observe an adequate braking distance between the forklift truck and the vehicle in front and must be in control of the truck at all times. Abrupt stopping (except in emergencies), rapid U turns and overtaking at dangerous or blind spots are not permitted.
Travel visibility: The operator must look in the direction of travel and must always have a clear view of the route ahead. Loads that affect visibility must be positioned at the rear of the truck. If this is not possible, a second person must walk in front of the truck as a lookout.
Negotiating slopes and inclines: Slopes or inclines may only be negotiated if they are designated traffic routes, are clean and have a non-slip surface and providing they can be safely negotiated in accordance with the technical specifications of the truck. The truck must always be driven with the load unit facing uphill. The industrial truck must not be turned, operated at an angle or parked on inclines or slopes. Inclines must only be negotiated at slow speed, with the driver ready to brake at any moment.
Negotiating lifts and docks: Lifts and docks must only be used if they have sufficient capacity, are suitable for driving on and authorised for truck traffic by the owner. The driver must satisfy himself of the above before entering these areas. The truck must enter lifts with the load in front and must take up a position which does not allow it to come into contact with the walls of the lift shaft. People travelling in the lift with the forklift truck must only enter the lift after the truck has come to a halt and must exit the lift before the truck.
Nature of loads to be carried: The operator must make sure that the load is in a satisfactory condition. Do not carry loads unless they are positioned safely and carefully. Use suitable precautions to prevent parts of the load from tipping or falling down,
D 3
0107.GB
4 Industrial Truck Operation
4.1 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.
Travel conduct: The operator must adapt the travel speed to local conditions. The truck must be driven at slow speed when negotiating bends or narrow passageways, when passing through swing doors and at blind spots. The driver must always observe an adequate braking distance between the forklift truck and the vehicle in front and must be in control of the truck at all times. Abrupt stopping (except in emergencies), rapid U turns and overtaking at dangerous or blind spots are not permitted.
Travel visibility: The operator must look in the direction of travel and must always have a clear view of the route ahead. Loads that affect visibility must be positioned at the rear of the truck. If this is not possible, a second person must walk in front of the truck as a lookout.
Negotiating slopes and inclines: Slopes or inclines may only be negotiated if they are designated traffic routes, are clean and have a non-slip surface and providing they can be safely negotiated in accordance with the technical specifications of the truck. The truck must always be driven with the load unit facing uphill. The industrial truck must not be turned, operated at an angle or parked on inclines or slopes. Inclines must only be negotiated at slow speed, with the driver ready to brake at any moment.
Negotiating lifts and docks: Lifts and docks must only be used if they have sufficient capacity, are suitable for driving on and authorised for truck traffic by the owner. The driver must satisfy himself of the above before entering these areas. The truck must enter lifts with the load in front and must take up a position which does not allow it to come into contact with the walls of the lift shaft. People travelling in the lift with the forklift truck must only enter the lift after the truck has come to a halt and must exit the lift before the truck.
Nature of loads to be carried: The operator must make sure that the load is in a satisfactory condition. Do not carry loads unless they are positioned safely and carefully. Use suitable precautions to prevent parts of the load from tipping or falling down,
0107.GB
D 4
4.2 Travel, Steering, Braking
F
Never carry passengers.
Travel
– Start up the truck (see Chapter C). – The truck can be pulled or pushed with
the tiller (2) handle (4).
Steering
– Move the tiller (2) to the left or right,
within a range of approx. 115°.
Braking
In an emergency you can brake the truck by lowering the load.
– Press the handle (1) in the "S"
direction to lower the load.
o Braking with the tiller parking brake
– Apply the tiller parking brake (3) until the brake engages. – Gently pull the lever to brake the truck during travel.
o Braking with the foot parking brake
– Push the foot parking brake (5) in
direction "A" as far as the stop. The brake shoe acts on the wheels and blocks them.
– To release the foot parking brake
depress the left side of the pedal in direction "B". The spring will push the brake shoe back, releasing the wheels.
F
Never attempt to apply the foot parking brake manually.
3
4 1
2
5
S
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0107.GB
D 4
4.2 Travel, Steering, Braking
F
Never carry passengers.
Travel
– Start up the truck (see Chapter C). – The truck can be pulled or pushed with
the tiller (2) handle (4).
Steering
– Move the tiller (2) to the left or right,
within a range of approx. 115°.
Braking
In an emergency you can brake the truck by lowering the load.
– Press the handle (1) in the "S"
direction to lower the load.
o Braking with the tiller parking brake
– Apply the tiller parking brake (3) until the brake engages. – Gently pull the lever to brake the truck during travel.
o Braking with the foot parking brake
– Push the foot parking brake (5) in
direction "A" as far as the stop. The brake shoe acts on the wheels and blocks them.
– To release the foot parking brake
depress the left side of the pedal in direction "B". The spring will push the brake shoe back, releasing the wheels.
F
Never attempt to apply the foot parking brake manually.
3
4 1
2
5
S
H
D 5
0107.GB
4.3 Lifting and depositing loads
Lifting
M
Before lifting a load, the operator must ensure that it is correctly palletised and that the capacity of the truck is not exceeded. Do not lift long loads at an angle.
– Fully insert the forks of the truck
underneath the load. – Press handle (1) in the "H" direction. – Lift the forks by moving the tiller (2) up
and down until the desired lifting
height is achieved.
Z
Rapid lift is effective for loads of up to 120 kg. For pallets over 120 kg, rapid lift applies for the distance under the pallet. As soon as the load is raised, the truck switches to normal lift.
Lowering
– Press the handle (1) in the "S"
direction to lower the load. – Set the handle (1) to the “neutral”
position.
Z
When moving a laden truck, the handle (1) must be in the “neutral” (4) position.
5 Parking the truck securely
F
Always park the truck securely. Do not park the truck on inclines.
– Lower the forks.
F
When the truck is stationary the forks must always be fully lowered.
1
2
S
H
D 5
0107.GB
4.3 Lifting and depositing loads
Lifting
M
Before lifting a load, the operator must ensure that it is correctly palletised and that the capacity of the truck is not exceeded. Do not lift long loads at an angle.
– Fully insert the forks of the truck
underneath the load. – Press handle (1) in the "H" direction. – Lift the forks by moving the tiller (2) up
and down until the desired lifting
height is achieved.
Z
Rapid lift is effective for loads of up to 120 kg. For pallets over 120 kg, rapid lift applies for the distance under the pallet. As soon as the load is raised, the truck switches to normal lift.
Lowering
– Press the handle (1) in the "S"
direction to lower the load. – Set the handle (1) to the “neutral”
position.
Z
When moving a laden truck, the handle (1) must be in the “neutral” (4) position.
5 Parking the truck securely
F
Always park the truck securely. Do not park the truck on inclines.
– Lower the forks.
F
When the truck is stationary the forks must always be fully lowered.
1
2
S
H
0107.GB
D 6
6 Assembling the Wheel Support with Fork Shoes (o)
Place the fork shoe on the fork tines and secure it with the lock (6) on both sides.
– Enter the forks into the pallet. – Raise the forks to the maximum lift
height.
– Insert the wheel support and spigots
(8) into the fork tips (7) .
– Fasten the wheel support with red
locking levers (9) and lower the forks.
The load section of the truck now stands on the adapted wheels, offering greater ground clearance.
6
7
8
9
0107.GB
D 6
6 Assembling the Wheel Support with Fork Shoes (o)
Place the fork shoe on the fork tines and secure it with the lock (6) on both sides.
– Enter the forks into the pallet. – Raise the forks to the maximum lift
height.
– Insert the wheel support and spigots
(8) into the fork tips (7) .
– Fasten the wheel support with red
locking levers (9) and lower the forks.
The load section of the truck now stands on the adapted wheels, offering greater ground clearance.
6
7
8
9
E 1
0708.GB
E Industrial Truck Maintenance
1 Operational safety and environmental protection
The checks and servicing operations contained in this chapter must be performed in accordance with the intervals indicated.
F
Any modifications to the industrial truck assemblies, in particular the safety mechanisms, is prohibited. The operational speeds of the truck must not be changed under any circumstances.
M
Only original spare parts have been certified by our quality assurance department. To ensure safe and reliable operation of the truck, use only the manufacturer's spare parts. Used parts, oils and fuels must be disposed of in accordance with the relevant environmental protection regulations. For oil changes, contact the manufacturer’s specialist department.
Upon completion of checks and servicing, follow the instructions contained in the “Recommissioning” section.
2 Maintenance Safety Regulations
Maintenance personnel: Industrial trucks must only be serviced and maintained by
the manufacturer’s trained personnel. The manufacturer’s service department has field technicians specially trained for these tasks. We therefore recommend a maintenance contract with the manufacturer’s local service centre.
Lifting and jacking up: When an industrial truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When jacking up the truck, take appropriate measures to prevent the truck from slipping or tipping over (e.g. wedges, wooden blocks).
Cleaning operations: Do not use flammable liquids to clean the industrial truck. Prior to cleaning, implement all necessary safety measures to prevent sparking.
M
Do not clean with pressurised water.
On completion of the cleaning work, carry out the activities detailed in the “Recommissioning” section.
Settings: Always note the truck-specific settings when carrying out repairs or replacing hydraulic components.
Tyres: The quality of tyres affects the stability and performance of the truck. Always used original spare parts when replacing factory fitted wheels. Otherwise the performance of the truck cannot be guaranteed. When replacing wheels, ensure that the truck does not slew (e.g. always replace left and right wheels at the same time).
Hydraulic hoses: The hoses must be replaced every six years. When replacing hydraulic components, also replace the hoses in the hydraulic system.
3 Servicing and inspection
Thorough and expert servicing is one of the most important preconditions for safe
E 1
0708.GB
E Industrial Truck Maintenance
1 Operational safety and environmental protection
The checks and servicing operations contained in this chapter must be performed in accordance with the intervals indicated.
F
Any modifications to the industrial truck assemblies, in particular the safety mechanisms, is prohibited. The operational speeds of the truck must not be changed under any circumstances.
M
Only original spare parts have been certified by our quality assurance department. To ensure safe and reliable operation of the truck, use only the manufacturer's spare parts. Used parts, oils and fuels must be disposed of in accordance with the relevant environmental protection regulations. For oil changes, contact the manufacturer’s specialist department.
Upon completion of checks and servicing, follow the instructions contained in the “Recommissioning” section.
2 Maintenance Safety Regulations
Maintenance personnel: Industrial trucks must only be serviced and maintained by
the manufacturer’s trained personnel. The manufacturer’s service department has field technicians specially trained for these tasks. We therefore recommend a maintenance contract with the manufacturer’s local service centre.
Lifting and jacking up: When an industrial truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When jacking up the truck, take appropriate measures to prevent the truck from slipping or tipping over (e.g. wedges, wooden blocks).
Cleaning operations: Do not use flammable liquids to clean the industrial truck. Prior to cleaning, implement all necessary safety measures to prevent sparking.
M
Do not clean with pressurised water.
On completion of the cleaning work, carry out the activities detailed in the “Recommissioning” section.
Settings: Always note the truck-specific settings when carrying out repairs or replacing hydraulic components.
Tyres: The quality of tyres affects the stability and performance of the truck. Always used original spare parts when replacing factory fitted wheels. Otherwise the performance of the truck cannot be guaranteed. When replacing wheels, ensure that the truck does not slew (e.g. always replace left and right wheels at the same time).
Hydraulic hoses: The hoses must be replaced every six years. When replacing hydraulic components, also replace the hoses in the hydraulic system.
3 Servicing and inspection
Thorough and expert servicing is one of the most important preconditions for safe
0708.GB
E 2
operation of the forklift truck. Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment.
M
The application conditions of an industrial truck have a considerable impact on the wear of the service components. We recommend an application analysis carried out on site by a Jungheinrich customer service adviser to draw up specific service intervals to prevent damage caused by wear. The service intervals stated are based on single shift operation under normal operating conditions. They must be reduced accordingly if the truck is to be used in conditions of extreme dust, temperature fluctuations or multiple shifts.
The oil level must be checked every 4000 service hours, or at least every 2 years, and topped up as required (type HV 32 only, capacity: 0.36 litres) and the links lubricated with a MoS2 based lubricant.
During the run-in period – after approx. 100 service hours – the owner must check the wheel nuts/bolts and re-tighten if necessary.
4 Recommissioning
The truck may only be restored to service after cleaning or repair work once the following operations have been performed.
– Bleed the hydraulic system (see chapter C).
0708.GB
E 2
operation of the forklift truck. Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment.
M
The application conditions of an industrial truck have a considerable impact on the wear of the service components. We recommend an application analysis carried out on site by a Jungheinrich customer service adviser to draw up specific service intervals to prevent damage caused by wear. The service intervals stated are based on single shift operation under normal operating conditions. They must be reduced accordingly if the truck is to be used in conditions of extreme dust, temperature fluctuations or multiple shifts.
The oil level must be checked every 4000 service hours, or at least every 2 years, and topped up as required (type HV 32 only, capacity: 0.36 litres) and the links lubricated with a MoS2 based lubricant.
During the run-in period – after approx. 100 service hours – the owner must check the wheel nuts/bolts and re-tighten if necessary.
4 Recommissioning
The truck may only be restored to service after cleaning or repair work once the following operations have been performed.
– Bleed the hydraulic system (see chapter C).
E 3
0708.GB
5 Decommissioning the industrial truck
If the industrial truck is to be decommissioned for more than two months, e.g. for operational reasons, it must be parked in a frost-free and dry location and all necessary measures must be taken before, during and after decommissioning as described.
M
On decommissioning the truck must be jacked up so that all the wheels are clear of the ground. This is the only way of ensuring that the wheels and wheel bearings are not damaged.
If the truck is to be out of service for more than 6 months, further measures must be taken in consultation with the manufacturer’s service department.
5.1 Prior to decommissioning:
– Thoroughly clean the truck. – Check hydraulic oil, replenish if necessary – Apply a thin layer of oil or grease to any non-painted mechanical components. – Lubricate the links.
5.2 During decommissioning:
– No action required.
5.3 Returning the truck to operation after decommissioning
– Thoroughly clean the truck. – Lubricate the links. – Check hydraulic oil for condensed water and replace if necessary. – Start up the truck (see Chapter C).
E 3
0708.GB
5 Decommissioning the industrial truck
If the industrial truck is to be decommissioned for more than two months, e.g. for operational reasons, it must be parked in a frost-free and dry location and all necessary measures must be taken before, during and after decommissioning as described.
M
On decommissioning the truck must be jacked up so that all the wheels are clear of the ground. This is the only way of ensuring that the wheels and wheel bearings are not damaged.
If the truck is to be out of service for more than 6 months, further measures must be taken in consultation with the manufacturer’s service department.
5.1 Prior to decommissioning:
– Thoroughly clean the truck. – Check hydraulic oil, replenish if necessary – Apply a thin layer of oil or grease to any non-painted mechanical components. – Lubricate the links.
5.2 During decommissioning:
– No action required.
5.3 Returning the truck to operation after decommissioning
– Thoroughly clean the truck. – Lubricate the links. – Check hydraulic oil for condensed water and replace if necessary. – Start up the truck (see Chapter C).
0708.GB
E 4
6 Safety checks to be performed at regular intervals and following any unusual
incidents
Z
Carry out a safety check in accordance with national regulations. Junheinrich recommends checks in accordance with FEM Guideline 4.004. Jungheinrich has a special safety department with trained personnel to carry out such checks.
The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector. The inspector shall assess the condition of the truck from purely a safety viewpoint, without regard to operational or economic circumstances. The inspector shall be sufficiently instructed and experienced to be able to assess the condition of the truck and the effectiveness of the safety mechanisms based on the technical regulations and principles governing the inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition from a safety aspect. The truck must also be examined for damage caused by possible improper use. A test report shall be provided. The test results must be kept for at least the next 2 inspections.
The owner is responsible for ensuring that faults are immediately rectified.
Z
A test plate is attached to the truck as proof that it has passed the safety inspection. This plate indicates the due date for the next inspection.
7 Final de-commissioning, disposal
Z
Final, proper decommissioning or disposal of the truck must be performed in accordance with the regulations of the country of application. In particular, regulations governing the disposal of batteries, fuels and electronic and electrical systems must be observed.
0708.GB
E 4
6 Safety checks to be performed at regular intervals and following any unusual
incidents
Z
Carry out a safety check in accordance with national regulations. Junheinrich recommends checks in accordance with FEM Guideline 4.004. Jungheinrich has a special safety department with trained personnel to carry out such checks.
The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector. The inspector shall assess the condition of the truck from purely a safety viewpoint, without regard to operational or economic circumstances. The inspector shall be sufficiently instructed and experienced to be able to assess the condition of the truck and the effectiveness of the safety mechanisms based on the technical regulations and principles governing the inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition from a safety aspect. The truck must also be examined for damage caused by possible improper use. A test report shall be provided. The test results must be kept for at least the next 2 inspections.
The owner is responsible for ensuring that faults are immediately rectified.
Z
A test plate is attached to the truck as proof that it has passed the safety inspection. This plate indicates the due date for the next inspection.
7 Final de-commissioning, disposal
Z
Final, proper decommissioning or disposal of the truck must be performed in accordance with the regulations of the country of application. In particular, regulations governing the disposal of batteries, fuels and electronic and electrical systems must be observed.
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